SKILLED TRADES: APPLIED INDUSTRIAL TECHNOLOGY

Transcription

1 SKILLED TRADES: APPLIED INDUSTRIAL TECHNOLOGY 1

2 Applied Industrial Technology: CATIA V5 FUNDAMENTALS (CAT 101) The participant will understand the fundamentals of the CATIA V5 Computer Aided Design software and understand the basic philosophy of the software, as well as the Sketcher and Part Design Workbenches. 1. create new part files in the CATIA V5 software; 2. understand the basic philosophy of the CATIA V5 software; 3. create, constrain, and edit 2D sketches; 4. understand the various CATIA V5 solid-modeling commands; and 5. obtain necessary part information. To provide the participant with the skills necessary to create, constrain and edit a solid model using the CATIA V5 software. Creating Sketches Pad & Shaft Features Pocket & Groove Features Dress-Up Features Feature Duplication Rib & Slot Features Constraining Sketches Feature Techniques Feature Management Multi-Profile Sketches Part Information Loft Features None 9 2

3 Applied Industrial Technology: ELECTRICAL CONTROLS & SCHEMATICS (EST 100) This course provides participants with the skills to understand and use graphic representations by preparing detailed electrical drawings. Participants will demonstrate the use of lines, schematic drawings and interconnections, and wiring and terminal diagrams to display electronic and electrical circuits. 1. demonstrate an understanding of basic electrical theory as it relates to schematics and prints; 2. read and understand title blocks, drawing notes and revision systems; 3. read electrical symbols; 4. demonstrate an understanding of electrical print standards (ANSI, IEEE, JIC, NMTBA, NEMA, etc.); and 5. recognize and use different types of electrical prints. To provide the knowledge and skills required to read and understand electrical schematics and prints commonly found in a plant environment. Review of electrical theory Introduction to electrical schematics and prints Interpretation of electrical symbols Interpretation logic and gate symbols Interpretation of electronic symbols Recognition and use of electrical prints Power distribution drawings Industrial control prints None 12 3

4 Applied Industrial Technology: MECHANICAL SCHEMATICS (MST 100) This course provides participants with the necessary skills to read, understand, and interpret assembly drawings and diagrams to plan projects. Emphasis will be placed on how to interpret mechanical working drawings, read intermediate blueprints and schematics, and use construction specifications focusing on floor plans. 1. identify various industrial drawings; 2. read and understand title blocks, drawing notes and revision systems; 3. identify the various types of lines and views; 4. demonstrate an understanding of basic geometric dimensioning & tolerancing; and 5. demonstrate an understanding of basic building drawings. To provide the knowledge and skills required to read and understand mechanical schematics and prints commonly found in a plant environment. 3rd angle projection (American drawings) 1st angle projection (German drawings) German to English translation of drawings Welding symbols Pipe symbols and drawings Industrial drawings Title block Drawing notes Drawing revision system Sketching Multi-view drawings Section views Pictorial drawings Geometric Dimensioning & Tolerancing (GD&T) Building drawings None 12 4

5 Applied Industrial Technology: GEOMETRIC DIMENSIONING & TOLERANCING FOR MANUFACTURING (GDT 100) This 40-hour class will provide an overview for Skilled Trades, Design, and Engineering personnel whose responsibilities include the process of reading and interpreting blueprints or tube drawings. The course will present methods in the proper interpretation of blueprint drawings used in the manufacturing and inspection of parts and assemblies. 1. check parts using Geometric Dimensioning and Tolerancing; 2. recognize and sketch part views; 3. apply and interpret symbology, dimensioning, and tolerancing part features in order to provide a more thorough understanding; 4. be able to interpret drawings quicker; and 5. identify more useable parts To understand how Geometric Dimensioning and Tolerancing is used in the manufacturing and inspection of parts and assemblies. Geometric Dimensioning and Tolerancing symbology Dimensioning part features Tolerancing part features Interpreting drawings Review the use of precision measuring instruments Checking parts using Geometric Dimensioning and Tolerancing principles Using Geometric Dimensioning and Tolerancing as an international standard ISO and ASME y14.5m 1994 Dimensioning and Tolerancing Standards Participants should have a general knowledge of blueprint reading, be able to recognize part views and know how to apply and interpret symbology. 10 5

6 Applied Industrial Technology: DIE MAKING TECHNOLOGY (MDT 100) Industrial die making technology has undergone trermendous changes. This course updates participants with the current skills and techniques used in the die making industry. Upon successful completion of this course, participants will learn the latest technologies used in the die making field during the entire die construction process. Methodologies include lecture, discussion, lab exercises, demonstration, and computer activities. To train participants in the current and new technologies directly affecting the die making industry at Chrysler Corporation. Role of the Die Maker CATIA (V5 CATIA) SMIRT Metallurgy for Die Makers Rigging for Die Makers Welding technology Die making in Asia Next generation die making Super plastic forming The future of metal forming A general understanding of automation and computers is helpful. 8 6

7 Applied Industrial Technology: FUNDAMENTALS OF METALLURGY (WLT 200) The participant should be able to identify common metals used in auto plants; determine a metal s repair characteristics for welding or machining; quench and flame harden metals; perform hardness tests; and prepare metal for repair welding procedures. 1. identify common metals used in auto plants; 2. determine a metal s repair characteristics for welding or machining; 3. quench and flame harden metals; 4. perform hardness tests; and 5. prepare metal for repair welding procedures. The participant should acquire metallurgical knowledge and understand the processes regarding the manufacturing, processing, and utilization of six important metals that are used in the automotive industry. Properties of metals Metal identification Material specifications Crystal structures Effects of plastic deformation and heat treatment Applications of tool steels, cast irons, stainless steel, copper alloys, and aluminum None 6 7

