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GCE MAY 2009 : (AS 1) Product Design and Systems and Control - Revised

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Sp ec Ne i w ca tio n ADVANCED SUBSIDIARY (AS) General Certificate of Education 2009 Technology and Design Assessment Unit AS 1 Product Design and Systems and Control AV111 assessing [AV111] WEDNESDAY 27 MAY, MORNING TIME 2 hours. INSTRUCTIONS TO CANDIDATES Write your Centre Number and Candidate Number on the Answer Booklet provided and on the A3 pro forma answer page provided. Answer all eight questions in Section A and both questions in EITHER Section B OR Section C. An A3 pro forma is provided for Question 12((b), (c), (d), and (e)). At the conclusion of the examination, attach the A3 pro forma answer page securely to the Answer Booklet with the treasury tag supplied. INFORMATION FOR CANDIDATES The total mark for this paper is 80, including a maximum of 4 marks for quality of written communication. Marks for quality of written communication will be awarded for questions 7(ii), 8(ii), 9(iv), 10(a)(ii), 11(a)(v) and 12(f). Figures in brackets printed down the right-hand side of pages indicate the marks awarded to each question or part question. All questions do not carry equal weighting. 4971.03R Section A Product Design and Practice Answer all questions in this section. You are advised to spend approximately 1 hour on this section. 1 The mechanical properties of a material can greatly influence selection. (i) Briefly explain what is meant by the term mechanical properties. (ii) Briefly explain what is meant by the terms toughness and hardness. 2 [2] [2] Beech and ash are materials widely used for domestic products. (i) Give two main reasons why beech is used for kitchen utensils. (ii) Give two main reasons why ash is used for garden tool handles. [2] (iii) Stains and oils are common finishes applied to wood. Briefly explain the main purpose of stains and the main purpose of oils. 3 [2] [2] Cases for electric hand tools like drills, jig-saws and sanders can be manufactured using metal by the process of pressure die casting. (i) Give two main reasons why pressure die casting is the most suitable process for the manufacture of these products. [2] (ii) With the aid of an annotated sketch, describe the pressure die casting process. 4 [3] (i) Distinguish between thermoplastic and thermosetting plastics. [1] (ii) Give one main reason why: 4971.03R Acrylic is used for illuminated signs Nylon is used for gear wheels Polyvinyl chloride (PVC) is used for drain pipes and guttering Polythene is used for detergent bottles. 2 [4] [Turn over 5 Riveting, and knock down fittings are used to join materials. With the aid of annotated sketches, briefly describe how each of these is used to join materials. 6 [4] Computers are widely used in the design and manufacture of products. (i) Briefly outline two main advantages associated with the use of Computer Aided Design (CAD). [2] (ii) Briefly outline two main advantages associated with the use of Computer Aided Manufacture (CAM). [2] (iii) Briefly explain what is meant by the term Computer Integrated Manufacture (CIM). [1] 7 One-off, batch and mass are terms associated with manufacturing production. (i) Briefly compare the level of skill required by the workforce for one-off and mass production. [1] (ii) Outline one main characteristic other than the skill level of the workforce associated with one-off, batch and mass. [4] 8 Proportion and colour are two aspects of aesthetics that the designer needs to consider. (i) Briefly explain what is meant by the term proportion and give one main reason why it is an important consideration for the designer. [2] (ii) Outline three different ways that colours may be used in products in order to improve aesthetic appeal. [4] 4971.03R 3 [Turn over Section B Electronic and Microelectronic Control Systems Answer both questions in this section. You are advised to spend approximately 1 hour on this section. 9 The circuit shown in Fig. 9 has been designed to indicate if a security door in a building has been opened. R1 6V X 10 k 1 M 0V Fig. 9 (i) State two general safety features that can be incorporated into electronic circuits and explain how these features improve safety. [4] (ii) Name component X shown in Fig. 9. [1] (iii) Suggest a suitable type of switch that could be used to detect the movement of a door. [1] (iv) The resistors shown in Fig. 9 have been selected from the E12 series. Explain what is meant by the term E12 series. [3] (v) Calculate the power dissipated by the resistor R1 in Fig. 9 if the current flowing in the LED is 10 mA and the LED forward voltage is 2 V. (Assume that there is no voltage drop across component X). [3] (vi) Using a labelled circuit diagram, show how the circuit in Fig. 9 could be reset if the LED has been switched on. [2] (vii) The circuit shown in Fig. 9 is to be replaced by one using an SR flip flop. (a) Draw a circuit diagram of an SR flip flop. [2] (b) Add components to the SR flip flop and explain how it could be used to indicate if the security door was last opened from the inside or outside. [4] 4971.03R 4 [Turn over 10 (a) Fig. 10(a) shows part of a light sensing circuit. 