SAQA All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.
SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED UNIT STANDARD: 

Install, commission and maintain an industrial robot system 
SAQA US ID UNIT STANDARD TITLE
377004  Install, commission and maintain an industrial robot system 
ORIGINATOR
SGB Manufacturing and Assembly Processes 
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY
-  
FIELD SUBFIELD
Field 06 - Manufacturing, Engineering and Technology Manufacturing and Assembly 
ABET BAND UNIT STANDARD TYPE PRE-2009 NQF LEVEL NQF LEVEL CREDITS
Undefined  Regular  Level 5  NQF Level 05  10 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
Reregistered  2018-07-01  2023-06-30  SAQA 06120/18 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2024-06-30   2027-06-30  

In all of the tables in this document, both the pre-2009 NQF Level and the NQF Level is shown. In the text (purpose statements, qualification rules, etc), any references to NQF Levels are to the pre-2009 levels unless specifically stated otherwise.  

This unit standard does not replace any other unit standard and is not replaced by any other unit standard. 

PURPOSE OF THE UNIT STANDARD 
Learners accredited with this unit standard will perform a variety of tasks within the manufacturing environment, in the field of robotics. The learners will focus on the design parameters of an industrial robot system, position and secure the robot and its peripheral devices, connect robot controller, configure software and programme a robot system and maintain an industrial robot for optimum production. Learner will appreciate the importance of safe working practices.

Learners credited with this unit standard will be able to:
  • Explain the design parameters of an industrial robot system.
  • Position and secure the robot and its peripheral devices.
  • Connect robot controller and devices to power sources.
  • Configure software and programme a robot system.
  • Maintain an industrial robot for optimum production. 

  • LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    It is assumed that learners are competent in Communication and Mathematical Literacy at NQF Level 4. 

    UNIT STANDARD RANGE 
    N/A 

    Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Explain the design parameters of an industrial robot system. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The theory of robotics is explained in terms of the role of robots in manufacturing, production and assembly. 

    ASSESSMENT CRITERION 2 
    The design capabilities of a robot are discussed to develop an automation strategy for a variety of industrial applications. 

    ASSESSMENT CRITERION 3 
    Classes and types of robot kinematics are discussed in relation to their differences and features. 
    ASSESSMENT CRITERION RANGE 
  • Classes of robots include articulated, cartesian, parallel etc.
  • Types of robots include gantry robots, cylindrical robot, spherical/polar robot, SCARA robot, articulated robot and parallel robot.
     

  • ASSESSMENT CRITERION 4 
    Concepts related to a robot are explained in relation to how they apply to robots. 
    ASSESSMENT CRITERION RANGE 
    Concepts include acceleration, deceleration, velocity, speed, torque, accuracy path and motion of the manipulator.
     

    ASSESSMENT CRITERION 5 
    Primary power sources for the robots are discussed in terms of their differences. 
    ASSESSMENT CRITERION RANGE 
    Power sources include electrical, hydraulic and air motor.
     

    ASSESSMENT CRITERION 6 
    Safety, health, and environmental protection legislation and standards are described as they are applicable for robots. 

    ASSESSMENT CRITERION 7 
    The methodology used in programming robots is described for simple operations. 
    ASSESSMENT CRITERION RANGE 
    Programming can be for HMI, controlling, monitoring, fault-finding etc.
     

    ASSESSMENT CRITERION 8 
    The cross-compiler is discussed in terms of its role for converting the user programme into machine language. 
    ASSESSMENT CRITERION NOTES 
    Learners must also know the difference between an interpreter and a compiler. 

    ASSESSMENT CRITERION 9 
    The use of resolvers is explained to show how they enable the robot to maintain a programmed path is discussed. 

    ASSESSMENT CRITERION 10 
    The controller is discussed to show its role in controlling a robot in a master slave configuration. 

    SPECIFIC OUTCOME 2 
    Position and secure the robot and peripheral devices. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Specifications and installation procedures are used to install a robot. 

    ASSESSMENT CRITERION 2 
    The components and the peripherals of a robot are identified and described in terms of their position and functions. 
    ASSESSMENT CRITERION RANGE 
  • Major components include the mechanical unit, power source, control system, and tooling.
  • Peripherals attached to the robot include the robot's base plate, the provision of a platform on the underside of the robot for lifting by a fork lift, the various fixing plates, mechanical stops and limit or proximity switches.
     

  • ASSESSMENT CRITERION 3 
    The relationship between industrial robot systems and peripherals is described in order to understand the robot as a multi functional mechanical device. 

    ASSESSMENT CRITERION 4 
    Tools and equipment used to install robots and to mark off are identified and described in terms of their functions. 

    ASSESSMENT CRITERION 5 
    Machine screws, bolts and nuts are fastened to the recommended torque. 

    ASSESSMENT CRITERION 6 
    Appropriate mobile equipment is operated to position the robot in marked off area. 

    ASSESSMENT CRITERION 7 
    The manipulator arm and devices are fixed according to the kind of work to be performed by the robot. 