8 Applied Industrial Technology: ADVANCED METALLURGY-HEAT TREATING (WLT 300) This course should give the participant the knowledge and skills to select various steels, perform heat treating operations on steel, and strengthen and anneal aluminum. 1. select carbon, low alloy or tool steels for specific applications; 2. perform hardening or strengthening heat treating operations to specifications; 3. case harden low carbon and alloy steel; 4. anneal hardened steel; 5. normalize and stress relieve steel; 6. anneal aluminum for formability; and 7. strengthen annealed aluminum. The participant will perform basic heat treating operations on carbon steel, alloy steel, tool steel and aluminum. Microstructural analysis Quenching and tempering Normalizing and stress relieving Aluminum heat treating and case hardening Fundamentals of Metallurgy (WLT 200). Participants should bring their book and WLT 200 course material, as these will be the basis of the written training material. Clothing Requirements This hands-on class will require participants to perform some machining, grinding, and other shop-related tasks. Work clothing and safety shoes are required. 6 8

9 Applied Industrial Technology: PUNCH DIE FINISHING (PUT 100) THIS COURSE IS CURRENTLY UNDER DEVELOPMENT 9

10 SKILLED TRADES: INDUSTRIAL AUTOMATION 10

11 Industrial Automation: CNC SETUP & OPERATION FOR MILLS (CNT 120) This course covers the programming and operation fundamentals of the Bridgeport EZ-Trak CNC mill. Hands-on training emphasizes writing CNC programs for the mill, machine setup, setting and adjusting tool offsets, and troubleshooting programs. CNC-operated Bridgeport mills and EZ-Trak software are available for hands-on use. 1. manually program and edit basic parts on the Bridgeport EZ-Trak CNC mill; 2. understand setup and operation techniques for CNC mills; 3. startup and grid, jog, program upload and download, set datum, set tool offsets, and run parts on the Bridgeport EZ-Trak CNC mill; 4. set and change tool offsets to compensate for changes caused by cutter wear; 5. operate the Bridgeport EZ-Trak CNC mill control; and 6. understand the Cartesian coordinate system and basic mathematics used for CNC programming. The participant should gain the knowledge and skills required to set up, operate, and write basic programs for the Bridgeport EZ-Trak CNC mill. Bridgeport EZ-Trak mill hardware Coordinate systems CNC mill operation Training participants must be able to operate a milling machine. 8 11

12 Industrial Automation: PROTOTRAK MILL PROGRAMMING & OPERATION (CNT 130) This course covers the programming and operation fundamentals of the ProtoTrak CNC mill. Hands-on training emphasizes writing CNC programs for the mill, machine setup, setting and adjusting tool offsets, and troubleshooting programs. CNC-operated ProtoTrak mills and ProtoTrak CNC mill software are available for hands-on use. 1. manually program and edit basic parts on the ProtoTrak CNC Mill; 2. understand setup and operation techniques for CNC Mills; 3. start-up and grid, jog, program upload and download, set datum, set tool offsets, and run parts on the ProtoTrak CNC Mill; 4. set and change tool offsets to compensate for changes caused by cutter wear; 5. operate the ProtoTrak CNC Mill Control; and 6. understand the Cartesian coordinate system and basic mathematics used for CNC programming. The participant should gain the knowledge and skills required to set up, operate, and write basic programs for the ProtoTrak CNC mill. ProtoTrak CNC mill hardware Coordinate systems CNC mill operation None 8 12

13 Industrial Automation: ALLEN-BRADLEY CONTROLLOGIX PROCESSOR FAMILY USING RSLOGIX 5000 SOFTWARE (BAT 175) Using Rockwell Software RSLogix 5000, the participant will learn how to install, set up, and troubleshoot the A-B ControlLogix system family of programmable controllers. Upon completion of this course through use of the A-B ControlLogix trainer, participants should be able to: 1. install and set up ControlLogix 5000 family processors; 2. activate RSLogix 5000 and RSLinx software; 3. prepare and edit instructions; 4. develop fundamental ladder logic circuits; 5. set up the computer for processor communications; and 6. search and perform program back up and restore procedures. To provide the participant with the knowledge and skills to install, set up, and troubleshoot the A-B ControlLogix processor and software. Understanding Logix 5000 systems Navigating RSLogix 5000 software Saving and restoring programs Identifying system components Searching ladder logic Comprehending data storage and organization Understanding timer and counter instructions Communicating with the controller Learning and reviewing bit level instructions Using documentation Participants should have a knowledge of electrical sequence control systems and a working knowledge of the electrical control of machines. 8 13

14 Industrial Automation: TROUBLESHOOTING ALLEN-BRADLEY CONTROLNET (CRT 300) This course provides participants with the skills and knowledge to maintain and troubleshoot both hardware and software for A-B ControlNet. Emphasis is placed on effective maintenance and troubleshooting of the ControlNet hardware and software. 1. lay out and install an A-B ControlNet network; 2. understand and use PLC5 Memory; 3. successfully navigate through RS NetWorx software for ControlNet; and 4. troubleshoot the ControlNet network. To provide the knowledge and skills required for effectively maintaining and troubleshooting a ControlNet network. PLC5 memory layout Message instruction with the PLC5 Building an online network Error codes Data mapping Creating/modifying a scanlist Peer to peer scheduled and unscheduled ControlNet communications Participants should attend two weeks of training on A-B PLC5 Programmable Controllers and be familiar with RSLogix 5 Software

