Download Under Apprenticeship Training Scheme SYLLABUS

SYLLABUS
For the trade of
OPERATOR PLC System
Under
Apprenticeship Training Scheme
Government of India
Ministry of Labour & Employment
Directorate General of Employment & Training
New Delhi-110001
GENERAL INFORMATION
Name of the Trade
:
CNC Programmer cum Operator
N.C.O. Code No.
:
8211.90
Entry Qualification
:
Passed 10th class examination under
10+2 system of education or
its
equivalent.
Duration of the Apprenticeship Training
:
02 years
Rebate allowed in Apprenticeship Training
:
One year and six months for trainees
completed Broad Based Basic Training
in Production and Manufacturing Sector
under Centre of Excellence Scheme and
Advanced module of Centre of
Excellence Scheme in PLC and
Automation.
Ratio of apprentices to workers other than
unskilled workers
:
1:2
Terminal Behavior
: On completion of training, the trainee is
able to design & develop PLC Programs
Course Outline :
The training shall comprise ofa) On the job training
The actual training shall be depended on the facilities available in the
establishments with an idea to expose the trainees to as many activities as
possible. The trainee shall maintain a daily work for a job training, which shall
be periodically authenticated by the supervisor.
b) Project
Each apprentice shall under take a project in any of the areas
depending on his/her interest and facilities available in the establishment. The
duration of the project shall be two Weeks.
Syllabus for the trade of Operator PLC System
under
Apprenticeship Training Scheme
List of the members present in trade committee meeting held on 13th January 2007 at
ITI, Aundh, Pune, Maharashtra
S.No. Name and Designation
Organisation
1.
Shri Rajendra Gaikwad, Specialist Engineer, R & Force Motors Ltd., Pune
D-HCV
2.
Shri B.U.Bhandari, Works manager
TATA Motors, Pune
3.
Col. U.G.Umrani, G.M.
Maruti Suzuki
Syllabus for trade of ‘Operator PLC System’
SR.NO.
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17.
SHOPFLOOR TRAINING
Single & double actuator circuits (Pneumatics)
Programming as per application
Wiring of PLC, connecting relay logic with PLC
Replacement of burnt relays, contactors etc.
Checking the configuration of PLC as per Hardware
Crimping/soldering of communication cables
Fault finding of Pneumatic multi actuator circuits, checking the sequence.
Repairing the valves replacement of seals, maintenance of pneumatic
system i.e. valves, cylinders etc.
Simple ladder development using PLC like Siemens, ABB, Allen Bradley,
Fanuc, Mitsubishi, Omron, Messung etc.
Installation of Programming Software
Configuration of Driver
Multiple ladder development using PLC
Siemens, ABB, Allen Bradley, Fanuc, Mitsubishi, Omron, Messung etc.
Multiple ladder development
Use of timers in circuit. TON, TOF, RTO
Application of timer in ladder logic time base, preset value, accumulator
value (online checking)
Multiple ladder development
Use of Counters in circuit
CTU, CTD counting mechanism, sensors/LIMIT Switches used for counting
the production.
Connecting the sensor in PLC circuits
Installation of sensors
Replacement of damaged sensors
Speed control, types of attachment required for conveyer system., Belt
tightening, adjustments of speed as per production, maintenance etc.
Basic parameter setting of drives. (Programming) like Siemens, ABB,
ALLEN Bradley, DELTA DANFOSE, B&R, Mitsubishi etc.
Basic parameter setting of drives. (Programming) like Siemens, ABB,
ALLEN Bradley, DELTA DANFOSE, B&R, Mitsubishi etc.
Advanced parameter setting of drives by using keypad (programming) like
Siemens, ABB, ALLEN BRADLEY , DELTA, DANFOSE, B & R, Mitsubishi
etc.
Setting & checking the parameters by using HMI, ON-OFF CONTROL etc.
Controlling the devices by using HMI
Start & stop, DATA setting etc.
18.
Maintenance & servicing of hydraulic valves, power pack maintenance etc.
19.
Causes & remedies of different faults occurred in components rectification
of faults, replacement of valve/part, repairing etc.
Compressor maintenance. Dryer maintenance & servicing
Replacement of piston rings etc., attachments used with pneumatic
cylinders, accurate setting of attachments.
Connection of PT 100/RTD, pressure sensors, load cell, configuring
sensors as per output. Voltage/current input or output configuring it in
software as per voltage or current.
Checking of parameters by using of SCADA, data recording, parameter
setting/checking by using SCADA.
Checking of parameters by using of SCADA. Report generation
20.
21
22
23.
24.
25
Concept of Robotic operation
Welding, pick & place Robot Operation Sequence
Preparation of project
26
Preparation of project.
Related Instructions
1.
Introduction of Pneumatic & Hydraulic components
Introduction of PLC types of PLC (Revision)
2.
Industrial wiring diagram of PLC
Wiring diagram & fault finding & labeling of PLC
3.
Panel board wiring with PLC
Relay logic, relays used in panel board, isolation of PLC circuit & power circuit by
using relays.
4.
Configuration of PLC system available in shop floor
5.
Communication system, type of communication, RS232, DH+, DH485, TCPIP etc.
Data transfer
6.
Multi actuator circuits, operation & sequencing, displacement diagram
Fault finding of Pneumatic multi actuator circuits, checking the sequence. Repairing
the valves replacement of seals etc.
7.
Addressing method of PLC Siemens, ABB, Allen-Bradley, Fanaque, Mitsubishi,
Omron and Messung etc. Simple ladder development using PLC, installation of
programming software, configuration of driver.
8.
Multiple ladder development
Use of flags in circuit. Application of Multiple ladder programming
Case study addressing method of PLC. Siemens, ABB, Allen-Bradley, Fanaque,
Mitsubishi, Omron, Messung etc. Multiple ladder development using PLC.
9.
Multiple ladder development. Use of timers in circuit
Application of timer in ladder logic time base, present value, accumulator value
(online checking)
10.
Multiple ladder development
use of counters in circuits. Counting mechanism, sensors, used for counting the
production
11.
Sensors & types. Two wire, three wire etc.. Inductive, capacitive, optical etc.
12.
Industrial application of sensors, Pressure, temperature, speed, flow, level etc.
Analog programming (I/P, O/P)
13.
Conveyers & types of conveyers. Conveyer system application, speed control, types
of attachment required for conveyer system.
14.
Introduction of A.C. drives. Basic parameter setting of drives (programming)
15.
Single phase & three phase A.C. drives, Difference & application.
16.
Introduction to Human Machine Interface (HMI). Setting & checking the parameters
by using HMI
17.
Simple programming by using HMI, selection of PLC while programming
18.
Application of PLC in hydraulic system. Case study.
19.
Concept of low cost automation & applications
20.
Application of PLC in food industry, engineering industry, refinery, beverages etc.
preparation of air for food packing, pharmaceutical packing.
21.
RTD/PT 100 type sensors, importance, voltage/current type’s difference. Connection
of PT 100/RTD, pressure sensors, load cell, configuring sensors as per output.
22.
Introduction of SCADA. Checking of parameters by using of SCADA. Connecting
SCADA with PLC by using PC.
23.
Preparation of project on case study of industry
24.
Basic Robotics
25.
Concept of project
26.
Concept of project