Fitting fluid power components to mechanical assemblies
Overview
This standard identifies the competences you need to assemble and fit fluid power equipment (pneumatic, hydraulic, or vacuum) to mechanical assemblies, in accordance with approved procedures. You will be required to prepare the work area, ensuring it is safe and free from hazards, check the specified components are available and fit for purpose, obtain all relevant and current documentation, and to obtain the tools and equipment required for the assembly operations, checking that they are in a safe and usable condition. In carrying out the fitting and assembly operations, you will be required to follow company procedures and specified assembly techniques, in order to assemble the mechanical product.
The assembly activities will also include making all necessary checks and adjustments to ensure the fluid power components are correctly positioned, aligned, dimensionally accurate and secure; pipework is dimensionally accurate and free from ripples, twists, creases and damage; joints are checked for security, with threaded devices tightened correctly; electrical components are checked for safety, position, security and continuity; and test procedures (leak or pressure) are carried out to confirm that the fluid power assembly meets the operational performance required.
Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken, and to report any problems with the assembly activities, materials or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to ensure that all tools, equipment and materials used in the assembly are correctly accounted for on completion of the activities, and to complete all necessary job/task documentation accurately and legibly. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying fluid power assembly techniques and procedures. You will understand the mechanical product being assembled, and its application, and will know about the equipment, relevant components and joining techniques, in adequate depth to provide a sound basis for carrying out the activities to the required specification.
You will understand the safety precautions required when carrying out the assembly activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, assembly drawings and any other specifications
- check that the specified components are available and that they are in a usable condition
- prepare and assemble the components in their correct positions using the appropriate methods and techniques
- secure the components using the specified connectors and securing devices
- produce mechanical assemblies to required specification
- check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification
- complete the required production documentation
- deal promptly and effectively with problems within your control and report those that cannot be solved
Knowledge and Understanding
You need to know and understand:
- how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- the health and safety requirements of the work area in which you are carrying out the assembly activities, and the responsibility these requirements place on you
- Regulations with regard to the substances used in the assembly process
- the hazards associated with producing fluid power assemblies and how to minimise them and reduce any risks
- the personal protective equipment and clothing (PPE) to be worn during the assembly activities
- how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate standards) in relation to work undertaken
- how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
- how to extract the necessary information from data supplied in order to complete fluid power assemblies
- the general principles of fluid power, and the purpose and function of the components and materials used
- preparations that need to be undertaken on the components prior to fitting them onto the assembly
- the fitting and assembly methods and procedures to be used, and the importance of adhering to these procedures
- how the components are to be aligned, adjusted and positioned prior to securing, and the tools and equipment that are used
- the importance of using the specified components for the assembly, and why you must not use substitutes
- the specific methods used for leak detection, and when they should be applied
- how to conduct any necessary checks to ensure the safety, accuracy, position, security, function and completeness of the assembly
- how to detect assembly defects/faults, and what to do to rectify them
- the methods and equipment used to transport, lift and handle components and assemblies
- how to check that the tools and equipment to be used are correctly calibrated and are in a safe and serviceable condition
- the importance of ensuring that all tools are used correctly and within their permitted operating range
- the importance of ensuring that all tools, equipment and components are accounted for and returned to their correct location on completion of the assembly activities
- problems with the assembly operations, and the importance of informing appropriate people of non-conformances
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
- Carry out all of the following during the assembly activities:
- obtain and use the appropriate documentation
- adhere to procedures or systems in place for risk assessment, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- adhere to company specific contamination and control procedures at all times
- apply safe and appropriate fitting and assembly techniques
- check that all tools and measuring equipment are within current calibration/certification dates
- use lifting and slinging equipment in accordance with health and safety guidelines and procedures
- return all tools and equipment to the correct location on completion of the fitting activities
- leave the work area and assembly in a safe and appropriate condition on completion of the activities
- Assemble and fit one of the following types of fluid power systems:
- pneumatic
- vacuum
- hydraulic
- electro fluid power systems
- Prepare, assemble and secure seven of the following components and materials:
- rigid pipe
- compressors
- gauges/indicators
- cables and wires
- pumps
- flexible pipe
- regulators
- clips / supports
- seals/gaskets
- meters
- couplings
- manifolds
- lubricators
- locking wire
- filters
- intensifiers
- sensors
- heaters/driers
- actuators/cylinders
- motors
- valves
- accumulators
- coolers units
- separation units
- reservoirs/storage devices
- electrical/electronic control systems
- other specific component
- Carry out the quality checks using appropriate equipment, to include eight from:
- dimensions
- correct direction and flow
- electrical continuity
- positional accuracy
- leak or pressure tests
- completeness
- alignment
- component security
- function
- pipework/hoses (such as free from ripple, twists and creases)
- Produce assemblies which comply with one of the following quality and accuracy standards:
- relevant standards and procedures
- customer standards and requirements
- company standards and procedures
- specific system requirements
- organisational guidelines and codes of practice