Design and Operation of Robotic Production Systems

Course Structure:

Module I – Concepts and Fundamentals (Weeks 1–3)

1. Introduction: The role of robots in modern manufacturing

This topic introduces the evolution of industrial robotics within the context of Industry 4.0 and 5.0, highlighting the transformation from standalone automation to interconnected and adaptive production systems. Students will learn about the distinction between robotic cells and fully automated robotic lines, the growing importance of human–robot collaboration, and the role of robotics in achieving mass customization and sustainable manufacturing.

2. Components and flows in a robotic production system

The lecture covers the main building blocks of robotic production systems, including industrial robots, end-effectors, sensors, conveyors, AGVs, and auxiliary equipment. Emphasis is placed on the material flow within a production system, the relationship between stations, and the importance of synchronizing physical and informational flows for efficiency and scalability.

3. Process Layout

Students are introduced to layout design principles for robotic production systems, exploring the main layout types (linear, U-shaped, cellular). Using AutoDesk Process Layout, they will learn to model equipment placement, resource allocation, and material flows, while considering ergonomics, space efficiency, and flexibility in system design.

Module II – Design and Integration (Weeks 4–7)

4. Methodology for designing robotic cells

This lecture presents a systematic approach to designing robotic cells, starting from process requirements and specifications. Students will explore workflow analysis, task sequencing, equipment arrangement, and cycle time calculation, while applying optimization criteria related to productivity, cost, and safety.

5. Criteria for selecting robots and auxiliary equipment

Students will learn to evaluate robots based on technical parameters such as payload, reach, accuracy, and repeatability, as well as economic and ergonomic factors. Auxiliary equipment, including conveyors, storage systems, and fixtures, will be discussed as essential elements for ensuring seamless integration and efficient operation of robotic cells.

6. Communication protocols between equipment in robotic systems

The focus here is on understanding how robots, PLCs, sensors, and other devices communicate within a production system. Classical fieldbus protocols such as Modbus, Profibus, and DeviceNet will be introduced alongside modern industrial Ethernet protocols like Profinet, EtherCAT, and Ethernet/IP. Students will analyse practical examples of robot–PLC communication and discuss advantages, limitations, and industry use cases.

7. Simulation and validation of layouts in Process Layout

Students will explore simulation tools available in AutoDesk Process Layout, learning to validate robotic system designs by analysing cycle times, material flow efficiency, and potential bottlenecks. Emphasis will be placed on collision detection, resource utilization, and iterative improvement of system layouts.

Module III – Operation and Safety (Weeks 8–10)

8. Safety in robotic production systems

This lecture covers safety standards and regulations, including ISO 10218 and ISO/TS 15066, focusing on both traditional industrial robots and collaborative robots (cobots). Students will learn about safe zones, safety barriers, laser scanners, and risk assessment methods, gaining awareness of how safety considerations influence the design and operation of robotic systems.

9. Operation and monitoring of robotic systems

Students will analyse how robotic production systems are operated and monitored in real time, using key performance indicators (KPIs) such as availability, cycle time, and overall equipment effectiveness (OEE). Integration with supervisory systems like SCADA and MES will also be discussed as part of digital production management.

10. Maintenance and reliability of robotic systems

This topic addresses the importance of reliability engineering, preventive maintenance, and predictive maintenance in robotic systems. Students will be introduced to concepts such as condition monitoring, digital twins, and data-driven maintenance strategies to improve uptime and extend equipment lifespan.

Module IV – Trends and Advanced Projects (Weeks 11–14) 

11. Collaborative robots and AI in production layouts

This lecture explores the integration of collaborative robots (cobots) into production environments, emphasizing safe human–robot interaction and shared workspaces. The role of artificial intelligence in enabling adaptive layouts, dynamic task allocation, and learning-based optimization will also be presented.

12. Adaptive production systems

Students will analyse how flexibility and adaptability are achieved in modern factories, through modular layouts, rapid reconfiguration, and integration of IoT technologies. The lecture highlights the shift from mass production to mass customization, and the role of robotics in achieving this transformation.

13. Industrial case studies

Real-world case studies will be discussed to illustrate successful implementations of robotic production systems across industries such as automotive, electronics, and logistics. Students will critically analyze design decisions, integration challenges, and achieved performance improvements.

14. Commissioning of Robotic Production Systems

This session focuses on the final stage of integrating robotic systems into production environments: commissioning. Students will learn the methodology for commissioning robotic cells, including system verification, calibration, safety validation, and performance testing. The lecture will cover both virtual commissioning (simulation-based validation in tools like RoboDK/Process Layout) and on-site commissioning (real hardware integration). Emphasis will be placed on troubleshooting, risk analysis, and system acceptance tests according to industrial standards.