TEST PROJECT

DOCUMENT
WSC2015_TP01_AT_EN
Submitted by: SkillsAustria
Name: G. Zechner
Member country/region: Austria

WSC2015_TP01_AT_EN

CONTENTS
This Test Project proposal consists of the following documentation/files:
1. WSC2015_TP01_AT_EN.doc
2. WSC2015_TP01_AT_ISO-1.pdf (Attachment 1a with all drawings for the mechanical part in ISO1)
3. WSC2015_TP01_AT_ISO-3.pdf (Attachment 1 with all drawings for the mechanical part in ISO3)
Die Anhnge 1a und 1b bestehen aus den folgenden Zeichnungen:
WSC2015_TP01_AT_0a_A3
pencil sharpener positions
WSC2015_TP01_AT_0b_A3
pencil sharpener exploded assembly
WSC2015_TP01_AT_0c_A3
clamp mechanism exploded assembly
WSC2015_TP01_AT_0b01_A3 base plate
WSC2015_TP01_AT_0b02_A3 clamp mechanism holder
WSC2015_TP01_AT_0b03_A3 slide mechanism base
WSC2015_TP01_AT_0b04_A4 motor base
WSC2015_TP01_AT_0b05_A4 sharpener shaft male
WSC2015_TP01_AT_0b06_A4 sharpener shaft female
WSC2015_TP01_AT_0b07_A4 distance ring
WSC2015_TP01_AT_0b08_A4 iris mechanism guidance pin
WSC2015_TP01_AT_0c01_A3 iris base
WSC2015_TP01_AT_0c02_A4 iris mechanism ring
WSC2015_TP01_AT_0c03_A4 turn mechanism pin
WSC2015_TP01_AT_0c04_A4 iris base cover
WSC2015_TP01_AT_0c05_A3 clamp mechanism base
WSC2015_TP01_AT_0c06_A4 iris plate
WSC2015_TP01_AT_0c07_A4 iris turn bar
4. WSC2015_TP01_AT_automation.pdf (Attachment 2 with all documents for the automation part)
Attachment 2 consists of the following drawings:
WSC2015_TP01_AT_a0_A3
automation overview
WSC2015_TP01_AT_a1_A4
operation panel
WSC2015_TP01_AT_a2_A4
sensor positions
WSC2015_TP01_AT_a3_A4
flow chart manual mode
WSC2015_TP01_AT_a4_A4
flow chart automatic mode
WSC2015_TP01_AT_e1_A4
wiring diagram 1 power support
WSC2015_TP01_AT_e2_A3
wiring diagram 2 LOGO inputs
WSC2015_TP01_AT_e3_A3
wiring diagram 3 LOGO outputs
WSC2015_TP01_AT_p1_A3
pneumatic circuit

Test Project proposal for skill 01

WSC2015_TP01_AT_EN

Version: 1.1
Date: 30.07.2015

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INTRODUCTION
Dear experts of skill 01!
According to the new requirements of the technical description, which was recorded in Leipzig in 2013, we
have developed a very technical and challenging test project for each individual. By developing in an
independent company all competitors have the equal chance from the beginning to the end of the
competition. We hope you will not find mistakes in our documents but if you find some please act as experts
to solve these problems.
Please let us all learn from this test project to further improve the movement of WorldSkills International!
I can guarantee with my name that no other person of Austria involved in that competition has seen that test
project before!
Good luck to all competitors and experts and may the best competitor win!

Gerhard Zechner
Technical Delegate Assistant Austria

Test Project proposal for skill 01

WSC2015_TP01_AT_EN

Version: 1.1
Date: 30.07.2015

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DESCRIPTION OF PROJECT AND TASKS

The first step is to produce the mechanical parts according to the drawings. The drawings are provided in the
two projection methods E and A.
The automation system consists of two pneumatic cylinders and a dc motor. All the movements of the
cylinders and motor are controlled by a PLC.
Starting conditions of the automation system

A plug is connected to the electricity supply and a manual pneumatic valve is open in order to supply air
to the system.
All the components must remain in their starting position, the cylinder 1A1 is retracted, the cylinder 2A1
is extended and the motor will be off.
The operating mode of the system, manual or automatic, can be selected by the selector switch S2.
The system will start only, if the push buttons S3 is pushed and the emergency button S1 is not active.

