Textile Mechatronics

ITI Textile Mechatronics Syllabus (English)

Course Overview

• Trade Name: Textile Mechatronics
• Duration: 2 Years (4 Semesters)
• NSQF Level: Level 5
• Eligibility: 10th Grade Pass with Mathematics and Science
• Objective: To train candidates in operating, maintaining, and troubleshooting textile machinery by integrating mechanical, electrical, electronics, and automation skills, preparing them for roles such as textile machine operators, maintenance technicians, automation engineers, or self-employment in the textile industry.
• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Mechatronics: Definition, scope, and applications in the textile industry; overview of automation in textile manufacturing.
• Electrical Systems: Fundamentals of electricity, AC/DC circuits, transformers, relays, wiring standards, and electrical safety protocols.
• Textile Technology Basics: Types of fibers (natural, synthetic), yarn manufacturing, fabric production (weaving, knitting), and textile machinery overview.
• Mechanical Systems: Principles of mechanics, gears, belts, bearings, lubrication, and power transmission in textile machines.
• Tools and Instruments: Use of multimeters, oscilloscopes, vernier calipers, spanners, and screwdrivers; calibration techniques.
• Safety Practices: Workplace hazards, personal protective equipment (PPE), electrical safety, fire prevention, and first aid.
• IT Fundamentals: Basics of MS Office (Word, Excel), computer hardware troubleshooting, and internet usage for technical documentation.

Trade Practical

• Electrical Skills: Measuring voltage, current, resistance; assembling simple circuits; wiring control panels for textile machines.
• Textile Machine Familiarization: Identifying components of spinning, weaving, and knitting machines; understanding their functions.
• Mechanical Skills: Practicing fitting, drilling, filing, and assembling mechanical components like gears and shafts.
• Tool Handling: Using hand tools and precision instruments for maintenance tasks on textile equipment.
• Safety Drills: Implementing PPE usage, practicing electrical isolation, and simulating emergency response scenarios.
• IT Practice: Creating spreadsheets for machine maintenance logs; basic computer diagnostics.
• Project Work: Designing and wiring a control panel for a textile machine motor, ensuring safety compliance.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Electronics Fundamentals: Semiconductors, diodes, transistors, sensors (proximity, temperature), and microcontrollers in textile automation.
• Textile Manufacturing Processes: Detailed study of spinning (ring, rotor), weaving (shuttle, shuttleless looms), knitting (flat, circular), and dyeing machinery.
• Motors and Drives: Types of motors (AC, DC, stepper), motor starters, variable frequency drives (VFDs), and their maintenance.
• Pneumatic Systems: Principles of pneumatics, air compressors, valves, actuators, and their applications in textile machinery.
• Quality Control: Fabric inspection techniques, defect identification (e.g., slubs, knots), and quality standards in textiles.
• Workshop Management: Basics of inventory control, tool maintenance, and workplace organization (5S methodology).

Trade Practical

• Electronics Skills: Testing sensors and transistors; soldering electronic circuits for textile machine controls.
• Machine Operation: Operating spinning frames and weaving looms; adjusting settings for yarn/fabric production.
• Motor Maintenance: Dismantling, cleaning, lubricating, and reassembling motors; testing VFDs.
• Pneumatic Systems: Assembling pneumatic circuits for automated textile processes; troubleshooting leaks.
• Quality Testing: Inspecting fabrics for defects; using tensile testers and fabric analyzers.
• Project Work: Setting up and testing a motor-driven textile machine section (e.g., spinning unit) with sensor integration.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 3

Trade Theory

• Automation Systems: Programmable Logic Controllers (PLCs), Human-Machine Interface (HMI), and their role in textile machine automation.
• Hydraulic Systems: Principles of hydraulics, pumps, cylinders, valves, and applications in textile presses and looms.
• Advanced Textile Technology: Knitting machine types (warp, weft), modern looms (air-jet, rapier), and fabric finishing processes.
• Maintenance Techniques: Preventive maintenance schedules, condition monitoring, and failure analysis for textile machinery.
• Robotics in Textiles: Basics of robotics, robotic arms for material handling, and automation trends in textiles.
• Energy Efficiency: Power consumption analysis, energy-saving techniques in textile production.

Trade Practical

• PLC Programming: Writing and testing basic PLC programs for textile machine automation (e.g., loom control).
• Hydraulic Systems: Assembling and testing hydraulic circuits for textile presses; adjusting pressure settings.
• Machine Maintenance: Overhauling spinning, knitting, or weaving machines; replacing worn parts like belts and bearings.
• Robotics Practice: Simulating robotic arm operations for fabric stacking or yarn handling using trainers.
• Energy Audits: Measuring power usage of textile machines; suggesting efficiency improvements.
• Project Work: Automating a textile machine process (e.g., weaving cycle) using PLC and sensors, with HMI display.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 4

Trade Theory

• Advanced Automation: Internet of Things (IoT), Supervisory Control and Data Acquisition (SCADA), and their applications in smart textile factories.
• Production Management: Lean manufacturing, production scheduling, and downtime reduction in textile units.
• Troubleshooting: Diagnosing complex faults in electrical, mechanical, and automation systems of textile machinery.
• Textile Industry Trends: Industry 4.0, sustainable textiles, and innovations in textile automation.
• Entrepreneurship: Setting up a textile machine maintenance or automation service; business planning, costing.
• Environmental Safety: Waste management, effluent treatment, and compliance with emission norms in textile production.

Trade Practical

• IoT Integration: Connecting textile machine sensors to IoT platforms for real-time monitoring.
• Troubleshooting: Diagnosing and repairing faults in automated looms or spinning frames (e.g., PLC errors, motor failures).
• Industrial Exposure: Hands-on training in textile factories, focusing on automation and maintenance (4-6 weeks).
• Production Optimization: Analyzing machine performance, reducing cycle times in practical setups.
• Sustainable Practices: Implementing waste reduction techniques; recycling textile scraps in mock scenarios.
• Project Work: Designing and implementing a fully automated textile machine system (e.g., knitting unit) with IoT, PLC, and HMI integration.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science
  
  • Calculations: Power consumption, gear ratios, torque, production rates, efficiency metrics.
  • Science: Mechanics (force, motion), electricity (circuits, magnetism), fluid dynamics (hydraulics/pneumatics), and thermal effects in textiles.
  • Hours: 80 hours/year
• Engineering Drawing
  
  • Reading and interpreting textile machine blueprints, electrical schematics, pneumatic/hydraulic diagrams, and automation layouts.
  • Hours: 80 hours/year
• Employability Skills
  
  • Communication skills, teamwork, time management, resume writing, interview preparation.
  • IT literacy: Using ERP software, online technical resources, and maintenance apps.
  • Hours: 60 hours/year

Assessment and Certification

• Exams:
  
  • Theory: Written exams per semester (MCQs, descriptive questions).
  • Practical: Hands-on tasks (machine operation, programming, maintenance).
• Evaluation Criteria: Machine handling accuracy, automation proficiency, safety adherence, project quality.
• Certification: NCVT National Trade Certificate (NTC) upon passing all semesters.

Career Opportunities

• Employment: Textile machine operator, maintenance technician, automation engineer, or PLC programmer in textile manufacturing, garment industries, or machinery firms.
• Self-Employment: Textile machine repair services, automation consultancy, or small-scale maintenance workshops.
• Further Studies: Diploma in Mechatronics, B.Tech in Textile Engineering, or certifications in PLC programming, IoT, or robotics.