Heartland Community College
Technology Division
Course Syllabus for Students
Spring Semester 2016
Course prefix and number: MAIN 220
Course title: Mechatronics
Credit hours: 3
Contact hours: (Lecture hours: 2 Lab hours: 2)
Days and times the course meets: Tuesdays
Catalog Description:
Prerequisite: ELTC 206 with a grade of C or better, or ELTC 207 with a grade of C or
better, or MAIN 222 with a grade of C or better. This course covers the process required
for the planning and actual installation of industrial machinery. The course includes
preventive maintenance and planning for in-plant operations.
Instructor Information:
Instructor name: Chris Miller
Phone number to contact instructor: (309) 268-8855
Instructor e-mail address: Chris.Miller@heartland.edu
Location of instructor’s office: WDC 1213
Hours and days of instructor’s office hours: M,T,W 1-3pm, Fri apt.
Website: http://www.technology.heartland.edu/faculty/chrism/
Required Textbook:
Stenerson, Jon. Industrial Automation and Process Control Upper Saddle River, NJ:
Prentice Hall, 2003.
Recommended:
Online supplemental info will be announced
Supplies:
Multimeter
Relationship to Academic Development Programs and Transfer:
MAIN 220 was designed to meet the specific needs of an Associate of Applied Science
degree and not necessarily as a transfer course, particularly in relation to the Illinois
Articulation Initiative. This course may transfer to various institutions in a variety of
ways. Please see an academic advisor for an explanation concerning transfer options.
COURSE OBJECTIVES (Learning Outcomes)
Outcomes
1. Demonstrate an understanding of
proper safety used in an automation and
control environment.
2. Demonstrate a knowledge and
awareness of mechanical power,
electrical power and fluid power
concepts.
3. Create a preventative maintenance
program for a simple automated process.
4. Research and present information
relating to a machine installation and
maintenance technology as it relates to
the student’s field of study.
5. Describe how to install an automated
electrical circuit.
6. Apply appropriate techniques to
correctly measure mechanical, electrical
and fluid systems using bench top testing
devices.
7. Apply mechanical, electrical and fluid
theories to the work environment.
8. Compose a list of troubleshooting
techniques to determine best solution for
an industrial process.
General
Education
Outcomes
Range of
Assessment
Methods
Labs
Exams/Quizzes
Assignments
Labs
Written Project
Assignments
PS1
Labs
Graded Lab
Assignments
Assignments
Course/Lab Outline:
1. Move machinery using safe and effective procedures.
2. Select and use proper equipment to move / install and maintain machines.
3. Install new equipment in accordance with the manufacturer and engineering
specifications.
4. Perform pre-production activities and verify machine start-up.
5. Apply preventive maintenance programs; keep preventive maintenance records.
6. Maintain machinery in accordance with design and safety standards
7. Modify existing machinery to meet in-plant and governmental needs and regulations.
Course Policies:
Method of Evaluation (Tests/Exams, Grading System):
(To be determined by each instructor):
E-learn Robot
Assignments
FMS
Labs
Project
Midterm
Final
40%
10%
5%
15%
10%
10%
10%
Grades will be based on the following scale:
90 – 100%
A
80 – 89%
B
70 – 79%
C
60 – 69%
D
Below 60%
F
Participation (or Attendance)
Attendance will be taken for sake of monitoring when students were in lab.
Incompletes
An incomplete grade may be given to a student who, by the withdrawal date, can
reasonably be expected to pass the course. Incompletes may be granted only when
justified by extreme circumstances (e.g., serious illness, accident, death or serious
illness in the immediate family). Incomplete grades are not given for such reasons as
unjustified failure to appear for the final examination. A written agreement, outline
the requirements to be met, must be signed by the instructor and the student. The
agreed upon requirements must be completed no later than the end of the following
semester (spring semester for incompletes granted during the fall, and the following
fall for incompletes given during the spring and summer semesters). By the agreed
upon date, the instructor will assign a grade or the incomplete will be changed to an
‘F’ if the requirements are not completed.
Extra Credit
No none.
Missing an exam and assignments policy
You must be present at all exams when they are assigned. I will not allow you to
make up a test. Only if you have an exemption from me, confirmation by voice or
email, prior to the exam will I consider allowing you to take it at a different time.
REQUIRED WRITING AND READING:
There will be a final project which will include a written section. The project will relate
to an industrial maintenance and installation procedure. In addition students will be
expected to read assigned selections from the textbook. All labs are to include descriptive
comments within the write-up/answer section relating to each lab.
Syllabi disclaimer
Any changes will be posted and clearly communicated to students.
