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1
CURRICULUM
FOR THE TRADE OF
MECHANIC MECHATRONICS
UNDER
APPRENTICESHIP TRAINING SCHEME
GOVERNMENT OF INDIA MINISTRY OF SKILL DEVELOPMENT & ENTREPRENURESHIP
DIRECTORATE GENERAL OF TRAINING
2
CONTENTS
Sl. No. Topics Page No.
1. Acknowledgement 3-4
2. Background
2.1 Apprenticeship Training under Apprentice Act 1961
2.2 Changes in Industrial Scenario
2.3 Reformation
5
3. Rationale 6
4. Job roles: reference NCO 7
5. General Information 8
6. Course structure 9-10
7.
Syllabus
7.1 Basic Training
7.1.1 Detail syllabus of Core Skill
A. Block-I (Engg. drawing & W/ Cal. & Sc.)
B. Block-II (Engg. drawing & W/ Cal. & Sc.)
7.1.2 Detail syllabus of Professional Skill & Professional
Knowledge
A. Block – I
B. Block – II
7.1.3 Employability Skill
7.1.3.1 Syllabus of Employability skill
A. Block – I
B. Block – II
7.2 Practical Training (On-Job Training)
7.2.1 Broad Skill Component to be covered during on-job
training.
A. Block – I
B. Block – II
11-39
8.
Assessment Standard
8.1 Assessment Guideline
8.2 Final assessment-All India trade Test (Summative
assessment)
40-42
9. Further Learning Pathways 43
10. Annexure-I – Tools & Equipment for Basic Training 44-49
11. Annexure-II – Infrastructure for On-Job Training 50
12. Annexure-III - Guidelines for Instructors & Paper setter 51
3
1. ACKNOWLEDGEMENT
The DGT sincerely express appreciation for the contribution of the Industry, State Directorate,
Trade Experts and all others who contributed in revising the curriculum. Special acknowledgement to
the following industries/organizations who have contributed valuable inputs in revising the curricula
through their expert members:
1. Ordnance Factory, Medak
2. Voith Turbo, Hyderbad
3. Nuclear Fuel Complex, Hyderabad
4. Hindustan Flurocarbon Ltd., Hyderabad
5. NVIS Technologies, Hyderabad
6. Scientech Technologies P. Ltd., Hyderabad
7. Bharat Electronics Ltd., Hyderabad.
8. ECIL, Hyderabad.
Special acknowledgement is extended by DGT to the following expert members who had
contributed immensely in this curriculum.
Co-ordinator for the course: Shri L.K.Mukherjee, DDT & P. G. Rajendran, ADT
SI. No. Name & Designation Representing Org. Remarks
1. L. K. Mukherjee, DDT CSTARI, Kolkata Expert
2. P. G. Rajendran, ADT ATI-EPI, Hyderabad. Expert
3. D. Srinivasa Rao, DDT ATI (V), Hyderabad. Expert
4. N. Sabhapathi,
Additional Manager
Nuclear Fuel Complex, Hyderabad Expert
5. G. Pradeep Kumar,
Dy .Manager
Nuclear Fuel Complex, Hyderabad Expert
6. G. S. Sastry, Manager (C&I) Voith Turbo, Hyderbad Expert
7. Sanjay Mahagankar,
Manager (Inst)
Hindustan Flurocarbon Ltd., Hyderabad Expert
8. M. Abhinav Karthik,
Sr. Manager Engineer
NVIS Technologies, Hyderabad Expert
9. Vijay Singh Kushwah, Branch
Manager
Scientech Technologies P. Ltd., Hyderabad Expert
10. G. Satyanarayana,
Jr. Works Manager
Ordnance Factory, Medak Expert
11. P. Bheeshma Chary, Ordnance Factory, Medak Expert
4
Jr. Works Manager
12. V. Ramesh, Asst. Director Ordnance Factory Learning Institute.
Medak
Expert
13. A. Jagadeeshwar,
Sr.DGM(Assy.&Plng)
Bharat Electronics Ltd., Hyderabad. Expert
14. M. Balaiah, Manager
(Assembly)
Bharat Electronics Ltd., Hyderabad. Expert
15. K. C. Meenakshisundaram ECIL, Hyderabad. Expert
5
2. BACKGROUND 2.1 Apprenticeship Training Scheme under Apprentice Act 1961
The Apprentices Act, 1961 was enacted with the objective of regulating the programme of training of
apprentices in the industry by utilizing the facilities available therein for imparting on-the-job
training. The Act makes it obligatory for employers in specified industries to engage apprentices in
designated trades to impart Apprenticeship Training on the job in industry to school leavers and
person having National Trade Certificate(ITI pass-outs) issued by National Council for Vocational
Training (NCVT) to develop skilled manpower for the industry. There are four categories of
apprentices namely; trade apprentice, graduate, technician and technician (vocational)
apprentices.
Qualifications and period of apprenticeship training of trade apprentices vary from trade to trade.
The apprenticeship training for trade apprentices consists of basic training followed by practical
training. At the end of the training, the apprentices are required to appear in a trade test conducted by
NCVT and those successful in the trade tests are awarded the National Apprenticeship Certificate.
The period of apprenticeship training for graduate (engineers), technician (diploma holders and
technician (vocational) apprentices is one year. Certificates are awarded on completion of training by
the Department of Education, Ministry of Human Resource Development.
2.2 Changes in Industrial Scenario
Recently we have seen huge changes in the Indian industry. The Indian Industry registered an
impressive growth during the last decade and half. The number of industries in India have increased
manifold in the last fifteen years especially in services and manufacturing sectors. It has been realized
that India would become a prosperous and a modern state by raising skill levels, including by
engaging a larger proportion of apprentices, will be critical to success; as will stronger collaboration
between industry and the trainees to ensure the supply of skilled workforce and drive development
through employment. Various initiatives to build up an adequate infrastructure for rapid
industrialization and improve the industrial scenario in India have been taken.
2.3 Reformation
The Apprentices Act, 1961 has been amended and brought into effect from 22nd December, 2014 to
make it more responsive to industry and youth. Key amendments are as given below:
Prescription of number of apprentices to be engaged at establishment level instead of trade-
wise.
Establishment can also engage apprentices in optional trades which are not designated, with
the discretion of entry level qualification and syllabus.
Scope has been extended also to non-engineering occupations.
Establishments have been permitted to outsource basic training in an institute of their choice.
The burden of compliance on industry has been reduced significantly.
6
3. RATIONALE (Need for Apprenticeship in “Mechanic Mechatronics” trade)
Apprenticeship course in the trade of “Mechanic Mechatronics” is necessary due to
following reasons:
Learning opportunities in Mechatronics are limited in ITIs due to high investment
required to procure tools and equipment for conducting practical classes.
Apprenticeship in industry establishments where mechatronic systems and
machines are already available is the better and viable solution to meet manpower
requirements in the trade.
In today’s industry conventional machines are replaced by advanced mechatronic
machines like CNC, Flexible Manufacturing Systems (FMS), Computer Integrated
Manufacturing Systems (CIMS), etc. Hydraulic and Pneumatic systems are also
getting replaced by Electro-hydraulic and Electro-pneumatic systems.
Technicians with General Fitter, Electronic Mechanic qualifications cannot repair
and maintain these mechatronic equipment effectively.
To repair and maintain the advanced mechatronic equipment, technicians with
multi skills in the areas of mechanical, hydraulics, pneumatics, electrical and
electronics are required for the industry.
The present syllabus is revised accordingly to impart multi skills in the areas of
mechanical, hydraulics, pneumatics, electrical and electronics so that after
completion of the apprenticeship the trainees can effectively repair and maintain
the Mechatronics equipment effectively in the industry.
