Electrical/Electronics

Sensors/Actuators , Soldering
Some terms

Sensors
Computer(microcontroller)
Actuator

Autopilot
SENSORS
 Sensors

Active Passive

Generate electromagnetic Do not generate any

waves and hence should be electromagnetic
connected to a power source waves.Connection to any
power source not required.
Temperature Sensors(NTC & PTC)
(Passive sensor)

NTC Temp Sensors

Resistance decreases with increase in temperature

Ohm’s Law
I = V/R
PTC Temperature Sensors

Resistance increases with increase in temperature.

Ultrasonic sensors
(Active)

Transmitter - Sends the ultrasonic signals

Receiver - Receives the ultrasonic signals

Emits ultrasonic waves(constant speed) - travel at the speed of sound

Applications - Park Assist

V = 2d/t
ACTUATORS
Piezoelectricity
Piezoelectric actuators

Actuators - Generally used to convert electrical energy to mechanical energy to facilitate the
movement of the machine

Follows the inverse piezoelectric effect

Used in piezoelectric fuel injection..

Once the actuator
module is supplied
with voltage it
expands which opens
the valve set through
the nozzle module
and releases the fuel.
Soldering
Tools needed for manual soldering.
 Reflow soldering
Generally used to attach SMT(Surface Mount Technology) components.

Used to attach smaller components like leds and resistors on the PCB.
Wave soldering machine
Generally used to attach THT(Through Hole Technology) components

Used to attach large components like buzzers and connectors on the PCB.
Mechanical

Metal working , Manufacturing methods and

machinery.
Machining

- Used to give a good finishing to the manufactured product.

- It is a subtractive manufacturing process

Some terms related to machining:

Cutting speed : Speed at which the metal is removed from the workpiece by the cutting
tool.

Depth of the feed - Total amount of the metal removed by the cutting tool.

Feed rate - Relative motion of the tool in one revolution of workpiece.

Turning

Performed by a lathe(manual or CNC)

Lathe rotates the workpiece(Secondary Motion)

Cutting tool executes a linear motion to produce the desired specifications (Primary motion)

Generally a single edge cutting tool is used.

Milling

Generally a multi edge cutting tool is used.

Workpiece is stationary and the cutting tool moves linearly on it.

Drilling

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in
solid materials.

The drill bit is usually a rotary cutting tool, often multi-point.

Reaming

Done after drilling to give better finishes to the drilled holes

Generally executed by a helical reamer or a straight flute reamer.

 Welding
Welding is a technique of joining similar and dissimilar metals and plastics by adopting ways which do not
include adhesives and fasteners.

Types of joints

- Permanent
- Temporary

Welding - permanent joint

Temporary joint processes - Screw nut assembly , press fitting , fasteners

 Welding

Fusion Pressure welding(no

welding(application of application of heat , only
heat is required) pressure is applied )

Vibrational welding
High temperature Low temperature
welding(temperat welding
ure near the
melting point of
the metals) Soldering

Gas welding
Resistance
welding
 Gas welding - Oxy acetylene

Mixture of oxygen and acetylene is used to create a flame of high temperature(~3000 degree
celsius)

Neutral flame Oxidising flame Carburising flame

Acetylene = Oxygen
Used for welding most materials
Oxygen > Acetylene
Used for welding materials
which are not oxidised
readily like brass , bronze
Acetylene > Oxygen
Used to those materials
where the risk of oxidation
is more at high
temperatures like Al.
Resistance welding

H = I2Rt

H - Heat energy generated

I - Amount of current supplied

R- Resistance between the two materials on passage of current.

t - Amount of time for which the current is applied on the plates

Copper electrodes are used - good conductors of electricity.

Spot welding
Spot welding
Projection welding

Similar to spot welding but produces multiple joints at the same time.
Seam welding
Variation of resistance spot welding with the main difference being that the welding
electrodes are motor driven wheels rather than stationary rods.
 Vibrational Welding

Generally used to weld thermoplastics

Laser Welding
 3D printing

Fused Depositional modelling(FDM)

FDM is the abbreviation for Fused Deposition Modeling, also known as Fused Filament Fabrication (FFF). In
FDM, a strand of material (in this case thermoplastic) is deposited in layers to create a 3D printed object.
During printing, the plastic filament is fed through a hot extruder where the plastic gets soft enough that it can
be precisely placed by the print head. The melted filament is then deposited layer by layer in the print area to
build the workpiece.
 Stereolithography(SLA)

SLA is the abbreviation for Stereolithography Apparatus, or simply stereolithography. Like

FDM, SLA is an additive method: Models are built layer by layer. SLA, however, uses a curable
photopolymer – typically a liquid resin – that is hardened by applying focused light or UV light
(this process is called curing). SLA printers usually build the models upside-down, that is, the
build platform lifts the model upwards, out of the resin bath.
Selective Laser Sintering (SLS)