15 Industrial Automation: TROUBLESHOOTING ALLEN-BRADLEY DEVICENET (DNT 300) This course provides participants with the skills and knowledge to maintain and troubleshoot both hardware and software for A-B DeviceNet. Emphasis is placed on effective maintenance and troubleshooting of the DeviceNet hardware and software. 1. understand A-B DeviceNet components and how DeviceNet differs from other networks; 2. understand and use the PLC5 Memory; 3. successfully navigate through RS NetWorx software for DeviceNet; and 4. successfully troubleshoot a DeviceNet network. To provide the knowledge and skills required for effectively maintaining and troubleshooting a DeviceNet network. Block transfer instruction DeviceNet hardware and cabling Building an online network Error codes Data mapping Participants should attend two weeks of training on A-B PLC5 Programmable Controllers and be familiar with RSLogix 5 Software

16 Industrial Automation: INTERMEDIATE CONTROLLOGIX WITH CONTROLNET (BAT 275) This core program is intended for personnel who are migrating from the PLC-5 and SLC 500 controllers to ControlLogix. Participants should be those whose responsibilities include programming, program editing, and troubleshooting faults in applications using program instructions. The successful completion of this course should enable the participant to efficiently navigate a ControlLogix system using a Windows based terminal. ControlNet Communications Unscheduled Network Communication Messages & Remote IO RS Networks for ControlNet Scheduled Network Communication Participants should have a completed a ControlLogix Fundamentals (BAT 175) or Introduction program, and have working experience with the basic instructions and operations of a programmable logic controller. 8 16

17 Industrial Automation: ALLEN-BRADLEY PANELVIEW 1400E (BAT 310) The participant should be able to install, program, edit, troubleshoot, and repair the PanelView 1400e operator control panel using RS Linx software. 1. set up the PLC5 communication; 2. configure PanelView hardware and software; and 3. use PanelBuilder software to develop and edit programs including objects, screens, and addresses. To provide participants with the skills needed to set up a PLC5, configure PanelView hardware and software, and use PanelBuilder software to develop and edit programs. PanelView hardware Hardware overview Interconnections PanelView configuration Review A-B 6200 software PanelBuilder software Loading and pass through communications Data highway Remote I/O and disk operations Participants must have completed Allen-Bradley PLC5 Family/6200 Software (BAT 105) OR have equivalent work experience with the PLC5 programmable controllers. 8 17

18 Industrial Automation: RSLOGIX 5 SOFTWARE FOR ALLEN-BRADLEY SLC 500 (BAT 320) The participant will learn RSLogix 500 software to develop programs; carry out basic functions, including the development of fundamental ladder logic circuits; use the Tag editor; communicate with Remote I/O; and diagnose and troubleshoot. 1. activate RSLogix software; 2. develop and edit instructions; 3. develop fundamental ladder logic circuits; and 4. demonstrate an understanding of Forcing. To provide participants with the skills needed to develop programs for A-B SLC-500 using RSLogix 500 software. Basic review of DOS-based software Introduction to Windows 95 Basics of RSLogix Program development Program storage, retrieval, and printing Troubleshooting Participants must have completed Allen-Bradley SLC 500 Processor Family Using ICOM Software (BAT 115), OR the former TTC course Allen-Bradley SLC 500 Family Using 6200 Software (BAT 100), OR have had equivalent formal training on A-B SLC 500 equipment. 8 18

19 Industrial Automation: RSLOGIX 5 SOFTWARE FOR ALLEN-BRADLEY PLC5 (BAT 330) Participants will learn to use A-B RSLogix 5 software to develop programs; carry out basic functions, including the development of fundamental ladder logic circuits; communicate with Remote I/O; and diagnose and troubleshoot. 1. activate A-B RSLogix software; 2. develop and edit programs; 3. develop fundamental ladder logic circuits; and 4. demonstrate an understanding of Forcing. To provide the participant with the skills needed to develop programs for the A-B PLC5 using RSLogix 5 software. Basic review of DOS-based software Introduction to Windows 95 Basics of RSLogix Program development Program storage, retrieval, and printing Troubleshooting Participants must have completed Allen-Bradley PLC5 Family/6200 Software (BAT 105) OR have equivalent formal training on A-B PLC5 equipment. 8 19

20 Industrial Automation: ALLEN-BRADLEY PLC5 PROCESSOR FAMILY/RSLOGIX SOFTWARE (BAT 335) 3 hours Participants will gain the theory and principles of operation of the A-B PLC5 Processor Control System, which will enable them to edit ladder logic programs, troubleshoot and repair PLCs, set up computer terminals for communication with processors, and troubleshoot major faults on the A-B SLC 500 family of programmable controls. 1. use RSLogix 5 software and the PLC5 Controller to install and set up PLC5 family processor; 2. troubleshoot and repair the PLC5 Processor control system; 3. edit ladder files using RSLogix 5 software; 4. perform corrective action to isolate and repair faults; 5. set up computer for PLC5 processor communications; and 6. perform program backup and restore procedures. To provide participants with the knowledge and skills to install, set up, and troubleshoot the PLC5 Controller using RSLogix software. Power supply Processor board 1771 series I/O Fundamental programming Display modes Editing Basic MS-DOS commands Backing up programs Introduction to the PC terminal Participants should have a knowledge of electrical sequence control systems and a working knowledge of the electrical control of machines hours 20

