FANUC Robot training

Lesson 1 • Workplace Safety and Regulations

Establishes robot safety standards, lockout/tagout procedures, and safeguarding devices. Safe work habits introduced here are enforced throughout every subsequent chapter.

Lesson 2 • FANUC Robot System Overview

Covers robot anatomy, controller types, and mechanical unit classifications. Establishes the vocabulary and mental model needed for all subsequent hands-on training.

Lesson 3 • Industrial Applications and Use Cases

Surveys welding, material handling, assembly, and painting applications. Connects hardware knowledge to real production scenarios students will encounter on the job.

Lesson 1 • Menu Navigation and Screen Structure

Teaches menu hierarchy, function keys, and screen navigation shortcuts. Efficient navigation reduces programming time and minimises operator errors.

Lesson 2 • iPendant Hardware and Interface

Introduces pendant buttons, deadman switch, status LEDs, and touchscreen layout. Familiarity with physical controls is prerequisite to any software interaction.

Lesson 3 • Jogging the Robot Manually

Explains joint, world, tool, and user coordinate jogging modes. Manual jogging is the primary skill for positioning the robot during teaching and troubleshooting.

Lesson 4 • Coordinate Systems and Frames

Defines world, joint, tool, and user frames and their spatial relationships. Understanding frames is essential before recording accurate program positions.

Lesson 1 • Running and Testing Programs

Covers single-step execution, continuous run, and speed override during test runs. Safe test procedures protect tooling and personnel during initial program verification.

Lesson 2 • Motion Instructions and Motion Types

Teaches joint (J), linear (L), and circular (C) motion instructions with speed and termination settings. Motion type selection directly affects path accuracy and cycle time.

Lesson 3 • Teaching and Recording Positions

Explains how to jog to a target, record position registers, and verify taught points. Accurate position recording is the foundation of repeatable robot programs.

Lesson 1 • Tool Centre Point Calibration

Explains TCP definition, three-point and six-point calibration methods, and verification. An accurate TCP is mandatory for correct path execution and force control.

Lesson 2 • Tool Frame Configuration

Covers tool frame numbering, orientation entry, and active frame selection. Correct tool frame data ensures the robot moves relative to the end-effector tip.

Lesson 3 • User Frame Definition Methods

Teaches three-point user frame setup using origin, X-direction, and Y-direction points. User frames allow programs to be offset when fixtures or pallets are repositioned.

Lesson 1 • Monitoring and Forcing I/O Signals

Demonstrates live I/O monitoring screens and manual signal forcing for diagnostics. Forcing signals safely isolates faults without requiring full production restarts.

Lesson 2 • I/O Instructions in TP Programs

Teaches RO, DO, GO, and AO output instructions and RI, DI, GI, AI input wait conditions. I/O instructions synchronise robot motion with grippers, conveyors, and sensors.

Lesson 3 • Signal Configuration and Mapping

Covers I/O configuration screens, signal assignment, and comment labelling. Proper mapping and labelling reduce troubleshooting time during commissioning and maintenance.

Lesson 4 • PLC Communication and Handshaking

Explains robot-PLC handshake sequences, interlock signals, and fieldbus basics. Reliable handshaking prevents collisions and ensures coordinated multi-device operation.

Lesson 1 • Offset and Shift Instructions

Covers OFFSET CONDITION, PR offset, and tool offset instructions for dynamic path adjustment. Offset instructions enable vision-guided corrections and pallet pattern generation.

Lesson 2 • Conditional Logic and Branching

Teaches IF, SELECT, and JUMP label instructions for decision-based program flow. Conditional logic allows a single program to handle multiple part types or error states.

Lesson 3 • Macros and Subprogram Calls

Demonstrates CALL instruction, macro program creation, and argument passing. Modular subprograms improve maintainability and enable code reuse across multiple jobs.

Lesson 4 • Loops and Counters

Explains FOR-ENDFOR loops, register-based counters, and loop exit conditions. Loops reduce program length and simplify repetitive palletising or assembly sequences.

Lesson 1 • Mastering Concepts and Zero Position

Explains joint zero position, mastering data storage, and when re-mastering is required. Understanding mastering prevents positional drift after motor or encoder replacement.

Lesson 2 • Axis Limits and Interference Zones

Configures software joint limits and 3D interference zones to prevent collisions. Properly set limits act as a software safety layer supplementing physical hard stops.

Lesson 3 • Payload and Inertia Configuration

Teaches payload mass, centre of gravity, and inertia entry in the controller. Accurate payload data protects servo drives and ensures correct motion dynamics.

Lesson 1 • Preventive Maintenance Schedule

Establishes daily, monthly, and annual maintenance tasks including lubrication and inspection. Scheduled maintenance is the primary strategy for achieving maximum robot uptime.

Lesson 2 • Controller and Communication Faults

Diagnoses servo amplifier alarms, battery warnings, and fieldbus communication errors. Controller faults often require coordinated action between robot and PLC technicians.

Lesson 3 • Alarm and Fault Diagnosis

Covers alarm code structure, alarm history log, and root-cause analysis workflow. Systematic diagnosis reduces mean time to repair and prevents recurring faults.

Lesson 4 • Common Motion and Path Errors

Addresses singularity alarms, joint limit faults, and path deviation errors with corrective actions. Recognising motion errors early prevents tooling damage and production loss.