Industrial Robotics Programming Course

Lesson 1 • Robot Hardware and Drive Systems

Examines servo motors, gearboxes, encoders, and end-effectors as integrated mechanical systems. Understanding hardware constraints directly informs safe and efficient programming decisions.

Lesson 2 • Robot Controller Architecture

Describes the hardware and software layers inside a robot controller, including CPUs, I/O boards, and real-time operating systems. Provides context for how programs are stored and executed.

Lesson 3 • Coordinate Systems and Spatial Reasoning

Introduces world, base, tool, and workpiece frames and their mathematical relationships. Correct frame selection is prerequisite to accurate motion programming.

Lesson 4 • Safety Standards and Risk Assessment

Covers functional safety categories, risk assessment methodology, and safeguarding device types required before any robot is powered on. Compliance with safety standards is mandatory throughout the course.

Lesson 1 • Jogging in Joint and Cartesian Modes

Teaches axis-by-axis joint jogging and linear or rotational Cartesian jogging with active frame selection. Mastery of jogging modes is required before any position teaching.

Lesson 2 • Tool and Workpiece Frame Calibration

Explains three-point and six-point TCP calibration methods and workpiece frame teaching procedures. Correct calibration is the foundation for repeatable, accurate motion programs.

Lesson 3 • Teaching and Recording Positions

Covers methods for recording joint, Cartesian, and tool-relative positions into program registers. Accurate position recording prevents path errors during automatic execution.

Lesson 1 • Basic Debugging Techniques

Introduces alarm log interpretation, position error diagnosis, and motion path visualisation for simple programs. Systematic debugging skills reduce downtime and accelerate program development.

Lesson 2 • Digital I/O Instructions

Teaches output set/reset commands, input wait instructions, and I/O signal monitoring during program execution. I/O control enables robot programs to interact with external equipment.

Lesson 3 • Program Execution and Testing

Covers step-by-step execution, speed override during test runs, and fault recovery procedures. Safe testing habits prevent collisions and equipment damage during program validation.

Lesson 4 • Motion Instructions and Parameters

Covers joint (J), linear (L), and circular (C) motion instructions with speed, zone, and termination type parameters. Correct parameter selection determines path accuracy and cycle time.

Lesson 1 • Conditional Branching and Logic

Covers IF-THEN-ELSE, SELECT-CASE, and compound Boolean conditions for directing program flow. Conditional logic allows programs to respond dynamically to sensor inputs and process states.

Lesson 2 • Registers and Data Types

Explains numeric, position, and string registers and their roles in storing and passing data within programs. Registers are the primary data mechanism for all advanced programming constructs.

Lesson 3 • Loop Structures and Counters

Teaches FOR, WHILE, and label-based loop constructs along with counter register management. Loops enable repetitive pick-and-place and palletising patterns without redundant code.

Lesson 4 • Subroutines and Program Calls

Explains how to define, call, and pass data to subroutines and macro programs. Modular subroutines reduce code duplication and simplify large-scale program maintenance.

Lesson 1 • Generating and Editing Programs Offline

Teaches point-and-click path creation, instruction editing, and template-based program generation within the simulation environment. Offline editing accelerates programming and reduces teach-pendant time.

Lesson 2 • Building Virtual Workcells

Covers importing CAD geometry, placing fixtures and conveyors, and defining collision objects in the simulation. An accurate virtual workcell is required for meaningful reachability and collision analysis.

Lesson 3 • Offline Programming Software Environment

Introduces the 3D simulation workspace, robot model libraries, and project file structure of offline programming tools. Proficiency in the software environment is prerequisite to all simulation tasks.

Lesson 4 • Simulation, Reachability, and Collision Checking

Explains how to run motion simulations, analyse joint limits, detect singularities, and identify collision risks before deployment. Simulation validation prevents costly physical errors.

Lesson 1 • Interrupt and Event-Driven Programming

Explains how to configure hardware interrupts, background tasks, and condition handlers that respond to sensor events mid-motion. Event-driven logic enables safe, real-time reaction to unexpected conditions.

Lesson 2 • Force-Torque Sensor Applications

Teaches force threshold monitoring, compliant motion programming, and insertion force control using force-torque data. Force control is critical for assembly, polishing, and deburring tasks.

Lesson 3 • Conveyor Tracking and Dynamic Motion

Covers encoder-based conveyor tracking, dynamic path correction, and synchronisation of robot motion with moving workpieces. Conveyor tracking is essential for high-throughput pick-and-place lines.

Lesson 4 • Sensor Types and Integration Methods

Surveys 2D vision, 3D vision, force-torque, proximity, and laser sensors and their electrical and communication interfaces. Selecting the correct sensor type is the first step in any adaptive motion application.

Lesson 1 • PLC Ladder Logic for Robot Interlocking

Teaches PLC ladder logic rungs that manage robot start, stop, mode selection, and safety interlock signals. Correct interlocking prevents simultaneous motion conflicts in shared workspaces.

Lesson 2 • Fieldbus and Industrial Protocol Configuration

Covers PROFINET, EtherNet/IP, DeviceNet, and Modbus TCP configuration for robot-to-PLC and robot-to-sensor communication. Protocol selection and correct configuration determine data integrity and response time.

Lesson 3 • Cell Controller and Network Architecture

Describes Ethernet-based cell networks, controller addressing, and data routing between robots, PLCs, and HMIs. A well-designed network architecture is the backbone of reliable multi-device coordination.

Lesson 4 • HMI Design for Robot Cells

Covers HMI screen layout, status display, operator controls, and alarm management for robot cell supervision. Effective HMI design reduces operator error and accelerates fault response.

Lesson 1 • Arc Welding Robot Programming

Covers weld start and end instructions, weave patterns, torch angle control, and seam tracking for arc welding robots. Welding parameter accuracy directly determines weld quality and throughput.

Lesson 2 • Palletising and Depalletising Programming

Teaches layer-pattern definition, pallet register arrays, and approach-retract path strategies for palletising applications. Efficient palletising programs maximise throughput whilst protecting product integrity.

Lesson 3 • Machine Tending and Part Transfer

Covers door interlock sequencing, chuck open/close handshaking, and part presence verification for CNC machine-tending cells. Reliable handshaking prevents part drops and machine crashes.

Lesson 4 • Programme Validation and Production Handover

Covers formal test protocols, operator sign-off checklists, programme documentation standards, and handover procedures for production release. A structured handover ensures programs are maintainable and operators are prepared.