Engineering Training

Course Objectives

Have an understanding of workplace safety, including maintaining an awareness of the work environment, ensuring its cleanliness, identifying potential hazards and awareness of emergency procedures and emergency exit routes. Students also receive training on personal protective equipment (PPE), as well as basic safety precautions for working with robots.

Have an understanding of safety functionality, including the safe use of tools and machinery. Students learn the importance of checklists when operating equipment and machinery.

Read a basic blueprint and determine the critical features of a part to ensure proper installation and that quality standards are being met.

Have an understanding of basic electrical theory, including electrical terminology and fundamental measures, and the basics of electrical hazards and safe work practices.

Have an understanding of the basics of programmable logic controllers (PLCs), their functions and operation.

Have an understanding of basic pneumatic theory, the different components of pneumatic power systems, how they function and how pneumatics are integrated into robotic systems.

Have an understanding of the most common applications of industrial automation and collaborative robotics and how they work together; the basics of robotic components, including arms, end effectors and axes; and how axes are used to control robot movement.

Develop an understanding of sensors that provide feedback data to robots and be able to explain the categories of sensors and show how sensors are used in industrial and collaborative robotics.

Learn the basics of robotic connectivity, including proper electrical and pneumatic connections, verification of connections and how to make adjustments.

Develop an understanding of the fundamental concepts required for programming collaborative robots, including the use of the pendant controller and reteach points.

Know the robot machine modes (automatic and manual), understand when each should be used, know how to switch from one to the other quickly in the event of an emergency, how to operate the robot at variable speeds to identify mechanical issues and ensure the robot is operating safely in the work environment.

Develop a working understanding of the troubleshooting process and how to identify problems, including quality control issues, and their causes.

Learn how to start, stop and clear errors that might occur during the operation of the robot and develop an understanding of why the errors might have occurred.

Learn how to recover from a robot crash, understand why the crash occurred and evaluate the robot to ensure the crash did not damage the system.

Gain a working understanding of the importance of maintenance, as well as when to call in a maintenance technician for repairs.

Learn the importance of personal interaction with customers and co-workers and the need to focus on customer service and satisfaction.

Outline of Instruction

Workplace Safety Lab
Demonstrate proper use of PPE and have students show how to apply PPE and under what circumstances.

Safety Functionality Lab
Demonstrate use of simple tools and machines, demonstrate and have students display proper lifting methods, demonstrate use of check lists prior to equipment operation. Have students generate a checklist.

Blueprint Reading Lab
Have students read and review mechanical print drawings to ensure fit, form and function requirements are met. Have students inspect parts using calipers and, as needed, inspection gauge to verify parts are in specification.

Basic Electrical Theory Lab
Have students review basic electrical safety and how to use a digital VOM (volt/ohmmeter) then have them read resistance, continuity, voltage and current in a prewired circuit. Have students wire a simple series and parallel control circuit and verify proper function.

Basic PLC Theory Lab
Have students identify common PLC hardware and describe and demo relay ladder logic. Students then review PLC safety and demo wire a PLC, verify inputs and outputs, load pre-written code and verify function. Students then make simple modifications to existing code, save changes, download and verify function.

Basic Pneumatic Theory Lab
Have students review pneumatic safety and demo, then have them build a pneumatic circuit, verify inputs and outputs and verify function.

Industrial Automation and Collaborative Robotic Applications Lab
Describe industrial automation processes, including material handling systems, material identification systems and manufacturing execution systems. Students also describe collaborative robotic components, including servomotors, arms, end effectors, grippers and encoders. Students then demo methods for axis control and describe types of end effectors and grippers and their uses.

Collaborative Robotic Sensors Lab
Describe various types of sensors, their uses and potential limits. Students demonstrate use of sensors in a robotic system and common controls for stopping robot motion in emergencies.

Connect Robot Electronically and Pneumatically Lab
Identify the terminology used to specify a robot safeguarding system. Distinguish between pneumatic and electric drives. Demo and then have students perform lockout/tagout procedures. Review NIOSH guidelines for robot safety.

Collaborative Robot Programming Lab
Students demonstrate a basic understanding of programming methods. They demo the use of the teach pendant, including the use of "teach mode." They also demonstrate "walk through" and "lead through" programming, as well as the advantages and disadvantages of online and offline programming. Students then describe computer-integrated manufacturing, identify common coordinate systems and distinguish between different types of CNC program codes. Finally, they explain the importance of maintaining current backups of all programs and demo proper procedures for performing backup procedures.

Robot Machine Modes Lab
Explain common types of robot accidents and causes of hazardous robot movement. Students demo common controls for stopping robot motion in emergencies, two-hand control safety devices and identify various types of presence-sensing safety devices and safety guards. Students then review robot programming and perform offline and online programming projects requiring movement of various robot axes. They demonstrate an understanding of point-to-point path control and continuous path control and generate robot simulator programs.

Troubleshooting Lab
Laboratory exercises provide an opportunity for students to identify problems specific to robots and devise appropriate solutions.

Start, Stop and Clear Errors Lab
Have students explain common causes of hazardous robot movement. Have students perform a lockout/tagout safeguards for robots. Have students show competency in the use of common controls for stopping robot motion in emergencies. Have students show competency in the use of two-hand control safety devices. Have students replace and calibrate different types of presence-sensing safety devices. Have students show competency in the use of different types of safety guards. Review NIOSH guidelines for robot safety.

Recover from a Crash Lab
Describe techniques for identifying problems. Describe and demo the process of evaluating troubleshooting data. Describe and demo the process of working backwards. Describe the process of proposing potential fixes. Describe and demo the process of testing solutions. Describe and demo the process of applying permanent solutions. Describe and demo the process of troubleshooting end effectors. Identify common causes of pneumatic system problems. Identify common causes of lack of robot motion. Describe and demo mechanical reasons for a robot's loss of positioning. Describe and demo feedback errors that cause a robot's loss of positioning.

Robot Maintenance Lab
Explain the importance of maintenance work for robots. Describe preventive maintenance for robots. Describe maintenance practices for servomotors. List common causes of pneumatic system problems. Define lubricant. Identify common lubricant delivery methods for robots. Describe safety practices for robot maintenance. Describe tuning maintenance. Describe the procedure for replacing robot wires. Explain how regular maintenance prevents downtime.

Customer Service Lab
Students are evaluated in customer service during interactions with other individuals in the class and through a series of customer service simulations throughout the class.

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

FANUC: Robot safety and safety devices, robot systems and components, initial robot installation and start up, basic robot operations using teach pendant, basic robot programming, program file manipulations, robot integration, troubleshooting system errors and simulations for robots

SACA:
Electrical system safety, electrical circuits, electrical diagrams and measurements, electrical circuits, electrical motor controls, pneumatic systems, pneumatic troubleshooting, programmable controller systems and programmable controller troubleshooting

CE or CU Articulation

No

Prerequisites

Basic math and general computer skills

Learning Supplies Needed

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

Clinical Site/Special Facilities

Advanced Manufacturing Center.

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 Collaborative Robotics Operators

Specific Industry or Business Support Needs

Robotics Operator

Wake County Need for Industry Positions

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

Industry or Job Titles Related to Training Outcomes for Employment

Robotics Operator

Related Courses

Course Contact Information