7
4. JOB ROLES: REFERENCE NCO Brief description of Job roles:
The breakdown cost of CNC machines and other mechatronic systems is very high. The
role of Mechanic Mechatronics is very important in the industry to keep the breakdown
cost to minimum.
The job roles expected from Mechanic Mechatronics is described below:
To repair and maintain CNC machines and other Mechatronic systems in working
condition.
To analyze the alarm messages displayed by the CNC system and to initiate
necessary action to solve the problem.
Read and understand the circuit diagrams of hydraulics, pneumatics, electrical and
electronics to analyze the problem for solution.
To coordinate with the production section to ensure strict adherence to the daily,
weekly, quarterly maintenance schedules of the CNC machines and other
Mechatronics systems to avoid costly breakdowns.
To plan and execute preventive maintenance of CNC machines and other
Mechatronics systems to avoid breakdowns.
To dismantle mechatronic systems like spindle assembly, ball screw, gear box, feed
mechanism, lubrication system, coolant system, feedback devices, check different
parts, make necessary repairs and reassemble the systems.
To check the repaired and reassembled systems for proper functioning and fit them
in the machine.
To advice management in maintenance of necessary spares inventory of CNC
machines to reduce breakdown time.
Reference NCO: 7233.38,
7233.46
8
5. GENERAL INFORMATION
1. Name of the Trade : Mechanic Mechatronics
2. N.C.O. Code No. : 7233.38, 7233.46
3. Duration of Apprenticeship Training (Basic Training + Practical Training): 2years
3.1 For Freshers :- Duration of Basic Training: -
a) Block –I : 3 months
b) Block – II : 3 months
Total duration of Basic Training: 6 months
Duration of Practical Training (On -job Training): -
a) Block–I: 9 months
b) Block–II : 9 months
Total duration of Practical Training: 18 months
3.2 For ITI Passed :- Duration of Basic Training: - NIL
Duration of Practical Training (On -job Training): 12 months
4. Entry Qualification : Passed 10th class examination under 10+2system of
education with Science and Mathematics or its equivalent.
5.Selection of Apprentices: The apprentices will be selected as per Apprentices Act
amended time to time.
6. Rebate to ITI Passed out Trainees : i) One year in the trade of Mechanic Mechatronics ii) One year in the trade of Mechanic Machine Tools Maintenance
Note: Industry may impart training as per above time schedule for different block,
however this is not fixed. The industry may adjust the duration of training considering
the fact that all the components under the syllabus must be covered. However the
flexibility should be given keeping in view that no safety aspects is compromised.
9
6. COURSE STRUCTURE Training duration details: -
Time (in months)
1-3 4-12 13-15 16-24
Basic Training Block– I ----- Block – II ------ Practical Training (On - job training)
---- Block – I ------ Block – II
10
Components of Training
Duration of Training in Months
1 2 3 4 5 6 7 8 9 1 0
1 1
1 2
1 3
1 4
1 5
1 6
1 7
1 8
1 9
2 0
2 1
2 2
2 3
2 4
Basic Training Block - I Practical Training Block - I
Basic Training Block - II
Practical Training Block - II
11
7. SYLLABUS
7.1 BASIC TRAINING (BLOCK – I & II) DURATION: 06 MONTHS
GENERAL INFORMATION
1) Name of the Trade : MECHANIC MECHATRONICS
2) Hours of Instruction : 1000 Hrs. (500 hrs. in each block)
3) Batch size : 20
4) Power Norms : 8.0 KW for Workshop
5) Space Norms : 192 Sq.m.
6) Examination : The internal assessment will be held on
completion of each Block.
7) Instructor Qualification :
a) Degree / Diploma in Mechanical/ Mechatronics Engg. from recognized university/ Board with one/two years post qualification experience respectively in the relevant field.
OR
b) NTC/NAC in the trade of “Mechanic Mechatronics” with three years post
qualification experience in the relevant field.
Preference will be given to a candidate with Craft Instructor Certificate (CIC).
c) Tools, Equipments & Machinery required : - As per Annexure – I
12
7.1.1 DETAIL SYLLABUS OF CORE SKILL A. Block– I Basic Training
Topic
No.
a) Engineering Drawing Duration
(in
hours)
b) Workshop Science &
Calculation
Duration
(in
hours)
30 20
1 Engineering Drawing:
Introduction and its
importance
- Viewing of engineering
drawing sheets.
- Method of Folding of
printed Drawing Sheet as per
BIS SP:46-2003
Unit: Systems of unit- FPS,
CGS, MKS/SI unit, unit of
length, Mass and time,
Conversion of units
2 Drawing Instruments : their
uses
Drawing board, T-Square,
Drafter (Drafting M/c), Set
Squares, Protractor, Drawing
Instrument Box (Compass,
Dividers, Scale, Diagonal Scales
etc.), Pencils of different Grades,
Drawing pins / Clips.
Fractions: Fractions, Decimal
fraction, Addition,
Subtraction, Multiplication
and Division of Fractions and
Decimals, conversion of
Fraction to Decimal and vice
versa. Simple problems using
Calculator.
3 Lines :
- Definition, types and
applications in Drawing as per
BIS SP:46-2003
- Classification of lines
(Hidden, centre, construction,
Extension, Dimension, Section)
- Drawing lines of given
length (Straight, curved)
- Drawing of parallel lines,
perpendicular line
Methods of Division of line
Properties of Material :
properties -Physical &
Mechanical, Types –Ferrous
& Non-Ferrous, difference
between Ferrous and Non-
Ferrous metals, introduction
of Iron, Cast Iron, Wrought
Iron, Steel, difference
between Iron and Steel, Alloy
steel, carbon steel, stainless
steel, Non-Ferrous Alloys.
13
segment
4 Drawing of Geometrical
Figures: Drawing practice on:
- Angle: Measurement and
its types, method of bisecting.
- Triangle -different types
- Rectangle, Square,
Rhombus, Parallelogram.
- Circle and its elements.
Average: Problems of
Average.
Ratio &Proportion: Simple
calculation on related
problems.
5 Dimensioning:
- Definition, types and
methods of dimensioning
(functional, non-functional and
auxiliary)
- Types of arrowhead
- Leader Line with text
Mass, Weight and Density:
Mass, Unit of Mass, Weight,
difference between mass and
weight, Density, unit of
density.
6 Free hand drawing of
- Lines, polygons, ellipse,
etc.
- geometrical figures and
blocks with dimension
- Transferring
measurement from the given
object to the free hand sketches.
7 Method of presentation of
Engineering Drawing
- Pictorial View
- Orthogonal View
- Isometric view
Percentage: Introduction,
Simple calculation. Changing
percentage to decimal and
fraction and vice-versa.
8 Symbolic Representation (as
per BIS SP:46-2003) of:
- Fastener (Rivets, Bolts
and Nuts)
- Bars and profile sections
- Weld brazed and
soldered joints.
- Forces definition.
- Definition and example of
compressive, tensile, shear
forces, axial and tangential
forces.
Stress, strain, ultimate
strength, factor of safety for
14
- Electrical and electronics
element
- Piping joints and fittings
MS.
Speed and Velocity: Rest
and motion, speed, velocity,
difference between speed and
velocity, acceleration,
retardation.
9 Dimensioning practice:
- Position of dimensioning
(unidirectional, aligned, oblique
as per BIS SP:46-2003)
- Symbols preceding the
value of dimension and
dimensional tolerance.
Mensuration: Area and
perimeter of square,
rectangle, parallelogram,
triangle, circle, semi circle.
Volume of solids – cube,
cuboids, cylinder and Sphere.
Surface area of solids – cube,
cuboids, cylinder and Sphere.
- Area of cut-out regular
surfaces: circle and segment
and sector of circle.
