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Instructional Materials for Industrial Skills:

Controllers

COMPUTER NUMERICAL CONTROL

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CNC001 
COMPUTER NUMERICAL CONTROL
Video
Current, state-of-the-art information explaining how computers operate all kinds of equipment, ranging from automated machine tools like milling machines, lathes, turning centers, and even more complex manufacturing cells.  CNC automatically measures parts, controls robotic welders, and moves materials through today’s manufacturing facilities.  A must-see video that provides a basic understanding of CNC for anyone working in today’s manufacturing industry.  26 minutes.

CNC003 
COMPUTER NUMERICAL CONTROL
Video Series
This series of 15 videotape lessons (CNC004-CNC017) and their accompanying workbooks form a learning resource which will enable learners to master the fundamentals of computer numerical control for milling operations.  While the entire series is designed to train the new CNC programmer, the individual videos also offer CNC operators the opportunity to review basic information.  The series covers program preparation, multi-axis milling, circular milling, drilling, subroutines, loops, special cycles, translation, polar coordinates, rotation, scaling, and cutter radius compensation.

STUDENT WORKBOOK
The video series is accompanied by separate workbook lessons for each video lesson.  This student workbook can be used by learners to enhance their understanding, and retain permanent notes from the lessons.  The lessons restate the purpose and objectives for each program.  By using them in conjunction with the pre-view and post-view tests, the instructor can measure learning and ensure subject matter mastery.  A Glossary is included to highlight terms which are introduced or emphasized in the lessons.  Real-world problems are included to promote high order thinking skills.

CNC004 
TAPE 1 INTRODUCTION TO COMPUTER NUMERICAL  CONTROL
Video
Identify the major components of a CNC milling machine.  Describe motion in terms of the X, Y and Z axes.  Identify the basic capabilities of the CNC system.  11 minutes.

CNC005 
TAPE 2 PREPARING FOR PROGRAMMING
Video
Identify required operations; methods of holding the work piece; tool selection factors; safety practices; origin points and tool length offsets.  Establish an origin point.  16 minutes.

CNC006 
TAPE 3 ABSOLUTE AND INCREMENTAL POSITIONING
Video
Identify the X, Y and Z dimensions of the cartesian coordinate system.  Describe absolute positioning, incremental positioning, and program rapid transit movements in both incremental and absolute systems.  17 minutes.

CNC007 
TAPE 4 ONE- AND TWO-AXIS LINEAR MILLING
Video
This presentation introduces programming techniques which will allow milling in up to two axes simultaneously.  Program milling on the Z axis at a feed rate, the X and Y axes at a feed rate, two-axis simultaneous milling.  Describe climb and conventional milling.  20 minutes.

CNC008 
TAPE 5 THREE-AXIS LINEAR  MILLING AND CIRCULAR MILLING
Video
For three-axis linear milling, identify sequence numbers; program a tool change; define a compound angle; and program a three-axis linear milling.  For circular milling, define clockwise and counterclockwise milling; define the elements necessary for circular milling; determine the start point, end point and direction of a circular path; program a circular path.  17 minutes.

CNC009 
TAPE 6 COMPLETED MILLING PROGRAMS
Video
Identify standard miscellaneous functions.  Write and test a completed milling program.  21 minutes.

CNC010 
TAPE 7 DRILLING, BORING AND SPOT FACING
Video
Write a drill cycle, spot facing cycle, deep hole cycle, chip breaking deep hole cycle, and boring cycle statement.  Calculate and write a dwell statement.  18 minutes.

CNC011 
TAPE 8 SUBROUTINES
Video
Define and execute a subroutine.  Write a nested subroutine.  Define and execute a subroutine with variables.  14 minutes.

CNC012 
TAPE 9 LOOPING
Video
Write a loop statement.  Terminate a loop statement.  Identify what information can be contained in a loop statement.  Write a program containing a nested loop.  13 minutes.

CNC013 
TAPE 10 SPECIAL CYCLES
Video
Program a face milling operation, a rectangular pocket and a mill boring cycle.  17 minutes.

