High-performance advanced maintenance electrician skills training and assessment device

Ø Product Introduction

This device is designed according to the requirements of the "Worker Grade Standards" and "Vocational Skills Appraisal" issued by the Ministry of Labor and Social Security. It is applicable to the electrical control circuits required by the textbooks "Elementary Electrician," "Intermediate Electrician," and "Advanced Electrician." Through training with the PLC programmable controller, frequency converter, and corresponding training modules equipped with the device, users can quickly master the practical application techniques and operational skills required by the courses. It is targeted, practical, scientific, and advanced, and can meet the requirements of the technician technical and intermediate and advanced electrician assessment outlines. It is an ideal device for various labor and vocational skills appraisal departments, colleges and universities, and technical schools to conduct intermediate and advanced electrician skills assessments.

Ø Product Features

1. All electrical control circuit components are mounted on a mounting plate, making operation and replacement convenient and facilitating functional expansion or the development of new training programs. The selected operational content is typical and practical.

2. The operating console requires only a three-phase four-wire AC power supply for operation.

3. The control circuits and specially designed small motors used for skills training can simulate various electrical drive systems in a factory and meet the technical requirements of maintenance electricians for installation, debugging, fault analysis, and troubleshooting.

4. The device is equipped with voltage-type and current-type leakage current protectors to ensure the operator's safety.

5. All components are led to terminal blocks via wires. Students only need to connect wires to the terminals, which helps protect the components.

6. Wiring is routed through cable trays for process wiring training.

Ø Technical Specifications

1. Input Voltage: Three-phase four-wire (or three-phase five-wire) ~380V±10% 50Hz

2. Operating Environment: Temperature -10～+40℃, Relative Humidity <85% (25℃), Altitude <4000m

3. Device Capacity: <1.5KVA

4. Weight: 100Kg

5. Dimensions: 2080×700×1630mm3

6. Leakage Protection Operating Current: ≤30mA; Leakage Protection Operating Time: ≤0.1s.

Ø Basic configuration and functions of the device

(I) DW01 Power Control Chassis

 The power control chassis is a double-layered matte textured powder-coated iron structure with an aluminum panel. It provides AC power, DC power, and safety protection for experiments. The specific functions are as follows:

1. Main Control Function Board

(1) Three-phase four-wire power input, after passing through the leakage current protector, passes through the main switch, and is operated by the contactor via start and stop buttons;

(2) There is one 450V pointer AC voltmeter on the control panel, which can be switched by a band switch to observe the voltage of the three power grids;

(3) Laboratory Smart Power Safety Control System

The intelligent power management system has seven major protection functions: over-temperature, short circuit, over-current, over-voltage, under-voltage, loss of voltage, and power limitation; the power supply has a one-key locking function to prevent the leakage current protector from closing and causing electric shock when handling faults; the power supply has a fault locking function, so that when a fault causes the circuit breaker to trip, it cannot be manually powered on, and can only be powered on successfully after the fault is cleared remotely;

1) Repair Management: Users can remotely report device faults, edit repair requests, and the backend can perform remote maintenance and timely follow-up to effectively resolve user device maintenance issues.

2) User Management: Can be linked to mobile phone numbers, providing one-to-one secure encryption and real-name authentication to prevent account leaks and theft. On-site data is connected to the cloud platform's backend database for management.

On-site demonstrations of each function are required, along with valid and authoritative supporting documentation to demonstrate the product's reliability, safety, and legality.

2. AC and DC Power Supply

(1) Excitation Power Supply: DC 220V/0.5A, with short-circuit protection.

(2) Armature Power Supply: One continuously adjustable DC 0～220V/2A power supply, with short-circuit protection.

(3) DC Regulated Power Supply: One 24V supply, two ±12V supplies, and one +5V supply, with short-circuit soft-cutoff automatic recovery protection function.

(4) Constant Current Source: Provides a 0-20mA constant current source.

(5) AC Power Supply: ① A transformer is provided. The primary side of the transformer can be supplied with 220V or 380V AC power depending on the wiring. After closing the switch, the secondary side of the transformer can output AC voltages of 36V, 110V, 20V, 20V, 12V, and 6.3V; ② A single-phase voltage regulator is provided, which can provide an adjustable AC voltage of 0～250V; ③ The control panel is equipped with a single-phase three-pole 220V power socket and a three-phase four-pole 380V power socket.

3. Four 5408 diodes are used in the rectifier circuit for regenerative braking.

4. Three 75Ω/50W resistors are used for reduced-voltage starting of the motor, and one 10Ω/25W resistor is used for regenerative braking of the asynchronous motor.

(II) Main Experimental Equipment:

1. DW-01 Electrical Maintenance Training Component (I): The mounting plate is equipped with an AC contactor, push-button indicator lights (6.3V), terminal blocks, and safety sockets.

