iti 14 April 2025
Mechanic Mechatronics

ITI Mechanic Mechatronics Trade Syllabus 

The ITI Mechanic Mechatronics trade is a two-year vocational training program under the Craftsman Training Scheme (CTS), governed by the National Council for Vocational Training (NCVT). This course equips trainees with skills in maintaining, troubleshooting, repairing, and integrating mechatronic systems, combining mechanical components, electrical circuits, electronics, and computer control systems used in automated machinery, robotics, and industrial automation. The syllabus integrates theoretical knowledge, practical skills, and employability skills to prepare students for roles such as mechatronics technicians, automation engineers, or maintenance specialists in industries like manufacturing, automotive, or aerospace, or as self-employed service providers.

Course Overview

  • Duration: 2 years (4 semesters, each 6 months)
  • NSQF Level: Level 5
  • Eligibility: Minimum 10th grade pass with Science and Mathematics (or equivalent)
  • Objective: To train individuals in ensuring the seamless operation of mechatronic systems through maintenance, repair, and system integration.

Detailed Syllabus Breakdown

1. Trade Theory (Theoretical Knowledge)

Covers principles of mechatronics, automation, and system integration.

  • Semester 1
    • Introduction to Mechatronics
      • Overview: definition, scope, applications (robotics, automation, CNC machines).
      • Industry scope: roles in manufacturing, safety standards, Industry 4.0.
      • Safety: PPE (gloves, goggles, ESD straps), handling electronics, lockout-tagout.
    • Basic Mechanics
      • Concepts: force, torque, levers, gears, cams in mechanical systems.
      • Components: bearings, shafts, couplings, belts in mechatronic setups.
      • Materials: metals, composites, properties for automation systems.
    • Electrical Fundamentals
      • Principles: voltage, current, resistance, Ohm’s law, AC/DC circuits.
      • Components: wires, relays, switches, transformers, circuit breakers.
      • Safety: grounding, insulation, avoiding electrical hazards.
    • Electronics Basics
      • Devices: diodes, transistors, capacitors, resistors, ICs.
      • Circuits: analog vs. digital, rectifiers, amplifiers, timers.
      • Tools: multimeters, oscilloscopes, soldering kits for diagnostics.
    • Tools and Measuring Instruments
      • Mechanical: spanners, torque wrenches, vernier calipers, micrometers.
      • Electrical: clamp meters, insulation testers, signal generators.
      • Precision: laser alignment tools, vibration analyzers for mechatronics.
    • Workshop Practices
      • Operations: drilling, filing, tapping, assembling mechanical parts.
      • Techniques: soldering, crimping, PCB assembly for electronics.
      • Documentation: maintenance logs, wiring diagrams, part lists.
  • Semester 2
    • Hydraulic and Pneumatic Systems
      • Components: pumps, valves, actuators, compressors, reservoirs.
      • Operation: pressure control, fluid flow, air supply in automation.
      • Maintenance: checking leaks, replacing seals, fluid top-ups.
    • Digital Electronics
      • Concepts: logic gates, flip-flops, counters, microcontrollers.
      • Applications: PLCs, embedded systems in mechatronic control.
      • Programming: basics of ladder logic, microcontroller coding (e.g., Arduino).
    • Sensors and Actuators
      • Types: proximity, temperature, pressure, optical, ultrasonic sensors.
      • Actuators: motors (DC, stepper, servo), solenoids, linear actuators.
      • Calibration: setting sensor ranges, tuning actuator responses.
    • Control Systems
      • Basics: open-loop vs. closed-loop, feedback mechanisms.
      • Controllers: PID control, PLC programming for automation.
      • Applications: motor speed control, robotic arm positioning.
    • Preventive Maintenance
      • Schedules: daily, weekly checks for mechatronic systems.
      • Techniques: cleaning, lubricating, inspecting electrical connections.
      • Records: logging faults, downtime, predictive maintenance data.
    • Troubleshooting Basics
      • Methods: fault tree analysis, signal tracing, error code reading.
      • Tools: diagnostic software, PLC debuggers, circuit testers.
      • Solutions: replacing sensors, recalibrating controls, rewiring.
  • Semester 3
    • Programmable Logic Controllers (PLCs)
      • Components: CPU, I/O modules, power supplies, communication ports.
      • Programming: ladder logic, function block diagrams, SCADA basics.
      • Applications: conveyor control, robotic automation, process control.
    • Robotics Fundamentals
      • Types: industrial robots, collaborative robots (cobots), AGVs.
      • Components: joints, end effectors, vision systems, controllers.
      • Maintenance: calibrating arms, updating software, inspecting drives.
    • CNC Machine Integration
      • Systems: CNC lathes, milling machines, control units (Fanuc, Siemens).
      • Maintenance: checking servos, ball screws, spindle drives.
      • Programming: basics of G-code, M-code for CNC automation.
    • Industrial Communication Systems
      • Protocols: Modbus, Profibus, Ethernet/IP, CAN bus.
      • Devices: gateways, routers, HMI panels in mechatronics.
      • Troubleshooting: diagnosing network errors, cable faults.
    • Quality Control in Mechatronics
      • Standards: ISO 9001, tolerances in automated systems.
      • Tests: sensor accuracy, actuator response, system integration checks.
      • Documentation: calibration reports, performance logs.
    • Customer Interaction
      • Skills: explaining system faults, downtime estimates to clients.
      • Coordination: working with vendors for spares, software updates.
      • Documentation: preparing service agreements, warranty records.
  • Semester 4
    • Advanced Automation Systems
      • Systems: IoT-enabled machines, smart factories, cyber-physical systems.
      • Maintenance: cloud diagnostics, firmware updates, data analytics.
      • Integration: linking PLCs, robots, and HMIs for automation.
    • Robotics Maintenance
      • Tasks: servicing vision systems, recalibrating multi-axis robots.
      • Diagnostics: reading error logs, troubleshooting AI-based controls.
      • Repairs: replacing drives, updating robotic OS.
    • Condition Monitoring
      • Techniques: vibration analysis, thermal imaging, IoT sensors.
      • Tools: data loggers, predictive maintenance software, cloud platforms.
      • Analysis: trending failures, scheduling proactive repairs.
    • Entrepreneurship and Management
      • Business: starting a mechatronics service, sourcing components.
      • Planning: budgeting repairs, managing automation projects.
      • Marketing: promoting services, building client networks.
    • Industry Trends
      • Innovations: AI in automation, digital twins, additive manufacturing.
      • Standards: ISO 27001 for cybersecurity, lean automation principles.
      • Future: cobots, autonomous maintenance, green automation.
    • Professional Ethics
      • Practices: transparency in repairs, quality assurance.
      • Responsibilities: ensuring system uptime, operator safety.
      • Compliance: adhering to data privacy, environmental regulations.