9V R3 22 k VR1 100 k + LDR V1 Z + V2 0V 9 V Fig. 10(a) (i) Calculate the voltage V2 when the variable resistor VR1 on Fig. 10(a) is adjusted to its mid position. [2] (ii) Explain the function of component Z in the circuit shown in Fig. 10(a). [3] (iii) The resistance of the LDR in Fig. 10(a) varies between 100 k in a low light level and 10 k in a high light level. Calculate the voltage range of V1 between low and high light levels. [4] (iv) State whether the buzzer in Fig. 10(a) will be turned on or off when the light level is high and justify your answer. Assume VR1 is adjusted to its mid position. [3] 4971.03R 5 [Turn over (b) The following two modifications have been suggested for a basic temperature alarm circuit shown in Fig. 10(b). Replacing TR1 with a darlington pair Providing a latching action when the alarm is activated. 6V 24 V SPST Relay Alarm 0t TR1 0V 0V Fig. 10(b) (i) State one reason why darlington pairs are used. (ii) Show with the aid of a diagram how transistors are arranged in a darlington pair. [3] (iii) Explain with the aid of a diagram how a latching action can be achieved using a double pole double throw (DPDT) relay. 4971.03R [1] [4] 6 [Turn over BLANK PAGE (Questions continue overleaf) 4971.03R 7 [Turn over Section C Mechanical and Pneumatic Control Systems Answer both questions in this section. You are advised to spend approximately 1 hour on this section. 11 (a) Fig. 11(a) opposite shows part of a moving belt and attached gear/pulley system as used in industry. (i) Vee, round and flat belts are commonly used with pulleys. Name one other common belt type. (ii) State the direction of rotation of pulley G if gear A rotates in a clockwise direction. [1] (iii) Calculate the velocity ratio between gear A and pulley G. [3] (iv) Calculate the distance moved by block P each second if pulley D rotates at 10 rev/min. Roller H has a diameter of 50 mm and assume = 3.14. [3] (v) Shaft Z is to be connected to a crank and slider. Using an annotated sketch, draw a typical crank and slider mechanism and explain how it would be attached to shaft Z. 4971.03R [1] [4] 8 [Turn over 4971.03R 9 [Turn over Moving belt Block P Fig. 11(a) D Diameter 100 mm Shaft Z C 48 Teeth B 25 Teeth Roller H Motor attached to shaft A 48 Teeth F Diameter 60 mm E Diameter 80 mm G Diameter 60 mm (b) Fig. 11(b) shows part of a prototype lifting system used to move heavy industrial components. (i) Calculate the effort required of the lifting system if the load is 200 N and the mechanical advantage is 1.25. [2] (ii) The velocity ratio is 3:2 and the effort moves 1.2 m. Calculate the distance moved by the load. [3] (iii) Calculate the efficiency of the simple lifting system. [3] 1.2 m Effort Load 200 N Fig. 11(b) 4971.03R 10 [Turn over BLANK PAGE (Questions continue overleaf) 4971.03R 11 [Turn over 12 Fig. 12 opposite shows part of an incomplete pneumatic system. (a) (i) Name the activation method at C. [1] (ii) Name the activation method at X. [1] (b) On the pro forma provided (answer number 12(b), (c), (d) + (e)), complete the circuit enabling the double acting cylinder D1 to go negative following a delay in time after A is activated. [3] (c) On the pro forma provided (answer number 12(b), (c), (d) + (e)), complete the circuit enabling a combined activation at B and C or D to outstroke the double acting cylinder D1. [5] (d) As a safety measure it is intended that a NOT logic function is to be incorporated to prevent the double acting cylinders outstroking or instroking unnecessarily. On the pro forma provided (answer number 12(b), (c), (d) + (e)), complete the circuit to include the safety measure. [3] (e) On the pro forma provided (answer number 12(b), (c), (d) + (e)), complete the circuit enabling a second double acting cylinder D2 to be added which goes positive as D1 goes negative. [2] (f) The double acting cylinder is supplied with an air pressure of 0.4 N/mm2, has a piston diameter of 80 mm and a piston rod diameter of 6 mm. Calculate the force produced by the cylinder during the instroke and explain why it would be different from the force produced during the outstroke. Please assume = 3.14. 4971.03R 12 [5] [Turn over D1 2 4 12 A 14 5 X 3 1 B D C Fig. 12 THIS IS THE END OF THE QUESTION PAPER 4971.03R 13 Permission to reproduce all copyright material has been applied for. In some cases, efforts to contact copyright holders may have been unsuccessful and CCEA will be happy to rectify any omissions of acknowledgement in future if notified. 938-044-1

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Additional Info : Gce Technology and Design May 2009 Assessment Unit AS 1, Product Design and Systems and Control - Revised
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