2. DW-02 Electrical Maintenance Training Component (II): The mounting box is equipped with plug-in fuses, low-voltage circuit breakers, thermal relays, time relays, terminal blocks, and safety sockets.

3. DW-03 Electrical Maintenance Training Component (III): The mounting box is equipped with a changeover switch, solenoid valve, cross switch, limit switch, etc.

4. PLC Main Unit Mounting Box:

Equipped with a Mitsubishi FX3U-48mR main unit, integrating digital I/O (24 digital inputs, 24 digital outputs), RS-422 communication port, SC-09 communication programming cable, and adapter input/output ports, switches, etc.

5. PLC Training Demonstration Module

Includes analog and digital signals, capable of simulating equipment operation in industrial settings. Provides simulated control training for scenarios such as a three-story elevator, vending machine, robotic arm, automatic door, a light tower, fully automatic washing machine, automatic molding machine, traffic lights, assembly line, four-way quiz buzzer, musical fountain, rolling mill, mail sorting, material sorting, multi-stage conveyor belt, automotive circuitry, escalators, and machine tool circuit modification (no fewer than 36 training modules). Indicator lights use surface-mount dual-color LEDs, and the panel features a 3D color design for a more intuitive and three-dimensional simulation. Switches employ a self-resetting and self-locking design for flexible and practical training, compatible with various PLC modules and featuring high/low level input signal switching. Compatible with various PLC mainframes.

6. Inverter Training Box

Configured with a Mitsubishi FR-D720S 0.4KW inverter, featuring an RS485 communication interface and a BOP operation panel.

7. Motor guide rail and optical encoder speed measurement system

Including one set of optical encoder speed measurement system (equipped with photoelectric encoder), one guide rail, with good flatness, no stress deformation, and good concentricity.

8. One set of industrial control configuration software:

Open the software programming environment, and any training can edit a visually intuitive, dynamic, and digitally effective configuration bar diagram, and conduct dynamic tracking teaching for training.

9. One set of PLC simulation training software:

(1) Display the PLC's operating status in real time through the PLASH virtual environment

(3) PLC programming training, PLC program writing and testing functions

(4) Realize PLC operation simulation and check for error programs.

11. Comprehensive Electronic Technology Application Training Module

The training circuit board module consists of a PCB panel and a magnetic fixing mechanism. Each training project is equipped with an independent training circuit board module. The training circuit board is equipped with parameter test points and fault setting switches. The PCB panel surface is clean, the training circuits and symbols are clearly defined, the surface is wear-resistant, and component replacement is easy. The component circuit symbols marked on the panel adopt the latest national standards. It features a compact overall structure, beautiful appearance, simple installation, and convenient use and storage. The wire sockets use anti-rotation sockets, and the wires are equipped with flexible plugs for reliable connection to the module for various training exercises. During training, the appropriate training circuit board module can be selected according to the training content and skill training needs.

The training circuit board module is equipped with a common training base. The common training base is matched with the magnetic fixing mechanism of the training circuit board module. During training, simply place the training circuit board module on the common training base, and it will be firmly attached to the base. Then, perform the required training project. The common training base has an ergonomic design, making training operation convenient and scientifically sound.

12. Motors:

(1) Three-phase squirrel-cage motor AC220V (Y)

(2) Three-phase squirrel-cage motor AC380V (Y/Δ)

(3) Dual-speed asynchronous motor AC380V (Δ/YY)

(4) Three-phase wound-rotor asynchronous motor AC380V (Y)

(5) Three-phase synchronous motor AC380V (Y)

(6) DC shunt motor DC220V

(III) Training Table

The main structure of the experimental table is made entirely of high-performance surface-oxidized aluminum profiles and one-piece die-cast aluminum frame connecting components. The connecting components are die-cast (non-welded), machined, shot-blasted, sandblasted, and surface electrostatically sprayed. Installation is convenient and quick, and users can DIY assemble it themselves. The table's uprights are made of industrial aluminum profiles using a molding process, with an anodized surface. The cross-sectional dimensions are 70×70mm, with grooves on all four sides, each approximately 8mm wide, and plastic end caps. The tabletop is made of 25mm E1 grade melamine-faced panel, with a supporting frame underneath capable of bearing at least 300kg. A storage cabinet is included for storing training boxes, etc., and the cabinet has four high-strength, universal, brakeable PU casters for easy movement. The overall design of the training device is simple yet sophisticated, high-end and elegant, conforming to modern product aesthetics and development trends.

Two legs at the rear of the table extend upwards, forming an electrical experiment box support frame with two specially molded aluminum profiles with sliding grooves. This frame is compatible with the electrical control experiment box, allowing for easy vertical and horizontal movement. The power control cabinet is mounted on top of the support frame.

