Lesson 1 - Robotics in Automated Manufacturing

Topics:

Evolution of Robotics; What is an Industrial Robot?; Essential Characteristics; Robots and Automated Manufacturing; Project Manufacturing; Job Shop; Batch Manufacturing; Repetitive (Flow) Manufacturing; Continuous Manufacturing; Robot Safety

Learning Objectives:
– Identify why robots did not appear in large numbers in manufacturing until the late 1970s.
– State the Robot Industries Association’s definition of an industrial robot and explain the two key words.
– Describe how industrial robots are used in batch production systems.
– Explain how industrial robots are used in repetitive manufacturing systems that utilize transfer lines.
– List at least three factors that should be considered as part of a risk assessment when a robot system is in the development stage.
– Describe and contrast the following guarding methods: barrier, presence-sensing device, awareness device, warning system.
– Define the term zero-energy state.


Lesson 2 - The Basic Robot System

Topics:

Manufacturing and Robot Systems; Robot Arm; Robot Controller; Power Source; Tooling; Teaching/Programming Device; Data Storage; Definition of Terms; Critical Specifications; Payload; Degrees of Freedom; Drive Power; Repeatability; Accuracy; Work Envelope Dimensions; Speed; Memory Capacity; Programming Support; End-of-Arm Tooling; Environmental Requirements

Learning Objectives:
– Name and describe the basic building blocks of an industrial robot.
– Name and describe the additional components that make up a robot system.
– Define the following robot terms: degrees of freedom, position axes, orientation axes, work envelope, tool center point.
– Define and give an example of the following specifications for industrial robots: payload, repeatability, memory capacity, and environmental
   requirements.
– Explain the difference between accuracy and repeatability in robots.


Lesson 3 - Robot Classification I

Topics:

Robot classification; Classification by control system; Open-loop control; Nonservo operation; Advantages of open-loop control; Disadvantages of open-loop control; Applications for open-loop control; Closed-loop control; Advantages of closed-loop control; Disadvantages of closed-loop control; Applications for closed-loop control; Classification by application

Learning Objectives:
– Identify the five methods of classifying industrial robots.
– Explain the difference between robots with closed-loop control and those with open-loop control.
– Describe the techniques used in closed- and open-loop control in robot systems.
– List the advantages and disadvantages of open-and closed-loop control in robot systems.
– Distinguish between assembly and nonassembly robots according to the application for which they were designed.


Lesson 4 - Robot Classification II

Topics:

Classification by arm geometry; Cartesian (rectangular) arm geometry; Cylindrical arm geometry; Spherical (polar) arm geometry; Articulated arm geometry; Classification by power source; Classification by path control; Classification by intelligence level

Learning Objectives:
– Classify robots by arm geometry, power source, and path control techniques.
– Identify the basic robot work envelopes and name the arm geometries that produce them.
– Name the basic power sources used for robot motion and give an advantage and disadvantage of each.
– Identify the basic path-control techniques and describe their characteristics.


Lesson 5 - Work-Cell Sensors

Topics:

Sensor overview; Simple contact sensors; Simple noncontact sensors; Simple process control sensors; Complex sensors; Complex sensor interface; Complex contact sensors; Complex noncontact sensors; Complex process control sensors

Learning Objectives:
– List the two types of interfaces and three groups of sensors used in industrial robot systems.
– Describe the primary simple contact sensor commonly found in robot systems.
– Identify and explain the operation of the two simple noncontact sensors most often used in industrial robot installations.
– Explain the difference between the simple sensor interface and complex sensor interface.
– Identify and describe vision and tactile sensors and the systems required to support them.


Lesson 6 - End-of-Arm Tooling

Topics:

General requirements; Tooling terms; Tooling power sources; Tooling overview; Standard grippers; Servo or nonservo grippers; Vacuum devices; Magnetic devices; Flexible pneumatic devices; Special-purpose tooling; Protecting end-of-arm tooling; Compliance

Learning Objectives:
– Name the five general requirements all tooling must satisfy.
– Identify and describe briefly the four basic tooling power sources.
– Describe the five categories of end-of-arm tooling used in robot applications.
– Explain the function and advantages of a quick-change device.
– Define the term compliance and explain why it is important.


Lesson 7 - Robot Teaching and Programming

Topics:

Work-cell programming; Controller functions; Robot programming; On-line programming; On-line programming example; Off-line programming; Defining programmed points; Writing program statements; Work cell control with a PLC; PLC programming example

Learning Objectives:
– List and describe the four basic functions of the computer(s) controlling an automated work cell.
– Name the two major types of robot programming and give advantages and disadvantages of each.
– Name and describe two basic methods of teach programming and tell when each is used.
– List three advantages of off-line programming.
– Name the two elements of a computer program for off-line robot programming.
– Explain the basics of ladder logic programming.