Robotics & Automation Workforce Bootcamp Series: Bootcamp 3 – Industrial Wiring, Sensors & I/O Troubleshooting

The Robotics & Automation Workforce Bootcamp Series is a stackable, hands-on training pathway designed to take learners from foundational robotics concepts to advanced industrial automation applications. Across four immersive bootcamps, participants develop skills in robot programming and motion control, industrial safety and workcell integration, electrical wiring and I/O troubleshooting, and advanced robotic platforms including 6-axis industrial arms, autonomous quadrupeds, and humanoid systems. Utilizing industry-relevant equipment such as collaborative robots, industrial conveyors, sensors, and autonomous robotic platforms, students gain practical experience performing the same tasks found in modern manufacturing and Industry 4.0 environments.

Each bootcamp is structured as a two-day, instructor-led intensive followed by a certification-focused third day aligned with the SME Robotics in Manufacturing Fundamentals (RMF) Body of Knowledge. While each bootcamp can be taken independently, together they form a comprehensive learning pathway that progressively builds technical competency across robot programming, safety, hardware, sensors, controls, and manufacturing automation systems. Students who complete all four bootcamps will have covered the major domains of the RMF certification framework and will be well-prepared to earn the nationally recognized Robotics in Manufacturing Fundamentals (RMF) certification, validating their readiness for careers in robotics, automation, advanced manufacturing, and industrial technology.

Goal of Bootcamp 3

Develop the practical electrical and troubleshooting skills required to integrate robots, conveyors, sensors, and control systems in a manufacturing environment. Students learn industrial wiring practices, digital I/O configuration, sensor integration, and structured fault diagnosis.

Day 1 (6 Hours): Industrial Controls, Schematics & Digital I/O

Lecture (2.5 Hours)

• Reading industrial electrical schematics
• Terminal block identification
• Industrial control architecture
• 24VDC control systems
• Digital Inputs vs Digital Outputs
• Sinking (NPN) vs Sourcing (PNP) devices
• Industrial signal flow fundamentals

Hands-On Lab (3.5 Hours)

• Navigate Standard Bots Core controller
• Navigate uFactory xArm controller
• Identify power supplies
• Locate digital input/output terminals
• Trace signal paths
• Verify voltages with multimeters
• Create controller I/O maps

Day 2 (6 Hours): Sensor Integration & Equipment Communication

Lecture (2 Hours)

• Photoelectric sensor operation
• Proximity sensing technologies
• Sensor alignment techniques
• Wire preparation best practices
• Ferrule crimping
• Conveyor-to-robot communication
• I/O handshaking fundamentals

Hands-On Lab (4 Hours)

• Install Navigate Standard Bots Core Controller
• Navigate uFactory xArm controller
• Identify power supplies
• Locate digital input/output terminals
• Trace signal paths
• Verify voltages with multimeters
• Create controller I/O maps

Day 2 (6 Hours): Sensor Integration & Equipment Communication

Lecture (2 Hours)

• Photoelectric sensor operation
• Proximity sensing technologies
• Sensor alignment techniques
• Wire preparation best practices
• Ferrule crimping
• Conveyor-to-robot communication
• I/O handshaking fundamentals

Hands-On Lab (4 Hours)

• Install photoelectric sensors
• Wire sensor outputs to robot inputs
• Configure digital input monitoring
• Wire robot outputs to conveyor controls
• Verify run/start signals
• Test automated sensor-triggered conveyor operations
• Validate signal exchange between systems

RMF Certification Day 3

RMF Modules
Robot Hardware & Software

• 5.3 Limit Switches
• 5.6 Robot Sensors
• 5.6.1 Vision Sensors
• 5.6.2 Proximity Sensors
• 5.6.3 Collision Sensors
• 5.9 Conveyors
• 5.10 Input Devices
• 5.10.1 Hardware/User Interface
• 5.10.2 Software/User Program

Robot Programming & Operations

• 6.4.1 Inputs/Outputs (I/O)
• 6.4.1.1 Commands
• 6.4.1.2 Controller
• 6.4.1.3 Controlling I/O
• 6.4.2 Input/Output Monitor and Instructions
• 6.4.2.1 Variable Monitor
• 6.4.2.11 Calibration
• 6.4.3 Device Configuration

Supporting RMF Modules
Robot Hardware & Software

• 5.4 Power Supply
• 5.5 Registers

Robot Programming & Operations

• 6.3 Control Systems
• 6.3.3 Closed Loop Systems