- Volume of cut-out solids:
hollow cylinders, frustum of
cone, block section.
- Volume of simple solid
blocks.
10 Construction of Geometrical
Drawing Figures:
- Polygons and their values
of included angles.
Conic Sections (Ellipse)
Algebra: Addition,
Subtraction, Multiplication,
Division, Algebraic formula,
Linear equations (with two
variables).
- Circular Motion: Relation
between circular motion and
Linear motion, Centrifugal
force, Centripetal force.
11 Projections:
- Concept of axes plane and
quadrant.
- Orthographic projections
- Method of first angle and
Work, Power and Energy:
work, unit of work, power,
unit of power, Horse power,
mechanical efficiency, energy,
use of energy, potential and
15
third angle projections
(definition and difference)
- Symbol of 1st angle and
3rd angle projection as per IS
specification.
Drawing of Orthographic
projection from isometric/3D
view of blocks
kinetic energy, examples of
potential energy and kinetic
energy.
16
B. Block- II Basic Training
Topic
No. a) Engineering Drawing Duration
(in hours)
b) Workshop Science & Calculation
Duration (in hours)
1 - Machined components;
concept of fillet & chamfer; surface finish symbols.
30 Trigonometry: Trigonometric ratios, Trigonometric tables. - Finding the value of unknown sides and angles of a triangle by Trigonometrical method. - Finding height and distance by trigonometry.
20
Friction and its application in Workshop practice.
2 - Screw thread, their standard forms as per BIS, external and internal thread, conventions on the features for drawing as per BIS.
Heat & Temperature: Heat and temperature, their units, difference between heat and temperature, boiling point, melting point, scale of temperature, relation between different scale of temperature, Thermometer, pyrometer, transmission of heat, conduction, convection, radiation.
3 - Reading & interpretation of assembly drawing and detailing.
Basic Electricity:
Introduction, use of
electricity, Types of
current_ AC, DC, their
comparison, voltage,
resistance, their units.
Conductor, insulator, Types
of connections – series,
parallel, electric power,
17
Horse power, energy, unit
of electrical energy.
Concept of earthing.
Heat treatment – Necessity, different common types of Heat treatment.
Graph: - Read images, graphs, diagrams – Bar chart, pie chart. - Graphs: abscissa and ordinates, graphs of straight line, related to two sets of varying quantities.
4 - Reading of drawing. Simple exercises related to missing lines, dimensions and views. How to make queries.
Transmission of power: By belt, pulleys & gear drive.
5 - Simple exercises related to trade related symbols. - Solution of NCVT test papers.
Concept of pressure – units of pressure, atmospheric pressure, gauge pressure – gauges used for measuring pressure. Introduction to pneumatics & hydraulics systems. Solution of NCVT test papers
18
7.1.2 DETAIL SYLLABUS OF PROFESSIONAL SKILLS & PROFESSIONAL KNOWLEDGE
A. Block –I Basic Training
Week No.
Professional Skills Professional Knowledge
1 Job role of “MECHANIC MECHATRONICS” in industry. Identification of the tools used in the trade. Importance of Cleanliness & orderliness at the workplace.
Safety, accidents & causes of accidents. General Safety, Precautions & personal safety to be observed while working, Safe working habits.
Overview of mechanical, electrical, electronic, hydraulic and pneumatic systems. 02-03 Use of hand tools such as screw driver,
spanners, circlip pliers, wrenches, pullers, extractors, drifts, etc.
Basic Filing operations for fitting. Use of simple measuring instruments
such as Steel Rule, vernier caliper, Micrometers.
Drilling practice on varying thickness & different materials such as Mild Steel, cast Iron, Copper, Brass, Nylon, epoxy etc. Counter sinking, counter boring operations using bench drilling machine.
Exercises on Reaming with hand reamers & machine reamers.
Internal threading by hand Tap Sets. External threading by dies.
Types of hand tools such as spanners, screw drivers, nuts, bolts, etc. Types of Screws and their functions. Measuring instruments: steel rule, vernier caliper, Micrometers. Study of Sine bar and slip gauges.
Types of files and filing operations.
Introduction to drilling machines – hand
drilling machine, bench and pillar
drilling machine. Drill chuck and nut.
Types of drills, reamers, hand tap sets,
dies, etc. Drilling, Reaming, Tapping,
external threading by dies.
04-05 Machine tool technology : 1. Lathe 2. Milling machine 3. Grinding machine.
Dismantling, checking, repair and maintenance of different parts of above machines like gear box, feed mechanism, coolant system and accessories like machine vice, three jaw chuck, etc.
Introduction to Machine Tool technology : 1. Lathe 2. Milling machine 3. Grinding machine. Study of above three machines in the following areas:
Constructional features Study of the gear box Feed Mechanism Coolant system Accessories
19
06-07 Joining of flexible cables by soldering. Staggered joints in case of twin wires or multi- core cables. Familiarization with different types of plugs, sockets, switches, fuses and fuse holders, etc. Testing of switches, buttons, limit switches, micro switches by using continuity tester for their operation. Identification of live, neutral and earthling wires before connecting cable to plugs, sockets, switches, etc. Use of test lamp and multi-meter for identifying single phase/three phase power supply. Use of multi-meter for voltage, current and resistance measurement. Checking of DC supply. Use of voltmeter and ammeter for voltage and current measurement respectively. Connecting portable single phase AC operated industrial equipment such as drilling machine and domestic applications such as washing machines, cooking range, geyser etc. Practice of series and parallel connection of loads and measurement of voltage drops across the loads and line current. Practice of logic development for control.
Basic Electrical & Electronics: Classification of materials as conductors and insulators, semiconductors and resistors. Concept of voltage, current and Resistance. Electrical safety rules and precautions. Ohm’s Law and Kirch off voltage and current law. Types of circuits – series, parallel and series – parallel. Electrical work, power and energy – definitions and units of measurement and their inter relationship. Primary sources of electromotive force /electrical energy. Primary and Secondary cells. Introduction to electrical supply system with special reference to AC. Different voltages in use AC and DC.
08 Practical on basic Electronics: Scope of industrial electronics with reference to its applications in machine tool operation. Identification of basic components such as registers, capacitor, inductors etc. from their outlook. Types, specifications and general applications of these components. Testing and measurement of their values using multi-meter. Use of resistance colour codes. Soldering and de-soldering of component on and from printed circuit boards (PCB). Precautions to be taken while soldering on PCB. Study of rectifiers circuits – half wave, full wave and bridge rectifiers. Use of oscilloscope for checking of input and output wave forms. Study of solid state devices such as diodes, transistors, SCRs and
Basic Electronics: Semi-conductor theory. Intrinsic and extrinsic semi conductors. P and N type semiconductors and P-N junction – semiconductor diode – two layers and two terminal devices. Use of PN junction as switch. Use of PN junction for rectification. Half wave, full wave and bridge rectifiers. P-N-P and N-P-N junction devices –transistor – three layer three terminal devices. Use of transistor of a switch and its simple applications. Use of transistor for amplification – how amplification takes place. Soldering technique as applied to PCB soldering DO’s and Don’ts.
20
ICs available in different packages. Types and applications. Identification of leads and testing by multi-meters. Assembly of simple battery eliminator circuit using bridge rectifier and filter capacitor. Measurement of input and output voltages. Familiarization with soldering station, Desoldering station, IC tester.
09 Introduction to leveling of machines. Practice on leveling – use of sprit level, straight edge, etc. Leveling of surface plates, marking table, milling machine, grinding machine etc. – preparation of test report indicating degree of flatness. Introduction to machine alignment. Checking lathe, milling, grinding machines for alignment and preparing test reports, comparing with standard test charts.
