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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. 1 2 3 4 5 6 7 8. 9. 10. 11 12. 13. 14. 15. 16. 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