Lego Challenge Mechanics In Practice...Pupil Booklet OPITO Lego Challenge Mechanics In Practice 2...

Name

Pupil Booklet

OPITO

Lego Challenge

Mechanics In Practice

2

Contents

[email protected] T:+44(0)1224787862Minerva House | Bruntland Road | Portlethen | Aberdeen | AB12 4QL

www.myOilandGasCareer.com

What is the OPITO Lego Challenge? 3What is in the box? 4Capacities Questionnaire - Before 5Capacities Questionnaire - After 6

Lessons 1 & 2:

Simple Machines: Lever 7Simple Machines: Inclined Plane 10

Lessons 3 & 4:Simple Machines: Cam 14Big Build 1: Hammer 18Extension: Bouncing Ballerina 21

Lessons 5 & 6:Simple Machines: Pulley 22

Lessons 7 & 8:Big Build 2: Crane 27Glossary 32Evaluation 34

3

Have you ever played with Lego?Almost all of you will have come across Lego before now.

This is an opportunity for you to use one of LEGO Education’s ac-tivity packs, generously loaned to Meldrum Academy by OPITO andwork as young scientists, engineers and designers, whilst “playing”with actual Lego.

You are being encouraged to:

• Involve yourself in real world investigations• Problem solve• Make assumptions & predictions• Design and make models and then see how these work• Reflect (think about) and then perhaps re-design your model• Record and present your findings.

Wha

t i

s theOPITO Lego Challenge

OPITO

4

There are 396 different Lego pieces in the box, including a motor.

Buddy Building SystemAll the models you build for the Activities are designed so two pupils can build at the sametime. Each buddy builds his or her own subsystem using either the A or B instructions booklet.

These subsystems are then put together to become one complete model.

Principle ModelsYou will start by building some of the Principle Models. These are mechanical and structuralprinciples that are normally hidden away in inside everyday machines and structures e.g.

gears and cams under a car bonnet.

ActivitiesYou will quickly move on to Activities which use some of the Principle Models. These Activities

follow LEGO Education’s 4C approach: Connect, Construct, Contemplate and Continue.

What isin theblue box?

ConnectYou add to your brain’s knowledge when youconnect a new learning experience to thoseyou already have. What everyday examplescan you think of that use the models?

ConstructLearning is best when hands and mindsare engaged

Contemplate (Think)When you take time to think about whatyou’ve done, you have the chance to makeconnections between previous knowledge andnew experiences. Questions in this bookletwill help you to make connections

ContinueThe core tasks aren’t the end of thestory. There are extension ideas: you areencouraged to change or add features toyour models and to investigate further

5

OPITO Lego ChallengeLearner’s Questionnaire - BEFORE

To see how the OPTIO Lego Challenge has helped your learning you will be asked tocomplete 2 questionnaires; this one BEFORE you start the challenge and a similar oneAFTER you have completed the challenge. Please answer each section.

Name: Tutor Group:

Using a scale from 1 to 4, where 1 = No confidence and 4 = Very confidentRate your confidence in each of the following Subjects:

Noconfidence

3Confident

2Not veryconfident

Physics (eg. Forces or Electricity)MathsTechnical Studies(eg. Materials, Making models)

1. Successful Learner

Rate your confidence in each of the following Personal Skills:

Noconfidence

3Confident

2Not veryconfident

Reading and following technical instructionsOrganising my workProblem Solving

2. Confident Individual

Working and Communicating with a partner

Using a scale from 1 to 4, where 1 = No confidence and 4 = Very confidentRate how effective you are working as a member of a Team:

Noconfidence

4Very confident

2Not veryconfident

Communicating my own ideas to othersListening to the ideas of othersContributing to decision making

3. Effective Contributor

Being reliableBeing responsibility

Managing timeMeeting deadlines

Looking ahead: Please tick √ any that applyIn 5 years time, I think I will be

4. Responsible Citizen

Using a scale from 1 to 4, where 1 = No confidence and 4 = Very confident

In 10 years time, I think I will be

Job

Job:Please name if you can

UniversityCollege6th Year

College University

3Confident

4Very confident

4Very confident

1

1

1

6

OPITO Lego ChallengeLearner’s Questionnaire - AFTER

To help assess how this challenge has contributed to your learning please completethis final questionnaire. Thank you.

