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Scheme of workThis scheme of work for GCSE Engineering suggests activities and resources that you may find useful in your teaching. It follows the Ofqual guidance of 120 hours Guided Learning Hours (GLH) and is based on a model of two hours per week over 60 weeks (35 weeks in year one and 25 weeks in year two).Year oneProject one – Working with metalsAim: To introduce understanding and working to formal engineering drawings.Week Activities and contentSpecification reference Skills and understanding1–4A project that shapes and forms steel/aluminium/ brass and produces a component from drawings.Workshop processes:cutting turningdrilling.Quality control methods, working to tolerances, checking using Vernier calipers/micrometer.Follow a production plan.Material removal 3.2.2Shaping 3.2.3Joining and assembly 3.2.5Practical engineering skills 3.6Students should have used some equipment before in KS3 Design and Technology lessons and have the following understanding:reading and understanding orthographic drawings, engineering conventions, dimensioningmarking out methods using rule, square, dividersmeasurement with varying degrees of accuracy, using rule, calipers, micrometer and Vernier calipersturning, using manual or CNC lathe (or both if available), turning, facing, drillingtool types and parts of the lathe; headstock, tail stock (if fitted), slidesmethods of producing tapers or radiuscutting: using hacksaw, tinsnipsdrilling, using both pillar drill and lathe, twist drills, countersinking. Using a jigbending and forming, using the vice/folding bars, bending jigs or fixtures. Hot working/forgingshaping and finishing, filing, milling if available, use of abrasivesfollowing a provided production planawareness of health and safety. Using PPE and risk assessmentsworkshop safety proceduresthe need for different feeds. Cuts, choice of tools and equipmentorthographic drawings and engineering conventions/dimensioningtolerances.Project two – Systems: building a small robotAim: To introduce working with a systems approach using mechanical and electronic components/devices.Week Activities and contentSpecification reference Skills and understanding5–10Several short tasks using a combination of the following, finishing with an open task requiring synoptic application on knowledge and understanding. Using either a graphical programming language, eg Blockly, LabVIEW, Flowol, or text based, eg Robot C, PBasic, program microcontroller based devices to control a system.Sensing, using sensors (as available) to detect and measure:touch switches, used for detecting objects (bump switch) or as manual input stop/startlight/colour sensingtemperature sensingsoundpH aciditymagnetismposition – by compass or rotational (gyro)distance, ultrasonicaccelerationforce.Mechanisms:gearing, using:spur gearscrown wheelsbevel gearsbeltspulleystransmitting power using shafts, gearing systems, belts and pulleys, chains and sprocketslinkages, push-pull, bell crank, cranks and four bar mechanisms including crank-slider, parallel motioncamsthe need for bearings.Pneumatics:using or demonstrating how pneumatics can be used to activate or control mechanical systemssingle and double acting cylindersapplications, bus/train doors, testing rigs eg IKEA, tailgate operation on hatchback cars.Programming:Using either a graphical programming language, eg Blockly, LabVIEW, Flowol, or text based, eg Robot C, PBasic, program microcontroller based devices to control a system.Operations:reading from a sensor or switchtime delaysabsolute and relative measurementsdecisions (switches)loops, conditional, unconditionalvariables and constantsoutput to devices – lamps, motors, solenoidsanalogue to digital conversion, using a PIC with this facility.Mechanical systems 3.3.1Electrical systems 3.3.2Electronic systems 3.3.3Pneumatic systems 3.3.5Practical engineering skills 3.6Velocity ratiosMechanical advantageProblem solvingAnalysing procedures to enable control programs to be constructedKinematic chainsForcesLeversConversion of motionAnalysing situationsProblem solving CollaborationPreparing flowchartsProject three – Understanding materials 1Aim: Introduce materials testing as a design method of predicting performance under load.Week Activities and contentSpecification reference 11Materials testing:Using CAD simulations. Physical testing eg tensile strength, extension under puter Aided Design:Using a standard engineering CAD package eg Creo, SolidWorks, Fusion 360 or SpaceClaim model the performance of components under load.Physical testing:tensile testing a variety of materials under load, eg nylon fishing line, cotton, hair, copper fuse wire, using a commercial tester or by improvised methodsmeasuring extension under strain, total length v original length and comparing the thickness of end sections with middle to detect waisting.Calculations:Stress, strain and Young's modulus.Modelling and calculating 3.4.1Testing 3.4.2Project four – Making an electronic lock/alarmAim: Introduce circuit design, use a CAD package for modelling circuit behaviour and test the outcomes of changing component values. Become aware of Ohm’s law equations. Construct a working circuit. Compare the use of discrete integrated circuits with programmable devices.Week numberActivities and contentSpecification reference 12–17Design and test electronic circuits. Draw block diagrams and use sensors, output devices, buzzer piezo sounder, light emitting diodes (LEDs), process devices and logic and programmable devices.Systems approach:looking at circuit design in terms of input, process, outputunderstanding the function of sensing devices eg light dependent resistors, thermistors.Understanding how to match required function with available process devices:timers eg 555NEcounters eg 4017B decade countercomparators eg CA 3140 logic and, or, not 4001B, ponent level:resistance in series/parallelknowing the following components and their function within a circuit:bi-polar transistor, field effect transistorLED, rectifier diode and signalcapacitors, polarised and non-polarisedresistors fixed and variablemicrocontrollers (PIC)buzzers, bells, piezo sounder, lamps and solenoid.Circuit design:using a circuit design package eg Circuit Wizard, Design SparkPCB, Techsoft 2D PCBusing a simulation package eg Circuit Wizard, Picaxe VSM, Yenkaphysical modelling, using prototyping board for circuit construction and testing.Printed board and circuit construction:producing a PCB by either etching or millingbuild a circuit using a PCBtesting the circuit for continuity and short circuits.Modelling and