Syllabus For the trade of

MECHANIC MECHATRONICS
Under

APPRENTICESHIP TRAINING SCHEME

Designed by Government of India

Ministry of Labour & Employment (D.G.E.&T.)
CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE

EN- Block, Sector- V, Salt Lake, Kolkata-700091.

List of members of the Trade Committee Meeting to design the Syllabus for the Trade of MECHANIC MECHATRONICS under ATS held on 21.05.2009 at I.T.I. Dadar, Mumbai, Maharashtra Director: Shri S.D. Lahiri, C.S.T.A.R.I., Kolkata SL NO 1 2 3 4 5 6 7 8 9 10 11. 12 13 14 NAME & DESIGNATION S/SHRI Hitesh Mehta Chairman Ilesh Shah, Managing Director Hemant Monaya, Director Ganesh Rahate, Sr. Engineer M Loynmoon, Sr. Engineer Paras Dagli, Director Shabbir Shaikh, Director Dipak Ghule, Sr. Engineer Abhoy Dhotra, Director Jitin Doshi, Executive Director K.W. Khatavkar, Principal H N Bargal, Training Officer L.K. Mukherjee, Dy. Director Abhinoy Nandi, Dy. Director REPRESENTING ORGANIZATION Advance Electronics Industries, Mumbai Advolt Technologies, Vikroli Mumbai Adtron Technologies Pvt. Ldt., Mumbai G- Byte Technologies Pvt. Ltd., Vikhroli, Mumbai Signet Instruments, Bhandup, Mumbai Kencraft India Pvt. Ltd., New Mumbai Labtron Technologies, Mumbai Oasis Tech. Pvt. Ltd. Pune. Bi-Tronics Pvt. Ltd. Thane REMARKS Chairman Member Member Member Member Member Member Member Member

Dashy Corporation for Dental Member Occupation, Chambur Mumbai I.T.I. Mumbai Member I.T.I. Mumbai C.S.T.A.R.I., Kolkata C.S.T.A.R.I., Kolkata Member Member Member

General Information

1. 2. 3.

Name of the Trade N. C. O. Code No. Entry Qualification

: MECHANIC MECHATRONICS : 7243.10 : Passed 12th class examination under 10+2 system of education with Physics, Chemistry & Mathematics or its equivalent. : Two year

4. 5.

Duration of Craftsman Training

Duration of Apprenticeship Training: Three years including two years craftsman training. Rebate : Two year ITI/ITC passed out trainees in the trade of Mechanic Mechatronics. : 1: 5

6.

7.

Ratio of Apprentice to Workers

SYLLABUS FOR THE TRADE OF MECHANIC MECHATRONICS UNDER APPRENTICESHIP TRAINING SCHEME

Duration of Training : Three year First two year: - During first two year the apprentices will undergo the syllabus same as CTS Next one year: - The apprentice will undergo shop floor training in the related establishment/Industry as per the under mentioned syllabus. Shop Floor Training 1. 2. Safety: Safety precautions, first aid and artificial respiration, Elements of fire Fighting-various types of fire fighting equipments. Manufacturing Techniques/ Processes : The shop floor training to be given in as many manufacturing techniques/ processes as possible depending upon the facilities available in the industry concerned e.g. i) Soldering, brazing and welding ii) Wire stripping & forming iii) Sheet metal working, punching & drilling iv) Finishing processes-polishing, buffing, spray painting v) Electrode position of metals on non-conductors vi) Electroplating processes vii) P.C.B. single layer-multilayer. viii) Vacuum impregnation ix) Bakelite and plastic molding

3. General Testing (a) Testing of components such as : 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Resistors Coils Capacitors Ferrite components Transducers Crystals Relays Micro-switches Plugs and sockets Active components Plated metal parts

(b) Bulk Testing of Electronic Components using Test Rigs & Jigs (c) Use of Test Instruments such as : 1. 2. 3. 4. 5. 6. Insulator Tester Megger Transistor Tester I.C. tester Logic circuit Tester Logic analyzer

4. Inspection Step-wise and final inspection procedures and other quality control techniques. 5. Maintenance 1. Wiring of an electronic maintenance/test bench 2. Modern trouble shooting sequences & techniques for electronic equipments. 3. Replacement of defective components in a. Simple electronic circuits on chassis. b. P.C.B. circuits c. Hybrid circuits 4. Care and replacement of sockets for a. Transistors b. I.Cs. 5. Wiring of solenoid valve, Actuator & relays 6. Wiring of PLC based system 7. Wiring of PID controller 8. Wiring or cable connection in CNC Machine

5. Transformers & Coils (a) Care and maintenance of the following transformers: 1. Power 2. A.F.-Input-Driver-output 3. I.F. 4. R.F. 5. Rewinding of small transformers 6. Winding of R.F. coils, deflection coils, etc.

