# Automation and Material Handling Courseware

AI and Robotics

Nov 13, 2013 (4 years and 6 months ago)

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Level Two

Automation and Material Handling Courseware

Level Two

Topic 1

Introduction to Automation and Material Handling

Objective

When your students have completed this topic, they will have reviewed the skills
necessary to prepare them to operate the entire ro
botic system in an integrated program.
They will run both the 5100 and 5200 robots, the peripheral feeders and conveyors, and
the PLC trainer.

Skills

Operate 5100 robotic arm using the teach pendant

Identify the vital statistics of the 5100 and how it oper
ates

Create a program with the 5100 robotic arm

Operate 5200 robotic arm, the gravity feeder, the conveyor,
and the carousel
while
creating a program

Recall types of conveyors and control devices

Recall the place of sensors, PLCs, and ladder logic in manuf
acturing

Load a program into the PLC

Verify the operation of the PLC

Topic 2

RSLogix Programming

Objective

When you have completed this topic, you will have gained the knowledge necessary to
program timers, counters, math, and compare functions in
RSLog
ix
.

Skills

Program and address inputs and outputs in the timer rung

Program the Timer On
-
Delay function

Use the sensors and conveyor with the timer function

Program and address inputs and outputs in the counter rung

Use the counter function to initiate ot
her events in a routine

Use the sensors and conveyor with the counter function

Describe the values needed to program an add, subtract or multiply function

Add a math function to the ladder diagram and insert the correct values

Program a compare function

Ru
n a program that uses math functions

Level Two

T
OPIC
3

-

T

Objective

When your students have completed this topic, they will be able to create and use
flowcharts to provide visual representations of manufacturing operations. They will gain
the knowledge and

skills necessary to initiate and program tasks using both the 5100 and
5200 robotic systems.

Skills

Create flowcharts.

Apply flowcharts to a manufacturing process.

Save and recall 5100 robots t

Create point program with 5200 robot.

Upload point program into windows software.

Create a program using conditional statements.

Program a Do/Until loop.

Program an IF/End statement.

Topic 4

Plant M
anagement Today

Objective

When students have completed this topic, they will be able to identify flexible
manufacturing cells and systems, computer
-
integrated manufacturing (CIM), and
proportional, integral, and derivative (PID) controls. They will be able

to explain the
impact of computer
-
integrated manufacturing, what local area networks (LANs) and wide
area networks (WANs) are, and how PID control works. They will also learn of the latest
ic is and how it is
applied.

Skills

Identify a flexible manufacturing system

Trace the organizational hierarchy of an industrial plant from a flexible

manufacturing cell to computer
-
integrated manufacturing (CIM)

Explain the latest advances in robotics

Describe the function of CIM and evaluate its importance in industry

Identify and apply four basic controls found in industry

Explain the functions of the four basic controls

Level Two

Discuss fuzzy logic and apply its principle

Topic 5

Troubleshooting an Automa
ted System

Objective

When your students have completed this topic, they will be able to properly document
and monitor ladder logic programs. They will also be able to troubleshoot a PLC system
for connection and program errors

Skills

der logic program symbols

Utilize and observe real time monitoring tools

Assess system parameters through monitoring outputs

Determine and
fix programming errors

Determine and correct wiring errors

Isolate equipment malfunctions

Repair system faults

Topic 6

Automated Manufacturing Project

Objective

When your students have completed this topic, they will be able to design, integrate,
prog
ram and test an operational flexible manufacturing system (FMS). To complete the
topic project, they will design and develop a flow chart, input/output map, wiring
diagram and various software programs. They will also be required to troubleshoot the
FMS
for connection and program errors.

