MEM29013 — Integrate sensors into digital manufacturing processes

Elements & performance criteria

Performance evidence

• report on the current use of sensors in the workplace including descriptions of:  types and locations of sensors  physical properties measured by the installed sensors  range of data collected  sensor data transmission, processing and networking
• report on the opportunity to increase the amount and quality of collected data through:  use of additional sensor locations and types  use of intelligent sensors including sensors incorporating self-testing and self-calibration  use of feedback loops and edge processing of sensor data
• read logic flow and state diagrams
• install and correctly calibrate four different types of sensors including:  installing and calibrating at least one transducer,  connecting at least two sensors to a 5G network
• following networking protocols and interfacing standards for installing sensors including:  input/output (I/O) – digital and analog  handshaking.

Knowledge evidence

• sensors in a smart factory or workplace and their contribution to:  providing data for visibility on processes, materials and equipment  issue identification and troubleshooting  reliability including preventative and predictive maintenance
• sensors and transducers as sources of data for different levels in an organisation including:  process or equipment control  operations management and quality control  predictive and preventative maintenance  fault diagnosis  data analytics for economic gain
• similarities and differences between a sensor and a transducer including:  sensors and transducers as devices that detect changes in their surrounding environment or the object to which they are attached  a sensor gives output in the same format as its input information  a transducer converts the input signal into an electrical signal
• principles for classifying sensors including:  output signal –  energy source - active (requiring external power) and passive (no power source required)  contact and non-contact with input stimulus  type of output measurement - absolute or relative measurement of input stimulus  other classifications
• characteristics to consider when selecting sensors including:  robustness including:  sensitivity to interference  shielding/housing needs  environmental limits– dust, moisture, temperature etc.  interfacing and signal conditioning  networking including:  5G  WiFi  wired  cloud  two-way communication  data processing requirements including:  on board processing  adjacent or edge processor  network or cloud-based processor  location requirements including:  physical connections  positioning to maximise gathering of information  current and voltage  output devices/ actuators  cost  status register functions: carry©, Digit Carry (DC), Zero (Z) bits  accuracy – measured value versus true value  sensor saturation or threshold point
• developments in sensor technology including awareness of the following and their potential application:  nano sensors  micro sensors  nuclear sensors 

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