In collaboration with Omron, Hytech Automation has successfully established a state-of-the-art Industry 4.0 Automation Training Centre at IIT Roorkee, enabling industry-aligned skill development.
Industry Challenge
In today’s rapidly evolving industrial landscape, driven by Industry 4.0, smart manufacturing, and digital transformation, a significant gap exists between academic learning environments and real-world industrial requirements.
Most educational institutions continue to rely on theory-based teaching methodologies or isolated laboratory setups, which do not adequately reflect the complexity of modern automation systems. As a result, students often lack exposure to:
- Integrated automation systems combining PLC, motion control, robotics, vision, and process automation
- Real-time industrial communication protocols and smart sensing technologies such as IO-Link and IIoT
- Multi-disciplinary workflows that simulate actual manufacturing environments
- Practical understanding of system integration, troubleshooting, and industrial safety standards
Additionally, conventional training setups are often fragmented, where individual components are taught independently without demonstrating how they function together within a complete automated system.
👉 This leads to a critical challenge:
Graduates are not fully industry-ready, lacking hands-on experience in integrated automation systems.
Industry Initiative
Recognizing this gap, Omron Automation India Pvt. Ltd., a global leader in industrial automation, initiated a strategic effort to strengthen industry–academia collaboration.
The objective was to enable institutions to adopt real-world automation technologies and create learning environments aligned with modern industrial practices.
Institutional Challenges
At Indian Institute of Technology Roorkee, the need for an advanced, integrated training platform was identified due to:
- Limited access to comprehensive industrial automation systems
- Existing laboratories focused on isolated components rather than integrated solutions
- Lack of exposure to advanced automation technologies in sensing, control, and safety
- Absence of platforms demonstrating end-to-end smart manufacturing workflows
- Limited opportunities for students to gain hands-on experience in multi-technology integration
👉 This resulted in a clear gap between academic training and industry expectations.
Solution Implementation
To address this challenge, Omron partnered with Hytech Automation as a design, manufacturing, and system integration expert to establish a comprehensive Industry 4.0 training centre.
Hytech Automation translated Omron’s technological vision into a fully integrated, modular training ecosystem by:
- Designing custom automation training kits aligned with industry applications
- Manufacturing industrial-grade modular workstations
- Integrating multiple technologies into a unified platform, including:
- Motion control systems
- Smart sensing (IO-Link enabled devices)
- Machine vision systems
- Robotics and handling applications
- Industrial safety systems
- Process automation modules
- Developing a system architecture that simulates real industrial production workflows
Outcome
The result is a smart factory-oriented training environment that enables:
- Hands-on learning with real industrial automation technologies
- Understanding of end-to-end manufacturing processes
- Skill development in multi-disciplinary automation systems
- Improved alignment with industry requirements and employability standards
👉 This initiative successfully transforms traditional learning into an application-driven, industry-aligned training experience.
Training Kit Descriptions
- Lean Automation Kit – Servo Motor System
This kit is designed to provide hands-on training in precision motion control using servo technology. It consists of a rotary indexing table integrated with a servo motor and encoder feedback system, along with a linear slide driven by a ball screw mechanism.
- Servo Motor: A high-performance motor equipped with a permanent magnet rotor. Unlike standard motors, it uses a feedback loop to maintain precise control over position, speed, and acceleration.
- Encoder: A rotary sensor mounted on the motor shaft. It converts the angular position or motion of the shaft into digital signals, allowing the controller to know the motor’s exact location within a fraction of a degree.
- Rotary Indexing Table: A mechanical device used to rotate a workpiece to a fixed set of positions. It uses high-precision bearings to ensure the table stops at the exact same coordinates every time.
- Ball Screw & Linear Slide: A mechanical assembly where a threaded shaft (screw) provides a helical raceway for ball bearings. It translates the motor’s rotational torque into linear thrust with extremely low friction and zero backlash.
The system enables learners to understand:
- Servo Fundamentals: Understanding the core concepts, working principles, and operation of servo motors.
- PLC Integration: Learning how to program and integrate servo systems with a PLC.
- Control Modes: Mastering different servo modes of operation and closed-loop feedback systems.
- Application Logic: Implementing position control, indexing applications, and synchronization between rotary and linear motion.
It simulates real industrial applications such as indexing tables, packaging systems, and assembly operations.
- Lean Automation Kit – AC Motor & VFD System
This kit focuses on motor control and drive technology, featuring an AC motor integrated with a Variable Frequency Drive (VFD) and a temperature control module.
It enables learners to study:
- VFD Operations: Understanding the working principles of a Variable Frequency Drive (VFD).
- Speed & Torque Control: Learning how to control motor speed and torque variations via a VFD.