Emergency stop
At any time, if the emergency button is pushed, the pneumatic cylinders stop in their position and the motor
will be off.
Automatic mode
Starting conditions: the motor is turned off; the cylinders 1A1 and 2A1 are in starting position. The switch S2
is ON. The switch S8 is OFF. The system readiness of the automatic mode is shown by a flashing green
signal light (~ 1 Hz). The pencil is placed per hand and has to be held during Step 1 of automatic program.
Pushing the push-button S3 start the automatic cycle as follows:

step

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

The cylinder 1A1 move to the operating position. The green signal light is continuously on.
The automatic cycle stop. The stop is shown by the additional flashing yellow signal light (~ 1 Hz).
Pushing the push-button S3 again continues the automatic cycle.
The motor switch on.
A timer starts for 2 seconds.
The cylinder 2A1 move to the operating position.
A timer starts for two turns (~ 9 seconds).
The cylinder 2A1 move to the starting position.
The motor switch off.
The cylinder 1A1 move to the starting position.
The automatic cycle is finished. The green signal light is flashing.
switch
signal
S1 S2 S3 S4 S5 S6 S7 S8 P1
P2
0 1 1 0 0 0 0 0 0 1 (1Hz)
0
1 1 1 1 0 0 0 0 0
1
0
2 1 1 0 0 0 0 0 0
1
1 (1Hz)
3 1 1 1 0 0 0 0 0
1
0
4 1 1 0 0 0 0 0 0
1
0
5 1 1 0 0 0 0 0 0
1
0
6 1 1 0 0 0 0 0 0
1
0
7 1 1 0 0 0 0 0 0
1
0
8=0 1 1 0 0 0 0 0 0 1 (1Hz)
0

Test Project proposal for skill 01

WSC2015_TP01_AT_EN

P3
0
0
0
0
0
0
0
0
0

0V1
1
1
1
1
1
1
1
1
1

1V1
0
1
1
1
1
1
1
0
0

valve
1V2 2V1
0 0
0 0
0 0
0 0
0 1
0 0
0 0
1 0
0 0

Version: 1.1
Date: 30.07.2015

2V2
0
0
0
0
0
1
1
1
0

motor
Q1
0
0
0
1
1
1
0
0
0

limit switch
timer
1B1 1B2 2B1 2B2 t position
1 0 0 1
0 start
0 1 0 1
0 clamping
0 1 0 1
0 stop
0 1 0 1 2 s motor on
0 1 1 0 9 s sharpening
0 1 0 1
0 sharpening done
0 1 0 1
0 motor off
1 0 0 1
0 unclamp
1 0 0 1
0 start

4 of 10

Manual mode
Starting conditions: the motor is turned off; the cylinders 1A1 and 2A1 are in starting position. The switch S2
is OFF. The system readiness of the manual mode is shown by a continuous shining yellow signal light.
In this mode, each movement of the cylinders and the motor is independent of the cycle sequence.

step

Pushing the push-button S4 start the cylinder 1A1 to get in operating position.
Pushing the push-button S5 start the cylinder 1A1 to get in starting position.
Pushing the push-button S6 start the cylinder 2A1 to get in operating position.
Pushing the push-button S7 start the cylinder 2A1 to get in starting position.
Turning ON the switch S8 start the motor.
Turning OFF the switch S8 stops the motor.
Emergency stop interrupts the power supply to valves and motor, also it interrupts the air supply to the
valves and cylinders. The red signal light is continuously on.

0
1
2
3
4
5

S1
1
1
1
1
1
1
0

S2
0
0
0
0
0
0
0

S3
0
1
1
1
1
1
0

switch
S4
0
1
1
1
1
1
0

S5
0
1
0
0
0
0
0

S6
0
0
0
1
0
0
0

S7
0
0
0
0
0
1
0

P1
0
0
0
0
0
0
0

signal
P2
1
1
1
1
1
1
0

P3
0
0
0
0
0
0
1

valve
motor
1M1 2M1 Q1
1B1
0
0
0
1
1
0
0
0
0
0
0
1
0
1
0
1
0
0
0
1
0
0
1
1
0
0
0
0

limit switch
1B2 2B1
0
1
1
1
0
1
0
0
0
1
0
1
0
0

2B2
0
0
0
1
0
0
0

position
start
op
start
op
start
op
e-stop

INSTRUCTIONS TO THE COMPETITOR

According to modular assessment it is possible that you have to produce the mechanical parts in a certain
order. You will get more information about this from your Jury!

