The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

A person who demonstrates competency in this unit must be able to evaluate industrial robotic applications and integration into automation systems. This includes working individually and as part of a team in accordance with organisational procedures.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Assessors must be satisfied that the candidate can competently and consistently:

identify WHS, regulatory and risk management requirements, and compliance with particular emphasis on automation safety

investigate sustainability implications of robotic applications

identify, review and classify features and functions of robotic applications and robotic devices, robotic principles and techniques, analysis techniques and software

evaluate robotic hardware

evaluate robotic motion, load capability, accuracy, precision and repeatability

evaluate system integration, networking, data sharing, control and human machine interfaces, software and programming

apply mock-up, prototyping and virtual techniques for robot and subsystem testing

report and document results.

Context of and specific resources for assessment

This unit may be assessed on the job, off the job or a combination of both on and off the job. Where assessment occurs off the job, then a simulated working environment must be used where the range of conditions reflects realistic workplace situations.

The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.

Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of the MEM05 Metal and Engineering Training Package.

Assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with application of underpinning knowledge.

Assessment methods must be by direct observation of tasks and include questioning on underpinning knowledge to ensure correct interpretation and application.

Assessment may be applied under project-related conditions (real or simulated) and require evidence of process.

Assessment must confirm a reasonable inference that competency is not only able to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.

Assessment may be in conjunction with assessment of other units of competency where required.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed.

Required skills

Required skills include:

identifying, reviewing and classifying features and functions of robotic applications and robotic devices, including relevant robotic principles and techniques, analysis techniques and software

ensuring safe electrical working practice, including use of licensed personnel, where required

identifying WHS and regulatory requirements, and risk management compliance with particular emphasis on automation safety

investigating sustainability implications of robotic applications

determining safety, condition, efficiency and functionality of robotics and associated applications, including:

controller functions and programming

network and system interfacing

compliance with WHS and regulatory requirements

automation safety

robotic hardware

sensors/transducers

signal conditioning

controllers

power interfaces

actuators and end effectors

evaluating robotic motion, including:

load capability

accuracy

repeatability

efficiency

determining efficiency and effectiveness of robotic interfacing, including:

system integration and networks

data sharing

control and human machine interfaces

software and programming

SCADA or DCS and system simulation

applying mock-up, prototyping and virtual techniques for robot and subsystem testing

reporting and documenting results of evaluation, including calculations, specifications, diagrams, computer programs and files, and mock-ups or prototypes

Required knowledge

Required knowledge includes:

compliance requirements of WHS and regulatory requirements, codes of practice, standards and risk management requirements for robotic applications

classifications and applications of industrial robotic devices or systems

features, mechanisms and components of robots

advantages and disadvantages of different types of actuators for engineering applications

types of actuator power interfaces

end effectors and their applications

robot sensors, such as:

contact, proximity and interrupted beam

distance sensing

pressure and temperature

relative and absolute encoders

vision and smart cameras

sensor interface/transducer signal conditioning techniques and analog to digital converter (ADC)

online and offline programming methods

mechanical, fluid power, electrical, electronic, programming, communications and networking principles and techniques related to robotics

the role of kinematic and kinetic analysis of robot mechanisms

analysis of motions, loads, accuracy, precision and repeatability

situations requiring licensed trade, technical or professional assistance (e.g. actuator power interfacing)

interfaces for sensors and actuators, such as the use of signal conditioning techniques and ADC, power interfacing and digital to analog converter (DAC), and pulse-width modulation (PWM)

programming techniques for motion control and load handling with specialist input, such as vision systems, proximity and distance measurement inputs, and variable velocity control which may be implemented using packaged routines

automation safety in systems and programs, including appropriate use of emergency stop, failsafe design, redundancy, interlocks, guarding and data integrity

system integration of sensing, control, end effectors and actuators, data requirements, network topology and communication protocols required

software for simulation, motion analysis, control, DAC and SCADA

sustainability implications of industrial robotics

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Robotic device or system

Robots are mechanical, programmable self-controlling machines used widely in engineering and related applications where location, work environment, costs, accuracy, quality, repeatability and reliability dictate their use in preference to human or other machines. The robot may be networked so as to serve an automated environment

Industrial robotic applications

Industrial robotic applications vary widely. Examples include:

palletising and depalletising robots

welding and cutting robots

packaging robots

transfer robots

interactive remote surgery robots

interactive nuclear fuel cell robots

Mobile robotic applications

Mobile robotic applications may include:

military robots, including land mine detection and improvised explosive demolition

police bomb detection robots

automated guidance vehicles

Review features and functions of robotic applications

Features and functions may be assessed by analysis of specifications and drawings, ‘reverse engineering’ of robotic applications and performance analysis using simulation and dynamic performance software. The review may include motion control but does not require validation of dynamic stability which is included in other units and dependant on solution of differential equations

Sensor and actuator interfacing techniques

Sensor and actuator interfacing techniques include the use of:

signal conditioning techniques and ADC, power interfacing and DAC and PWM

Controller programming techniques for motion control and load handling

Controller programming techniques may include the use of various motion pathway methods, including:

‘teach’ mode or coordinate and path programming

use of variable velocity algorithms

provision for input variables, such as contact, proximity, measured distance or load and vision, pressure and temperature, and open and closed loop actuator control

Sustainability

Sustainability is used to mean the entire sustainable performance of the organisation/plant, including:

meeting all regulatory requirements

conforming to all industry covenants, protocols and best practice guides

minimising ecological and environmental footprint of process, plant and product

maximising economic benefit of process plant and product to the organisation and the community

minimising the negative WHS impact on employees, community and customer

Analysis

Analysis may include:

static and dynamic analysis of loads

the stresses and deformations resulting

graphical and mathematical methods and software options

WHS, regulatory requirements and enterprise procedures

WHS, regulatory requirements and enterprise procedures may include:

WHS Acts and regulations

relevant standards

codes of practice from Australian and overseas engineering and technical associations and societies

risk assessments

registration requirements

safe work practices

state and territory regulatory requirements

Standards and codes

Standards and codes refer to all relevant Australian and international standards and codes applicable to a particular robotic application

Automation safety

Automation safety refers to the reliance on emergency stop, failsafe design, redundancy, interlocks, guarding and data integrity. Standards apply to general plant design and use as well as the functional safety of safety-related electrical, electronic and programmable electronic control systems

Appropriate technical and professional assistance

Appropriate technical and professional assistance may include:

licensed electrical tradespersons

technical support and advice relating to elements which have intrinsic dangers, such as:

high pressure

energised fluid vessels

high temperatures and heat energy capacity

wiring with high current control voltages above extra low voltage

professional support for technologies, such as:

specialist electric motor drives and controllers

specialist materials, plastics, metal alloys and nano materials

special processes, foundry, alloy welding, heat treatment, sealing and fastening