Course Calendar:
Please visit my website or Blackboard for specific dates and times for materials.
1. MAIN 220
Date
Videos
Week #
1-12-16
Spring 2016
Objectives Reading
What is Mechatronics Course Set-up
Chapter 1
Chapter 2
#1
Labs
HW
Pre Class
Assessment
Sign Safety Sheet
Questions Ch1
p.18
PETS-II section 1-3 entire class
overview
Questions Ch 3
p.54
Questions Ch 2
p.35
Campus Safety Video
Electrical Safety / Arc Flash
Instructional Set-up
Introduction to PLCs / Fundamentals of
programming
Chapter 3
1-19-16
#2
Ch 13 Eaton Industrial Hydraulics
Proportional Valves
Gain, dead band, dither, ramp
1-26-16
Fluid Power
Chapter 11
#3
Fundamentals of Process Control
Chapter 12
Fundamentals of Process Control
Chapter 13?
PETS-II Section 4 Electronic Circuit
Configuration p.5-p.16
PETS-II Section 5
Open-Loop Velocity Lab with PLC
Control p.17-30
Pets-II Section 6
Closed-Loop Proportional Valve
p.31-37
Questions Ch
12 p.280
Questions ch
13 p. 304?
Ch 14 Eaton Industrial Hydraulics
Read a hysteresis curve
2-2-16
Motor Resistance
Wye Delta
Intro to industrial motors ch 5 ch 8 ho
Questions Ch
9 p.153
Basic insulation testing ho
#4
Motor Rotation
meter
Identifying
Unmarked 9 Lead
Troubleshooting electrical schematics ho
Motor Rotation class guided
How Real Electric Motors Work web
Megger Lab
Delta
Identifying
Unmarked 9 lead
Wye
Buying an energy efficient electric motor
DOE ho
ACME megger ho
Reducing Power Factor Cost DOE ho
TheoryMegger ho
Understanding insulation resistance testing
ho
2-9-16
VFD
VFD Lab
#5
VFD presentation summer 2015 ho
SMC Trainer Part 1
2-16-16
Sensors
Chapter 9
SMC Trainer Part 2
#6
Troubleshooting
Chapter 16
Questions Ch
16 p.389
In class activity grafcet
I/O wiring and advanced programming
Chapter 7
Siemens STEP website PLC intro
SMC Trainer Part 3
2-23-16
REVIEW
#7
MIDTERM EXAM
3-02-16
#8
3-16-16
Roboguide Tutorial
System Variables on a
Fanuc Robot MATC
#9
Tool Fames MATC
User Frames MATC
3-23-16
How to Program a circle
MATC
Position Register MATC
#10
3-30-16
Robots
Chapter 10
Questions Ch
10 p.227
Fanuc Robot
Unit 2 Pre-Test (Instructor Led Activity)
Unit 3 Safety
Unit 4 Robot System
Elearning
Robot
Operations
Fanuc Robot
Unit 5 Power Up and Jogging
Procedure 5-1 Turning On Robot
Procedure 5-4 Displaying the Alarm Log p.70
Procedure 5-5 Recovering from an Overtravel Error p.74
Procedure 5-6 Recovering from a Hand
Breakage p.76
Procedure 5-7 Chain Failure Detection Error Recovery
p.78
Procedure 5-8 Jogging the Robot and other axes p.80
Procedure 5-9 Setting Up Axis Limits p.87
Procedure 5-10 Displaying the Version
Identification Status p.88
Fanuc Robot
Lab 2 Set Axis Limits p.95
Lab 3 Jog the robot in WORLD mode p.97
Elearning
Robot
Operations
Lab 4 Alternating Between Quick /Full Menu
p.99
Lab 5 Viewing the Version Identification p.100
Elearning
Unit 6 Frame Set up
Procedure 6-1 Setting Up Tool Frame Using the Three
Point Method p.107
Procedure 6-2 Setting Up Tool Frame Using the Six Point
Method p.112
Procedure 6-3 Setting Up Tool Frame Using the Direct
Entry Method p.117
Procedure 6-4 Using the Jog Menu p.121
Procedure 6-5 Selecting a Tool Frame p.122
Procedure 6-6 Setting Up the User Frame Using the
Three Point Method p.132
Procedure 6-7 Setting Up the User Frame Using the Four
Point Method p.138
Procedure 6-8 Setting Up the User Frame Using the
Direct Entry Method p.145
Procedure 6-9 Selecting a User Frame p.148
Procedure 6-10 Setting Up the Jog Frame Using the
Three Point Method p.152
Procedure 6-11 Setting Up the Jog Frame Using the
Direct Entry Method p.157
#11
4-06-16
Fanuc Robot
Unit 7 Creating and Writing a Program
Unit 8 Motion Instructions
#12
Procedure 7-1 Change Wrist Orientation p.172