Types of vibrators, causes and prevention of vibrations. Methods of insulation of machines of machines against vibration. Anti-vibration devices and their locations. Different types of instruments used for checking the vibrations. Leveling machines, importance of leveling. Methods of grouting. Use of machine levelling screws. Methods of leveling, precautions to be taken while leveling, levelling accuracy – its measurement.
10 Familiarization with plain/journal bearings, anti-friction bearings used on machine assembly. Specification & selection for appropriate use. Mounting of bearing on shafts & axis alignment. Removal of bearings from shafts & housing by using pullers.
Method of reducing friction, Use of bearing advantages & disadvantages. Bearings-different types. Specification of bearings, dimensional relationship of the shaft with bearing-the type of loads. Method of clamping and fitting the bearing in the mounting and dismounting. Anti- friction bearings-their types and uses. Lubrication of bearing high speed bearing. Care and Maintenance and inspection of bearings.
11-12 Familiarization with electrical symbols being used in electrical circuit diagrams. Practice in reading electrical circuit/connection diagrams from the instructional manual. Circuit tracing practice. Identifying electrical hardware items from their outlook. Checking/testing Contactors. Developing control circuit using ladder/schematic diagrams. Use of control elements to
Advanced electrical electromagnetism. Concept of a coil (Electromagnetic) and Capacitors-principles of operations. Use of a coil in hydraulic and Pneumatic solenoids. Use of capacitors to store energy. Electromagnetic induction, Motor effect and generator effect. Electrical motors- construction and features, types of both AC and DC motors
21
build and test manual, inching, hold on and start/stop push button control circuits. Circuit building practice. Wiring of power and control circuit on test board such as direct on line starter, automatic star-delta starter and forward/reverse control for 3 dia. Induction motors etc. Study and use of safety elements such as miniature circuit breaker (MCB), over load relay, earth leakage repay, protecting fuses in power circuit wiring and testing. Measurement of winding and body resistance of DC motors and induction motors by Multimeter. Connecting induction motor to panel and measurement of line current. Simulated fault finding on control panel. Isolation of machines from electrical cabinet by removing back up fuses, switching off main switch. Replacement of brushes, setting of brushes. Locating over loaded motor and finding out its causes such as fuse blown, mechanical jamming, loose connections, faulty settings etc. Locating faults in power circuit such as power fuse blown, MCB tripped, control fuse blown etc. Checking of electrical motors by measuring winding resistance, balance of resistance, body resistance. Checking of electromagnetic clutches, brakes, chuck magnet etc.
and applications. Measurements of electrical quantities –Use of voltmeter, Ammeter and Multimeter-principles of operation. Elements of electrical system control power and safety elements. Circuit breakers, fuses, contractor, relays, timers-principles of operation & constructional details. Simple motor control, inching control, star delta control starter, push button switches, limit switches. Micro switches, pressure switches over load relays etc. Safety inters locks, Speed control of AC induction & DC motors. Automatic operation-use of control circuits-logical development of control circuit diagram using contractors and relays. Concept of ladder diagram. Understanding of power and control circuit in general (with few examples). Inter related between them. Safety in handling and operating electrical equipments.
13 Assessment / Examination (03 days)
22
B. Block –II Basic Training
Week
No. Professional Skills Professional Knowledge
01 Logic gates: Building logic gates such as AND, OR, NOR, INVERTER, NAND, EX-OR using diodes and transistors output lamps indicating conditions in truth table (Analogy of logic gates to series and parallel combination of switches).
Introduction to logic gates e.g. AND, OR, INVERTER, NAND, NOR, EX-OR, etc. Their truth table analogy of logic gates, combination of series and parallel switches
02 Hydraulic Circuit building practice: Regenerative (sequencing) circuit with speed and pressure (clamping) control. Counter balance circuits with speed control. Traverse and feed circuits. Differential check valve, pressure regulator valve, pressure relief valve etc. Study of stackable (modular) type hydraulic control valves. Study of manifolds, accumulator, intensifier, rotary joints etc. Study of machine tool applications of the hydraulic drives for rotary, reciprocating, speed changing, clamping, unclamping and feed motions. Trouble shooting in hydraulic drive circuits. Repairs and maintenance of the pumps. Repairs and maintenance of valves. Adjustment of valves. Repairs and maintenance of actuators, hydraulic motors, etc. Hydraulic power source and circuits. Study of different hydraulic circuits of CNC Turning, Milling, Grinding machines. Study of hydraulic oil.
Construction features of pumps. Constructional features valves: directional control, pressure control, flow control, check valves, pilot operated check valve, simple relief valve. Meter in circuit, meter out circuit, bleeding off circuits. Pressure, temperature and flow. Hydraulic actuators: Hydraulic motor and hydraulic cylinders. Study of manifolds, accumulator, intensifier, etc. Study of machine tool application of the hydraulic drives for rotary, reciprocating, speed changing, clamping, unclamping and feed motions. Study of different types of hydraulic and lubricant oils. Introduction to seals. Regular care of hydraulics. Hydraulic power and circuits. Study of different hydraulic circuits Of CNC Turning, Milling, Grinding m/cs.
03 Pneumatic Circuit building practice: use of shuttle valves for control, circuit for speed regulation of single and double acting cylinder, circuits for indirect control on single and double acting cylinders, time dependent control circuits etc. Study of machine tool applications of pneumatics
Constructional details, specifications, application of power unit, actuating unit, control unit. Power unit-types of compressors reservoirs, condensers, filters, service units. Actuating units-single/double acting cylinders, rotary actuators, sander, disc grinder, nut runner
23
.Use in low cost automation, manipulators, material handling equipment and pneumatic hand tools. Setting of pneumatic circuit elements for proper functioning – adjusting cushioning of the cylinders, flow, pressure etc. Repairing of pneumatic chisels, grinders, sanders, hammers, nut-spanners etc. Pneumatic power source and circuits. Study of different pneumatic circuits of CNC Turning, Milling, Grinding m/cs. Study of air, coolant filtration system.
etc. Control units-directional control, pressure control and flow control valves. Pipe and pipe fittings materials, types, specifications and applications. Types of seals, packing and glands. Pneumatic power and circuits. Study of different pneumatic circuits Of CNC Turning, Milling, Grinding m/cs. Study of air filtration system.
04 (a) Testing of components : 1. Resistors
2. Coils
3. Capacitors 4. Ferrite components 5. Transducers
6. Crystals
7. Relays
8. Micro-switches
9. Plugs and sockets
10. Active components 11. Plated metal parts (b) Bulk Testing of Electronic Components using Test Rigs & Jigs (c) Use of Test Instruments such as : 1.Insulator Tester
2. Megger
3. Transistor Tester
4. I.C. tester
5. Logic circuit Tester 6. Logic analyzer
Electro Mechanical/Magnetic Devices & components: i) Various types of relays and their
applications ii) Micro switches, limit switches, Solenoid,
Actuator & relays, Sensors, Proximity switches and other types of switches and their applications in electronic systems
iii) 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,etc. 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
24
etc. and integrated circuits. Application of the above components in common electronic equipment. Display devices-Nixie tubes, LEDs, LCDs, etc.
05 5. Transformers & Coils : 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.
Transformers: Input, output, power, driver, EHT & pulse transformers, their windings and applications. 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
06 CNC Technology:
Computer basics: CPU, Monitor, RAM, ROM, etc. Use of computers as a CNC workstation, communication between CNC and computer communication hardware, software. Study of special constructional and operational features with reference to driving mechanism, machine tool design, lubrication system. Familiarization with co-ordinate system, use of CNC codes and programming for simple test jobs. Manufacturing of simple jobs programmed on CNC trainer. Demonstrating the CNC machine features such as i) Flexibility, efficiency, repeatability. ii) Axis movement-rapid, feed, jog, manual data input modes, over travel limits. iii) Axis driving elements-Servomotors, gear
Computer basics: CPU, Monitor, Memory - RAM, ROM, PPROM, EPROM. Basic DOS commands, use of computer as CNC work station, communication between CNC & computer. Introduction to CNC machines: Difference between NC, CNC and GPM Importance of CNC machines over other mass production processes. Constructional details & working principles of CNC machines machine beds-ball screw mechanism-servo drives-feedback mechanism etc. Axes designation. Introduction to G and M codes. CNC tooling and fixtures. Manual part programming.