EQUIPMENT, MACHINERY, INSTALLATIONS AND MATERIALS

REQUIRED
The Test Projects can be done by competitors with the equipment and materials specified in the
Infrastructure List.

Test Project proposal for skill 01

WSC2015_TP01_AT_EN

Version: 1.1
Date: 30.07.2015

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MATERIALS REQUIRED
raw material
Wide [mm]

Thickness
[mm]

Length
[mm]

ISO material
(DIN EN number)

raw material
dimensions [mm]

raw material dimensions [mm]

100 (+0/0,22)

30 (0,4)

150 (0,4)

S235JRC+C (1.0122)

flat stock bright

100x30

flat stock bright EN 10278 - 100x30 x 3000 - EN 10277-2 S235JRC+C

80 (0,4)

15 (0,4)

105 (0,4)

S235JRC+C (1.0122)

flat stock bright 80x15

flat stock bright EN 10278 - 80x15 x 3000 - EN 10277-2 S235JRC+C

55 (0,4)

30 (+0/-0,13)

70 (0,4)

S235JRC+C (1.0122)

flat stock bright 55x30

flat stock bright EN 10278 - 55x30 x 3000 - EN 10277-2 S235JRC+C

60 (+0/-0,19)

35 (0,4)

75 (0,4)

S235JRC+C (1.0122)

flat stock bright 60x35

flat stock bright EN 10278 - 60x35 x 3000 - EN 10277-2 S235JRC+C

40 ( 0,4)

75 (0,4)

PA 6, Polyamid 6

round stock 40

round stock EN 15860 40 x 3000 - EN 1043-1 - PA 6

40 ( 0,4)

100 (0,4)

CuZn39Pb3
(CW614N)

round stock 40

round stock EN 12164 - 40 x 3000 - EN 12164 CW614N

SW60

20 (0,4)

S235JRC+C (1.0122)

hexagonal bar SW60

hexagonal bar EN 10278 - SW60 x 3000 - EN 10277-2 S235JRC+C

50 ( 0,4)

20 (0,4)

CuZn39Pb3
(CW614N)

round stock 50

round stock EN 12164 - 50 x 3000 - EN 12449 CW614N

8 ( 0,2)

75 (0,4)

11SMnPb37 (1.0737)

round stock bright 8

round stock bright EN 10278 - 8 x 3000 - EN 10277-2 11SMnPb37

SW60

15 (0,4)

AlSi1MgMn (EN AW6082)

hexagonal bar SW60

hexagonal bar ISO 6362-5 - SW60 - EN 573-1 and 3 AW-6082

25 (0,4)

35 (+0/-0,16)

120 (0,4)

AlSi1MgMn (EN AW6082)

flat stock 25x35

flat stock EN 754-5 - 25x35 - EN 573-1 und 3 - AW-6082

15 (0,4)

6 ( 0,2)

15 (0,4)

CuZn39Pb3
(CW614N)

flat stock 15x6

flat stock EN 12164 - 15x6 x 3000 - EN 12164 - CW614N

8 ( 0,2)

8 ( 0,2)

95 (0,4)

S235JRC+C (1.0122)

flat stock bright 8x8

flat stock bright EN 10278 - 8x8 x 3000 - EN 10277-2 S235JRC+C (or Parallel key DIN 6885-1 - A - 5x5x16)

Test Project proposal for skill 01

WSC2015_TP01_AT_EN

Version: 1.1
Date: 30.07.2015

6 of 10

Standard parts
Product
Hexagon head screw M4 x 10
Hexagon head screw M3 x 20
Hexagon socket countersunk head screw M4 x 12
Hexagon socket countersunk head screw M4 x 16
Hexagon nut M3
Parallel pin 3 h8 x 10
Parallel pin 3 x 10
Parallel pin 3 x 16
Parallel pin 3 x 18
Hexagon head screw M8 x 25
Hexagon socket head cap screw M6 x 45
Hexagon socket head cap screw M5 x 20
Hexagon socket head cap shoulder screw 6 x 12
Hexagon socket head cap shoulder screw 6 x 30
Hexagon socket set screw with dog point M4 x 12
Hexagon socket head cap screw M6 x 25
Helical spring (ballpoint pen)
Stainless steel tube
Parallel key