21 Industrial Automation: ADVANCED CONTROLLOGIX (BAT 375) This course is intended for participants who are migrating from PLC-5 and SLC 500 controllers to the ControlLogix. Participants attending should be those whose responsibilities include programming, program editing, and troubleshooting the controller and ControlLogix networks. The successful completion of this course should enable the participant to efficiently navigate a ControlLogix system using a Windows based terminal. Ethernet Communications IP Configuration Advanced Instructions IO Buffering Messages & Message Types Faults and Fault Codes Power Up Routines Trends Analog IO Participants should have a completed a ControlLogix Fundamentals (BAT 175) or Introduction program, and have working experience with the basic instructions and operations of a programmable logic controller. 8 21

22 Industrial Automation: ALLEN-BRADLEY 1394 MOTION CONTROL OPERATIONS & MAINTENANCE (BAT 410) This course provides the knowledge and experience needed to install, program, troubleshoot, and repair A-B 1394 motion control systems using GML software. 1. install, program, troubleshoot, and repair A-B 1394 motion controls; 2. understand power and motor wiring, digital and analog input wiring, power loss, bus under and over voltages, and motor parameters (i.e., stall, overload, over temperature); 3. understand programming and display panels such as operating display, fault display, speed output display, special and other displays; 4. understand local or remote control programming; and 5. understand theory of operation, speed source priority, operational modes, and programming of parameters. The participant should gain the ability to operate and troubleshoot A-B 1394 motion control systems utilizing both the GML software and installed indicators. Servo basics AC servo motors 1394 motion control system physical components Test equipment use GML programming language introduction A basic knowledge of electrical controls. 8 22

23 Industrial Automation: IN-PLANT CONTROL SYSTEMS TROUBLESHOOTING (BAT 420) This course provides the participants with the skills and knowledge to identify and isolate specific problems found in overall plant control systems. Although this course will use Allen- Bradley family components and software, the course focus is on troubleshooting techniques, skills and applications to efficiently locate and solve problems regardless of the system used. The successful completion of this course should enable the participant to: 1. Understand I/O communications and typical in-plant hardware (e.g., remote racks, drives, PanelViews, etc.) as controlled with a PLC. 2. Understand and use various Allen-Bradley software packages to troubleshoot each device type, both as a single device and as an integral system. 3. Successfully navigate, for troubleshooting purposes, using the A-B RSLogix 5, PanelView, Drive Manager, Drive Tools, and RSLogix 500 software. 4. Successfully troubleshoot multi-device/ plant control systems. s To provide the knowledge and skills required to effectively communicate with, maintain and troubleshoot various in-plant systems and remote hardware devices with an emphasis on Allen-Bradley components. Combined in-plant systems PLC5 - PanelView, A/C Drive, Communications setup and troubleshooting PLC5 Remote I/O configuration and troubleshooting for each device individually and all devices as a remote I/O system System and device Error and Fault recognition and troubleshooting Troubleshooting techniques Participants should have completed Allen Bradley RSLogix 5 (BAT 330 or 335) and/or Allen Bradley PanelView (BAT 300 or 310) or AC drive (BAT 400) training OR other similar training such as Telemecanique, Siemens, or others Hours 23

24 Industrial Automation: DEVICENET WITH CONTROLLOGIX (BAT 475) This course is intended for personnel who are migrating from the Rockwell Automation PLC-5 controller to the ControlLogix architecture. Participants should be those whose responsibilities include programming, program editing, and troubleshooting faults in applications using program instructions and hardware. 1. return a malfunctioning DeviceNet network to normal operation and complete basic hardware and software maintenance tasks with minimum downtime; 2. verify proper network installation and perform both hardware and software-based tasks used to isolate network problems; 3. efficiently add and replace network devices; and return a malfunctioning DeviceNet network to normal operation to minimize downtime. Scanner module numeric and alphanumeric codes Scanner module and device status indicators (LEDs) RSNetWorx for DeviceNet RSLogix 5000 software RSLinx Participants should have a completed a ControlLogix Fundamentals (BAT 175) or an introduction program, and have working experience with the basic instructions and operations of a programmable logic controller (PLC). 8 24

25 Industrial Automation: ROBOTICS: ABB S4C/C+ PROGRAMMING LEVEL 1 (BBT 100) This course is designed to prepare each participant to operate and program the ABB S4 C/C+ Robot Controller and Manipulator. 1. follow all robotic safety and lock out procedures; 2. locate and identify components of the robot system; 3. identify and use of the teach pendant buttons, menus, function keys, and indicators; 4. jog the robot using different coordinate systems to quickly obtain desired motion; 5. set up and verify TCP and Work Object (User frame); 6. select programs for test cycling forward and backward for touch up of positions; 7. utilize all program edit functions; 8. utilize and move offset instructions; 9. use and manipulate most commonly used program instructions; 10. program and manipulate all commonly used I/O types; and 11. file utilities for program backup, and restore. General safety guidelines Communications Basic teach pendant functions Jogging the robot File utilities Program creation, edit, mod pos Inputs and outputs Controller and manipulator components TCP/Wobj creation and use Program selection and test cycling A general understanding of automation and computers. 6 25

