Service and Training

1.    Overview
The FPT training program is structured according to standalone training modules which can be combined individually and tailored to the customer-specific requirements.
Interested persons can also attend advanced courses.
The maximum number of participants per course is 2 persons per robot cell available. General subjects such as system overview or safety training can be attended by up to 5 persons at a time.

1.1    Training documentation
The manuals pertaining to the equipment are used in the training. They are available as hardcopies and in electronic format. These should be made available for the duration of the training course. A mini-manual with the essential content of the overall documentation is optionally available.

1.2    Completion of a course
Every course is completed with a final examination. Every participant receives a certificate evidencing attendance or successful attendance, as applicable.

1.3    General requirements
In addition to the requirements specified with each training module, understanding the German language is a requirement. Optionally the training can be held in English language. Other languages are available on request, each with the assistance of an interpreter.

The training modules may be structured according to a theoretical and a practical part. During the practical part, the equipment is not available for normal production.

 
2.    Training modules

2.1    System overview
Objectives:    Familiarization with the system and its function
Target group:    All persons with direct contact with the FPT robot system.
Requirements:    Basic understanding of the customer-specific process (palletizing, machine feeding,...)
Contents:    Function of the customer-specific process
Structure of the robot system
Function of the modules
Particular aspects in handling the modules used
Structure and contents of the documentation
Duration:    1 to 4 hours (depending on system)

2.2    Safety training
Objectives:    Knowing the sources of hazards and the safety instructions for working with the system.
Target group:    All persons with direct contact with the FPT robot system.
Requirements:
Contents:    Safety instructions for working with the robot system
Demonstrating the points of danger on the robot and the modules
Test operation with safety doors open (setup mode), function of the confirmation button
Existing safety elements (emergency stop button, light guard, muting function, roller switch, door switch)
Duration:     1 to 2 hours

2.3    Basics of operation of FPT robot cells
Objectives:    Acquiring all the necessary skills to be able to operate the FPT robot cell.
Target group:    Operators
Requirements:    Training module “Safety training” attended
Basic understanding of the customer-specific process (palletizing, machine feeding,...) or training module “System overview” attended.
Contents:    Overview of the controls and indicators of a typical FPT robot cell
Introduction into the FPT user interface
Typical operator actions:
- Starting up/shutting down the robot cell
- Preparing (setting up)/starting/stopping/resuming/aborting (system reset) a production job.
Eliminating process-related malfunctions (minor problems that may occur during normal production operations).
Recognizing and diagnosing alarms on the control panel and technically correct action.
Changing the operating mode (manual/automatic mode)
Using the manual functions of the modules in manual mode:
Actuator control, home position travels, maintenance positions
Duration:     4 hours

2.4    Advanced operation of FPT robot cells
Objectives:    Advanced skills in using the robot system, learning advanced operating functions for alarm diagnosis and maintenance (manual processes, re-teaching, axis calibration, ...).
Target group:    Advanced operators, setters, maintenance personnel
Requirements:    Training module “Safety training” attended
Training module “Basics of operation” attended
Sound school education (basic mathematical-geometrical understanding)
Own axis calibration set available
Contents:    Introduction into the control elements of the KRC user interface:
- Changing between user interface and FlexOP
- Structure of the user interface
- Program selection & deselection
- Screen windows (inputs/outputs, actual position)
- Handling the KRC messages
- KRC operating modes (keylock switch & operating mode table, function of the SoftPLC)
- Function of the confirmation buttons
Manual operation of robot axes, clearing the axes:
- Basic knowledge of various coordinate systems and their use in the controller
- Work envelope monitoring
Performing simple start-up tasks:
- Initial calibration using the EMT
- Tool & base measurements
Verification and correction of target positions by executing teach programs
Modifying process variables using the configurable screen window and the FlexOP parameter window
Program change, starting a new product
Duration:     4 to 8 hours


2.5    Servicing & maintenance
Objectives:    Acquiring basic skills for proper maintenance and troubleshooting for electrical and mechanical components.
Target group:    Setters, maintenance personnel
Requirements:    Training module “Safety training” attended
Training module “Basics of operation” attended
Training module “Advanced operation” attended
Contents:    Documentation on servicing and maintenance
Using the spare parts and wear parts list
Particular aspects of the specific system
Exemplary maintenance of the robot cell using the maintenance schedule

Electrical:
Review of the electrical diagrams and descriptions of the electrical components
Function of the individual components of the computer hardware and the drive system
Maintenance work on the control cabinet
Quick fault detection

Mechanical:
Performing sample repair jobs: Dismounting guide carriages, replacing toothed belts, replacing the motor unit incl. drive shaft, replacing complete cable assemblies and the external power supply
Mechanical maintenance work on the gantry robot (adjusting the belt tension, adjusting the toothed rack play, lubrication, …)
Review of the pneumatic diagrams and descriptions of the mechanical components
Duration:     4 to 12 hours

2.6    Robot programming functions
Objectives:    Acquiring the basic knowledge to understand existing robot programs and make simple modifications/additions if necessary.
Target group:    System programmers, maintenance personnel
Requirements:    Training module “Safety training” attended
Training module “Basics of operation” attended
Training module “Advanced operation” attended
Contents:    Introduction into the system concept of KRC+SoftPLC+FlexTools
- Overview of hardware and software
- Interaction of the individual components
Introduction into the programming interface
Summary of the scope of motion commands
Summary of the scope of logic commands
Creating, editing, executing and deleting programs
Robot program data backup
Creation of several simple test programs (test programs for single axes, axis systems)
Duration:     1 to 2 days

2.7    SoftPLC functions
Objectives:    Acquiring the basic knowledge for diagnosing existing PLC programs.
Target group:    System programmers, maintenance personnel
Requirements:    Training module “Safety training” attended
Training module “Basics of operation” attended
Training module “Advanced operation” attended
Knowledge of a PLC programming system
A programming PC with a licensed version of the PLC programming system must be made available (may be provided by FPT against extra charge):
- Ethernet RJ45 network connection
- NETBEUI or TCPIP protocol installed
Contents:    Introduction into the system concept of KRC+SoftPLC+FlexTools
- Overview of hardware and software
- Interaction of the individual components
Introduction into the SoftPLC and the creation of PLC programs
Using the Multiprog programming tool
I/O control
Creating a simple project
Debugging a project
Forcing variables
Duration:     1 to 2 days

2.8    Programming with the FPT FlexTools
Objectives:    Acquisition of basic knowledge for creating a project using the FlexTools as well as for extending an existing program.
Target group:    System programmers
Requirements:    Training module “Safety training” attended
Training module “Basics of operation” attended
Training module “Advanced operation” attended
Contents:    Introduction into the functionality of the FlexTools software components
Overview of the individual components FlexManager, FlexPro, FlexOP, FlexEvents, Flex-Libraries
Program installation
Configuring a new project
Changes to existing projects
Duration:    1 day