What you will be able to do
- Turn a belt speed and belt pull into a gearbox ratio, a motor size and an encoder count to the pusher.
- Size a pneumatic cylinder from the force needed to slide a load, and the 24 V supply from the loads it feeds.
- Choose a safeguard and wire it so that a broken wire, a forgotten reset or a software fault leaves the machine stopped.
- Write a sensor-confirmed PLC cycle and say what it does when a movement never finishes.
- Put commissioning checks in a safe order and trace a symptom to the discipline it came from.
- 01
Capstone 1: size the conveyor drive
Free15 min · labChoose a gearbox ratio and motor for a carton conveyor from its belt speed and belt pull, then convert encoder counts into the pusher position.
- 02
Capstone 2: size the pusher and the electrical supply
Pro20 min · labSize the pneumatic pusher from the force needed to slide a carton, choose its valve and flow controls, then size the 24 V supply and set the motor overload.
- 03
Capstone 3: safeguard the pusher station
Pro18 min · labChoose the safeguard for the pusher trap point, wire the gate and E-stop so failures leave the machine stopped, and decide what a reset must do.
- 04
Capstone 4: write and test the PLC cycle
Pro25 min · labBuild the cycle as a step table, run it against a cell model with a healthy pusher and with a stalled one, and decide how it reacts to a timeout and to the gate opening.
- 05
Capstone 5: commission and document the cell
Pro20 min · labOrder six commissioning checks safely, trace three symptoms across mechanics, pneumatics and electrical, and say what is handed over with the machine.
5 of the units are graded or interactive practice on simulated equipment rather than reading:
- Capstone 1: size the conveyor drive: Choose a gearbox ratio and motor for a carton conveyor from its belt speed and belt pull, then convert encoder counts into the pusher position.
- Capstone 2: size the pusher and the electrical supply: Size the pneumatic pusher from the force needed to slide a carton, choose its valve and flow controls, then size the 24 V supply and set the motor overload.
- Capstone 3: safeguard the pusher station: Choose the safeguard for the pusher trap point, wire the gate and E-stop so failures leave the machine stopped, and decide what a reset must do.
- Capstone 4: write and test the PLC cycle: Build the cycle as a step table, run it against a cell model with a healthy pusher and with a stalled one, and decide how it reacts to a timeout and to the gate opening.
- Capstone 5: commission and document the cell: Order six commissioning checks safely, trace three symptoms across mechanics, pneumatics and electrical, and say what is handed over with the machine.
Who this track is for
Maintenance technicians, apprentices and controls people who have met the mechanical, electrical, motion and PLC topics separately and want to see how one machine ties them together.
1 of the 5 units are free with a free account, with no card and no expiry. The other 4 are part of a paid plan; compare them on the pricing page.
Related tracks
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- Mechanical FoundationsThe mechanical half of mechatronics in plain language: torque, gears, belts, bearings and troubleshooting, in 12 short units.12 units, 3 free
- Industrial SafetyWhy machines are guarded, how stops and interlocks work, and the safe habits that keep technicians and controls engineers out of trouble.12 units, 4 free
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What is mechatronics?
Mechatronics is the combined design of mechanical parts, electronics, sensors and control software as one system, rather than handing a finished machine to a programmer afterwards.
What is a good mechatronics project for a beginner?
A small conveyor or sorting cell is a good start because it needs a motor, a sensor, a simple mechanism and a control sequence, and each part can be tested on its own before they are joined.
Is this a degree-level mechatronics programme?
No. It is a practical, simulation-based capstone that shows how the layers connect. It does not replace an accredited programme or supervised work on real equipment.
How much of Mechatronic system design is free?
1 of the 5 units are free with a free account, no credit card and no expiry, starting with Capstone 1: size the conveyor drive. The remaining 4 units are included with a paid plan; see the pricing page for the current plans.
Do I need a PLC or any hardware?
No. Everything runs in the browser against simulated equipment. It is training material: it does not replace supervised practice on real equipment, and lockout/tagout and a qualified person are required for real equipment.
Start with the free units
Browser-based, no install, no hardware.
Start free: Capstone 1: size the conveyor drive