SACA Robotics and Automation 5 — Questions and Answers
Question 1: In an automated welding cell, what is the purpose of a 'touch sensing' routine before the welding pass begins?
- To preheat the workpiece surface
- To locate the actual weld joint position to correct for fixture variation (Correct answer)
- To test the welding wire feed rate
- To verify the shielding gas flow
Correct answer: To locate the actual weld joint position to correct for fixture variation
Touch sensing uses the welding wire as a probe to detect the actual joint location and compensate for part placement variation before welding begins.
Question 2: Which IEC standard defines the safety requirements for industrial robot systems and integration?
- IEC 61511
- ISO 10218 (Correct answer)
- IEC 62061
- ISO 13849
Correct answer: ISO 10218
ISO 10218 (Parts 1 and 2) defines safety requirements for industrial robots and their integration into manufacturing systems.
Question 3: What is the function of a robot's 'teach pendant' in online programming?
- It compiles and uploads programs from a PC to the robot controller
- It allows an operator to manually jog the robot and record positions (Correct answer)
- It monitors robot cycle times and generates performance reports
- It programs the PLC signals connected to the robot cell
Correct answer: It allows an operator to manually jog the robot and record positions
A teach pendant is a handheld device that lets operators manually move (jog) the robot to desired positions and record those positions into the program.
Question 4: In a robotic assembly cell, an operator must enter the robot's guarded space for maintenance. According to ISO 10218-2, what must occur before entry?
- The robot must be paused and the operator must wear PPE only
- Energy must be locked out/tagged out and the robot must be in a safe state (Correct answer)
- The robot speed must be reduced to 250 mm/s or less
- A second operator must monitor the robot from outside the cell
Correct answer: Energy must be locked out/tagged out and the robot must be in a safe state
Lockout/tagout (LOTO) procedures must be applied to isolate all energy sources before personnel enter the robot's safeguarded space for maintenance.
Question 5: What is 'offline programming' (OLP) in robotics, and what is its primary advantage?
- Programming done on the teach pendant while the robot is idle; advantage is simplicity
- Programming done in simulation software without using the physical robot; advantage is no production downtime (Correct answer)
- A backup programming mode activated when the robot controller fails; advantage is redundancy
- Remote programming via cloud connection; advantage is global access
Correct answer: Programming done in simulation software without using the physical robot; advantage is no production downtime
Offline programming uses simulation software to create and test robot programs without stopping production, then downloads the verified program to the robot.
Question 6: A robotic palletizer must stack boxes in an alternating layer pattern for pallet stability. Which programming approach best handles the repetitive, pattern-based task?
- Recording each individual box placement position manually
- Using a palletizing software function with parametric layer patterns (Correct answer)
- Hard-coding absolute XYZ coordinates for every box position
- Using random path generation with collision avoidance
Correct answer: Using a palletizing software function with parametric layer patterns
Palletizing software functions accept layer pattern definitions and automatically calculate all box positions, handling multiple layers and patterns efficiently.
Question 7: Which type of robot drive system provides the highest positional accuracy and eliminates backlash, making it ideal for precision machining applications?
- Pneumatic cylinder drive
- Hydraulic servo drive
- Electric servo motor with harmonic drive gearbox (Correct answer)
- Stepper motor with spur gear transmission
Correct answer: Electric servo motor with harmonic drive gearbox
Harmonic drive gearboxes have zero backlash and very high gear ratios in a compact form, providing excellent positional accuracy for precision robots.
SACA Robotics and Automation 5
In an automated welding cell, what is the purpose of a 'touch sensing' routine before the welding pass begins?