Skills

Develop a plan to integrate the PLC with the 5100 robot

Make the correct wiring connections between the 5V and 24V equipment

Program the 5100 to accept inputs from, and send outputs to, the PLC

Program the PLC to
initiate tasks and accept inputs from the 5100

Design and develop a flow chart to based on a flexible manufacturing system
specification

Generate an input/output map for the PLC, 5100 and 5200 robot

Wire a flexible manufacturing system

Program the PLC to w
ork within the system

Develop a point program with the 5200 robot

Develop and integrate a program using the
Level 4 Robotic Software

Develop a point program with the 5100 robot

Level Two

Test and troubleshoot a flexible manufacturing system

Level Two

Manufacturing Process
es Courseware

Level Two

Topic 1

Industrial Engineering

Objective

When your students have completed this topic they will be able to identify the
development of a product from research and development through concept sketch. They
will also be able to cre
ate plant layouts using flowcharting software.

Skills

Understand research and development

Develop a product from idea to concept sketch

Define the different manufacturing systems

Determine the best manufacturing system for a particular product

Create a pla
nt layout using flowcharting software

Understand Just
-
in
-
Time manufacturing concepts

Modify the plant layout to incorporate Just
-
in
-
Time concepts

Topic 2

Designing for the CNC Lathe

Objective

When students have completed this topic, they will have learne
for the CNC lathe through the use of the CAD/CAM feature. They will be able to use this
feature to design a program on the computer, convert it to computer (CNC) code, and
transfer that code to the CNC lathe for machining. They wil
l also be able to load stock
and set the PRZ (programmed reference zero) on the CNC lathe.

Skills

Explains the similarities and differences between the CNC lathe and mill

Identifies the various parts of the CNC lathe

Understands and applies the X
-

and Z
-
co
ordinate system.

Recognizes and understands the G
-

and M
-
coding system

Understands and practices safety procedures

Loads stock and sets the PRZ

Defines and describes the
Lathe

Level 4

Describes the open, setup, and save procedures

Understan
ds how to use the tools on the lathe CAD screen

Explains how to compile and emulate a part program

Describes how to view a part from several perspectives

Level Two

Follows directions to create a design with the CAD/CAM feature

part program

Understands and uses the Help feature of the
Lathe Level 4

software

Designs and lays out a game piece on a grid sheet

Understands and applies game piece design specifications to the

Designs own game pieces using the CAD/CAM

software

Topic 3

Production on the CNC Lathe

Objective

When students have completed this topic, they will be able to use the CNC lathe and the
Level 4 CAD/CAM feature to create and machine their own designs. They will be able to
understand the purpose o
f prototypes and how to use them in the product development
process.

Students will apply all the skills they have learned about designing a part for the CNC
lathe. They will accomplish this by designing prototypes for their game pieces and then
machining
the finished products. They will be able to design programs on the computer,
convert them to computer (CNC) code, transfer that code to the CNC lathe, and machine
the parts.

Skills

Defines a prototype

Classifies the different prototypes

Distinguishes among

the various prototype applications

Understands and describes the principles of prototype design

Devises a prototype planning process sheet

Creates his or her own prototypes

Tests the prototypes, making any neces
sary changes

Interprets and verifies prototype planning information

Applies prototype planning information to a finished product

Follows directions to create a finished product with the CAD/CAM feature

Uses the
Lathe

Level 4

CAD/CAM feature to create a fin
ished product

Integrates CNC lathe
-
created designs with CNC mill
-
created designs

Level Two

Topic 4

Designing for the CNC Mill

Objective

When your students have completed this topic, they
will have learned the difference
between absolute and incremental coordinates. They will have also gained a basic
knowledge of
Virtual Gibbs

(a CAD/CAM program) by designing a part, and converting

Skills

Understand how to
use a CAD/CAM program to design a pattern to be machined
on the CNC mill

Gain a basic understanding of how to use
Virtual Gibbs

Topic 5

Production on the CNC Mill

Objective

When your students have completed this topic, they will have learned how to creat
e
machining operations, and will assign these operations to specified geometry. They will
post their designs as part programs and download the programs to the CNC Mill. They
will then machine their parts.