25
box, bal screw, position feedback, open loop, close loop control, following error, position loop. iv) Reference point v) Execution of part programme in dry run.
07 Study and practice of various CNC operating elements on CNC vertical machining center. CNC operation-referencing (zeroing), part programming. Use of M/S/T/G codes, and tool offsets, zero offset. Cutter radius compensation facilities. Precautions to be followed while executing commands and part programmes. Practice on CNC machining center incorporating all available facilities.
Spindle speed system: - 1) True running of spindle assembly 2) To withstand for radial and axial load. 3) Types of spindle bearing-anti-friction, hydrodynamics, hydro statics. 4) Pre-loading of spindle bearing. 5) Temperature rise test of spindle for proper preloading, lubrication of spindle. 6) Study of gear box and automatic speed range for constant power & constant torque. 7) Maintenance of same as mentioned above.
08 CNC machine maintenance: use of maintenance card, history card & recording the data. Reading and analyzing of CNC alarm message during machine operation. Preventive maintenance of machine such as checking of lubrication oil level, coolant level, hydraulic oil levels.
Linear axis feed system: - 1) Study of re-circulating ball screw. 2) Basic elements of ball screw(external &
internal) 3) Pre loading of ball screw, tension &
compression of nut assemblies study of nut assembly.
4) Assembly of ball screw. 5) Maintenance of ball screw, proper
lubrication, proper preloading to eliminate backlash, to reduce deflection & to optimize stiffness.
09 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: gauges, comparison of characteristics of different pressure measuring devices. Level measurement, strain measurement – strain gauges, theory, types, strain gauge circuits, temperature compensation, and load cells.
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: gauges, comparison of characteristics of different pressure measuring devices. Level measurement, strain measurement – strain gauges, theory, types, strain gauge circuits, temperature compensation, load cells.
26
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, feedback and feed forward control systems and their applications. Analog signal processing Digital Signal Processing : Programming Logic Controllers
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, feedback and feed forward control systems and their applications. Analog signal processing Digital Signal Processing : Programming Logic Controllers
10 Study of Spindle speed system :- True running of spindle assembly
with radial & axial load. Types of spindle bearing –
antifriction, hydrodynamics, hydrostatics.
Pre-loading of spindle bearing, etc. Study of axis feed system :-
Re-circulating ball screw. Pre-loading of ball screw, tension &
compression of nut assemblies, study of nut assembly.
Assembly of ball screw. Maintenance of ball screw Study of Coolant and lubrication
systems. Rotary axis, automatic tool changer,
pallet changer assemblies. Curvic coupling- to ensure
indexing accuracy, to ensure mechanically high load bearing capacity
Clamping and De-clamping
Study of : 1. Coolant and lubrication systems. 2. Rotary axis, automatic tool changer
pallet changer assemblies. 3. Curvic coupling- to ensure indexing
accuracy, to ensure mechanically high load bearing capacity.
4. Clamping and De-clamping – clamping by disc, springs and de-clamping by Hydraulics or pneumatic.
5. Drive to rotary table-using servomotor or hydrometer.
6. Mounting of rotary encoder & linear optical scale on the axis.
7. Worm & Worm Wheel to eliminate backlash.
8. Turret on CNC lathes, automatic tool changer, spindle orientation.
9. Hydraulic clutch, tail stock, quill. 10. Accuracy & performance of CNC m/cs.
Problem and remedies. 11. Inaccuracies such as backlash
repeatability. 12. Counter balancing mechanism
27
Drive to rotary table.
11 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
Study of :- 1. Electrical /electronic circuits for a CNC machine. 2. CNC system hardware. 3. Feed and spindle drives. 4. Feedback devices. 5. Programmable logic controller 6. Safety interlocks.
12 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
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
28
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
13. Assessment / Examination (03 days)
29
7.1.3 EMPLOYABILITY SKILLS
GENERAL INFORMATION
1) Name of the subject : EMPLOYABILITY SKILLS
2) Applicability : ATS- Mandatory for fresher only
3) Hours of Instruction : 110 Hrs. (55 hrs. in each block)
4) Examination : The examination will be held at the
end of two years Training by NCVT.
5) Instructor Qualification :
i) MBA/BBA with two years experience or graduate in sociology/social welfare/Economics with two years experience and trained in Employability skill from DGET Institute.
And Must have studied in English/Communication Skill and Basic Computer at 12th /diploma level
OR ii) Existing Social Study Instructor duly trained in Employability Skill from DGET Institute.
30
7.1.3.1 SYLLABUS OF EMPLOYABILITY SKILLS A. Block – I Basic Training
Topic
No.
Topic Duration
(in hours)
English Literacy 15
1 Pronunciation :
Accentuation (mode of pronunciation) on simple words, Diction
(use of word and speech)
2 Functional Grammar
Transformation of sentences, Voice change, Change of tense,
Spellings.
3 Reading
Reading and understanding simple sentences about self, work and
environment
4 Writing
Construction of simple sentences Writing simple English
5 Speaking / Spoken English
Speaking with preparation on self, on family, on friends/ classmates,
on know, picture reading gain confidence through role-playing and
discussions on current happening job description, asking about
someone's job habitual actions. Cardinal (fundamental) numbers
ordinal numbers. Taking messages, passing messages on and filling
in message forms Greeting and introductions office hospitality,
Resumes or curriculum vita essential parts, letters of application
reference to previous communication.
I.T. Literacy 15
1 Basics of Computer
Introduction, Computer and its applications, Hardware and
peripherals, Switching on-Starting and shutting down of computer.
2 Computer Operating System
Basics of Operating System, WINDOWS, The user interface of
Windows OS, Create, Copy, Move and delete Files and Folders, Use
of External memory like pen drive, CD, DVD etc, Use of Common
applications.
31
3 Word processing and Worksheet
Basic operating of Word Processing, Creating, opening and closing
Documents, use of shortcuts, Creating and Editing of Text,
Formatting the Text, Insertion & creation of Tables. Printing
document.
Basics of Excel worksheet, understanding basic commands, creating
simple worksheets, understanding sample worksheets, use of
simple formulas and functions, Printing of simple excel sheets
4 Computer Networking and INTERNET
Basic of computer Networks (using real life examples), Definitions
of Local Area Network (LAN), Wide Area Network (WAN), Internet,
Concept of Internet (Network of Networks),
Meaning of World Wide Web (WWW), Web Browser, Web Site, Web
page and Search Engines. Accessing the Internet using Web
Browser, Downloading and Printing Web Pages, Opening an email
account and use of email. Social media sites and its implication.
Information Security and antivirus tools, Do's and Don'ts in
Information Security, Awareness of IT - ACT, types of cyber crimes.
Communication Skill 25
1 Introduction to Communication Skills
Communication and its importance
Principles of Effective communication
Types of communication - verbal, non verbal, written, email,
talking on phone.
Non verbal communication -characteristics, components-Para-
language
Body - language
Barriers to communication and dealing with barriers.
Handling nervousness/ discomfort.
Case study/Exercise
2 Listening Skills
Listening-hearing and listening, effective listening, barriers to
effective listening guidelines for effective listening.
Triple- A Listening - Attitude, Attention & Adjustment.
Active Listening Skills.