26 Industrial Automation: ROBOTICS: ABB S4C/C+ ELECTRICAL MAINTENANCE & TROUBLESHOOTING LEVEL 2 (BBT 200) This course is designed to prepare each participant with the necessary skills needed to troubleshoot the ABB S4, S4C and S4C+ style controllers and manipulators. For users of the ABB M-2000A M6600 Robot, please see BBT follow all robotic safety and lock out procedures; 2. locate and identify function of all electrical and mechanical components and schematics of the robot system; 3. locate, identify, and use the teach pendant buttons 4. jog the robot to perform maintenance and troubleshooting; 5. mastering, calibration, and rev. counter updating of the robot; 6. file utilities for program backup, loading, and software restoration; 7. connect, troubleshoot, and replace all components of the robot system; 8. use of position screen, alarms screen, status screens, LED s and indicators for troubleshooting; 9. locate robot inputs and outputs screen to determine system or equipment status; and 10. motor removal, replacement, and recovery of robot system. s To provide the participant with the skills necessary to electrically repair the ABB S4 robot controller and manipulator. It includes the local and remote I/O on the robot and to the cell controller where high incidents of faults can occur, to aid in minimal downtime. Main CPU Remote I/O Modules Relays K1, K2 and K3 Expansion Memory Robot Wiring & Safety Circuits Teach Pendant Main Power Supply Connector Unit/Backplane Floppy Disc Drive Robot Computer Serial Measurement Board Axis Board Fuses Ethernet Communication Manipulator Motors DC Link File Utilities Software reload Servo Amplifiers Panel Unit & System Board Participants should have completed Robotics: ABB Operations and Programming Levels (BBT 100) and have a general understanding of automation, computers, and electrical troubleshooting. 6 26

27 Industrial Automation: ROBOTICS: ABB M2000A, IRB 6600 S4C/C C+ ELECTRICAL MAINTENANCE & DCX PROGRAMMING STANDARDS LEVEL 2 (BBT 250) This course is designed to prepare each student to perform electrical maintenance and electrically troubleshoot the M2000A ABB S4C+ robot controller and 6600 series manipulator and use advanced user instructions and DCX Programming Standards. 1. follow all robotic safety and lock out procedures; 2. understand and troubleshoot fault diagnostic messages; 3. electrical schematics and component fault led diagnostics; 4. controller component troubleshooting and replacement; 5. robot calibration and rev. counter updating; 6. robot manipulator motor troubleshooting and replacement; 7. robot system software download through Rob Install; 8. DCX Robot programming software standards; 9. advanced user instructions used in DCX ABB Robot Programs 10. robot screen viewer for changes monitoring status in Auto Operation Mode; and 11. use screen Viewer and Production screen to hot edit production programs. s To provide the participant with the skills necessary to apply troubleshooting techniques including the manipulator, local and remote I/O on the robot and to the cell controller where high incidents of faults can occur, to aid in minimal downtime. Controller Fault Diagnostics Controller Component Replacement Controller Troubleshooting Robot System Software Reload Robot Calibration and Rev Counters DCX Robot Programming Standards DCX-ABB Special Instructions Robot Controller Electrical Schematics Robot Motor Troubleshooting DCX Screen View and Production Menus and Replacement Participants should have completed Robotics: ABB Operations and Programming Level 1 (BBT 100) and have a general understanding of automation, computers, and electrical troubleshooting. 6 27

28 Industrial Automation: ROBOTICS: FANUC RJ2-RJ3 OPERATION & PROGRAMMING (FRT 300) This program prepares the participant with the skills necessary to operate and program the Fanuc RJ2 or RJ3 Robot Controller and Manipulator. 1. follow all robotic safety and lock out procedures; 2. locate and identify components of the robot system; 3. locate, identify, & use the teach pendant buttons, menus, function keys, & indicators; 4. jog the robot using different coordinate systems to quickly obtain desired motion; 5. select programs for test cycling forward and backward for touch up of positions; 6. use and understand macros, manual function screens and abort all features; 7. utilize all program edit functions; 8. use and manipulate most commonly used program functions; 9. demonstrate advanced program shift and adjust features; 10. program and manipulate all commonly used I/O types; and 11. file utilities for program backup, loading and software restoration. To provide the participant with the skills needed for the operation and programming of the Fanuc RJ2 or RJ3 Controller and Manipulator. General safety guidelines Controller and manipulator components Basic teach pendant functions Jogging the robot Program selection and test cycling Program creation, edit, and touch up Communications Inputs and outputs Troubleshooting File utilities A general understanding of automation and computers. In addition, this course serves as a prerequisite for Fanuc RJ2-RJ3 Electrical Maintenance and Troubleshooting (FRT 350). 6 28

29 Industrial Automation: ROBOTICS: FANUC RJ2-RJ3 ELECTRICAL MAINTENANCE & TROUBLESHOOTING (FRT 350) This course prepares participants with the necessary skills needed to troubleshoot the Fanuc RJ2 and RJ3 style controllers, and Fanuc Manipulators. 1. locate and identify the functions of all electrical and mechanical components of the robot system teach pendant buttons and jog the robot; 2. connect, troubleshoot, and replace all components of the robot system; 3. use position, alarms, and status screens, and indicators for troubleshooting; 4. locate robot inputs and outputs screen to determine equipment status; remove motor, replace master and calibrate the robot system; and 5. file utilities for program backup, loading and software restoration. To provide the participant with the skills to diagnose, troubleshoot, and carry out electrical maintenance on the Fanuc RJ2 and RJ3 robotic equipment. Robotic Basics Review: Safety guidelines, fault recovery, power up controller using various methods, jogging the robot using different methods for troubleshooting. Robot Setup: Zero position and single axis mastering and calibration, Tool Center Point (TCP), Application specific setup screens and Inputs and Outputs. Communication: Robot Communications to peripheral equipment. Component Identification, removal and replacement: Install, remove, and identify the functions of all robot system components. Troubleshooting: Position, alarm and status screens, LEDs, robot inputs and outputs screen location, PLC to robot communications, common electrical components issues, and UOP input and output utilization. File Utilities: Robot Core Software files and configuration, Teach pendant programs, application programs and system variables. Fanuc RJ2-RJ3 Operation and Programming (FRT 300) or training that includes a general understanding of automation, computers and electrical troubleshooting. 6 29