Ø Practical Training Projects

(I) Electrical Control Training

1. Direct Starting Control Circuit for Three-Phase Asynchronous Motors

2. Jogging Control Circuit for Three-Phase Asynchronous Motors

3. Self-Locking Control Circuit for Three-Phase Asynchronous Motors

4. Push-Button Interlocking Forward and Reverse Control Circuit for Three-Phase Asynchronous Motors

5. Contactor Interlocking Forward and Reverse Control Circuit for Three-Phase Asynchronous Motors

6. Double Interlocking Forward and Reverse Control Circuit for Three-Phase Asynchronous Motors

7. Automatic Reciprocating Control Circuit for Three-Phase Asynchronous Motor Workbench

8. Sequential Starting and Stopping Control Circuit for Two Three-Phase Asynchronous Motors

9. Two-location control circuit for a three-phase asynchronous motor

10. Contactor-controlled Y-Δ control

11. Time relay-controlled Y-Δ control

12. Three-phase asynchronous motor unidirectional start-reverse braking control circuit

13. Three-phase asynchronous motor transformerless half-wave rectification unidirectional start-energy-consumption braking control circuit

14. Three-phase asynchronous motor with transformer full-wave rectification unidirectional start-energy-consumption braking control circuit

15. Three-phase asynchronous motor forward and reverse start-energy-consumption braking control circuit

16. Dual-speed AC asynchronous motor manual speed change control circuit

17. Dual-speed AC asynchronous motor automatic speed change control circuit

18. Power-off delay DC energy-consumption braking Y-Δ start control circuit

19. Three-phase asynchronous motor forward and reverse start-reverse braking control circuit

20. Three-phase asynchronous motor forward and reverse start-reverse braking control circuit

21. C620 lathe electrical control circuit

22. Three-phase wound asynchronous motor manual control circuit

23.Three-phase wound asynchronous motor automatic start control circuit

24. Energy Consumption Braking Control Circuit of a Simple Synchronous Motor

25. Starting and Speed Regulation of a DC Motor

26. Starting and Speed Regulation of a Shunt DC Motor with Series Resistance in the Armature Circuit

(II) Comprehensive Application Circuit Training in Electronic Technology

1. Electronic Alarm

2. Electronic Doorbell Circuit

3. Light Control Circuit

4. Light Control Circuit Switch

5. Navigation Light

6. Dimming Circuit for a Household Desk Lamp

7. Automatic On/Off Circuit for an Exhaust Fan

8. Flashing Light

9. Temperature Control Circuit

10. Musical Doorbell Circuit

★ (III) PLC Programmable Controller Basic Circuit Training

1. AND, OR, NOT logic function test

2. Timer and counter function test

3. Jump and branch function training

4. Shift register test

5. Data processing function training

6. Differentiation and bit operation test

7. Three-story elevator control

8. Vending machine

9. Robotic arm

10. Automatic door

11. Sky Tower

12. Fully automatic washing machine

13. Automatic molding machine

19. Mail sorting

20. Material sorting

21. Multi-level transmission

22. Eight-segment code display

23. Mixing of multiple liquids

24. Double-sided milling machine

25. Electroplating tank

26. AC motor forward and reverse rotation control

27. Cart movement 28. Mixing Plant

29. Automotive Lighting Control

30. Automotive Spark Plug Ignition Control

31. Machining Center Control

32. Tunnel Monitoring

33. Escalator

34. CA6140 General Lathe PLC Retrofit Control

35. X62W Universal Milling Machine PLC Retrofit Control

36. T68 Horizontal Boring Machine PLC Retrofit Control

37. M7120 Surface Grinding Machine PLC Retrofit Control

38. Z3050 Radial Drilling Machine PLC Retrofit Control

39. Electric Hoist PLC Retrofit Control

40. Z35 Radial Drilling Machine PLC Retrofit Control

41. M1432A Universal Cylindrical Grinding Machine PLC Retrofit Control

(IV) PLC Advanced Comprehensive Skills Training

1. PLC-controlled forward and reverse rotation control of a three-phase asynchronous motor

2. PLC-controlled Y-Δ starting control of a three-phase asynchronous motor

3. PLC-controlled reduced-voltage starting control of a three-phase asynchronous motor

4. PLC-controlled energy-saving braking control of a three-phase asynchronous motor

5. Inverter function parameter setting and operation

6. Inverter alarm and protection functions

7. Multi-speed selection variable frequency speed regulation

8. External terminal jog control

9. Controlling the forward and reverse rotation of a motor

10. Controlling the running time of a motor

11. Inverter parameter setting during instantaneous power outage

12. External voltage variable frequency speed regulation

13. External current variable frequency speed regulation

14. Variable frequency open-loop speed regulation of a three-phase asynchronous motor

15. PLC-controlled inverter speed regulation

16. Touch screen training

17. Touch screen and PLC communication training