1

Interpret design brief for fluid power systems

1.1

Confirm the design brief and operational requirements with the client

1.2

Establish technical, commercial and environmental parameters to the brief or contract

1.3

Determine stakeholders to be consulted in design process

1.4

Consider regulatory, sustainability or environmental issues relevant to the briefs

1.5

Provide preliminary advice to client on the feasibility for realising the fluid power system design

2

Prepare concept proposal

2.1

Analyse and establish worksite requirements for fluid power system realisation in conjunction with the client

2.2

Undertake initial design investigations for fluid power system capacity and responsiveness

2.3

Carry out required modelling, simulation and calculations using appropriate software, and test equipment to determine fluid power system, function, behaviour and safety

2.4

Generate a range of possible solutions to the design

2.5

Check feasibility and validate solutions against design criteria ensuring conformity to OHS requirements and relevant standards

2.6

Determine social and sustainability implications of solutions

2.7

Review concept proposals with client to identify preferred solution

3

Design fluid power system

3.1

Develop selected fluid power design to meet specifications, including dimensioning, sizing and positioning of system components

3.2

Evaluate sequence and mode control methods for multi-actuator circuit, stand alone and network designs for implementation

3.3

Determine options for design of compressed air supply for a multi-application facility, if applicable

3.4

Ensure that design solution is optimised with respect to the system specifications

3.5

Develop fluid power design documentation, including drawings, circuit diagrams, specifications, operating instructions, manuals and training materials, if appropriate

3.6

Check that the final design meets all required specifications and operational capabilities

3.7

Consult with client and stakeholders to obtain sign-off on design

Required skills

Required skills include:

determining features of fluid power systems, including OHS, regulatory and risk management requirements

interpreting parameters to the brief or contract

researching trends and techniques in:

fluid power design

reverse engineering

sustainability issues and implications

materials and components

assembly, fabrication and construction techniques

lean and other quality techniques

latest relevant modelling, simulation and validation techniques, and other software

investigating and presenting options

investigating faults in existing designs and propose solutions

selecting and using software and validation techniques, including 2-D and 3-D modelling

creating optimised design solutions for fluid power systems

evaluating fluid power solutions for feasibility against design criteria, including relevant engineering and financial calculations and analysis

communicating, negotiating and reviewing with stakeholders and clients throughout process to obtain agreement of proposal and sign-off on design

documenting design with drawings, specifications and instructions

Required knowledge

Required knowledge includes:

fluid power design methods

current options and trends in design, performance analysis, modelling and simulation software, including underpinning program techniques and software validation techniques

research and investigations methods

techniques for:

continuous improvement

problem solving and decision making

root cause analysis (RCA) or failure mode and effects analysis (FMEA) or design review based on failure mode (DRBFM), and Pareto analysis

principles of fluid power designs

dimensions, capacity and position of system components

system responsiveness

electrical and mechanical behaviours of fluid power systems

hydraulics and designing with hydraulics components

applications and characteristics of servo valves

electronic controllers for proportional and servo valves

sensor/transducer/amplifiers

pneumatics and designing with pneumatic components

multiple actuator control circuits

compressed air system design

OHS and regulatory requirements, codes of practice, standards, risk minimisation and registration requirements

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Assessors must be satisfied that the candidate can competently and consistently:

interpret features of plant and equipment and parameters to the brief or contract

advise client based on discipline knowledge and OHS and regulatory standards

research sustainability implications and current industrial design techniques

determine OHS, regulatory and risk management requirements

investigate options for fluid power design

measure, model, calculate, analyse and use software and validation techniques

generate and evaluate a range of solutions for feasibility against design criteria

design optimum fluid power system solution

communicate, negotiate and review with stakeholders and client throughout process to obtain agreement on proposal and sign-off on design

document design with drawings, circuit diagrams, specifications and instructions.

Context of and specific resources for assessment

This unit may be assessed on the job, off the job or a combination of both on and off the job. Where assessment occurs off the job, that is, the candidate is not in productive work, then a simulated working environment must be used where the range of conditions reflects realistic workplace situations. The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.

Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of the MEM05 Metal and Engineering Training Package.

Assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with application of underpinning knowledge.

Assessment methods must be by direct observation of tasks and include questioning on underpinning knowledge to ensure its correct interpretation and application.

Assessment may be applied under project-related conditions (real or simulated) and require evidence of process.

Assessment must confirm a reasonable inference that competency is able not only to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.

Assessment may be in conjunction with assessment of other units of competency where required.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed.

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Parameters to the brief or contract

The design brief may include the design of new equipment or fault analysis, rectification or modification to an existing design. Parameters to the design brief may include:

design cost and system capital cost

maintainability, product life cycle cost

durability, function, performance and aesthetics

energy and environmental sustainability and social issues

equipment availability and worksite restrictions

other special features and limits in the design brief

Sustainability

Sustainability may include:

resources and energy

social and economic

life cycle design of product raw material, solids and hazardous waste, and production by-products

contamination of land, air and stormwater pollutants, and discharge to sewerage

climate change

Appropriate software

Appropriate software may include software for:

computer-aided design (CAD)

circuit design and analysis

animation

simulation

modelling

performance analysis

Validation techniques

Validation techniques include:

comparison of traditional solutions for simple design problems with software solutions to the same design problems

review of previously implemented designs which were completed using the software

use of FMEA

Design criteria

Design criteria may include:

essential criteria, such as OHS and environmental criteria, which are pass/fail criteria for design option selection

desirable criteria, such as simplicity of design, which may be rated or scored to aid selection of design amongst options

OHS requirements

OHS requirements may include:

OHS Acts and regulations

relevant standards

industry codes of practice

risk assessments

registration requirements

safe work practices

state and territory regulatory requirements

Standards

Standards may include:

AS 4024.1-2006 Series Safety of machinery

AS/NZS ISO 31000:2009 Risk management – Principles and guidelines

NOHSC:1010 National standard for plant

NOHSC:1014 National standard for the control of major hazard facilities

AS 61508.1-2011 Functional safety of electrical/electronic/programmable electronic safety-related systems – General requirements

Sequence and mode control methods for multi-actuator circuit

Sequence may include:

sequential operations with or without conditional jumps

optimisation techniques

functions, such as:

timing, counting, stop start, cycle selection and boundary conditions

Control methods may include:

pneumatic and electrical relay cascade control

pneumatic and electrical relay step-sequenced control

PLC control

microcontrollers for special purpose machines

Stand alone and network control

Options for stand alone and network control of fluid power systems may include:

compressor control and application control

fluid powered machine control, including proportional-integral-derivative (PID) parameter control from remote host controller

communications bus systems and serial systems

distributed control systems (DCS)

system control and data acquisition (SCADA)

computer-integrated manufacture (CIM) options