Skills

Create Machining operations

Use the mill t
o machine the designs that were created in Topic 4

Topic 6

Management Concepts and Systems

Objective

When students have completed this topic, they will be able to understand and apply
modern manufacturing concepts and practices.

They will become famil
iar with various continuous
-
improvement tools, quality
-
assurance
methods, and innovative systems for current and future manufacturing processes.
Students will apply business management principles and tools to real
-
life manufacturing
situations.

Skills

Defi
nes total quality management (TQM)

Understands and describes the essential principles of TQM

Describes some continuous
-
improvement (CI) techniques

Comprehends and describes Deming's Cycle (PDCA)

Level Two

Understands and describes how the traditional manufacturing o
rganization is
affected by the principles of total quality management

Applies TQM’s principles and Deming's Cycle (PDCA) chart to a basic quality
-
improvement situation

Understands and defines statistical tools and decision
-
making tools

Differentiates betwe
en various statistical and decision
-
making tools

Explains how continuous improvement tools can help improve total quality
management organizations

Applies certain continuous improvement tools to real
-
life quality management
situations

Understands and defin
es CIM technology

Describes how computers have changed the nature of manufacturing processes

Identifies future job opportunities in manufacturing

Explores educational options

Evaluates the students’ own personal skills and preferences

Predicts how their sk
ills, preferences, and interests may match with future
manufacturing job opportunities

Level Two

Mechanical Systems Courseware

Level Two

Topic 1
-

Pneumatics

Energy Transmission

Objective

When your students have completed this topic, they will be able to connect an
d
disconnect components and perform safe verification and shutdown procedures of the
6081 Pneumatics
-
1 Trainer. They will learn about the pressure properties and volume
properties of gases. Your students will be able to use the formulas of Pascal’s law,
Bo
yle’s law, and Charles’ law to determine pressure and volume.

Skills

Create a functional pneumatic circuit.

Operate the pneumatics trainer safely.

Measure force, area, pressure, volume, and mechanical response to varied inputs.

Topic 2
-

Pneumatics

Ener
gy Control

Objective

When your students have completed this topic, they will be familiar with the basic design
and operation of pneumatic safety relief valves and pressure regulators. They will
measure and adjust airflow, and observe mechanical responses t
pneumatic energy. The students will be able to use a vacuum generator to create a
vacuum and an air bearing to demonstrate a reduction of friction.

Skills

Use a venturi to generate negative pressures.

Convert fluid power energy into mech
anical energy.

Operate a pressure regulator and flow control valve.

Install safety devices such as pressure regulators and safety relief valves.

Topic 3

Pneumatics

Control Circuits

Objective

When your students have completed this topic, they will have th
e knowledge and skills to
identify typical pneumatic components and their functions. They will determine circuit
functions by reading schematic diagrams. In addition, they will design and build a meter
-

Level Two

in circuit and a meter
-
out circuit. The students will
also control a double
-
acting cylinder
using pilot control lines and a pilot
-
operated directional control valve.

Skills

Design schematic diagrams.

Identify circuit and component functions.

Control the operation of a double
-
acting cylinder.

Match pneumatic s
ymbols to the components they represent.

Construct two different metered circuits by following schematics

Topic 4
-

Hydraulics

Fundamentals

Objective

When the students have completed this topic, they will be able to determine area, force,
and pressure. They

will be able to calculate volume, capacity, and fluid flow, and verify
their calculations using the Hydraulics I Training System.

Skills

Verify calculations using the hydraulics trainer.

Use various formulas to calculate volume, capacity, and fluid flow.

Determine the area and volume of different shapes and containers.

Calculate the time it takes for a piston to extend a certain distance.