ISO standard
ISO 4017 - M4 x 10
ISO 4017 - M3 x 20
ISO 10642 - M4 x 12
ISO 10642 - M4 x 16
ISO 4032 - M3
ISO 2338 - 3 h8 x 10 B
ISO 8734 - 3 x 10 - A
ISO 8734 - 3 x 16 - A
ISO 8734 - 3 x 18 - A
ISO 4017 - M8 x 25
ISO 4762 - M6 x 45
ISO 4762 - M5 x 20
ISO 7379 - 6 x 12
ISO 7379 - 6 x 30
ISO 4028 - M4 x 12
ISO 4762 - M6 x 25
DIN 2098 - 0,35 x 4 x
30
ISO 4200 - 21.3x2 - 10
DIN 6885-1 - A 5x5x16

sealing_disc
Cable tie 102x3,5
Wire end sleeve insulated 1,5mm
Wire end sleeve insulated 0,75mm
Wire end sleeve insulated 0,5mm
Wire end sleeve insulated 0,25mm
Wire end sleeve insulated TWIN 0,75mm
T-head nut 10 mm slot M3

Test Project proposal for skill 01

WSC2015_TP01_AT_EN

Qty.
4
2
3
1
3
10
5
1
3
2
2
4
1
3
1
3
3
1
5
1
30
4
50
30
30
30
2

Version: 1.1
Date: 30.07.2015

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micro SDHC 32 GB
wire flex 0,75mm - dark blue
wire flex 0,75mm - red
plug power supply 2P+T
wire flex 3x1,5mm

1
6m
20 m
1
3m
Siemens parts

Product
LOGO!POWER 24 V/4 A STABILIZED POWER SUPPLY INPUT: 100-240 V AC (110-300 V DC) OUTPUT: 24 V/4 A DC
LOGO! 8 TRAINING PACK. 12/24RCE WITH 6 PIECES LOGO! 12/24RCE, 6 LOGO! DM8 12/24R, 6 LOGO! SOFT COMFORT, 6
LANGUAGES GE/EN/FR/IT/SP/CN, EXECUTABLE UNDER WINXP (32 BIT), WIN7 (32&64 BIT), WIN8 (32&64 BIT), MAC OS X,
LINUX, REFERENCE-HW: LOGO! FOR EDUCATIONAL PURPOSES ONLY
SIMATIC NET INDUSTRIAL ETHERNET TP XP CORD RJ45/RJ45, CAT 6A, CROSSED TP CABLE 4X2, PREASSEMBLED W. 2 RJ45
CONNECTORS, LENGTH 6 M
LOGO! CONTACT 24 SWITCHING MODULE FOR DIRECT SWITCHING OF RESISTIVE CONS. UPTO 20A AND MOTORS UPTO 4
KW, 24V DC, 3 NO + 1 NC CONTACTS EAN: 4025515050742
22MM PLASTIC ROUND COMPLETE UNIT COMBINATION: EMERGEN.-STOP MUSHR.PUSHB. 40MM LATCH.W. ROT.-TOUNLATCH MECH. WITH YELLOW BACKING PLATE SCREW TERMINAL, 1NC WITH HOLDER RED INSCRIPTION: EMERGENCY
STOP
22MM PLASTIC ROUND COMPLETE UNIT COMBINATION: SELECTOR SWITCH LATCHING 2 SWITCH POSITIONS O-I NONILLUMINATED SCREW TERMINAL, 1NO+1NC WITH HOLDER BLACK
22MM PLASTIC ROUND COMPLETE UNIT COMBINATION: PUSHBUTTON WITH FLAT BUTTON SCREW TERMINAL,
1NO+1NC WITH HOLDER BLACK
CONNECTION ELEMENT WITH COVER FOR MOUNTING ON PIPES, FLOOR AND BRACKETS
ST.-LIGHT ELEMENTS LED, RED, AC/DC 24V
ST.-LIGHT ELEMENTS LED, YELLOW, AC/DC 24V
ST.-LIGHT ELEMENTS LED, GREEN, AC/DC 24V
PIPE, 10CM
SIGNAL COLUMNS, DIAMETER 70MM ACCESSORIES BASE (SINGLE), PLASTICS
FEED-THROUGH TERMINAL WITH SPRING CONNECTION, SECTION: 0.08 - 2.5 MM2, WIDTH: 5.2 MM, COLOR: GRAY
PE TERMINAL WITH SPRING CONNECTION, SECTION: 0.08 - 2.5 MM2, WIDTH: 5.2MM, COLOR:GREEN-YEL.
COMPARTMENT PARTITION FOR OPTICAL AND ELECTRICAL ISOL. FROM TERMINAL GROUPS, WITH SECTIONS UP TO 4
MM2, WIDTH: 2 MM, COLOR: GRAY
Test Project proposal for skill 01
WSC2015_TP01_AT_EN

