Course Offerings

Study the principles of collaborative robotic programming through online learning modules and hands-on lab exercises. This course reviews topics such as Robot Installation, Relocation, Maintenance, and Troubleshooting Robot Operations. Students will then progress to Program Feasibility, Robotic Programming, and Logic Maintenance, with a focus on ensuring all robotic functions are conducted in a safe manner.

Course Objectives

1. Review robot installation, relocation, maintenance, and troubleshooting.
2. Identify program feasibility based on equipment capabilities and limitations, risk assessments, and quality control features.
3. Program robots utilizing lead through programming, reteach points, and ladder logic.
4. Perform logic maintenance while ensuring adherence to company specific standards and requirements

Outline of Instruction

1.Review of Robot Installation
a. Connect robot mechanically
b. Connect robot electronically
c. Connect robot pneumatically
d. Reteach points
e. Install a program
f. Verify safety functionality (wiring, response, checklist)
2.Review of Robot Relocation
a. Determine disassembly needs
b. Determine rigging requirements for movement (per manufacturers manual).
c. Secure robot for shipping
d. Connect robot mechanically, electronically, pneumatically
e. Reteach points
f. Verify safety functionality
3.Review of Robot Maintenance
a. Consult manufacturers manual for preventative maintenance checks and services
b. Save current program prior to conducting new operations
c. Disassemble auxiliary items
d. Dress pack maintenance, includes cable routing
e. Change seals on pneumatic tooling
f. Explanation of joint replacement
g. Re-calibration of robot
h. Explain vision systems and how they work
i. Monitor and toggle input/output
j. Reteach points
k. Maintain current backup
l. Perform recovery operations from backups
m. Verify safety functionality
4.Troubleshoot Robot Operations
a. Ladder logic review
b. Sequencing review - flow chart on paper
c. Follow the steps/logic to determine the problem
d. Determine the root cause (mechanical, electrical, pneumatic, etc.)
e. Root cause analysis - five whys
f. Communicate with operator
g. Change machine modes (auto/manual)
h .Run robot at variable speeds to identify mechanical issues
i. Manipulate machine in manual mode
j. Start, stop, and clear errors
5.Identify Program Feasibility
a. Identify robots capabilities and limitations
b. Identify controller's capabilities and limitations
c. Conduct risk assessment
d. Identify quality control requirements
e. Interact with other areas/departments
f. Identify mechanical system features
6.Robotic Programming
a. Save current program prior to conducting additional operations
b. Define/flow chart the process
c. Define and configure I/O
d. Inputs fault messaging and recovery codes into the program
e. Define standard program modes/mode control
f. Comment and label code (label early, label often)
g. Implement standard program modes
h. Read current program code and determine how to modify if needed
i. Develop/program safety logic
j. Verify the quality of the programming through physical check/quality control
k. Debug programming
l. Ensure the programming will meet or improve production requirements
m. Program data reporting requirements
n. Communicate with field bus requirements
o. Interact with end of arm tooling and other interconnected automation equipment (Mechatronics Trainer)
p. Verify safety functionality
7.Logic Maintenance
a. Maintain firmware
b. Generate backups
c. Perform recovery operations using backups
d. Follow/adhere to company specific standards and requirements
8.Perform Basic Robot Operations
a. Perform operations to place the robot into T1 mode and document error codes, check tooling for proper operations through the I/O screen, jog the robot to absolute zero position, and check against visible mastering marks.
9.Create a Tool Frame and User Frame
a. Use a six-point method to set up a tool frame and use a three-point to create a user frame
10.Write and Execute a Simple Robot Program and Modify the Program
a. Write a simple program that maneuvers around obstacles with ne termination and copy the program from Part 1 and Part 2. Joint motions will be at 100%. Linear motions will be at 1,000 mm/sec.
11.Offset the Program in an Upward Direction Using Two Methods
a. Use the program created in Job 3 Part 1 to copy and rename the program to perform operations.
12.Perform Backups and Restoration
a. Perform operations to set removable device type path, format the removable disk and create directory, create a standard le backup, demonstrate to the instructor generating a directory of all files, and create an image
backup
13.Perform Basic Robot Operations
a. Create simulation of cell from previous job backup, add EOAT, add textures, add parts, add obstacles, run Job 3 Part 1, create AVI, and play for the instructor
14.Modify Simulation Program from Job 6 and Download Into Robot
a. Perform the operations in HandlingPRO and at the robot will generate a directory of the SV files on the removable device. The student will load the le, perform in single step test, notify the instructor and execute the program.
15.The student will use a six-point method to set up a tool frame. The instructor will determine the tool frame number. The student will jog the robot to the reference position to verify tool frame accuracy. The student will notify the instructor once this step has been completed. The instructor will have the student demonstrate accuracy of the Tool Center Point with the reference pointer.

Contact Hours

132

CEUs

No

Industry Standard, State or National Certification

Certification

FANUC HandlingTool Operation and Programming Certification and/or Smart Automation Certification Alliance

Website

fanucamerica.com; saca.org

Certification Learning Outcomes/Requirements

1. FANUC:
1. Robot safety and safety devices
2. Robot systems and components
3. Initial robot installation and start up
4. Basic robot operations using teach pendant
5. Basic robot programming
6. Program file manipulations
7. Robot integration
8. Troubleshooting system errors
9. Simulations for robots

SACA:
1. Electrical System Safety, Electrical Circuits, Electrical Diagrams and Measurements, Electrical Circuits
2. Electrical Motor Controls
3. Pneumatic Systems
4. Pneumatic Troubleshooting
5. Programmable Controller Systems
6. Programmable Controller Troubleshooting

CE or CU Articulation

No

Prerequisites

Collaborative Robotics Level 1, Collaborative Robotics Technician 2

Learning Supplies Needed

Student guides, Collaborative Robots, Robotics Systems training panels and associated tools and equipment.

Clinical Site/Special Facilities

Advanced Manufacturing Center; 8 Fanuc ER-4iA industrial robots.

Requirements for Successful Completion

90% attendance
Completion of all modules with a minimum score of 75% for each module.

Accreditation/Special Approval Requirements

N/A

Intended Audience

This course is intended for personnel who wish to be employed in an industry position that utilizes Manufacturing Production Technicians, Industrial Maintenance Technicians, Electrical Technicians, and Control Technicians.

Specific Industry or Business Support Needs

Robotics Operator; Robotics Technician Level I, II, or III

Wake County Need for Industry Positions

This is a skills gap area for light manufacturing in Wake County that is dependent on skilled technicians to keep manufacturing systems operating.

Industry or Job Titles Related to Training Outcomes for Employment

Robotics Operator

Robotics Technician Level 1

Robotics Technician Level 2

Robotics Technician Level 3

Related Courses

MEC-3010K1

MEC-3010N1

Course Contact Information