- System Integration: Integrating AC drives with PLC systems.
- Energy & Process Control: Studying energy-efficient motor operation and process control using temperature feedback via a Peltier modul
Widely applicable in industries such as conveyors, pumps, fans, and process systems.
- Advanced Automation Kit – Complex Motion System
This is a multi-axis motion control system comprising X, Y, and Z servo-driven linear axes, designed to simulate advanced automation applications.
- XYZ Gantry/Cartesian Robot: A configuration of three linear axes mounted perpendicular to each other.
- Linear Actuators: Each axis (X, Y, Z) has its own dedicated drive (usually a ball screw or belt drive) and motor to allow independent movement.
- Limit Switches & Home Sensors: These are physical or inductive sensors located at the boundaries of the machine. “Home” establishes the (0,0,0) coordinate, while “Limit” sensors act as a hard-stop to prevent mechanical over-travel.
Key learning areas include:
- Coordinated Motion: Mastering multi-axis interpolation and coordinated movement across X, Y, and Z axes.
- Path Programming: Understanding CNC and plotter-based operations.
- Motion Safety: Implementing hardware safety features such as limit switches (POT/NOT) and motion safety logic.
- Robotics Logic: Developing a foundational understanding of robotics motion logic and precision automation.
👉 Ideal for understanding robotics motion logic, CNC systems, and precision automation applications.
- Advanced Automation Kit – IO-Link & Sensor System
This kit provides hands-on experience with smart sensing technologies and industrial communication protocols, particularly IO-Link-based devices.
It includes multiple sensor mounting arrangements.
- IO-Link Master: An industrial gateway (often IP67 rated) that acts as the communication hub. It translates the IO-Link protocol into a standard fieldbus like EtherNet/IP or PROFINET.
- Point-to-Point Communication: Unlike traditional wiring where one wire equals one signal, IO-Link uses a 3-wire unshielded cable to transmit process data, device parameters, and detailed events/diagnostics simultaneously.
Learners gain knowledge in:
- Communication Protocols: Understanding the operation and configuration of an IO-Link master.
- Smart Diagnostics: Configuring smart sensors and utilizing remote diagnostics for system health monitoring.
- Data Exchange: Implementing IO-Link communication for real-time data exchange between field devices and the PLC.
- Sensor Logic: Developing sensor-based control logic for automated systems.
👉 Represents modern Industry 4.0-enabled sensing systems used in smart factories.
- Machine Safety Training Kit
This kit is designed to demonstrate industrial safety systems and standards, integrating safety components within a controlled environment.
It helps learners understand:
- Safety Circuitry: Understanding the design and implementation of safety circuits and protection mechanisms.
- Emergency Systems: Learning to integrate emergency stop systems and safety interlocks.
- Risk Mitigation: Practicing safe machine operation and understanding industrial compliance and risk reduction.
Critical for industries focusing on operator safety, compliance, and risk reduction.
- Machine Vision Kit
The Machine Vision Kit includes a conveyor system integrated with vision inspection setup, along with controlled lighting and mounting arrangements.
Key learning outcomes:
- Object Detection: Learning the fundamentals of object detection and automated inspection using industrial cameras.
- Quality Control: Implementing vision-based sorting and quality control logic on a moving conveyor.
- Vision Integration: Understanding how to integrate vision systems into broader automation lines.
Simulates real-world applications such as defect detection, sorting, and inspection in manufacturing lines.
- Robot Training Cell
This is a comprehensive robotic automation system designed for hands-on training in industrial robotics and system integration.
It includes:
- Robotic workstation with tool changer and grippers
- Multiple application tables:
- Color-based sorting (IO-Link)
- RFID-based sorting
- Assembly operations
- Vision-based sorting (future-ready)
Learners can perform:
- Robot Programming: Mastering both online and offline robot programming techniques.
- System Integration: Integrating a robotic arm with PLC systems and external sensors.
- Advanced Handling: Performing complex pick-and-place, sorting, and assembly tasks.
- Multi-Technology Sorting: Learning to use IO-Link color sensors and RFID for intelligent part sorting.
Represents a complete robotic manufacturing cell used in modern industries.
- Process Automation Kit
This kit is designed to simulate process industry applications using a dual-tank system with control mechanisms.
Learners can study:
- Process Programming: Learning PLC programming specifically for process-heavy industries.
- HMI Design: Designing Human-Machine Interface (HMI) screens for process monitoring.
- Closed-Loop Control: Studying feedback-based control systems for level and flow regulation.
- Parameter Monitoring: Learning to monitor and adjust critical process parameters in real-time.
Applicable to industries such as oil & gas, water treatment, and chemical processing.