Version: 1.1
Date: 30.07.2015

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MLFB
6EP1332-1SH52
6ED1057-3SA20-0YA1

Qty.
1
1

6XV1870-3RH60

6ED1057-4CA00-0AA0

3SB3203-1HR20

3SB3201-2HA11

3SB3201-0AA11

8WD4208-0AA
8WD4220-5AB
8WD4220-5AD
8WD4220-5AC
8WD4208-0EF
8WD4308-0DB
8WH2000-0AF00
8WH2000-0CF07
8WH9070-0AA00

1
1
1
1
1
1
20
4
10

PLUG-IN JUMPER 4 DIVISIONS, AS TRANSVERSE JUMPER IN TERM. MIDDLE, 2-POLE, COLOR: SIEMENS COLOR
QUICK-ASSEMBLY END HOLDER, CAN BE EQUIP. WITH LABELS 5/6 WIDTH: 5.15 MM, COLOR: GRAY
LABELS, LONGIT. 1 - 10 SIZE ZB4
DESIGN BLANK FRONT KP8 APPEARANCE FOR EASY MOUNTING OF STANDARD 22.5 MM CONTROL ELEMENTS IDEAL FOR
MODULAR OPERATING PANELS ALSO OPTIMIZED FOR MOUNTING IN EXTENTION UNITS FOR PRO DEVICES

Product
doubele acting cylinder ADN
doubele acting cylinder DSNU
foot mounting
one-way flow control valve GR
proximity sensor
mounting kit

non-return valve
valve terminal
push-in fitting
3/2-way solenid valve
Plug socket with cable
silencer
quick coupling socket
plastic tubing 6 mm
plastic tubing 4 mm

FESTO parts
Model
ADN-12-15-I-P-A
DSNU-12-80-P-A

Part no.

HNA-12
GR-QS-4
SME-8-K-LED-24
SMBR-8-12
HGL-M5-B
10P-10-2B-IC-R-U-CC+H4DA-E
QSM-M5-4-I-R
CPE10-M1BH-3GL-QS-6
KMYZ-9-24-2,5-LED-PUR-B
UC-M7
KD3-CK-4
PUN 6x1-BL
PUN 4x0,75-BL
0270SWMK, Typ: 403033

aluminium profile plate, 350 x 700mm

rubber feet
DIN rail set
T-head nut M5
cable holder
cable duct set
Test Project proposal for skill 01
WSC2015_TP01_AT_EN

Version: 1.1
Date: 30.07.2015

Qty.
536213
1
19193
1
537237
1
193967
4
150855
4
175093
2
530029
4
18200
1
133004
8
196847
1
193687
1
161418
1
531629
1
159664 10 m
159662 10 m
540691
1
652345
1
162386
1
158343
1
548637
1
254490
20
196965
2
548638
1

start-up Valve with filter control valve

DC gear motor

8WH9020-6AC10
8WH9150-0CA00
8WH8120-1AB05
6AV3688-3XY38-3AX0

9 of 10

20
5
2
2

MARKING SCHEME
Every Test Project must be accompanied by an associated marking scheme matching the assessment criteria and standards specifications as given in
the Technical Description. For each of these criteria a detailed list of aspects to be assessed must be defined (this would be a draft proposal that is
discussed and finalised with the experts during preparation time at the Competition).
According to WSI the competitors get the Mark Summery Form prior to the start of competition.

Test Project proposal for skill 01

WSC2015_TP01_AT_EN

Version: 1.1
Date: 30.07.2015

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