Name: Tutor Group:

4Very confident

4Very confident

4Very confident

Rate your confidence in each of the following Subjects:

Noconfidence

3Confident

2Not veryconfident

Physics (eg. Forces or Electricity)MathsTechnical Studies(eg. Materials, Making models)

1. Successful Learner

Rate your confidence in each of the following Personal Skills:

Noconfidence

3Confident

2Not veryconfident

Reading and following technical instructionsOrganising my workProblem Solving

2. Confident Individual

Working and Communicating with a partner

Using a scale from 1 to 4, where 1 = No confidence and 4 = Very confidentRate how effective you are working as a member of a Team:

Noconfidence

2Not veryconfident

Communicating my own ideas to othersListening to the ideas of othersContributing to decision making

3. Effective Contributor

Being reliableBeing responsibility

Managing timeMeeting deadlines

Looking ahead: Please tick √ any that applyIn 5 years time, I think I will be

4. Responsible Citizen

Using a scale from 1 to 4, where 1 = No confidence and 4 = Very confident

In 10 years time, I think I will be

Job

Job:Please name if you can

UniversityCollege6th Year

College University

3Confident

1

1

1

7

The lever is probably the most commonly used simple machine.A lever is a rigid bar or solid object that is used to transfer force.

Effort, a pivot and a load are the 3 features that are commonin every lever. Depending on the positions of these 3 features, you cantell the difference between first, second or third class levers

First class levers have the pivot positioned between the effort and the load.Examples of first class levers include a seesaw and scissors.

Second class levers have the pivot and the effort at opposite endsand the load positioned between the two. Examples of second classlevers include wheel barrows and bottle openers.

Third class levers have the pivot and the load at opposite ends and theeffort positioned between the two e.g. tweezers and ice tongs.

OPITO

Simple Machines: Lever

Pivot

Pivot

Pivot

Load

Load

LoadEffort

Effort

Effort

8

OPITO

A2: Build A2 book I, pages 4 to 5Raise the lever.Describe how hard or easy it was to lift the load.Label the pivot, load, and effort.Use a circle to show exactly where each one is.Which class of lever is this?

A3: Build A3 book I, pages 6 to 7Raise the lever.Describe how hard or easy it was to lift the load.Label the pivot, load, and effort.Use a circle to show exactly where each one is.Which class of lever is this?

A1: Build A1 book I, pages 2 to 3Press down on the lever to lift the load.Describe how hard or easy it was to lift the load.Label the pivot, load, and effort.Use a circle to show exactly where each one is.Which class of lever is this?

LEGO and the LEGO logo are trademarks of the/sont des marques de commerce de/son marcas registradas de LEGO Group. ©2009 The LEGO Group.

How do you think you did?

What could you improve on?

A Butterfly Valve is a good example of the practical use ofa lever in the oil and gas industry.

Butterfly valves are used in pipes to control the flow of liquid or gas.

The ‘Butterfly shaped’ disc can be opened to allow the fluid to flowthrough the pipe or closed to stop it.

Turning the lever at the top make is much easier to open the butter-fly valve against the tight seal that is in place.

Turning the lever makes it easier to open the butterfly valve againstthe tight seal.

Tight rubber seal locks the disc in place.

‘Butterfly shaped’ disc can be opened or closed tocontrol the flow of the liquid or gas.

9

OPITO

The diameter of the pipe can be between 15cms and 65cms.

Lever –An Industry Example

Skills at Work

Lever - Butterfly Valve -http://youtu.be/HRIPHrWIvos

Lever - Hydraulic Press -http://youtu.be/MrgGEOp1xtc

People who do this in their job include:

Mechanical Technician Production Technician

Mechanical Engineer

10

The advantage of using an inclined plane has been knownand used for thousands of years. The ancient Egyptians

used inclined planes made of earth to ease the transport oftheir giant stone blocks to the top of the pyramids.

OPITO

Simple Machines:Inclined Plane


Did you know?

11

Simple Machines: Inclined Plane an inclined plane is a slanted surface used toraise objects, e.g. a ramp.

Using an inclined plane to raise an object to a given height, the objectmust be moved a longer distance, but with less effort needed, than if the objectwas to be raised straight up.

It’s a trade-off either to use a lot of effort to raise a given load a short distancestraight upwards or to apply much less force to raise it gradually over the longerdistance of an inclined plane.

Common examples of inclined planes are ramps, ladders and stairs.

Simple Machines: Inclined Plane


OPITO

Distan

ceHeight

12

Simple Machines: Inclined Plane

D1:Build D1 book II, pages 2 to 12

Let go of the load. Describe what happens.

D2: Build D2 book II, pages 13 to 15

Let go of the load. Describe what happens.


OPITO



13

OPITO

A ‘mud hopper’ is an example of an inclined plane used in the oil and gas industry.

Drilling mud is a specially-made liquid used in the drilling process. It is made from amixture of dry and liquid materials mixed in the ‘mud hopper’.