Procedure 7-2 Create a New Program p.181
Procedure 7-3 Adding Motion Instructions to a TP
Program p.188
Procedure 7-4 EMERGENCY STOP p.190
Procedure 7-5 Recovery from EMERGENCY STOP p. 191
Procedure 7-6 HOLD and Recovery p.191
Procedure 7-7 Setting Up Test Cycle Conditions p.194
Procedure 7-8 Single Step Testing p.197
Procedure 7-9 Continuous Testing Using the Teach
Pendent p. 201
Procedure 7-10 Continuous Testing Using the Operation
Panel CYCLE START Button p. 203
Procedure 7-11 Running Production Using Standard
Operator Panel (SOP) Cycle Start
Procedure 8-1 Defining Default Motion Instructions
p.229
Procedure 8-2 Displaying and Setting Position Registers
p.235
4-13-16
#13
AET 3103 Robotics and
Controls CALL
programming EIU
Fanuc Robot
Unit 9 Copy and Editing Programs
Unit 10 Program Instructions
Unit 11 I/O Programming Instructions &
Operation
Procedure 9-1 Copying a program within SELECT menu
p.246
Procedure 9-2 Deleting a Program p.247
Procedure 9-3 Modifying a Program p.250
Procedure 10-1 Displaying and Setting Registers p.275
Procedure 11-1 Setting Up Digital I/O p.310
Procedure 11-2 Setting Up Group I/O p.316
Procedure 11-3 Forcing Outputs p.322
Procedure 11-4 Simulating and Unsimulating Inputs
p.323
4-20-16
Fanuc Robot
Unit 12 Miscellaneous Instructions
Unit 13 System Variables
#14
Procedure 12-1 Displaying the Program Timer Screen
p.341
Procedure 13-1 Displaying and Setting System Variables
p.351
Lab 6 TOOL Frame Set Up p.125
Lab 7 Create a USER and JOG Frame p.163
Robot
Operations
Completed
Elearning
Handling
Tool
Lab 8 Create a Program p.208
Lab 9 Motion Instruction p.241
Elearning
Handling
Tool
Lab 10 Optional Program p.242
Lab 11 Select / Modify and Execute a Program p.
261
Lab 12 Register Instructions p. 285
Lab 13 Modifying Programs using Branching
Instructionsp.289
Lab 14 Calling Programs p.290
Lab 15 Input/Output p.337
Lab 16 Miscellaneous and Other TP Instructions
p.345
Lab 17 System Variable $SHFTOV_ENB and
$DMAURST p.353
Lab 18 System Variable $SCR_GRP[1] p.354
Elearning
Handling
Tool
completed
4-27-16
#15
5-04-16
#16
Fanuc Robot
Unit 14 Macro Commands
Lab 19 MACRO Commands p.367
Procedure 14-1 Setting Up Macro Commands p.359
Procedure 14-2 Assigning a Macro to SOP p.362
Procedure 14-3 Assign Macro to USER key on teach
Pendant p.363
Procedure 14-4 Assign Macro to a Digital Input p.363
Procedure 14-5 Assign Macro to a Manual Function Key
p.364
Fanuc Robot
Unit 15 Program Adjust
Unit 16 Program & File Manipulation
Lab 20 Program Adjust p.381
Lab 21 Program and File Manipulation p.417
Procedure 15-1 Adjusting Programs During Program or
Production Run
Procedure 16-1 Using the Memory Card Interface p.384
Procedure 16-2 Setting the Default Device p.386
Procedure 16-3 Formatting a Memory Card from the File
Menu p.391
Procedure 16-4 File Backup p.392
Procedure 16-5 Backing Up System and Program Files
p.397
Procedure 16-6 Generating a Directory of Files p.397
Procedure 16-7 Deleting a Program from the SELECT
Menu p.402
Procedure 16-8 Loading Files Using the FILE Menu p.404
Procedure 16-9 Loading a Program p.407
Procedure 16.10 Backing up a Controller as Images p.410
Procedure 16-11 Restoring Controller Images p.413
Project
5-11-16
#17
Project Due
FINAL
Subject to change all updates will be clearly defined prior to implementation.
Industrial automation jon stenerson
Fanuc Robotics System R-J3 Series Training Manual
Fanuc Robot Training Elearning Web Training
Eaton Industrial Hydraulics


My polices:
Spring 2016
Maintenance 220 Mechatronics
To avoid confusion and problems for all of us, this is a supplemental policies sheet used in conjunction with the
syllabus.