Introduction to Mechatronics: Mechatronics system, measurement systems, control systems and response of systems. Measurement systems : static characteristics

Flow measurement : Rotameter, anemometer and comparison of characteristics of different flow meters. Pressure measurement : Mcleod gauges, comparison of characteristics of different pressure measuring devices. Level measurement, strain measurement strain gauges, theory, types, strain gauge circuits, temperature compensation, load cells. Temperature measurement : RTD, Thermocouples, pyrometers. Displacement and position sensors : LVDT, optical encoders transitional and rotary. System Models : Mathematical models, introduction to mechanical, electrical, fluid and thermal systems. Rotational and transnational systems, electro mechanical, hydraulic mechanical systems. Control Systems : open loop, closed loop systems, transfer functions, feed back and feed forward control systems and their applications. System Response, modeling of dynamic systems, dynamic response of first order, second order systems to step, ramp and impulse inputs. Transfer functions, Bode plots, stability of systems. Control Actions : On Off, proportional, proportional + integral, P ID . proportional + integral + derivative control actions. Control systems Components : Transmitters,controllers/pressure/flow/level/temperature/limit/proximimity/magnetic switches and relays.

Analog signal processing, introduction, principle, passive circuits, operational amplifiers - characteristics and specifications. Op amp circuits for inverting, non inverting, difference amplifiers, integrator, differentiator, comparator and sample and hold applications (no analytical treatment.) Digital Signal Processing : Timing diagrams, sequential logic, flip flops, D flip flop, JK flip flop, master slave flip flop. Applications of flip flop, decade counters, Schmitt trigger, 555 timers. A/D and D/A converters. Programming Logic Controllers : Relay logic, basic structure, input/output processing, timers, internal relays and counters, shift resisters, ladder diagram and programming, selection of PLCs, introduction to microcontrollers. List of Experiments : Minimum of 10 experiments from the following; out of which experiment no. 12 is compulsory, four shall be from serial no. 1 to 5, three from serial no. 6 to 11 and two from 13 to 17. Record of experiments and assignments shall be submitted in the form of journal. 1. Calibration of flow meters. 2. Calibration of Thermocouples/ RTD.

3. Study of Load Cells. 4. Vibration measurement using accelerometers. 5. Displacement measurement/ level measurement. 6. Verification of P, P+I, P+D, P+I+D control actions. 7. Study of XY position control systems. 8. Study of linear conveyor control system. 9. Study of rotary table positioning systems. 10. Study of different switches and relays. 11. Analysis of control system using software like MATLAB/SIMULINK or equivalent. 12. Development of ladder diagram/programming PLC for level control, position control or any other mechanical engineering application. 13. Study of A/D and D/A converters. 14. Study of Flip Flops and Timers. 15. Study of Application of Op Amp circuits. 16. Study of Data acquisition system. 17. Study of Microcontrollers.

SYLLABUS FOR RELATED THEORY: (1) Safety at Work Safety devices and measures in handling electrical and electronic equipment. Fire fighting equipment. (2) Small Motors : Constructional features, principle of operation and applications of fractional hours power motors and micro motors. Electro Mechanical/Magnetic Devices & components: i. ii. Various types of relays and their applications Micro switches, limit switches, Solenoid, Actuator & relays, Sensors, Proximity switches and other types of switches and their applications in electronic systems Transformers : Input, output, power, driver, EHT & pulse transformers, their windings and applications. Plugs, sockets, multipoint connectors, PCB connectors, R.F. & A.F. connectors, tube, transistor and I.C. sockets.

(3)

iii. iv.

(4)

Electronics Devices

Transducers : Types of transducers and their application in electric systems. Crystals : Types of crystals and their applications. Insulators : Electrical properties of ceramic, plastic bakelite, mica and other insulating materials and their applications in electronic components and systems. Active Components Principle of operations and performance characteristics of devices such as vacuum tubes, gas tubes, photo-tubes, CRT (including picture tubes), semiconductor diodes (zener, rectifying, detection, tunnel, switching, diodes, gunn diodes, varactor diode and photo diodes) thermistors, VDRs, silicon and Germanium transistors, FETS, UJT, DIACS, TRIACS etc. and integrated circuits. Application of the above components in common electronic equipment. Display devices-Nixie tubes, LEDs, LCDs, etc.

(5) Electronic Modules Operating principles, testing and maintenance of electronic modules such as (i) Rectifier (ii) Amplifier modules (iii) Detector modules (iv) Modulator modules (v) Oscillator modules (a) Sine Wave (b) Square Wave (c) Saw Tooth Wave (vi) Mixer modules (vii) Differentiating modules (viii) Integrating modules (ix) Logic circuit modules (x) Multivibrator modules (xi) Multiplexer modules (xii) Recorder modules (xiii) Timer modules (xiv) Voltage regulator modules

(6) System Assembly General principles of the working and block diagrams of systems such as AC / DC Drives Single Phase & Three Phase, Online/ Offline UPS, Stabilizers & power supply Controlled Rectifiers Single Phase & Three Phase , Battery Chargers Function Generator C.R.O. Speed control DC motors Analytical instruments (Electronic) Communication systems. Microprocessor / Microcontroller based system PID controller PLC, SCADA & DCS CNC Machine

(7) Testing and Calibrations Testing procedures for domestic and professional electronic equipments Calibration standards, ISI standards for various electronic equipment Quality testing of components and systems

(8) Maintenance and Servicing Trouble shooting techniques, modern techniques etc. proper use of electronic testing instruments/equipments for servicing electronic systems. Use of test rigs & jigs, components substitution in handling of P.C.B. circuits and hybrid circuits etc.

10