ITI Technician Mechatronics (AITT Theory) study plan
ITI Technician Mechatronics (AITT Theory) · Give each week a clear focus.
8 weeks · About 7 hours per week
Pneumatics and Hydraulics & Trade Safety, Occupational Health and Environmental Practices
Draw and label a complete pneumatic circuit (compressor, FRL unit, 5/2 solenoid valve, double-acting cylinder) from memory and trace the air path in both stroke directions
Calculate force, bore area and air consumption for a double-acting cylinder at a given pressure, and explain how rod-end back pressure reduces effective thrust
Identify the safety hazards of stored pneumatic energy and write the correct isolation, venting and lock-off sequence before maintenance
Explain hydraulic pressure intensification, relief valve setting and the danger of trapped pressure in a closed circuit
List the PPE, machine-guarding and permit-to-work requirements that apply when working on a live fluid power system
Your checkpoint
A one-page hand-drawn pneumatic and hydraulic schematic set with worked force/consumption calculations and a written lock-off and venting procedure for each
Programmable Logic Controllers and Control Systems & Pneumatics and Hydraulics
Convert a written sequence-of-operations description into a PLC ladder logic rung set with correctly assigned inputs, outputs and internal memory bits
Implement and explain latching (seal-in), interlock and safety-relay logic so that a stop or guard-open condition always wins over a start command
Describe the scan cycle, input/output image updating and the effect of scan time on fast sensor events
Differentiate sinking and sourcing I/O wiring and state what happens when a sensor type is mismatched to the input module
Explain how directional control valve solenoids are driven from PLC outputs, including suppression and inrush considerations
Your checkpoint
A documented ladder logic program (printout or simulator screenshot) for a two-cylinder sequence with interlocks, plus a labelled I/O assignment table
Programmable Logic Controllers and Control Systems & Sensors, Transducers and Instrumentation
Tune and explain a simple PID loop: identify proportional band, integral time and derivative action and predict the response to a step change
Select the correct sensor for a given task by comparing inductive, capacitive, photoelectric, magnetic and ultrasonic proximity devices on range, target material and environment
Wire and interpret a 4-20 mA current loop, including why it is preferred over voltage signalling and how to detect an open loop
Convert raw analog counts from a PLC analog input module into engineering units and state the resolution achieved
Explain NPN versus PNP sensor output wiring and the common cause of a sensor that lights up but gives no PLC input
Your checkpoint
A sensor selection and wiring sheet covering five plant scenarios, with one worked 4-20 mA to engineering-unit conversion and a sketch of the analog input scaling
Electrical Drives, Motors and Actuators & Basic Electrical and Electronic Fundamentals
Compare DC brushed, brushless DC, stepper and three-phase induction motors on torque characteristics, control method and typical mechatronics application
Explain how a variable frequency drive controls induction motor speed, including the volts-per-hertz relationship and why low-speed torque is limited
Read a motor nameplate and calculate full-load current, slip and synchronous speed from the given data
Apply Ohm's law and series/parallel resistance rules to simple control circuits, and explain the role of a flyback diode across a DC coil
Describe the function of contactors, overload relays, soft starters and braking resistors in a drive circuit
Your checkpoint
A comparison table of four motor types with selection justification for three named applications, plus a solved numerical set on nameplate, slip and drive-frequency calculations
Mechanical Components, Power Transmission and Machine Elements & Engineering Drawing, Fits, Tolerances and Metrology
Identify and state the function of bearings, couplings, belts, chains, gears and lead screws, and select the right one for a described duty
Calculate gear ratio, output speed and torque for a multi-stage gear train and a belt-and-pulley pair
Interpret a limit-and-fit designation and determine whether a shaft-hole pair gives clearance, transition or interference
Read a component drawing with geometric tolerancing symbols and explain what each control frame constrains
Use vernier caliper, micrometer and dial gauge correctly and state the resolution and typical measurement error of each
Your checkpoint
A worked problem set on gear ratio, torque and fit calculation, plus a completed measurement record of five real components with instrument, reading and estimated uncertainty
Mechatronics System Integration, Robotics and Automation & Sensors, Transducers and Instrumentation
Describe the anatomy of an industrial robot: axes, wrist configuration, end effector, teach pendant and controller, and explain the difference between joint and Cartesian coordinate motion
Explain the purpose of homing, limit switches, hard stops and safety-rated monitored stop in an automated cell
Trace a complete signal path from sensor through PLC to actuator in an integrated station and identify every interface where a fault could break the chain
Explain the safety hierarchy for robot cells: perimeter guarding, light curtains, interlocks, enabling device and emergency stop categories
Describe how fieldbus or industrial Ethernet networks connect PLC, drive and remote I/O, and state one diagnostic advantage over hard wiring
Your checkpoint
A block diagram of one complete automated station showing sensor, controller, drive and actuator with signal type at each link, annotated with three plausible failure points
Maintenance, Troubleshooting and Fault Diagnosis & Trade Safety, Occupational Health and Environmental Practices
Apply a structured fault-finding sequence (symptom, information gathering, hypothesis, test, confirm) to at least three written mechatronics fault scenarios
Distinguish symptoms caused by mechanical wear, electrical failure, sensor drift, software logic error and fluid power leakage
Use a multimeter safely to check continuity, voltage presence and insulation, and state the correct meter setting and category rating for each test
Interpret PLC diagnostic indicators and fault codes to localise a stopped machine to a module, device or program condition
Write a preventive maintenance schedule for a pneumatic actuator, a proximity sensor and a drive, with interval and acceptance check for each
Your checkpoint
Three completed fault-diagnosis case write-ups, each ending in a confirmed root cause, the corrective action and a preventive measure added to the maintenance schedule
Engineering Drawing, Fits, Tolerances and Metrology & Basic Electrical and Electronic Fundamentals & Mechanical Components, Power Transmission and Machine Elements & Pneumatics and Hydraulics & Sensors, Transducers and Instrumentation & Programmable Logic Controllers and Control Systems & Electrical Drives, Motors and Actuators & Mechatronics System Integration, Robotics and Automation & Maintenance, Troubleshooting and Fault Diagnosis
Complete two full-length timed mock tests under exam conditions and score each by domain to expose weak areas
Re-derive the ten formulas most used in the exam (cylinder force, air consumption, gear ratio, slip, Ohm's law, analog scaling, PID terms) from a blank sheet
Redo every previously missed question type until the underlying principle, not just the answer, is explained aloud
Consolidate one condensed revision sheet per domain with the key facts, symbols and standard values
Your checkpoint
Two scored mock tests with a domain-wise error log and a set of ten single-page revision sheets covering all domains