Download MECHANIC MECHATRONICS Syllabus For the trade of

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.
1
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
NAME & DESIGNATION
S/SHRI
Hitesh Mehta
Chairman
Ilesh Shah, Managing Director
3
Hemant Monaya, Director
4
Ganesh Rahate, Sr. Engineer
5
M Loynmoon, Sr. Engineer
6
Paras Dagli, Director
7
Shabbir Shaikh, 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
REMARKS
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Dipak Ghule, Sr. Engineer
Oasis Tech. Pvt. Ltd. Pune.
Member
9
Abhoy Dhotra, Director
Bi-Tronics Pvt. Ltd. Thane
Member
10
Jitin Doshi, Executive Director
11.
K.W. Khatavkar, Principal
Dashy Corporation for Dental Member
Occupation, Chambur Mumbai
I.T.I. Mumbai
Member
12
H N Bargal, Training Officer
I.T.I. Mumbai
Member
13
L.K. Mukherjee, Dy. Director
C.S.T.A.R.I., Kolkata
Member
14
Abhinoy Nandi, Dy. Director
C.S.T.A.R.I., Kolkata
Member
Chairman
Member
Member
Member
Member
Member
Member
2
General Information
1.
Name of the Trade
: MECHANIC MECHATRONICS
2.
N. C. O. Code No.
: 7243.10
3.
Entry Qualification
: Passed 12th class examination under 10+2
system of education with Physics, Chemistry &
Mathematics or its equivalent.
4.
Duration of Craftsman Training
: Two year
5.
Duration of Apprenticeship Training: Three years including two years craftsman
training.
6.
Rebate
: Two year ITI/ITC passed out trainees in the
trade of Mechanic Mechatronics.
7.
Ratio of Apprentice to Workers
: 1: 5
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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
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(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
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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.
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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.
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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.
(3)
Electro Mechanical/Magnetic Devices & components:
i.
ii.
iii.
iv.
(4)
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.
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, FET’S, UJT,
DIAC’S, TRIAC’S etc. and integrated circuits. Application of the above components in
common electronic equipment. Display devices-Nixie tubes, LEDs, LCDs, etc.
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(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
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(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.
……………
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