3 Motivational Training
Characteristics Essential to Achieving Success
32
The Power of Positive Attitude
Self awareness
Importance of Commitment
Ethics and Values
Ways to Motivate Oneself
Personal Goal setting and Employability Planning.
Case study/Exercise
4 Facing Interviews
Manners, Etiquettes, Dress code for an interview
Do's & Don'ts for an interview
5 Behavioral Skills
Organizational Behavior
Problem Solving
Confidence Building
Attitude
Decision making
Case study/Exercise
33
B. Block– II Basic Training
Topic No.
Topic Duration (in
hours) Entrepreneurship skill 15
1 Concept of Entrepreneurship
Entrepreneurship- Entrepreneurship - Enterprises:-Conceptual issue Entrepreneurship vs. Management, Entrepreneurial motivation. Performance & Record, Role & Function of entrepreneurs in relation to the enterprise & relation to the economy, Source of business ideas, Entrepreneurial opportunities, the process of setting up a business.
2 Project Preparation & Marketing analysis
Qualities of a good Entrepreneur, SWOT and Risk Analysis. Concept & application of Product Life Cycle (PLC), Sales & distribution Management. Different Between Small Scale & Large Scale Business, Market Survey, Method of marketing, Publicity and advertisement, Marketing Mix.
3 Institutions Support
Preparation of Project. Role of Various Schemes and Institutes for self-employment i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for financing/ non financing support agencies to familiarizes with the Policies /Programmes & procedure & the available scheme.
4 Investment Procurement
Project formation, Feasibility, Legal formalities i.e., Shop Act, Estimation & Costing, Investment procedure - Loan procurement - Banking Processes.
Productivity 10
1 Productivity
Definition, Necessity, Meaning of GDP.
2 Affecting Factors
Skills, Working Aids, Automation, Environment, Motivation
How improves or slows down.
3 Comparison with developed countries
Comparative productivity in developed countries (viz. Germany, Japan and
Australia) in selected industries e.g. Manufacturing, Steel, Mining,
Construction etc. Living standards of those countries, wages.
4 Personal Finance Management
Banking processes, Handling ATM, KYC registration, safe cash handling,
Personal risk and Insurance.
Occupational Safety, Health & Environment Education 15
34
1 Safety & Health
Introduction to Occupational Safety and Health importance of safety and health at workplace.
2 Occupational Hazards
Basic Hazards, Chemical Hazards, Vibro-acoustic Hazards, Mechanical
Hazards, Electrical Hazards, Thermal Hazards. Occupational health,
Occupational hygienic, Occupational Diseases/ Disorders & its prevention.
3 Accident & safety
Basic principles for protective equipment. Accident Prevention techniques - control of accidents and safety measures.
4 First Aid
Care of injured & Sick at the workplaces, First-Aid & Transportation of sick person
5 Basic Provisions Idea of basic provision of safety, health, welfare under legislation of India.
6 Ecosystem
Introduction to Environment. Relationship between Society and Environment, Ecosystem and Factors causing imbalance.
7 Pollution
Pollution and pollutants including liquid, gaseous, solid and hazardous
waste.
8 Energy Conservation
Conservation of Energy, re-use and recycle.
9 Global warming
Global warming, climate change and Ozone layer depletion.
10 Ground Water
Hydrological cycle, ground and surface water, Conservation and Harvesting
of water
11 Environment
Right attitude towards environment, Maintenance of in -house
environment
Labour Welfare Legislation 5
1 Welfare Acts
Benefits guaranteed under various acts- Factories Act, Apprenticeship Act,
Employees State Insurance Act (ESI), Payment Wages Act, Employees
Provident Fund Act, The Workmen's compensation Act.
Quality Tools 10
1 Quality Consciousness :
35
Meaning of quality, Quality Characteristic
2
Quality Circles :
Definition, Advantage of small group activity, objectives of quality Circle,
Roles and function of Quality Circles in Organization, Operation of Quality
circle. Approaches to starting Quality Circles, Steps for continuation Quality
Circles.
3 Quality Management System :
Idea of ISO 9000 and BIS systems and its importance in maintaining
qualities.
4 House Keeping :
Purpose of Housekeeping, Practice of good Housekeeping.
5 Quality Tools
Basic quality tools with a few examples
36
7.2 PRACTICAL TRAINING (ON-JOB TRAINING) (BLOCK – I & II)
DURATION: 18 MONTHS (9 months in each block)
GENERAL INFORMATION
1) Name of the Trade : Mechanic Mechatronics
2) Batch size : : a) Apprentice selection as per Apprenticeship
Guidelines
b) Maximum 20 candidates in a group
3) Examination : i) The internal assessment will be held on
completion of each block
ii) NCVT exam will be conducted at the end of
2nd year.
4) Instructor Qualification :
a) Degree/Diploma in Mechanical/Mechatronics Engg. from recognized university/Board with one/two years post qualification experience respectively in the relevant field.
OR
b) NTC/NAC in the trade of “Mechanic Mechatronics” with three years post qualification experience in the relevant field.
Preference will be given to a candidate with Craft Instructor Certificate (CIC)
5) Infrastructure for On Job Training : - As per Annexure – II
37
7.2.1 BROAD SKILL COMPONENT TO BE COVERED DURING ON-JOB TRAINING
A. BLOCK – I 1. Safety and best practices (5S, KAIZEN etc.)
2. Record keeping and documentation
3. Identification and testing of mechanical, hydraulic, pneumatic, electrical and
electronic components/devices
4. Repair & Maintenance work
DURATION: 09 MONTHS
SL.
NO.
AREAS OF BROAD SKILLS TO BE IMPARTED TO THE TRAINEES
DURING ON JOB TRAINING IN THE INDUSTRY
1 Filing skills for precision fitting: Surface flatness, perpendicularity, Angular
surface, Radius, balancing of file, draw filing, etc.
2 Drilling, reaming and tapping skills: on drilling machine, sensitive drilling
machine, hand reaming, machine reaming, hand tapping, etc.
3 Lathe machine: Maintenance and repairing skills of lathe machine.
Dismantling and assembling of gear box, feed mechanism, etc.
4 Milling machine: Maintenance and repairing skills of milling machine.
Dismantling and assembling of gear box, feed mechanism, etc.
5 Grinding machine: Maintenance and repairing skills of grinding machine.
Dismantling and assembling of gear box, feed mechanism, etc.
6 Drilling machine: Maintenance and repairing skills of bench drilling and
pillar type drilling machines.
7 Soldering skills, SMD soldering
8 Machine leveling skills for lathe, milling, grinding machines. Test reports
against standards.
9 Guideways adjustment skills and Machine alignment setting skills: for lathe,
milling, grinding machines.
10 Bearing Maintenance: mounting of bearings with proper fit & axis
alignment, bearing removal from shafts, use of proper tools like pullers, etc.
11 Dismantling, maintenance, repair and assembling skills of simple
mechanisms such as machine vice, three jaw chuck, tail stock, index head,
coolant pump, etc.
12 Gear repairing and fitting skills: spur, helical, bevel gears, worm and worm
wheels, rack and pinion, etc.
38
13 Test various electrical/electronic components using proper measuring
instruments.
14 Assemble various electronic circuits using SMD components and test them
using suitable test equipment and perform the repair work on the PCB
tracks.
39
B. BLOCK – II
1. Safety and best practices (5S, KAIZEN etc.)
2. Record keeping and documentation
3. Identification and testing of electronic components/devices
4. Repair & Maintenance work
DURATION: 09 MONTHS
S. NO. AREAS OF BROAD SKILLS TO BE IMPARTED TO THE TRAINEES DURING ON
JOB TRAINING IN THE INDUSTRY
1 Understand and apply the principle of electronic sensors, mechanical actuators
and computer control. Install, test, and troubleshoot sensors, switches, and other
control devices.