20% of your grade comes from tests. You must be present at all exams. I will not allow you to make up a test.
Only if you have an exemption from me, confirmation by voice or email, prior to the exam will I consider
allowing you to take it at a different time.
Midterm
= 10%
Final
= 10%



10% of your grade will come from assignments and reading / activity assessments. Assignments must be turned in on the
date due. Unless otherwise stated the homework assignment will be due the following week it was assigned. I will not
accept late work.
Assignments
=10%
The following must be done in order for the assignment to be accepted:
o No torn up paper, no spiral paper
o Must be completed in either pencil, or black, blue ink.
o It must be legible: readability, grammatically, and numerically professionally done
o In upper right hand side the following must appear

Name

Date assignment is due

Chapter and question numbers
o You must show every step in your solution of the problem. If there is no work shown the entire
assignment will not be counted.
5% of your grade will come from FMS 200 Functional Analysis, Start-Up and Block Analysis Activities, Electrical
Analysis and Pneumatic Analysis. Each section must be completed and submitted in a presentable in a 3 ring binder form.
We will discuss the specifics throughout the course. Late portions will have 25% marked off up to 1 week late. After that I
will not accept it. The following must be done in order for the assignment to be accepted:
o Must be electronically created.
o Readability, grammatically, and numerically correct
o Diagrams must be clearly labeled
o You must show every step in your solution of the problem. If there is no work shown the entire
assignment will not be counted.
40% of your grade will come from Elearning training. This a complete pass / fail opportunity. You must be successfully
pass the Elearn Robot Operations prior to actually being able to use the robot. You will have three attempts to pass each
Elearning training operation. To receive the full points both modules must successfully be done.








Completed E-learn GE Fanuc Robots operation from GE’s website and obtained successful completion certificate
________________ signature
_______________ date (Must be verified by Fanuc for 5%)
Completed E-Learn GE Fanuc Handling Tool operation from GE’s website and obtained successful completion
certificate
________________ signature
_______________ date (Must be verified by Fanuc for 5%)
Robot Operations online ____________ out of 500 points 10%
Handling Tool and Operations __________ out of 700 points 10%
Handling Pro _____________ out of 100 points 10%
15% of your grade will come from labs. Labs must be turned in on the due date, typically the week after in which it was
assigned. No lab will be allowed after taking the exam in which it was used to prepare for. If you cannot complete the lab
during in class time, the lab will be open for open lab time to complete.
Fanuc Programing Procedures=5% (spot check for completion)
Fanuc Robot Labs
=5% (spot check for completion)
PLC / Sensors Labs
=5% graded activities
The following must be done in order for the assignment to be accepted:
o Lab clean up. You are responsible for lab clean up and returning of equipment. If you do not put
equipment away and more importantly the components correctly away you will not get credit for that
lab.
o Your name must be included on the program you are submitting.
o
o
o
Your name and date shall be on every lab.
If the lab is using ladder logic it must be a print of the ladder logic from PLC software.
You must follow the guidelines provided for the activity being completed.
10% of your grade will come from a final project. If it is not turned in according to the directions and or not submitted on
the final due date it will not be accepted. Please see final project info on website for the specific information.
Midterm Withdrawal
Students are expected to attend class during the regularly scheduled times and participate in both the lectures and labs. It is
the responsibility of the student to keep up with all posted materials. Meaningful and timely participation is required for
success in this course. Any student who is not participating in the course and making reasonable attempts to successfully
complete all course activities (labs, exams, homework, quizzes, usw.) will be withdrawn from the course at midterm.
All answers must be clearly denoted if in doubt it will be wrong!
Grades will be based on the following scale:
100 – 90% A
89 – 80% B
79 – 70% C
69 – 60% D
Below 60% F
Name: _____________________________________
Date:__________________________
Elearning Robot Operations
Elearning Handling Tool
Lab activities/ programming the robot through Fanuc Robotics Training Manual
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aa.