30 Industrial Automation: ROBOTICS: NACHI OPERATION/PROGRAMMING FOR THE AR 11/AR 52 CONTROLLERS (RNT 320) Upon successful completion of this course, the participant should be able to effectively operate and program the AR 11 and the AR 52 Nachi controllers. 1. understand robot safety; 2. use control cabinet operations and panel functions; 3. perform pendant operation and functions; 4. use manual and automatic robot motion control; 5. perform I/O and programming; 6. manipulate memory files; and 7. display and recover from errors. To provide the participant with the skills needed for operation and programming of the Nachi AR 52 robot. Operations Programming systems Screen displays Mode selections Practical applications Error reporting/recovery Writing/editing robot programs Fundamental robot concepts Communication with external equipment Participants should have completed a basic robot course or have equivalent industrial manufacturing work experience. 6 30

31 Industrial Automation: ROBOTICS: NACHI OPERATION/PROGRAMMING FOR THE AW11 CONTROLLER (RNT 330) This course covers the programming and safe and effective operation of the AW11 Controller and robot arm. 1. use the operation panel and teach pendant; 2. set up operation modes; 3. program the robot s motions; 4. perform error recovery; and 5. manipulate memory files. To provide participants with the knowledge and skills to operate and program the Nachi AW11 Controller and robot arm. Robot safety Operation panel functions Teach pendant operation File manipulation Robot programming Operation modes and codes Robot motion and associated attributes Participants should have completed a basic robot course or have equivalent industrial manufacturing work experience. 6 31

32 Industrial Automation: ROBOTICS: NACHI AR 52 ELECTRICAL MAINTENANCE (RNT 360) This course covers the safe maintenance, operation, and troubleshooting of the Nachi AR 52 robot arm and control cabinet. 1. understand robot safety and safety devices; 2. understand basic operation and major robot system components, including control systems and power supply distribution; 3. understand the robot encoder system, servo drive system analysis, schematic diagram analysis, and PC board description/function; 4. perform troubleshooting, including error code troubleshooting and hands-on troubleshooting; 5. monitor and maintain a control cabinet and replace cabinet components; 6. replace and adjust the power supply; and 7. perform robot arm wiring. The participant should attain the knowledge and experience necessary to diagnose, troubleshoot, and carry out electrical maintenance and repair on the Nachi AR 52 robot arm and control cabinet. Operation of major robot systems Robot safety and devices Robot encoder system Writing/editing programs Error reporting/recovery Control cabinet functions Robot arm wiring Participants should have completed Nachi AR 52 Operation/Programming (RNT 310) or Nachi Operation/Programming for the AR 11/AR 52 Controllers (RNT 320) or have equivalent industrial manufacturing work experience. Use of a digital voltmeter and prior machine control troubleshooting experience is required. 6 32

33 Industrial Automation: ROBOTICS: NACHI AW 11 ELECTRICAL MAINTENANCE (RNT 375) This 40-hour Electrical Maintenance course is intended for Skilled Trade and Engineering personnel whose responsibilities are electrical maintenance and repair of the Nachi robot. The successful completion of this course should enable participants to: 1. utlize robot safety procedures; 2. understand the basic operation; 3. utilize the robot encoder system; and 4. repair the base AW Nachi control cabinet and Nachi robot arm. To provide the participant to effectively maintain, diagnose, troubleshoot, and repair the base AW Nachi control cabinet and Nachi robot arm. Major robot system components Control system overview Power supply distribution Servo drive system analysis PC board description and functions Schematic diagram analysis Error code troubleshooting Control cabinet monitoring Cabinet component replacement procedure Power supply replacement and adjustments Hands-on troubleshooting Robot arm wiring Motor replacement procedure Control cabinet maintenance Participants should have completed a Nachi AW Operation/Programming course or have equivalent work experience with the AW controller. Work experience with a digital volt meter and prior machine control troubleshooting is recommended. 6 33

34 Industrial Automation: ROBOTICS: NACHI AX OPERATION PROGRAMMING (RNT 500) This 40-hour Operation/Programming course is intended for skilled trades personnel whose responsibilities are operation, programming, program modifications, and repair or maintenance of the AX Controller and Robot arm. The successful completion of this course should enable the participant to effectively operate and program the Nachi robot arm. Robot Safety Online HELP Message Review AX Cabinet Operation Panel & Functions Display Units Layout & Function Manual Robot Motion Control Program Step Attributes Program Modifications Cycle Time Monitoring & Modification Step Function Operation & Programming Operations Code Menus & Selection Step Function Modifications Verifying Program Files for Modification Safety Devices Teach Pendant Operation & Functions Controller Operation Modes Automatic Robot Motion Control Recording Programs External Control Selections Input and Output Operation & Programming Memory File Manipulation & Backup Operation Interface Panel Operation Error Display & Recovery Operation Levels Participants scheduled for this course should have completed a basic robot course or have equivalent industrial manufacturing work experience. 6 34

35 Industrial Automation: ROBOTICS: NACHI AX ELECTRICAL MAINTENANCE & TROUBLESHOOTING (RNT 550) THIS COURSE IS CURRENTLY UNDER DEVELOPMENT 35