Topic 5
-

Hydraulics

System Details

Objective

When your students have completed this topic, they will be able to perfo
rm simple
maintenance and troubleshooting on the Hydraulics I Training System. They will be able
to change the direction and rate of fluid flow in a circuit. The students will also be able to
identify the advanced components that are included with the trai
ner, and build and

Skills

Build a fixed
-
displacement circuit.

Use an accumulator for emergency power.

Perform basic troubleshooting and preventive maintenance.

Construct and operate two advanced hydraulic circuits, on
e with cylinders
connected in series and the other with cylinders connected in parallel.

Level Two

Topic 6
-

HVAC

Objective

When your students have completed this topic, they will have the knowledge and skills to
identify the energy principles of heating, ventilati
ng, and air conditioning (HVAC), and
refrigeration. In addition, they will be able to determine component and circuit functions
in both HVAC and refrigeration systems. The students will also be able to specify the
different types of pollutants and allergen
s that affect indoor air quality.

Skills

Estimate the volume of a building.

Perform velocity pressure calculations.

Estimate the rate of air exchange that occurs in a home.

Determine the number of calories that a particular volume of water releases as it
c
ools.

Calculate the heat energy required to raise the temperature of a specific volume of
water.

Compare the heat energy lost through conduction between glass windows of
similar size and different R
-
values.

Level Two

Electricity and Electronics Courseware

Level T
wo

Topic 1

Introduction to Motor Controls

Objective

When students have completed this topic, they will be able to describe and demonstrate
the operation of selected types of motor controller components as well as typical
applications.

Skills

Learns the b
asic theory of industrial motors and controllers

Understands and follows electrical safety procedures

Demonstrates the operation of a variety of motor control components

Connects and operates practical motor control circuits on an industrial
-
trainer

Topic 2

Control Pilot Devices

Objective

When students have completed this topic, they will be able to identify different control
pilot devices, their symbols, and demonstrate their uses and functions by connecting them
in simple circuits.

Skills

Learns

the operation of several control pilot devices

Identifies the devices by schematic symbol and system function

Connects and demonstrates practical circuit applications

Topic 3

Basic Motor Control Circuits

Objective

When students have completed this top
ic, they will be able to construct and demonstrate
the operation of two
-
wire and three
-
wire control circuits. They will use schematic
diagrams to gain a basic understanding of the differences between two
-
wire and three
-
wire control circuits.

Students wil
l also gain an understanding of how a normally high
-
voltage control circuit
can be reduced to a much safer low
-
voltage control circuit in circumstances where high
-

Level Two

voltage can be extremely dangerous to the operator. They will accomplish this by
constructing

a control circuit using a control transformer. They will demonstrate the
control transformer on the trainer by simulating a circuit for a pump station.

Skills

Learns the operation of basic two
-
wire and three
-
wire motor control circuits

Demonstrates the di
fferences between high
-
voltage and low
-
voltage control
circuits

Connects and operates practical control circuits using a squirrel
-
cage motor

Topic 4

Semiconductor Devices

Objective

When students have completed this topic, they will be able to explain t
he composition
and operation of semiconductor diodes and transistors.

Skills

Learns the theory and composition of basic semiconductor diodes and transistors

Uses a multimeter to check a semiconductor junction

Demonstrates semiconductor operation by constru
cting practical circuits

Measures semiconductor circuit parameters with a multimeter and oscilloscope

Topic 5

Op
-
Amp Fundamentals

Objective

When you have completed this topic, you will be able to calculate and measure the input
and output signals and ci
rcuit gain of an inverting, non
-
inverting, and summing
operational amplifier circuit.

You will learn how to set
-
up and adjust a voltage divider and attenuator circuit to provide
specific input voltages to the op amp circuits. You will also learn how to

set
-
up and
operate a digital multimeter, function generator, and dual channel oscilloscope.