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Procedure 5-1 Turning On Robot
Procedure 5-4 Displaying the Alarm Log p.70
Procedure 5-5 Recovering from an Overtravel Error p.74
Procedure 5-6 Recovering from a Hand Breakage p.76
Procedure 5-7 Chain Failure Detection Error Recovery p.78
Procedure 5-8 Jogging the Robot and other axes p.80
Procedure 5-9 Setting Up Axis Limits p.87
Procedure 5-10 Displaying the Version Identification Status p.88
Procedure 6-1 Setting Up Tool Frame Using the Three Point Method p.107
Procedure 6-2 Setting Up Tool Frame Using the Six Point Method p.112
Procedure 6-3 Setting Up Tool Frame Using the Direct Entry Method p.117
Procedure 6-4 Using the Jog Menu p.121
Procedure 6-5 Selecting a Tool Frame p.122
Procedure 6-6 Setting Up the User Frame Using the Three Point Method p.132
Procedure 6-7 Setting Up the User Frame Using the Four Point Method p.138
Procedure 6-8 Setting Up the User Frame Using the Direct Entry Method p.145
Procedure 6-9 Selecting a User Frame p.148
Procedure 6-10 Setting Up the Jog Frame Using the Three Point Method p.152
Procedure 6-11 Setting Up the Jog Frame Using the Direct Entry Method p.157
Procedure 7-1 Change Wrist Orientation p.172
Procedure 7-2 Create a New Program p.181
Procedure 7-3 Adding Motion Instructions to a TP Program p.188
Procedure 7-4 EMERGENCY STOP p.190
Procedure 7-5 Recovery from EMERGENCY STOP p. 191
Procedure 7-6 HOLD and Recovery p.191
Procedure 7-7 Setting Up Test Cycle Conditions p.194
Procedure 7-8 Single Step Testing p.197
Procedure 7-9 Continuous Testing Using the Teach Pendent p. 201
Procedure 7-10 Continuous Testing Using the Operation Panel CYCLE START Button p. 203
Procedure 7-11 Running Production Using Standard Operator Panel (SOP) Cycle Start
Procedure 8-1 Defining Default Motion Instructions p.229
Procedure 8-2 Displaying and Setting Position Registers p.235
Procedure 9-1 Copying a program within SELECT menu p.246
Procedure 9-2 Deleting a Program p.247
Procedure 9-3 Modifying a Program p.250
Procedure 10-1 Displaying and Setting Registers p.275
Procedure 11-1 Setting Up Digital I/O p.310
Procedure 11-2 Setting Up Group I/O p.316
Procedure 11-3 Forcing Outputs p.322
Procedure 11-4 Simulating and Unsimulating Inputs p.323
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ggg.
Procedure 12-1 Displaying the Program Timer Screen p.341
Procedure 13-1 Displaying and Setting System Variables p.351
Procedure 14-1 Setting Up Macro Commands p.359
Procedure 14-2 Assigning a Macro to SOP p.362
Procedure 14-3 Assign Macro to USER key on teach Pendant p.363
Procedure 14-4 Assign Macro to a Digital Input p.363
Procedure 14-5 Assign Macro to a Manual Function Key p.364
Procedure 15-1 Adjusting Programs During Program or Production Run
Procedure 16-1 Using the Memory Card Interface p.384
Procedure 16-2 Setting the Default Device p.386
Procedure 16-3 Formatting a Memory Card from the File Menu p.391
Procedure 16-4 File Backup p.392
Procedure 16-5 Backing Up System and Program Files p.397
Procedure 16-6 Generating a Directory of Files p.397
Procedure 16-7 Deleting a Program from the SELECT Menu p.402
Procedure 16-8 Loading Files Using the FILE Menu p.404
Procedure 16-9 Loading a Program p.407
Procedure 16.10 Backing up a Controller as Images p.410
Procedure 16-11 Restoring Controller Images p.413
Robot Labs A. Lab 1 Power Up and Jog the Robot in JOINT p.93 5
B. Lab 2 Set Axis Limits p.95 5
C. Lab 3 Jog the robot in WORLD mode p.97 5
D. Lab 4 Alternating Between Quick /Full Menu p.99 5
E. Lab 5 Viewing the Version Identification p.100 5
F. Lab 6 TOOL Frame Set Up p.125 6
G. Lab 7 Create a USER and JOG Frame p.163 6
H. Lab 8 Create a Program p.208 7
I. Lab 9 Motion Instruction p.241 8
J. Lab 10 Optional Program p.242 8
K. Lab 11 Select / Modify and Execute a Program p. 261 9
L. Lab 12 Register Instructions p. 285 9
M. Lab 13 Modifying Programs using Branching Instructionsp.289 10
N. Lab 14 Calling Programs p.290 10
O. Lab 15 Input/Output p.337 11
P. Lab 16 Miscellaneous and Other TP Instructions p.345 12
Q. Lab 17 System Variable $SHFTOV_ENB and $DMAURST p.353 13
R. Lab 18 System Variable $SCR_GRP[1] p.354 13
S. Lab 19 MACRO Commands p.367 14
T. Lab 20 Program Adjust p.381 15
U. Lab 21 Program and File Manipulation p.417 16
FMS 200 Troubleshooting
PLC / Sensors Labs
Project