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Beginner Level (30 Hours)

Objective: Introduce the fundamental concepts and practices required

to design, program, and control robotic manufacturing cells. Focus on

integrating CNC machines, industrial robots, and basic automation systems

tailored for specific applications.

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Module 1: Introduction to

Robotic Manufacturing Cells

(4 Hours)

• Overview of robotic cells and their role in manufacturing.

• Key components of a robotic cell:

  • CNC machines.

  • Industrial robots.

  • Programmable Logic Controllers (PLCs).

  • Sensors and actuators.

• Applications of robotic cells in industry (e.g., machining, assembly, welding).

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Module 2: Cell Design and

Configuration Basics (6 Hours)

• Principles of designing a robotic cell for specific applications:

  • Analyzing workflow and material handling.

  • Determining the number and type of robots required.

  • Integrating CNC machines and robots.

• Basics of robot placement and workspace optimization.

• Understanding payload and workspace requirements.

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Module 3: Introduction to

PLC Systems (6 Hours)

• Overview of PLC systems:

  • Master and slave PLCs.

  • Common PLC brands and configurations.

• Basics of PLC programming using ladder logic.

• Introduction to communication protocols:

  • ModBus.

  • DeviceNet.

  • Ethernet/IP.

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Module 4: Sensors and Basic

Automation (6 Hours)

• Introduction to sensors used in robotic cells:

  • Proximity sensors.

  • Photoelectric sensors.

  • Pressure and force sensors.

• Basics of closed-loop control systems.

• Implementing sensor feedback for robot and CNC operation.

• Hands-on exercises: integrating sensors into a basic robotic cell.

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Module 5: Basic Communication

and Integration (4 Hours)

• Establishing communication between robot controllers and PLCs.

• Setting up basic data exchange using ModBus and Ethernet.

• Synchronizing operations between CNC machines and robots.

• Hands-on project: designing a simple robotic cell with integrated communication.

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Module 6: Practical Project (4 Hours)

• Designing and simulating a simple robotic cell.

• Implementing basic programming and sensor integration.

• Presenting project results.

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Advanced Level (30 Hours)

Objective: Provide advanced training in the design, programming, and control of

complex robotic manufacturing cells,

focusing on multi-robot systems, advanced PLC programming, and closed-loop control.

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Module 1: Advanced Robotic Cell Design (4 Hours)

• Optimizing robotic cell layouts for complex applications.

• Integrating multiple CNC machines and robots in a single cell.

• Advanced considerations for space and workflow optimization.

• Ensuring safety and compliance in robotic cell design.

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Module 2: Advanced PLC Systems

and Communication

(6 Hours)

• Advanced PLC programming techniques:

  • Sequential Function Charts (SFC).

  • Structured Text (ST).

• Configuring master-slave PLC systems for large-scale cells.

• Advanced communication protocols:

  • OPC-UA.

  • Profinet.

  • Multi-protocol integration.

• Real-world examples of PLC-controlled robotic cells.

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Module 3: Advanced Sensor Integration

and Closed-Loop

Control (6 Hours)

• Implementing advanced sensors:

  • Vision systems for part detection and alignment.

  • Load cells for force monitoring.

  • Temperature sensors for process control.

• Designing robust closed-loop control systems.

• Practical exercises: integrating advanced sensors into a robotic cell.

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Module 4: Multi-Controller Communication

and Integration

(6 Hours)

• Establishing communication between multiple robot and CNC controllers.

• Synchronizing operations across different devices using advanced protocols.

• Troubleshooting communication issues.

• Hands-on project: creating a multi-controller robotic cell.

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Module 5: Application-Specific Cell

Configuration (4 Hours)

• Designing robotic cells for specific applications:

  • Assembly and machining.

  • Palletizing and packaging.

  • Welding and inspection.

• Selecting appropriate robots, CNC machines, and PLCs for each task.

• Advanced robot programming for application-specific tasks.

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Module 6: Capstone Project (4 Hours)

• Designing, programming, and simulating a complex robotic manufacturing cell.

• Implementing advanced communication and control systems.

• Presenting project outcomes and discussing optimization strategies.

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