Skills

Learns the basic theory and operation of operational amplifiers

Connects and compares different op
-
amp circuit configurations

Understands the applications o
f positive and negative feedback loops

Measures op
-
amp circuit parameters with a multimeter and oscilloscope

Level Two

Topic 6

Thyristor Concepts

Objective

When students have completed this topic, they will be able to explain and demonstrate
the operation of SCRs

(silicon controlled rectifiers) in ac and dc switching and control
applications.

Skills

Learns the basic operation of thyristors

Recognizes the schematic symbols for SCR’s and triacs

Applies thyristor concepts to wire and demonstrate practical circuits f
or ac and dc
switching and control applications

Topic 7

Fundamentals of Digital Logic

Objective

When students have completed this topic, they will be able to explain and demonstrate
the operation of basic digital logic gates.

Skills

Recognizes the schem
atic symbols of basic digital gates and flip
-
flops

Learns the functions of basic logic elements

Uses truth tables to define and understand logic functions

Draws basic digital circuits using CircuitMaker and simulates their operation

Level Two

Quality Control Co
urseware

Level Two

Topic 1

Statistical Process Control

Objective

When students have completed this topic, they will gain an understanding of Statistical
Process Control (SPC) and its relation to sampling. They will be able to organize large
amounts of
data into reduced, manageable forms and solve for statistical measures.

Skills

Compares current quality methodology with earlier concepts.

Contrasts sample with a universe.

Explains the use of sampling.

Calculates range.

Understands the concept of cells an
d cell interval.

Determines the mode, median, and mean.

Calculates standard deviation.

Identifies three measures of dispersion.

Topic 2

Measurements and Drawings

Objective

When students have completed this topic, they will be able to relate the shape o
f the
curve to the distribution of values. They will be able to plot standard deviation on the
normal curve. By using a table known as Z Scores, they will also solve for probability
using the curve.

Skills

Describes and draws a normal curve.

Locates measu
res of central tendency on a normal curve.

Identifies the skew of a curve.

Relates the shape of a curve to measures of central tendencies.

Understands the concept of standard deviation.

Explains how the standard deviation value affects the shape of a curve
.

Contrasts specification limits to control limits.

Relates normal curve percentages to standard deviation.

Level Two

Calculates Z values.

Uses a Table of Z Scores.

Determines the percent below and above a given value.

Finds the percent between two values.

Topic 3

Introduction to SPC Software

Objective

When students have completed this topic, they will be familiar with a software package
used in industry for working with statistical process control. They will develop a control
chart and apply the theory they lear
ned in earlier topics to computer
-
generated reports
and charts.

Skills

Contrasts variable and attribute data.

Creates charts with SPC software used by industry Quality Control departments.

Compares manual statistical information with software generated sta
tistics.

Analyzes SPC
-
PC IV control charts.

Calculates control limits.

Uses tables.

Relates control charts to normal curves.

Recognizes the purpose of control charts.

Identifies patterns to determine an out
-
of
-
control process.

Calculates process capability

ratios.

Analyzes Process Capability Charts to determine a process capability.

Topic 4

Making the Instruments Work With the Software

Objective

When students have completed this topic, they will be able to make electrical
measurements and enter their rea
dings with the keyboard. They will able to make
measurements with the digital caliper and digital micrometer and enter them
automatically to the SPC software with the footswitch or mouse.

Skills

Interprets resistor color codes using a color code table.

Use
s a digital multimeter to read resistance.

Creates a data file of resistance values with SPC software.

Analyzes
SPC
-
PC IV

output to determine if the process is in control and capable.

Connects digital tools to the GagePort.

Configures the software to inter
face with the GagePort.

Level Two

Configures gage cursors to collect data from two devices in one session.

Configures the software to collect multiple measurements from one part.

Inserts columns to an
SPC
-
PC IV

Creates formulas to add a series of values

in an
SPC
-
PC IV

Uses an X
-
bar, R Chart to determine if a process is in control and capable.

Topic 5

Attribute and Pareto Charts

Objective

When students have completed this topic, they will be able to create attribute charts to
analyze cou
ntable data for defective parts and defects per unit. They will learn to create
Pareto Charts and explain how to use them.