2. Trade Practical (Hands-On Skills)

Focuses on practical tasks in mechatronics labs and automation setups.

  • Semester 1
    • Safety Practices
      • Using PPE: wearing ESD straps, goggles, gloves in labs.
      • Procedures: applying lockout-tagout, handling live circuits.
      • Drills: ESD safety, chemical spill response, first aid.
    • Mechanical Operations
      • Performing: assembling gears, shafts, bearings in mock setups.
      • Measuring: checking tolerances with calipers, micrometers.
      • Maintaining: lubricating components, cleaning assemblies.
    • Electrical Circuit Work
      • Building: wiring basic AC/DC circuits in lab setups.
      • Testing: measuring voltage, current with multimeters.
      • Repairing: replacing fuses, switches, soldering connections.
    • Electronics Practice
      • Assembling: building simple circuits (rectifiers, timers) on PCBs.
      • Testing: verifying signals with oscilloscopes, logic probes.
      • Repairing: desoldering faulty components, replacing ICs.
    • Workshop Tasks
      • Performing: drilling, tapping, filing for mechatronic fixtures.
      • Assembling: mounting motors, sensors in mock systems.
      • Documenting: preparing wiring diagrams, part lists.
    • Project Work
      • Building a circuit: assembling, testing a motor control circuit.
      • Report: documenting design, faults fixed, outcomes.
  • Semester 2
    • Hydraulic/Pneumatic Maintenance
      • Servicing: inspecting valves, actuators in mock systems.
      • Repairing: replacing seals, topping fluids in labs.
      • Testing: verifying pressure, flow in automation setups.
    • Digital Electronics Practice
      • Building: assembling logic gate circuits, microcontroller boards.
      • Programming: coding Arduino for sensor-actuator control.
      • Testing: debugging logic errors, verifying outputs.
    • Sensor and Actuator Work
      • Installing: wiring proximity, temperature sensors in mock setups.
      • Calibrating: tuning servo motors, linear actuators in labs.
      • Testing: verifying sensor accuracy, actuator response.
    • Control System Practice
      • Setting up: configuring PID controllers for motor speed.
      • Programming: writing basic PLC ladder logic in labs.
      • Testing: ensuring stable feedback in mock automation.
    • Preventive Maintenance
      • Performing: cleaning, lubricating mock mechatronic systems.
      • Inspecting: checking wiring, sensor alignment in labs.
      • Logging: preparing maintenance schedules, fault reports.
    • Project Work
      • Automating a conveyor: integrating sensors, motors, testing.
      • Portfolio: presenting logs, photos, system performance.
  • Semester 3
    • PLC Programming and Maintenance
      • Programming: writing ladder logic for mock conveyor control.
      • Servicing: inspecting I/O modules, wiring in PLC setups.
      • Testing: debugging PLC programs, verifying outputs.
    • Robotics Practice
      • Assembling: setting up robotic arms in lab setups.
      • Calibrating: programming joint movements, end effectors.
      • Repairing: replacing motors, fixing vision system faults.
    • CNC Machine Work
      • Servicing: inspecting servos, spindles in mock CNC setups.
      • Programming: writing basic G-code for machining tasks.
      • Testing: verifying axis accuracy, tool paths.
    • Communication System Practice
      • Setting up: configuring Modbus, Ethernet networks in labs.
      • Troubleshooting: diagnosing cable faults, HMI errors.
      • Testing: ensuring data transfer between PLCs, HMIs.
    • Quality Control Practice
      • Testing: checking sensor accuracy, system integration in labs.