2 Hydraulic circuits: reading and construction skills, setting of hydraulic elements
for proper functioning, trouble shooting in hydraulics, repair and maintenance of
hydraulic valves, etc.
3 Pneumatic circuits: reading and construction skills, setting of pneumatic elements
for proper functioning, trouble shooting in Pneumatics, repair and maintenance of
pneumatic valves, etc.
4 Understand pnuematic/hydraulic and VFD/electric-motor control diagrams and
construct them with appropriate hardware.
5 Install, integrate and troubleshoot servo and stepper motor controls
6 Understand and apply program on mechatronics modules and systems, especially PLCs, connect and configure PLC networks and data transfer using bus systems.
7 Understand and apply the principle of operation of mechatronics systems
8 Demonstration of the procedure of Installation and commissioning of CNC
machine.
9 CNC Machine spindle assembly: spindle play setting, runout inspection, repair, etc.
10 Ball screw assembly: ball screw mounting, preloading, assembling, lubrication,
dismantling, repair, etc.
11 Feedback devices: proper setting, repair and maintenance of feedback elements,
etc.
12 Lubrication & Coolant system of CNC Machines: Centralized lubrication system,
friction, guide ways, repair, etc.
13 Preventive maintenance skills of CNC machines: Daily, weekly, quarterly
maintenance schedules to avoid breakdowns.
14 Understand and apply CNC Programming.
40
8. ASSESSMENT STANDARD
8.1 Assessment Guideline:
Appropriate arrangements should be made to ensure that there will be no artificial barriers to assessment. The nature of special needs should be taken into account while undertaking assessment. Due consideration to be given while assessing for team work, avoidance/reduction of scrape/wastage and disposal of scarp/wastage as per procedure, behavioral attitude and regularity in training. The following marking pattern to be adopted while assessing: a) Weightage in the range of 60-75% to be allotted during assessment under following performance level:
For this grade, the candidate with occasional guidance and showing due regard for safety procedures and practices, has produced work which demonstrates attainment of an acceptable standard of craftsmanship. In this work there is evidence of: Good skill levels in the use of hand tools, machine tools and workshop equipment Many tolerances while undertaking different work are in line with those demanded
by the component/job. A fairly good level of neatness and consistency in the finish Occasional support in completing the project/job. b) Weightage in the range of above75%- 90% to be allotted during assessment under following performance level:
For this grade, the candidate, with little guidance and showing due regard for safety procedures and practices, has produced work which demonstrates attainment of a reasonable standard of craftsmanship.
In this work there is evidence of: Good skill levels in the use of hand tools, machine tools and workshop equipment The majority of tolerances while undertaking different work are in line with those
demanded by the component/job. A good level of neatness and consistency in the finish Little support in completing the project/job
41
c) Weightage in the range of above 90% to be allotted during assessment under following performance level:
For performance in this grade, the candidate, with minimal or no support in organization and execution and with due regard for safety procedures and practices, has produced work which demonstrates attainment of a high standard of craftsmanship.
In this work there is evidence of: High skill levels in the use of hand tools, machine tools and workshop equipment Tolerances while undertaking different work being substantially in line with those
demanded by the component/job. A high level of neatness and consistency in the finish. Minimal or no support in completing the project
42
8.2 FINAL ASSESSMENT- ALL INDIA TRADE TEST (SUMMATIVE
ASSESSMENT)
SUBJECTS Marks Sessional
Marks
Full
Marks
Pass Marks Duration
of Exam.
Practical 300 100
20
10
20
400 240 08 hrs.
Trade Theory 100 120 48 3 hrs.
Workshop Cal. & Sc. 50 60 24 3 hrs.
Engineering Drawing 50 70 28 4 hrs.
Employability Skill 50 50 17 2 hrs.
Grand Total 550 150 700 -
Note: - The candidate pass in each subject conducted under all India trade test.
43
9. FURTHER LEARNING PATHWAYS
On successful completion of the course,
The trainees will be employed in reputed Industries / Organizations.
On successful completion of the course trainees can opt for Diploma course
(lateral entry). {Applicable for candidates only who undergone ATS after CTS}
They can also undergo CITS course in the relevant trade to become instructor in
the ITI’s
Employment opportunities:
On successful completion of this course, the candidates shall be gainfully employed in the following industries: 1. Production & Manufacturing industries.
2. Fabrication and aero-space industry.
3. Automotive industry
4. Service industries like road transportation and Railways.
5. Ship building and repair
6. Government organisations like DRDO, DLRL, Department of Space, ISRO, Department of Atomic Energy, BARC, etc.
7. In public sector industries like BHEL, BEL, BEML, NTPC, etc and private industries in India & abroad.
8. Multinational companies (MNCs)
9. Self employment
44
ANNEXURE – I 10. TOOLS & EQUIPMENT FOR BASIC TRAINING
INFRASTRUCTURE FOR PROFESSIONAL SKILL & PROFESSIONAL KNOWLEDGE
TRADE: MECHANIC MECHATRONICS
LIST OF TOOLS & EQUIPMENTS FOR 20 APPRENTICES
A: TRAINEES TOOL KIT:
Sl. No. Name of the items Qty
(indicative)
1 Steel rule 300 mm graduated both side in Metric and English 21 Nos.
2 Try square 150 mm 21 Nos.
3 File flat bastard 300 mm, File flat 2nd cut 250 mm; File flat
smooth 200 mm
21 Nos. each
4 Round Nose Pliers 200 mm 21 Nos.
5 Combination pliers 200 mm 21 Nos.
6 Smooth Files: half round 2nd cut 250 mm; round and square
200 mm
21 Nos. each
7 File three square smooth 200 mm 21 Nos.
8 File needle set of 12 nos. 21 Nos.
9 Allen Hexagonal keys 2 to 16 mm 21 Nos.
B: TOOLS, INSTRUMENTS AND GENERAL SHOP OUTFITS:
Sl. No. Name of the items Qty
1 Tap and die M6 to M 12 with tap wrench and die holder. 1 set
2 Spanner socket set of 25 pieces (10 to 25, 27, 30, 32 mm = 18
pieces and accessories = 7 Nos.)
1 set
3 Pipe wrench 45 mm 1 No.
4 Tap extractor 1 No.
5 Stud extractor 1 No.
6 Granite surface plate 1600 x 1000 with stand and cover. 1 No.
7 Bearing and gear tester 1 No.
8 Bar type torque wrench 1 No.
9 Circlip pliers (inside and outside and straight) 1 set
10 Hammer soft (faced 30 mm dia. Plastic tipped) 1 No.
11 Accumulator 1 No.
45
12 Pneumatic tools (portable nut spanner/runner, chisel, grinder,
sander and hammer)
1 each
13 Hydraulic, pneumatic trainer with necessary aggregates for
different machine circuit with all transparent valves and
pressure gauge, reservoir etc.
1 each
trainer
14 Hydraulic valves (relief, sequence, pressure reducing, check, flow
control, directional control valves etc.).
1 each
15 Transparent hydraulic cylinders: single acting and double acting 1 each
16 Vibrometer 1 No.
17 Flow detector (magnetic crack detector) 1 No.
18 Solenoid valve 1 No.
19 Pneumatic meter 1 No.
20 Head lamp 1 No.
21 Master test bars (different size) 1 set
22 Spirit Level 1 No.
23 Self alignment roller ball bearing 1 No.
24 Telescopic gauges 13 mm to 300 mm 1 set
25 Gear pump 1 no.
26 Vane pump fixed and variable delivery 1 each
27 Hydrometer 1 No.
28 Machine tool calibrator 1 No.
29 Hydraulic wheel and bearing puller 1 No.
30 Tube expander up to 62 mm 1 set
31 SRDG ball bearing, DRDG ball bearing, self aligning ball bearing,
SRAC ball bearing, needle bearing, single raw cylindrical roller
Bearing, tapered roller bearing, plain bush bearing, thin walled
bearing.