    ASSESSMENT CRITERION 8 
    Components are assembled, cables and the human machine interface (HMI) controls are fastened using the manufacturer's and user's guide and the circuit diagram. 

    ASSESSMENT CRITERION 9 
    The theory of lubrication is discussed and the lubrication requirements of the robot are determined according to the manufacturer's manual. 

    ASSESSMENT CRITERION 10 
    Safety beacon(s) are positioned around the operating envelope of the robot as per safety guidelines. 

    ASSESSMENT CRITERION 11 
    Safe working procedures are applied while positioning and securing the robot and the implications of not working safely are discussed. 

    SPECIFIC OUTCOME 3 
    Connect robot controller and devices to power sources. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The relationship between industrial robot systems and electricity is explained using the basics about electrical devices and pneumatic and hydraulic power sources. 

    ASSESSMENT CRITERION 2 
    The user's manual, manufacturer's specifications, a variety of diagrams, and symbols are read and interpreted prior to performing any installations or power connections. 
    ASSESSMENT CRITERION RANGE 
    Diagrams include manufacturer's circuit diagrams, flow diagram, wiring diagrams, electrical drawings, circuit diagrams, schematic drawings, pneumatic diagrams and hydraulic diagrams.
     

    ASSESSMENT CRITERION 3 
    Power sources are isolated according to recommended procedures for isolating or locking-out primary power sources, within the learner's authority. 
    ASSESSMENT CRITERION RANGE 
    The primary power sources include a hydraulic accumulator, air receiver or high voltage supplies.
     

    ASSESSMENT CRITERION 4 
    Controller(s) are connected to primary source using the main circuit diagram of a robot controller and manufacturer's manual. 

    ASSESSMENT CRITERION 5 
    Diagnostic tests and fault analysis are performed using appropriate series of standard procedures. 

    ASSESSMENT CRITERION 6 
    Electrical, hydraulic and pneumatic connections are terminated according to manufacturer's specifications. 

    ASSESSMENT CRITERION 7 
    The system is powered-up and the man machine interface is initialised using the manufacturer's reference manual. 

    ASSESSMENT CRITERION 8 
    Safe working practices are applied while making electrical connections to prevent injury to self, others and the environment. 

    SPECIFIC OUTCOME 4 
    Configure software and programme a robot system. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The relationship between industrial robot systems and information technology is explained by discussing the technologies and supporting technologies related to industrial robots. 

    ASSESSMENT CRITERION 2 
    Software and computer components are identified and discussed in terms of their functions. 

    ASSESSMENT CRITERION 3 
    Software configuration procedures for HMI and I/O parameters are discussed and applied using ready-to-use commands. 

    ASSESSMENT CRITERION 4 
    The software is installed onto a computer bearing in mind administrative rights, support licensing and software warranty. 

    ASSESSMENT CRITERION 5 
    The modes of operation in which a robot can be selected and used are explained by describing the cabinet that contains the Central Processing Unit (CPU). 

    ASSESSMENT CRITERION 6 
    The robotic controller interface is initialised into learn mode through a teach mode that consists of buttons and functions. 
    ASSESSMENT CRITERION RANGE 
    Buttons include selection and operation buttons, motion buttons, and data entry buttons.
     

    ASSESSMENT CRITERION 7 
    The teaching utility is connected to the robot controller via communication cables. 

    ASSESSMENT CRITERION 8 
    A robot is taught the required motion parameters using appropriate methodology. 

    ASSESSMENT CRITERION 9 
    Programmes for the controllers are written and/or edited and run to verify robot accuracy and production effectiveness. 
    ASSESSMENT CRITERION RANGE 
    Controllers include manipulator arm, wrist and end effectors.
     

    ASSESSMENT CRITERION 10 
    Vision systems and proximity switches are checked to ensure that they are working correctly. 

    ASSESSMENT CRITERION 11 
    All emergency stops and the safety interlocking systems are checked to ensure safety and the integrity of the robot's operation. 

    ASSESSMENT CRITERION 12 
    A maintenance schedule is prepared as per manufacturer's recommendations. 

    SPECIFIC OUTCOME 5 
    Maintain an industrial robot for optimum production. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The relationship between industrial robot systems and maintenance is explained in order to track the performance. 

    ASSESSMENT CRITERION 2 
    Maintenance procedures and techniques are described and used as outlined by the manufacturers manual. 

    ASSESSMENT CRITERION 3 
    Maintenance schedules are interpreted using knowledge of the theory and design of a robot. 

    ASSESSMENT CRITERION 4 
    Exact parameters to automate a series of coordinated motions are specified in relation to the capabilities of an industrial robot. 

    ASSESSMENT CRITERION 5 
    The angles of the robot's joints are observed to determine the robot's movement co-ordinates and to ensure that the stresses placed on the robot are not too severe. 

    ASSESSMENT CRITERION 6 
    The effectiveness of the robot is monitored in terms of the production/manufacturing/assembly output. 