36 Industrial Automation: INTRODUCTION TO TELEMECANIQUE (TMT 100) The participant should be able to enter, edit, and troubleshoot the Telemecanique TSX 57 system using the PL7 JR software. 1. monitor, troubleshoot, and replace TSX 57 system hardware; 2. search, edit, save and restore existing logic diagrams with PL7 JR software; 3. restore and backup existing logic programs with PL7 JR software; and 4. install components properly and safely, identify problems, and demonstrate the appropriate corrective procedures. To provide the participant with the skills necessary to apply troubleshooting techniques including interpretation of status indicators, understanding diagnostic messages, and using the terminal to isolate faults and take corrective action. Identify control system components Monitor, troubleshoot, and replace TSX 57 hardware Configure and program Telemecanique TSX 57 Controllers Connect and establish communication Prerequisite A basic knowledge of electrical sequence control panels and Windows software, as well as a working understanding of the electrical control of machines and Programmable Logic Controllers. 8 3 hours 36

37 Industrial Automation: ADVANCED TELEMECANIQUE (TMT 200) The participant will gain hands-on experience in both troubleshooting and maintenance techniques for rapid fault isolation and correction with a TSX-57 Premium Controller, Magelis HMI, FIPWAY Communications, and the CAY-21 Linear Axis Control module. 1. monitor a ladder logic program; 2. troubleshoot the Modicon Premium system; 3. replace Premium system hardware; 4. edit existing logic programs with the PL7 Pro software; and 5. identify the proper procedures for replacing Premium system components safely. To provide the participant with the skills necessary to use the TSX Premium PLC PL7 Pro programming software and the Magelis HMI programming software. GRAFCET programming CAY Servo Module (Linear Axis Control) SMOVE Instructions for the CAY Module Troubleshooting and fault Isolation Safety techniques FIPWAY communications Tying all system components together Prerequisite All participants must have successfully completed Introduction to Telemechanique (TMT 100). 8 1 hour 37

38 SKILLED TRADES: INDUSTRIAL MAINTENANCE 38

39 Industrial Maintenance: TROUBLESHOOTING AC MOTORS (ACT 100) The course provides participants with the knowledge to troubleshoot and repair AC motor drives. 1. Know the effect of Volts, Hertz and electronic fundamentals on motor operation; 2. Troubleshoot Power Control Devices such as inverter components, transistors, SCRs, and GTOs; 3. Identify three-phase bridge operation and faults; 4. Know the different types of motors with an emphasis on three-phase field rotation; 5. Identify failures in converters and inverters; and 6. Troubleshoot AC drives (VVVF and PWM drives) to the board level. To provide the participant the skills necessary to troubleshoot AC motor faults, determine the root cause and decide upon a plan of action for AC motor repair. The participant will be able to perform routine maintenance on various AC motors. AC motor theory, AC advantages, magnetic principles, synchronous speed, three-phase motor control, rated torque, horsepower curves Motor control, AC motor operations, three-phase measurement, inverters, power circuits, control circuits, troubleshooting tips Prerequisite Electrical/Electronic Fundamentals (IET 105) or a demonstrated knowledge of the fundamentals of electrical and electronic troubleshooting and repair procedures

40 Industrial Maintenance: REFRIGERANT TRANSITION & RECOVERY CERTIFICATION (AIT 100) This course provides participants with a good working understanding of air conditioning. Upon completion of this course, the participant should have all of the necessary tools to successfully complete the Air Conditioning Contractors of America (ACCA) standards for A/C Refrigeration Reclamation Certification. 1. have a solid understanding of A/C components; and 2. troubleshoot units using drawings by applying their relationship to the various stages of the electrical/mechanical functions in the manufacturing environment. To provide the participant with the knowledge of BTU, proper system size, forced air principles, duct size and location, pipe size, basic electrical controls, and safety in air conditioning reclamation. Refrigerant chemistry and applications Refrigerant oils and their applications Legislative and proposed regulations Safe handling and transport of refrigerants Ozone depletion Recovery, recycling and reclaim Waste oil Conservation servicing and testing Certification Upon completion of this course, each student will be tested for a certification from ACCA. This rating will give the student a universal refrigeration certification. 8 40

41 Industrial Maintenance: INDUSTRIAL AIR LOGIC (ALT 101) This course covers air logic control systems, including fundamentals of compressed air, the operation of air logic circuits, and troubleshooting procedures and techniques. 1. match circuit functions of air logic components to their symbols; 2. fabricate, operate, and analyze various air logic circuits; and 3. identify basic air logic circuits and the sequence of operation of the system. The participant will gain knowledge and skills in the application and troubleshooting of air logic control systems. Ladder diagrams Fundamentals of compressed air Power valve symbology Comparison of electrical relays Pneumatic air logic components and functions Troubleshooting procedures and techniques Participants should have a working knowledge of pneumatics, or have completed a 40-hour pneumatics course within the last year

42 Industrial Maintenance: PRINCIPLES OF REFRIGERATION & AIR CONDITIONING (ART 100) This 40-hour course introduces participants to fundamental concepts and theories of refrigeration and air conditioning systems and provides training and testing of proper safety, handling and application of the new R-410A refrigerant (replacement for R-22). The successful completion of this course should enable the participant to properly use tools associated with refrigeration and air conditioning. Basic physics Pressure/temperature relationships to various refrigerants Major component functions Gas laws None 8 42