CNC014 
TAPE 11 SUBROUTINES
Video
Identify the program requirements for translation.  Translate a program to a new location.  Translate to the first point of origin.  14 minutes.

CNC015 
TAPE 12 POLAR COORDINATE PROGRAMMING
Video
Define polar coordinates, program drilling on a radius, and program milling using polar coordinates.  20 minutes.

CNC016 
TAPE 13 SCALING
Video
Describe the use of a pen in the quill as a plotting device.  Write a scaling statement.  Terminate a scaling statement.  15 minutes.

CNC017 
TAPE 14 MULTI-QUADRANT INTERPOLATION AND ROTATION
Video
Program multi-quadrant interpolation; terminate multi-quadrant interpolation; and rotate an existing program and terminate a rotation.  15 minutes.

CNC018 
TAPE 15 CUTTER RADIUS COMPENSATION
Video
Enter compensation data into the control.  Write a G41 statement to establish cutter compensation to the left of the part surface.  Write a G42 statement to establish cutter compensation to the right of the part surface.  Write a G40 statement to terminate compensation.  20 minutes.

PROGRAMMABLE CONTROLLERS 

PRC001 
ANALOG AND SPECIAL  I/O MODULES
Video
Contains analog I/O modules, special I/O modules and motion control I/O modules.  1 hour.  Includes 1 student workbook, 1 instructor guide and transparencies.

PRC003 
AUTOMATIC  CONTROL SYSTEMS
Video
This program introduces the concept of automatic control by analyzing operations in three stages:  information, decision, and action.  Relays and relay ladder logic are explained, and programmable controllers are introduced.  24 minutes.  Also available in Spanish and French.

PRC005 
CENTRAL PROCESSING UNIT
Video
Covers CPU operation and components, CPU scanning and memory, CPU memory map, as well as CPU memory types and diagnostics.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC007 
COMMUNICATION  FUNDAMENTALS
Video
Discusses applications and overview, communications module, serial interface and communications line and data transmission.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC009 
CONTROL DEVICES
Video
This program shows how input, output, and logic devices function in a control system.  Analog and discrete devices are explained.  Electromechanical timers and counters are also covered.  22 minutes.  Also available in Spanish and French.

PRC011 
DEVELOPING A PROGRAM
Video
Centers on describing the system, flowcharts, ladder diagrams, and addressing and coding.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC013 
DISCRETE I/O MODULES
Video
Features I/O devices and modules, discrete input modules, discrete output modules and connections and addresses.  Includes 1 student workbook, 1 instructor guide’s and transparencies.  1 hour.

PRC015 
INSTALLATION  CONSIDERATIONS
Video
Describes selecting an installation site, PC component layout, grounding and electrical safety and start-up.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC017 
INTERPRETING  LADDER DIAGRAMS
Video
Introduces parts of the diagrams, techniques for interpreting ladder diagrams, common circuit arrangements and reading ladder diagrams.  1 hour.  Includes 1 student workbook, 1 instructor guide’s and transparencies.

PRC019 
INTRODUCTION TO PROGRAMMABLE CONTROLLERS
Video
Explains control technologies, input modules, the central processing unit and output modules and the user program.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC021 
NETWORKING
Video
Explains networks and access control methods.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC023 
NUMBER SYSTEMS
Video
Explains programmable controllers as digital devices which process information.   The following number systems are explained and related to the decimal system:  BCD, OCTAL, and Hexadecimal.  24 minutes.  Also available in Spanish and French.

PRC025 
NUMBERING SYSTEMS,  NUMBERING CODES AND  LOGIC CONCEPTS
Video
Presents number system principles, binary number system, Octal, Hex, BCD and logic functions.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC027 
PC HARDWARE AND  LADDER LOGIC
Video
Demonstrated here is how a sorting operation is transferred to PC management.  It discusses input/output in detail and introduces the concept of holding registers.  23 minutes.  Also available in Spanish and French.

PRC029 
PCs:  SPECIALIZED COMPUTERS
Video
This Video explains the internal operation of PCs and the importance of I/O addresses to the operation of the CPU.  The program also covers scan cycles, user program and memory registers.  24 minutes.  Also available in Spanish and French.