      • Measuring: using diagnostic tools for performance checks.
      • Documenting: preparing calibration logs, test reports.
    • Project Work
      • Building a robotic arm: programming, integrating sensors, testing.
      • Portfolio: presenting design, repair logs, performance data.
  • Semester 4
    • Advanced Automation Practice
      • Setting up: integrating IoT sensors, cloud dashboards in labs.
      • Servicing: updating firmware, troubleshooting network issues.
      • Testing: verifying real-time data, system integration.
    • Robotics Maintenance
      • Servicing: inspecting vision systems, multi-axis robots in labs.
      • Repairing: replacing drives, recalibrating AI controls.
      • Testing: ensuring precision, connectivity in mock setups.
    • Condition Monitoring Practice
      • Monitoring: using vibration sensors, thermal cameras on mock systems.
      • Analyzing: trending failure data, predicting faults in labs.
      • Reporting: preparing maintenance forecasts, logs.
    • Entrepreneurship Practice
      • Simulating: running a mock mechatronics service, sourcing parts.
      • Planning: budgeting automation projects, managing inventory.
      • Marketing: creating mock service ads, client proposals.
    • Safety and Compliance
      • Inspecting: checking ESD, grounding in mock setups.
      • Auditing: conducting mock cybersecurity, safety audits.
      • Testing: ensuring systems meet ISO, IEC standards.
    • Project Work
      • Automating a process: integrating PLC, robots, IoT, testing.
      • Portfolio: presenting logs, photos, system efficiency data.

3. Workshop Calculation and Science

Supports mechatronics with relevant concepts.

  • Semester 1: Arithmetic (circuits, tolerances), physics (mechanics, electricity).
  • Semester 2: Algebra (control equations), electronics (signal processing).
  • Semester 3: Geometry (robot kinematics), thermodynamics (heat in systems).
  • Semester 4: Statistics (failure analysis), applied physics (sensors, optics).

4. Engineering Drawing

Focuses on technical drafting for mechatronic systems.

  • Semester 1: Sketching mechanical parts, circuit diagrams, orthographic views.
  • Semester 2: Drawing hydraulic circuits, PCB layouts, sensor setups.
  • Semester 3: Designing PLC wiring, robotic arm assemblies, CNC schematics.
  • Semester 4: Creating blueprints for automation systems, IoT architectures.

5. Employability Skills

Enhances job readiness and soft skills.

  • Semester 1: Communication (fault reporting), time management, basic IT (CAD, coding).
  • Semester 2: Teamwork (with engineers), problem-solving (system faults).
  • Semester 3: Leadership (project supervision), negotiation (vendor deals), advanced IT (PLC, IoT).
  • Semester 4: Entrepreneurship (automation business), client management, trends (AI, cobots).

Assessment and Certification

  • Examinations: Semester-wise (theory + practical).
  • Certification: National Trade Certificate (NTC) from NCVT, recognized nationally.
  • Evaluation: Based on system integration, repair accuracy, automation efficiency, and project work.

Career Opportunities

  • Employment: Mechatronics technician, automation engineer, maintenance specialist in manufacturing, automotive, or aerospace industries.
  • Self-Employment: Starting a mechatronics or automation service business.
  • Further Studies: Diploma in Mechatronics, certifications in robotics, or industrial IoT.

Note

  • This syllabus aligns with NCVT guidelines and may vary slightly by institution or state.
  • For the latest version, refer to the Directorate General of Training (DGT) or local ITI.

Trade Type

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