In the pictures above:1. Mud flows through the pipe at the base of the blue hopper.

2. The dry ingredients are poured down the inclined plane and pick up speed.This enables them to mix smoothly and evenly into the drilling mud.

3. The drilling mud is then used to cool and lubricate the drill-bit during thedrilling operation. The mud also carries away any rock chipping's that arecreated during drilling. These chipping's are then inspected by a mudlogger.


3. Drilling mud2. Pouring in thedry ingredients

Sides of the funnelform an inclined plane

1. Mud flowsthrough the pipe

Inclined Plane –An Industry Example


Drilling Engineer Mudlogger

14

Simple Machines:Cam


OPITO

Spring-loaded cams are used by rock climbers totightly grip rock crevices so that they can then

attach climbing ropes.

Did you know?

15

A cam is used to control the timing and degree of movement of afollower.

Cams can be circular, pear shaped or irregular shapes.

Cams and cam followers are very prone to wear due to friction.

Cam followers often have tiny rollers attached to them to reduce thisfriction.

Common use of cam mechanisms are clamps, an electrictoothbrush and an engine camshaft.

Mechanisms: Cam

A cam is a shaped frame turning about an axis, like a rotating wheel.


OPITO

Cam

Follower

Axis

16

Mechanisms: CamH1Build H1 book III, pages 26 to 27Turn the handle and describe the movementof the follower.


OPITO



17

OPITO

Oil and gas platforms produce all the electricity that they needed on the platform.

Turbines are used to produce the electricity they are normally driven by gas.

A ‘back-up’ system is on stand-by should the main power system fail. The ‘back-up’ system is driven by diesel oil.

A cam system is used to open and close the valves needed for the diesel system

Cam –An Industry Example


The camshaft is the central,rotating axis

The 2 cam lobes turn allowingthe valves underneath to openand close in turn

http://en.wikipedia.org/wiki/cam

VIEW ANIMATION:


Mechanical Technician Production Technician

Mechanical Engineer

18


OPITO

Big Build 1: The Hammer

Watch the Lego video clip of the HammerThis is a building activity

The person building subsystem A is

The person building subsystem B is



19

Build the Hammer(all of book 4A and book 4B to page 11, step 14).

Make sure that the Hammer lifts and drops smoothly.If it is too stiff, loosen the bushings and make sureall other elements fit tightly together.

The Hammer

Which gears have most friction whentested by hand?


OPITO

How can you make a Hammer machine thatmakes it easy to hammer different nails intodifferent surfaces? Let’s find out!

Which gears have most friction whentested by the Hammer?

Which is the better test system, and why?

How much force is needed to push theaxle through each gear?

How many hits with the Hammer are neededto push the axle through each gear?

4 = most force, 1 = least force

8 tooth 24 tooth 24-toothcrown gear

40 tooth

8-toothspur gear

24 tooth 24-toothcrown gear

40-toothspur gear

20

Seismic is one of the most important tools in exploration work in the oiland gas industry. It uses sound waves to investigate the structure of rocksUnderground.

On land a ‘thumper truck’ is used. It hammers the ground repetitively witha heavy iron plate. The sound waves travel down into the ground and arereflected back up by the rock layers below. A system of listening microphonesin another truck picks up the reflected sound waves.

Thumper truck uses repetitive hammering on land to carry out seismic surveys.


OPITO

Thumper truckSeismographicrecording truck

Hammering –An Industry Example

21

(book 4B page 23, step 21)

• Try out these cam shaft designs (dance programme)• Connect each cam shaft with one of the 4 ‘dancediagrams’

Dance 1


OPITO

Extension: Bouncing Ballerina

Other Ideas* Hiding your cams - can anyone guess your dance programme* Making the ballerina’s arms wave* Making your own cam profiles

Dance 2 Dance 3 Dance 4


OPITO

TeamworkWorking with others

Working with others or working in a team is very important in theengineering industry and in many other industries too.

People in the team need to work together to get a big job done.

Often problems arise along the way and they need to be solved.

Good communication, talking with your team about a problem, can reallyhelp you find a solution.

Look at these videos to see how good team work helps these industryapprentices get their job done.

Video 1 - Teamwork 1 -

http://youtu.be/Lmjkc9mlIIc


http://youtu.be/QWxQ2lOypYE


http://youtu.be/n34nm-HTHRk

22


OPITO

Simple Machines:Pulley

Did you know?

100kg

50kg 50kg

50kg

Drive Wheel

Effort

A pulley is also called a drum and may have agroove around its circumference. The drive elementof a pulley system can be a rope, cable, belt orchain that runs over the pulley inside the groove.