    ASSESSMENT CRITERION 7 
    The quality of the production output is tested as part of total quality management as applied to the installation, commission and production of industrial robots. 

    ASSESSMENT CRITERION 8 
    The robots statistical results of output are analysed to help fine tune the robot's operating parameters to achieve consistent performance and produce the desired result. 

    ASSESSMENT CRITERION 9 
    Faults are analysed and rectified using common fault-finding methodologies and solutions to the problems are generated. 

    ASSESSMENT CRITERION 10 
    Robot's performance parameters are amended to achieve the desired production/manetc outputs. 
    ASSESSMENT CRITERION RANGE 
    Performance parameters include reach, acceleration, velocity and deceleration.
     


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
  • Anyone assessing a learner or moderating the assessment of a learner against this unit standard must be registered as an assessor with the relevant ETQA.
  • Any institution offering learning that will enable the achievement of this unit standard must be accredited as a provider with the relevant ETQA.
  • Assessment and moderation of assessment will be overseen by the relevant ETQA according to the ETQA policies and guidelines for assessment and moderation.
  • Moderation must include both internal and external moderation of assessments at exit points of the qualification, unless ETQA policies specify otherwise. Moderation should also encompass achievement of the competence described both in individual unit standards as well as the integrated competence described in the qualification. 

  • UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE 
  • Names and functions of:
    > The software.
    > Computer components.
  • Attributes, descriptions, characteristics and properties:
    > Lubrication and solvents.
  • Purpose of:
    > Tools and lifting equipment.
    > Robot safety.
    > Software and hardware configuration.
    > Tension and torque.
    > The cables and connectors.
    > Power units.
    > Installation and maintenance procedures.
  • Processes, events, causes, effects and implications:
    > Causes of damage and injury.
    > Implications of not applying installation and safety procedures.
    > Implication of not wearing personal safety equipment.
  • Procedures and techniques:
    > Installation procedures.
    > Maintenance procedures.
    > Software configuration procedures.
    > Safety procedures.
  • Regulations, legislation, agreements, policies and standards:
    > Applicable safety, health and environmental protection legislation and standards.
  • Theory: rules, principles and laws:
    > Principles of cross compilers.
    > Principles of resolvers.
  • Relationship systems:
    > Relationship between industrial robot systems and electricity.
    > Relationship between industrial robot systems and maintenance.
    > Relationship between industrial robot systems and information technology.
    > Relationship between industrial robot systems and peripherals. 

  • UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    Identify and solve problems in which responses display that responsible decisions using critical and creative thinking have been made when:
  • Performing diagnostic tests and fault analysis using appropriate series of standard procedures. 

  • UNIT STANDARD CCFO ORGANISING 
    Organise and manage oneself and one's activities responsively and effectively when:
  • Explaining the design parameters of an industrial robot system.
  • Positioning and securing the robot and peripheral devices.
  • Operating appropriate mobile equipment to position the robot in marked off area.
  • Connecting robot controller and devices to power sources.
  • Applying safe working practices.
  • Configure software and programme a robot system. 

  • UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information to:
  • Read and interpret the user's manual, manufacturer's specifications, a variety of diagrams, and symbols pertaining to robots. 

  • UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively using visual, mathematical and/or language skills in the modes of oral and/or written presentation to:
  • Install, commission and maintain an industrial robot system. 

  • UNIT STANDARD CCFO SCIENCE 
    Use science and technology effectively and critically, showing responsibility towards the environment and the health of others by:
  • Using tools and equipment according to manufacturer's specifications. 

  • UNIT STANDARD CCFO DEMONSTRATING 
    Demonstrate an understanding of the world as a set of related systems by recognising that the problem-solving contexts do not exist in isolation when engaging with problems related to the installation, commissioning and maintaining robot systems. 

    UNIT STANDARD ASSESSOR CRITERIA 
    N/A 

    REREGISTRATION HISTORY 
    As per the SAQA Board decision/s at that time, this unit standard was Reregistered in 2012; 2015. 

    UNIT STANDARD NOTES 
    This unit standard replaces unit standard 13137, "Install, commission and maintain an industrial robot system", Level 5, 10 credits.

    Learners must know the difference between an "encoder" and a "resolver.

    Learners must become familiar with different types of teaching pendants and their operating principles. 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Elective  79627   National Certificate: Mechatronics  Level 5  NQF Level 05  Passed the End Date -
    Status was "Reregistered" 
    2015-06-30  MERSETA 


    PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS UNIT STANDARD: 
    This information shows the current accreditations (i.e. those not past their accreditation end dates), and is the most complete record available to SAQA as of today. Some Primary or Delegated Quality Assurance Functionaries have a lag in their recording systems for provider accreditation, in turn leading to a lag in notifying SAQA of all the providers that they have accredited to offer qualifications and unit standards, as well as any extensions to accreditation end dates. The relevant Primary or Delegated Quality Assurance Functionary should be notified if a record appears to be missing from here.
     
    NONE 



    All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.