PRC031 
PRINCIPLES OF  LADDER DIAGRAMS
Video
Presents elements of control, information devices, decision and action devices and ladder diagrams.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC033 
PRINCIPLES OF LADDER LOGIC PROGRAMMING
Video
Explains programming principles, latching relays, master control relays and programming limitations.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC035 
PROGRAM DOCUMENTATION
Video
Takes a look at importance of documentation, types of documentation and computerized documentation.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC037 
PROGRAMMING DEVICES AND  PERIPHERAL EQUIPMENT
Video
Includes peripherals, programming devices, printers and tape loaders and simulators.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC039 
PROGRAMMING TIMERS AND COUNTERS
Video
Deals with ladder logic timing functions, functional blocks and cascading and counting functions.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC041 
PROGRAMMING:  ANALOG AND PID
Video
Takes a look at analog control, multiplexing analog inputs, programming analog systems and PID control.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC043 
PROGRAMMING:  DATA COMPARISON AND ARITHMETIC FUNCTIONS
Video
Treats data comparison, addition, subtraction, multiplication and division.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC045 
PROGRAMMING:  LOGICAL  OPERATIONS AND DATA MANIPULATION
Video
Covers data transfer, data manipulation and logic operations.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC047 
SIZING AND SELECTION
Video
Covers considerations for selecting a PC, determining I/O and memory requirements, programming and peripheral requirements and final selection.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC049 
TROUBLESHOOTING FIELD  DEVICE MALFUNCTIONS
Video
Treats internal versus external causes and the troubleshooting sequence.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC051 
TROUBLESHOOTING PC  MALFUNCTIONS
Video
Includes memory fault scenario, I/O module malfunction, and division method.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

PRC053 
TROUBLESHOOTING PCs (Part I)
Video
Takes a systematic approach to troubleshooting any PC-managed system.  Focuses on isolating problems by tracing the indicated flow of power through a network.  The importance of documentation is stressed.  Also available in Spanish and French.

PRC054 
TROUBLESHOOTING PCs (Part II)
Video
Details maintaining a programmable controller system.  The use of disabling and forcing coils is covered and proper troubleshooting methods are demonstrated using realistic situations.  21 minutes.  Also available in Spanish and French.

PRC056
TROUBLESHOOTING TECHNIQUES
Video
Illustrates the analytical framework, preliminary troubleshooting steps and troubleshooting with the PC.  1 hour.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

STATISTICAL PROCESSING

STP001 
MACHINE AND PROCESS CAPABILITY STUDIES
Video
Concentrates on capability studies, performing a machine capability study, calculating machine capability indexes, and process capability.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

STP003 
PROBLEM SOLVING  TECHNIQUES
Video
Centers on pareto diagrams, using pareto diagrams, brainstorming, cause and effect diagrams, and scatter diagrams.  Includes 1 student workbook, 1 instructor’s guide and transparencies.

STP005 
STATISTICAL PROCESS CONTROL (SPC) FOR OPERATORS
Video or CD-ROM Series
This series consists of one CD-ROM (STP006)or three video programs (STP007-STP009).  A Study Guide is available.
 
INTRODUCING SPC OPERATORS
STP006 CD-ROM
STP007 Video
This program presents the basic concepts of SPC.  It provides insight into the redefining of the roles of operators as it relates to SP integration.  10 minutes.

COLLECTING AND RECORDING VARIABLE DATA
STP006 CD-ROM
STP008 Video
Introduces the Xbar-R chart.  Explores the concept of sample data collection and recording on the chart.  Stresses basic computation skills required to insure accurate data collection.  14 minutes.

CHARTING ATTRIBUTES
STP006 CD-ROM
STP009 Video
Demonstrates data collection and recording on the P, Np, C and U charts.  Stresses required math skills.  Explains elements of chart interpretation.  12 minutes.

Maintenance Management  Mechanical Maintenance 
Industrial Electrical and Electronic Maintenance  Manufacturing 
Basic Instrumentation Process  Industrial Controls Controllers 
Welding Fluid Power, Hydraulics and Pneumatics

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