23

In a belt driven pulley a continuous belt joins two pulley wheels.The wheel to which an external force is applied (effort) iscalled the drive wheel,and the other the driven wheel.

When the drive wheel turns the belt moves and causesthe driven wheel to turn in the same direction. If the drivewheel is smaller than the driven wheel, the driven wheelwill turn more slowly than the drive wheel.

Belt driven pulleys rely on belt friction to transmit motion. If the belt is too tight thebelt will create wasteful friction forces on the pulley axle and bearing.If too loose the belt will slip and the effort is notused efficiently.

Slip is an overload protection safety feature of belt-operated machinery. For heavy lifting jobs; multiplepulley wheels can be combined into a lifting systemthat makes lifting heavy objects easier.

Using a single pulley to lift a load doesn’t make iteasier, but it changes the direction of motion. It only allows you to lift a loadup by the pulling of the Rope.

Pulleys can be either movable or fixed. The difference between fixed andmovable pulleys are that fixed pulleys do not move up or down when the loadis being moved.

Common examples of pulleys are found in window blinds, curtains andflagpoles.


OPITO

Pulleys are wheels that are moved by ropes, chains or belts around their rims.

Simple Machines: Pulley

VIEW VIDEO:

Pulley - http://youtu.be/8rcRP-Cj2kg

24


OPITO

C1Build C1 book I, page 18Turn the handle and describe the speeds ofthe drive and the driven pulley wheels.Then gently increase your grip on theoutput pointer and describe what happens.

C2Build C2 book I, page 19Turn the handle and describe the speeds ofthe drive and the driven pulley wheels.Then gently increase your grip on the outputpointer and describe what happens.

C3Build C3 book I, page 20Turn the handle and describe the speeds ofthe drive and the driven pulley wheels.Then gently increase your grip on the outputpointer and describe what happens.

25


OPITO

C4Build C7 book I, pages 26 to 27Turn the handle and describe the speeds ofthe drive and driven pulley wheels.Label the drive and driven pulley wheels. Usea circle to show exactly where each one is.

C5Build C9 book I, pages 32 to 35Pull the string to lift the load. Describe whathappens

C6Build C10 book I, page 36Pull the string to lift the load. Describe whathappens.



26

Pulleys are used on oil and gas drilling rigs to help raise and lower the ‘drill string’.This is the system of drill pipes, tools and the drill bit, essential for drilling oil orgas wells deep into the surface of the earth.The system is very heavy. It needs to be raised and lowered with great care at dif-ferent times throughout the drilling operations.

In this diagram of a drilling rig pulleysare part of:Part 13: the crown blockPart 11: the travelling blockThe drill string is Part 25 is and thedrill bit is Part 26.

People involved in the drilling practice are the drill crew.They include:- Driller- RoughneckThe role of a ‘Roustabout’ is to keep the drilling area in goodworking order.You can find out more about these roles at


OPITO

Pulley – An Industry Example

27


OPITO

Big Build 2: Tower Crane

Watch the Lego video clip of the Tower Crane.

For this big build activity you and your buddy should change roles from yourlast big build.

If you were A building the Hammer, you will be B building the crane.

The person building subsystem A is ________________

The person building subsystem B is _________________

Build the Tower Crane and Load(Building Instruction 16A and 16B to page 28, step 38)


OPITO

Big Build 2: Tower CranePlace the Tower Crane on the lid of the blue box.

Why do cranes use pulleys?

Cranes use pulley systems because they can pullwith less effort than is needed for a direct lift.

Two or more pulley wheels can be combined tomake the lifting easier or quicker.

Mechanical Advantage is a measure of how much easier or faster a machine doesa piece of work.

First, observe the mechanical advantage and predict with which speed pulley setupA will lift the load.

Test your prediction.

SpeedLifting timeMechanicaladvantage

Length liftedMy predictionfor Speed

A (page 28, 1step 38)

28




OPITO

Tower CraneFill in your results for A in the table below.

Change the pulley setups for B (page 29, step 39).

Observe the mechanical advantage then predict with which speed the load will be lifted.


Change the pulley setups for C (page 30, step 40).

Mechanicaladvantage

My prediction

(page 28,step 38)

(page 29,step 39)

(page 30,step 40)

SpeedLifting timeLength lifted

A

BC

Observe the mechanical advantage then predict with which speedthe load will be lifted.


1

29

30

Redesign Needed?

Tower Cranes are often built to match special needs.Now redesign the Tower Crane to make it the best in its class.We have highighted some question you could explore.Choose one area that you would like to investigate.