Skills

Describes the difference between attribute data and variable data.

Contrasts defective parts and defects per unit.

Develops ch
arts (p and np Charts) to monitor defective parts.

Solves for percentage defective.

Creates charts (u and c Charts) to monitor defects per unit.

Develops formulas to add values in an
SPC
-
PC IV

data file.

Explains the purpose of a Pareto Chart.

Relates exam
ples of the 80/20 rule.

Creates a Pareto Chart.

Uses the
SPC
-
PC IV

software to modify data files and create attribute charts.

Analyzes information from attribute charts.

Level Two

Design Process Courseware

Level Two

Topic 1

Introduction to Design

Objective

Wh
en students have completed this topic, they will have experience implementing the
design process. Students will brainstorm possible design solutions that satisfy the
requirements of a design brief. They will then use
Mechanical Desktop
to begin creating
a
three
-
dimensional model of their design solution.

Skills

Reviews the design process

Applies knowledge of design criteria to example presented

Draws design sketches

Uses
Mechanical Desktop
to draw a rough sketch of one proposed design

Creates a profile fr
om the sketch.

Adds geometric constraints and dimensions to the sketch.

Topic 2

Designing for Ease of Use Part 2

Objective

When students have completed this topic, they will be able to use
Mechanical Desktop

to
create a 3
-
D model of a part. Students wil
l add placed and sketched features to their
model, and then create 2D technical drawings from the model.

Skills

Uses
Mechanical Desktop

to create a 3D model of a part, including placed and sketched
features.

Differentiates between placed and sketched featu
res in
Mechanical Desktop
.

Develops the ability to view models from different viewpoints.

Creates multiview 2D technical drawings using Mechanical Desktop, including the
addition and editing of dimensions, dimension lines, and text.

Level Two

Topic 3

Final Desig
n Project

Planetary Rover

Objective

When students have completed this topic, they will be able to use
Mechanical Desktop

to
create a 3D model of a planetary rover. Students will model the rover body, the
instruments, and the systems. They will assemble t
he planetary rover, constrain it, and
check it for interference. They will create a multiview drawing of the rover body.
Students will then assign mass properties to the various parts using several types of
manufacturing material to determine the total mas
s of the planetary rover.

Skills

Brainstorm design of the body of a space rover.

Sketch, resolve, constrain, and extrude parts of the design as well as a variety of
instruments using
Mechanical Desktop.

Describe the structure and function of various system
s included on a space rover.

Model the systems used on a space rover using
Mechanical Desktop
.

Assemble the space rover using
Mechanical Desktop
.

Create a multiview drawing of the space rover using
Mechanical Desktop
.

Determine the existence of interferenc
e between parts of the space rover using
Mechanical Desktop
.

Use the
Mechanical Desktop

program to determine the mass of the rover and its
parts in a variety of construction materials.

Topic 4

Designing for Mobility

Objective

When students have completed

this topic, they will be able to test the motion of a space
rover in the simulated environment of an asteroid. They will use
Working Model

to
assemble a simulated rover and test it climbing over obstacles and hopping over
crevasses. They will then determi
ne how long it will take to map the entire surface of
Vesta. Students will also apply their skills to a new mission on a different planetary body.

Skills

Uses
Working Model

to assemble a simulated rover.

Tests the rover on flat ground and on various degree
s of incline.

Investigates the effect of low

gravity conditions on rover mobility.

Determines the maximum speed attainable in specified environmental conditions.

Determines the average speed gained over a given distance

Determines how large an obstacle th
e rover can scale and how big a crevasse the
rover can hop across.

Tests the ability of the rover to recover from accidental overturning.

Describes the function of the instruments contained within the rover body.

Level Two

Calculates how much area the rover can co
ver in a month long mission.

Adapts the rover design for use under different environmental conditions.