The Robert Manning College

School Postcode: PE10 9DT DCFS number:
Staff member who developed this case study: Peter Lound
Email contact: peterlound2001@yahoo.co.uk
School telephone: 01778 422365 No. on roll: 1100
Brief pen picture of school: The school is mixed gender and ability and was granted technology status in 2000. It has now been re-designated as a specialist school in vocational and technological education.

1. The Teacher CPD Course:

The Project Brief:
Design and Manufacture a digital lock
Specification:
Product must be compact enough to fit behind a safe door
It must be armed with a combination using a 4X3 keypad
It must include a user override feature
The case must be manufactured using commercial methods
The product must be suitable for high volume production
It must be reliable and fit for purpose
Concept Sketches:
1. Electronic circuit development:
a) Circuit diagrams/schematics
Basic Circuit for Digital Lock developed on Crocodile Clips
The Motor represents the solenoid
b) PCB artwork

The PCB design was produced using Techsoft PCB Design and Make. The PCB is 105mm X 55 mm

Circuit Wizard Simulation
c) Program details
The Final Circuit Board:

USING THE ROLAND CAM 2
USING PCB DESIGN AND MAKE

MODELLING USING BREADBOARD
THE ENGRAVED PCB

The Final PCB engraved using the Roland CAM 2
I decided to manufacture the PCB using CAD/CAM techniques as it would seem that this is in keeping with the ultimate aim of the project. We took the decision to abandon photo etch methods at our school about five years ago, mainly for health and safety reasons. The result of this is that students are constrained to be more precise with their soldering or they risk bridging tracks and shorting out the circuit board.
Commentary:
The initial concept sketches have given me a reasonable starting point. There are some features that will certainly be improved when parametric modelling has been explored
2. CAD/CAM Development:
This was the first model using ProDesktop This was the original model showing the lid and case assembly with name of product This is the rendered version of the original proposal
Final CAD Design:
CAM Manufacture:
Commentary:
I am satisfied with the course of actions taken on this project. The most painstaking stage was developing the design using ProDesktop. However, without this software, the task would have been far more problematic.
I have experienced the massive benefit by using laser cutting technology in terms of precision, quality and the saving of time, cost and materials. This, importantly, enables the majority of students to produce a high quality product in a fraction of the time.
The use of circuit wizard software is also a great aid in generating electronic circuits that eliminate the time consuming aspect of fault finding. In hindsight, there are always other ways of proceeding but I am reasonably happy with the outcome.

2. The Student Scheme of Work

Aimed at Key Stage: 4
Estimated time available for project: 32 periods of 60 minutes
National Curriculum PoS covered by Scheme of work:
The Scheme of Work:
Week Cross Curricular Content / Focus FPT/DMA/DEMO VAK Resources Differentiation Homework
1 All areas Intro project and write task, brief and task analysis FPT
DEMO
DISCUSS		 V ICT generated, show examples of clip art. Complete first task.
2/3 English
ICT		 Research the problem by looking at the market and establishing user requirements. Analyse a similar product. DMA
DEMO		 VAK Internet, the user and catalogues. Continue
4 English Write the design specification for the case and electronic circuit. FPT K A3 sheet, computers Continue
5 Art
 Produce initial concept designs for case and circuit. FPT
DEMO		 K A3 sheet Continue
6 Art
ICT		 Model, develop and refine a final solution for the case and circuit. FPT K A3 sheet, ProDesktop, Techsoft 2D Design Continue
7 ICT Produce a working drawing for the case. FPT
DEMO
DISCUSS		 K ProDesktop, Techsoft 2D Design Continue
8 Physics Model the final circuit design using breadboard. FPT K Breadboard and electronic components Continue
9 Art Design the circuit track layout. FPT
DEMO		 K PCB design and make Continue
10 Maths Engrave the circuit board using the Roland Cam 2 and drill the component holes.   K Copper clad board, Roalnd Cam 2 and PCB drill Continue
11 ICT
Maths		 Plan the production schedule for case and circuit manufacture FPT
DEMO		 K Computers Continue
12 Physics Focussed manufacturing activities FPT
DEMO		 K Various workshop tools and equipment, Laser cutter Continue
13 Physics Focussed manufacturing activities DISCUSS K Various workshop tools and equipment, Laser cutter Continue
14 Physics Focussed manufacturing activities DISCUSS K Various workshop tools and equipment Continue
15 Physics Focussed manufacturing activities FPT K Various workshop tools and equipment Continue
16 English
Maths
Physics
ICT		 Testing, evaluation and modification. DEMO K Various workshop tools and equipment Continue

CONTEXT
The theme of the project is security and the aim is to design and manufacture a digitally controlled lock to be used on a safe. The electronic circuit is to be modelled using CAD electronic software and ultimately housed in a case that is designed and manufactured using CAD/CAM techniques.

SPECIFICATION
• The product must fit onto the door of a prototype safe
• It must incorporate safety features that protect the user
• It must be of high quality and fit for purpose
• It must be reliable
• It must be able to be ultimately batch or mass produced
• It must be powered by a low voltage supply
• CAD/CAM must be integral during all stages of development and manufacture
• It must be easy for the user to operate
List the design decisions (from David’s Barlex’s Nuffield D&T pentagon) you will be asking pupils to make.
Individual Lesson Plans:
Student Outcomes:
Commentary:

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