Then design a test that will help you explore how it functions and possibleadditional improvements you could make to your new Tower Crane.

What if you wanted to lift loadsmore quickly – how would youchange the arrangement forraising the pulley?


OPITO

What if you wanted to liftheavier loads - how wouldyou change the pulley?

What if you want thecrane to lift loads higher- how would you changethe tower?

What if you wanted to pick up from one placeand put down to the left or right of that place– how would you change the structure wherethe jib meets the tower?

31

Cranes are used both offshore and onshore in the oil and gas industry.A crane on the offshore platform lifts containers and other essentialsupplies from the supply vessel onto the platform.

The containers hold smaller items like food and drinking water or smallpieces of equipment like valves, tools and drill bits.

Larger items like drill pipes and steel piping are loaded individually.Onshore cranes are used to load the supply vessel.

All lifting operations require specialist training.


OPITO

Cranes –An Industry Example

32

GlossaryAAcceleration: The rate at which speed increases. If a car is accelerating it is moving

faster.Advantage: The ratio of the output force to the input force of a machine.Axle A rod through the centre of a wheel. It transmits force from an

engine to the wheel in a car.

BBalanced Force An object is balanced and does not move when all the forces acting on

it are equal and opposite.

CCams A none-circular wheel that rotates and moves a follower. It converts

rotary movement of the cam into reciprocating or oscillating themovement of the follower.

Counter balance A force often provided by the weight of an object you use to reduce orremove the effects of another force. A crane uses a large concreteblock on the short arm of its jib to counter the unbalancing effect of theload on the other longer arm.

Crank An arm or handle connected to a shaft or axle at right angles enablingthe shaft to be easily turned.

DDriven gear See followerDriver The part of a machine, usually a gear, pulley, lever, crank or axle,

where the force first comes into the machine.

EEffort The force or amount of force that you or something else puts into amachine.Energy The .capacity to do work

FFair testing Measuring the performance of a machine by comparing its performance

under different conditions.Follower Usually a gear, pulley or lever driven by another one.Force A push or a pullFulcrum See Pivot

GGear A toothed wheel or cog. The teeth of the gears mesh together to

transmit movement.Gearing down A small driver turns a larger follower and amplifies the force

from the effort. The follower turns more slowly.

Gearing up A large driver turns a smaller follower and reducesthe force from the effort. But the followerturns more quickly. OPITO

33

IInclined Plane A slanted surface or ramp generally used to raise an object with less

effort that is needed to lift it directly. A cam is a special sort of inclinedplane.

LLever A bar that pivots about a fixed point when an effort is applied to it.Load Any force a structure is opposing, such as a weight or mass. The

amount of resistance placed on a machine.

MMachine A device that makes work easier or faster to do. It usually contains

mechanisms.Mass Mass is the quantity of matter in an objectMechanism A simple arrangement of components that transforms the size or

direction of a force, and the speed of its output.

PPivot The point around which something turns or rotates, such as the pivot of

a lever.Pulley A wheel with a grooved rim used with a belt, chain or rope.Pulley wheel Changes the direction of the applied force. A pulley does not move with

the load.Pulley block One or more pulleys in a moveable frame with ropes or chains running

around them to one or more fixed pulleys. The pulley block moves withthe load and reduces the applied force needed to lift the load.

SSlip A belt or rope slipping, usually on a pulley wheel as a safety feature.Speed See VelocityStrut A member of a structure that is in compression. Struts prevent parts of

structures from moving towards each other.

TTensile forces Forces in a structure that pull in opposite directions trying to stretch the

structure.Torque The turning force coming from an axle

UUnbalanced force A force that is not opposed by an equal and opposite force. An object

feeling an unbalanced force must begin to move in some way

WWeight See MassWork We calculate the work done by multiplying the force

needed to move an object by the distance it is moved.

OPITO

34

OPITO Lego Challenge

Your thoughts about this challenge will help us when we do it againwith other pupils.


OPITO

What 3 things did you ENJOY MOST in the OPITO Lego Challenge, and why?

Name: Tutor Group:

ENJOY MOST WHY?1.2.3.

Words that might help you:

hammer

real-life

constructing

challenging

buddy-build

models

cam

industry

Inclined

fun

crane

working

Now complete the form on page 6.

Thank you!

EnvironmentalAdvisor

GeologistMechanicalEngineer

ProductionTechnician

Geophysicist

HumanResources

Mudlogger

IT Technician

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Lego Challenge Mechanics In Practice...Pupil Booklet OPITO Lego Challenge Mechanics In Practice 2...

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