calculating 3.4.1Practical engineering skills 3.6Project five – Building a bridgeWeek Activities and contentSpecification reference 18–19Working in teams, build a trussed structure from lightweight materials eg balsa, paper and thin card, and destructively test. Calculating factor of safety, weight/load ratio.Building monocoque structures from card or form using vacuum moulding and test with dynamic and static loading.Analysing failed structure for evidence of compression failures, distortion and buckling under load. Packaging a fragile object.Testing a variety of materials for behaviour and failure modes in torsion and bending.Structural systems 3.3.4 Practical engineering skills 3.6Project six – CAD-CAM Week Activities and contentSpecification reference 20–24Using a 2D drawing package eg Techsoft 2D/Corel Draw or alternatively a 3D package, work on a single plane to produce drawings that conform to standard. If facilities permit, drawings could be produced for export to laser/vinyl cutters or CNC lathes.Using CAD to design 3D objects, working with a 3D package, using parametric constraints, and functions such as extrude, shell, chamfering with methods of joining or locating components eg mating.Testing using CAD simulation, for stress or to articulate and test movements.Outputting 3D designs for CAM processes including rapid prototyping, CNC milling, routing. Practical engineering skills 3.6Project seven – Producing engineering drawingsWeek Activities and contentSpecification Reference 25–27Orthographic drawings – third angle:placement of views, plan and elevationsdimensioningconventions:centre linesscrew threads.Holes and sectional views:cross hatchingconventions and rulesisometric projection including isometric circlesassembly drawing using a disassembled product.Practical engineering skills 3.6Project eight – Making a casting/mouldingWeek Activities and contentSpecification reference 28–29Using a prepared pattern, demonstrate sand casting including all relevant terminology, cope, drag, pourer, riser. Explain contraction and the need for venting.Making and using simple cut outs as moulds to cast pewter. If available, demonstrate injection moulding or, using a hot glue gun, an improvised method.Mindsets OnlinePractical engineering skills 3.6Casting and moulding 3.2.4Make it go faster?Week Activities and contentSpecification reference 30Introduce the aerodynamic concept of thrust, drag and lift. Look at applications including:F1 in schoolspaper dart launcherscommercial applications such as golf clubsAerodynamics 3.4.3Understanding materials Week Activities and contentSpecification reference 31–32Polymers, types and properties:thermoformingthermosettingworking with thermoforming polymersapplications of posites and reinforcements:GRP, carbon fibre, Kevlarreinforcements eg steel in concrete.Timber: structural grade timber, selection and testing, uses.Ceramics:properties and usesadvantages and disadvantages.Heat treatment of metals:annealinghardening and temperingcase hardening.Avoiding corrosion and finishes:platinggalvanizinganodizingpainting.Factors influencing design of solutions 3.1.3Composites 3.1.1.3Other materials 3.1.1.4Shaping 3.2.3Problem solvingWeek Activities and contentSpecification Reference 33–34Using a logical and systematic approach:producing flowcharts and systems block diagrams to describe operations and proceduresestablishing/describing systems boundaries and componentsdescribing sub-systems within systemsmapping problems.Analysing and evaluating existing solutions to problems:look at similar devices that perform the same function including disassemblyexamine different ways of doing thingsmaking judgements about the effectiveness of existing solutions.Using data and evaluating: data gathering methodsstatistical analysisdrawing conclusions.NEAWeek Activities and contentSpecification reference 35Planning for the NEA:analysing the opportunities of the set themelooking at the provided examples.Year twoWeek Activities and contentSpecification reference 36–50NEA: Working to the task within the approximate time limit set by us for this aspect of the course (30 hours).Produce the following:a written or digital design folder containing:detailed explanation of what the problem involvesalternative solutions – in outlinea solution that integrates different types of system – both electrical/ electronic and mechanicaldetailed design with sufficient detail to produce a fully working solution including any systems used to control the deviceexplanations of how the system functions.production plansmanufacturing diaryevidence of testing, planning and carrying out the test(s)reports of any remedial actions needed after testingan evaluation of the effectiveness of the solutionphotographic evidence of the final manufactured prototype.Additional clarification should be obtained from the specification, 4.4.2.1.Exam preparation/revision, dependent on timing of exam written paper.Exam dates can vary annually, so this needs to be a flexible programme. The time available to students will differ dependent on their available time as exams may have already begun and school policies, such as study leave, will vary.Link and supplement the processes used, with previous learning. 51Revision and exam preparation startsNEA marks to be submitted to AQA by due ic 1 – What influences design?Week Activities and contentSpecification reference 52–54Energy production:availability of supplyfossil fuelsrenewable energy sources:windsolartidal/wavegeo-thermal.Engineering lifespanMaintenance:recycling, by manufacturers, third partiesdisposal of harmful materials, heavy metals eg batteries, radioactive material.End of life disposal:recycling by manufacturers and third partiesdisposal of harmful materials, heavy metals eg batteries, radioactive material etc.Availability of materialsCost factorsUser requirementsFactors influencing design of solutions 3.1.3Material costs and supply 3.1.2Topic 2 – Impact of modern technologiesWeek Activities and contentSpecification reference 55–56Production methods, automation and robotics:reduced production costsgreater reliabilitydifferent skill set/working pattern required by work force.impact on numbers employed.Society, increased availability of products:social impact, creating demand, advertising/marketingchanges to living style, easier communication.The environment/pollution in cities, visual impact in the countryside.Impact of modern technologies 3.557–60Exam preparation/revision, dependent on timing of exam written paper.Exam dates can vary annually. ................
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