1 each
32 Straight edge (steel) 1000 mm 1 No.
33 Sprit level 1 No.
34 Spanner D.E. series 2 1 set
35 Machine vice swivel base 160 mm 1 No.
36 Twist drill 3 to 13 mm (Straight Shank) 1 set
37 Twist drill 13 to 25 mm by 1 mm (Taper Shank) 1 set
38 Grinding wheel dresser (diamond) 1.5 carat 1 set
39 Hand reamer 6 to 25 mm by 1 mm 1 set
40 Punch letter set 4 mm 1 No.
41 Punch number set 4 mm 1 No.
42 Mandrel 120 mm long different sizes 1 set
46
43 Wheel balancing stand with its accessories 1 No.
44 Machine reamer 6 to 25 mm by 1 mm 1 set.
45 Engineers parallel blocks 1 set
PRECISION INSTRUMENTS:
46 Vernier calliper 200mm with inside and depth measurement 1 No.
47 Outside micrometers: 0- 25; 25-50; 50-75; 75-100 1 each
48 Sine bar 200 mm 1 No.
49 Slip gauge metric set (for the whole institute) 1 set
50 Feeler gauge and Radius gauge (metric) 1 each
51 Indicator with magnetic base 1 No.
52 Straight edge 485 mm to 1445 mm 1 No.
53 Adjustable micrometer sprit level to measure flatness, indication
and taper with prismatic measuring base
1 No.
ELECTRICAL TECHNOLOGY AND ELETRONICS
54 Screw driver electrician 150 mm 21 Nos.
55 Screw driver Philips Nos. 860, 862, 862 21 Nos.
56 Long nose plier 150 mm insulated 21 Nos.
57 Combination plier 150 mm 21 Nos.
58 Diagonal cutter 150 mm 21 Nos.
59 Tweezers 21 Nos.
60 Knife 100 mm 21 Nos.
61 Neon tester 21 Nos.
62 Soldering iron 25 W 21 Nos.
63 Soldering iron 65 W 21 Nos.
64 Multimeter 2 Nos.
65 Ammeter 0 mA to 500 mA 1 No.
66 Ammeter 0-1 A DC 1 No.
67 Voltmeter 0-300-600 V AC 1 No.
68 Discrete component trainer 1 No.
69 P.F.Meter 1 No.
70 Frequency meter 1 No.
71 Megger 500 V. 1 No.
72 AC squirrel cage induction motor 30 with D.O.L. starter 1 No.
73 Star delta 30 starter 1 No.
74 C.T. single phase 1 No.
75 P.T. single phase 1 No.
76 Auto transport 0-300 V, 8 Amp. 1 No.
77 Audio signal generator 1 No.
47
78 DC power supply 0-30 V, 2 Amp. 1 No.
79 Demonstration model for thyristorised DC motor drive (1 HP) set
up
1 No.
80 Demonstration model for thyristorised AC motor drive (1 HP) set
up.
1 No.
81 Linear I.C. trainer 1 No.
82 Digital multi-meter 2.5 Amps./5 Amps 1 No.
83 Transducer 1 No.
84 Thermocouple kit 1 No.
85 L.D.R.S. kit 1 No.
86 Thermister kit 1 No.
87 L.V.D.T. kit 1 No.
88 Photo diode 1 No.
89 Photo transistor kit 1 No.
90 AC timer kit 1 No.
91 DC timer kit 1 No.
92 Decimal counter kit 1 No.
93 DC motor control kit 1 No.
94 Hand tachometer 1 No.
95 Ammeter portable type 0-15 Amps. AC 1 No.
96 Insulated handle screw driver 200 mm 2 Nos.
97 Insulated handle combination side cutting plier 200 mm 2 Nos.
FURNITURE 1 No.
98 Metal lockers 8-lockers type with individual locks 1980 x 910 x
480 mm
1 No.
99 Office chair with arms 1 No.
100 Office table 1 No.
101 Work bench 2 nos.
102 Metal shelving rack open type 1800 x 900 x 500 mm with
adjustable shelves
2 Nos.
103 Drawing desk 1 No.
104 Stool 1 No.
105 White board 1 No.
106 Portable fire extinguisher. 1 No.
107 Steel fire bucket 4 litres 2 Nos.
C: GENERAL MACHINERY INSTALLATIONS:
48
Sl. No. Name & Description of Machines Quantity
(indicative)
1 CNC Trainer 1 No.
2 Lathe general purpose, all geared, height of center 150 mm,
with 3 jaw and 4 jaw chuck, with all accessories
1 No.
3 Drilling machine pillar type 20 mm capacity 1 No.
4 Bench drilling machine 12 mm capacity 1 No.
5 Bench grinder 250 mm dia. (lighter type) 1 No.
MACHINES FOR REPAIR AND RECONDITIONING
6 Old center lathe 1 No.
7 Old milling machine (universal) 1 No.
8 Old grinding machine (universal) 1 No.
9 Old Universal indexing head 1 No.
10 Old CNC lathe / CNC Milling machine / Machining center (Any
one)
1 No.
Note: In case of basic training setup by the industry the tools, equipment and machinery available in the industry may also be used for imparting basic training.
49
INFRASTRUCTURE FOR WORKSHOP CALCULATION & SCIENCE AND ENGINEERING DRAWING
TRADE: Mechanic Mechatronics
LIST OF TOOLS& EQUIPMENTS FOR 20 APPRENTICES
1) Space Norms : 45 Sq. m.(For Engineering Drawing)
2) Infrastructure: A: TRAINEES TOOL KIT:
B : FURNITURE REQUIRED
Sl.
No. Name of the items
Quantity
(indicative)
1 Drawing Board 20 Nos. 2 Models : Solid & cut section as required 3 Drawing Table for trainees as required 4 Stool for trainees as required 5 Cupboard (big) 1 No.
6 White Board (size: 8ft. x 4ft.) 1 No.
7 Trainer’s Table 1 No.
8 Trainer’s Chair 1 No.
Sl.
No. Name of the items
Quantity
(indicative)
1. Draughtsman drawing instrument box 20 sets
2. Set square celluloid 45⁰ (250 X 1.5 mm) 20 sets
3. Set square celluloid 30⁰-60⁰ (250 X 1.5 mm) 20 sets
4. Mini drafter 20 sets
5. Drawing board (700mm x500 mm) IS: 1444 20 sets
50
ANNEXURE – II
11. INFRASTRUCTURE FOR ON JOB TRAINING
TRADE: Mechanic Mechatronics
For Batch of 20 APPRENTICES
Actual training will depend on the existing facilities available in the establishments. However, the industry should ensure that the broad skills defined against On-Job Training part (i.e. 9 months + 9 months) are imparted. In case of any short fall the concern industry may impart the training in cluster mode/ any other industry/ at ITI.
51
ANNEXURE-III 12. GUIDELINES FOR INSTRUCTORS AND PAPER SETTERS
1. Due care to be taken for proper & inclusive delivery among the batch. Some of the
following some method of delivery may be adopted:
A) LECTURE
B) LESSON
C) DEMONSTRATION
D) PRACTICE
E) GROUP DISCUSSION
F) DISCUSSION WITH PEER GROUP
G) PROJECT WORK
H) INDUSTRIAL VISIT
2. Maximum utilization of latest form of training viz., audio visual aids, integration of IT,
etc. may be adopted.
3. The total hours to be devoted against each topic may be decided with due diligence to
safety & with prioritizing transfer of required skills.