43 Industrial Maintenance: INDUSTRIAL BEARING PREDICTIVE MAINTENANCE (BMT 100) This course provides the skills and experience to carry out preventive maintenance on bearings, troubleshoot, repair, and prevent future failures. It will also cover bearings fundamentals such as bearing types, mounting, dismounting, and monitoring. 1. install, remove and lubricate bearings; 2. monitor roller bearing to prevent catastrophic failure; 3. troubleshoot bearing failures; 4. read and interpret troubleshooting charts for bearings; 5. understand the basics of root cause analysis; 6. identify different types of bearings; and 7. be familiar with predictive maintenance techniques such as infrared thermography, ultrasound, and oil analysis. To provide the participant with an introduction to different types of bearings, the ability to diagnose the root cause of bearing failure, and the skills to properly repair failed bearings. Bearing Fundamentals Root Cause Analysis Oil Analysis Conveyors Bearing Failures Troubleshooting Bearing Types Ultrasound, Infrared Thermography Lubrication Mounting & Dismounting Bearing Monitoring None 8 43

44 Industrial Maintenance: INDUSTRIAL CONDUIT INSTALLATION (ICT 200) The participant should be able to gain practical knowledge of conduit bending as well as hands-on experience. 1. identify the size and type of electrical conduit; 2. find and use take-up, gain, travel, shrink, and shrinkback; 3. bend (in rigid conduit) accurate 90 bends, 90 bends with a kick, back-back bends, offsets, combination bends, 3 point saddle, predetermined 4 point saddle; and 4. use the code book to find wire size area, size conduit using same and different size wires, box sizing and box fill. To provide the participant with the knowledge required to identify electrical conduit and carry out various electrical conduit bends effectively. Sizes and types of electrical conduit Identification and use of take-up, gain, travel, shrink, and shrinkback Rigid conduit bending Prerequisite None 12 44

45 Industrial Maintenance: ELECTRICAL TROUBLESHOOTING (ETT 200) THIS COURSE IS CURRENTLY UNDER DEVELOPMENT 45

46 Industrial Maintenance: ELECTRICAL/ELECTRONIC FUNDAMENTALS (IET 105) This course is designed for Skilled Trades workers who need to understand electrical and electronic fundamentals, as well as for Electricians coming from a non-industrial background. 1. identify resistors, diodes, and rectifiers; 2. recognize and understand the uses of input/output devices; 3. comprehend basic control protection and principles of AC, DC, and servo electrical motors using Ohm s Law; 4. use NEMA and IEC electrical standards; 5. work with machine controls; 6. identify components in schematic and ladder diagrams; and 7. hook up and use transformers, power supplies, and surge protectors. To provide participants with the knowledge and understanding of electrical and electronic fundamentals. Electrical safety Electrical testers Transformers, electric motors Power supplies, drives Electronic circuits Input/output devices PLCs/PanelViews NEMA vs. IEC components Machine control diagrams Positioning devices for CNC Electrical measurement and formulas Troubleshooting control circuits Control and protection of motors European wiring and disconnect switches Surge protection and power conditioning None 8 46

47 Industrial Maintenance: GROUNDING & BONDING (IET 210) This course focuses on the grounding requirements related to installation, testing, and inspection for commercial and industrial power systems. Based on Article 250 of the 2002 National Electrical Code, the course addresses the rules for minimizing the risk of electric shock, fires, and explosions. The instructor-guided presentation provides answers to the common elements for clearing ground faults, and the conventions for low-impedance and high-impedance systems. 1. properly ground circuits; 2. properly bond industrial electrical connections; and 3. practice safe procedures. To enable the participant to know, understand, and implement proper electrical bonding and grounding procedures. Proper grounding of circuits Equipment and facilities Understanding and applying the provisions of Article 250 of the 2002 National Electrical Code Proper bonding of electrical connection in industrial circuits Use of test equipment to monitor performance None 12 47

48 Industrial Maintenance: TRANSFORMERS & FEEDERS (IET 215) The participant should be able to work safely with transformers and feeders through knowledge of circuitry and connections and measuring the size of feeder services. 1. understand the principles of transformers and feeders, circuitry of transformers and three-phase circuits; 2. hook up delta and zig-zag transformer connections; and 3. know how to calculate the size of feeder services. The participants will understand the principles and circuitry of transformers and feeders and how to hook up and test transformers using different configurations. Principles and circuitry of transformers Delta connections Zig-zag transformer connections Feeder and conduit sizing None 12 48

49 Industrial Maintenance: FIBER OPTIC & COPPER COMMUNICATIONS CABLING 1 (FOT 110) The participant should learn D/C LAN and EIA/TIA 568 network concepts, and the basic skills to install and terminate both copper and optical fiber communications cabling. 1. identify the elements of D/C LANs and 568 networks, and their terminology; 2. recognize cable markings and correct installation procedures; 3. understand the concept of bandwidth and how it is applied in LANs; 4. terminate both multimode fiber and Category 5e copper cabling; 5. use the OTDR, OLTS, wire mapper, and other test equipment; and 6. install, test, and troubleshoot a simple fiber cable plant. To provide the participant with the knowledge required to select and pull both copper and fiber optic network cabling, and perform simple tests to evaluate cable performance. Fundamentals of network architecture Bandwidth: Why copper? Why fiber optics? Cabling safety Cable markings and pulling precautions Basic termination procedures Cable testing for loss, length, and wiring errors Restoration of service by splicing Circuit documentation required by D/C Certification All participants who complete the course will be: 1. 3M products certified. 2. After successful completion of a voluntary test, participants will be certified as a Fiber Optic Technician from the Fiber Optic Association. None 8 49