Robotics Safety

Guohua Cui, Dan Zhang and Marc A. Rosen

Faculty of Engineering and Applied Science
University of Ontario Institute of Technology
Oshawa, Ontario, Canada
 
July 2014
1. Introduction to 2. Types of robots & 3. Types and sources 4. Robotcs safety 5. Robot safeguards 6. Robot safety
robotics safety industrial robots of robotics hazards requirements standards

Contents
1. Introduction to robotics safety 5. Robot safeguards
5.1. Robot safeguards from design to operation
2. Types of robots and industrial robots 5.1.1. Risk assessment
2.1. Definition of robots and industrial robots 5.1.2. Robot safety begins with the design
2.2. Classifications of robots process
2.2.1. Classification based on design configuration
5.2. Robot safeguards and engineering
2.2.2. Classification based on control systems
2.2.3. Classification based on path generation applications
2.3. Industrial robot components 5.2.1. Today’s safeguarding methods
2.3.1. Mechanical unit 5.2.2. Instruction to improve robot safety
2.3.2. Power source 5.2.3. Typical engineering applications 
2.3.3. Control system
5.3 Lessons learned from key incidents involving

3. Types and sources of robotics hazards

robots
3.1. Types of robot accidents
3.2 Examples of robot accidents 6. Robot safety standards
3.3. Sources of hazards
6.1. Technology and standardization
development overview
4. Robot safety requirements
4.1. Requirements and safety measures in normal 6.2. Current standards for robotic safety
operation
4.2.Demands and safety measures in special References
operation modes
4.3. Demands on safety control systems
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Section 1---Introduction to robotics safety

1. Introduction to robotics safety

2. Types of robots and industrial robots

3. Types and sources of robotics hazards

4. Robot safety requirements

5. Robot safeguards

6. Robot safety standards

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Section 1---Introduction to robotics safety

Robot safety is extremely important

Most accidents with robots occur during programming, maintenance,

repair, setup and testing, all of which involve human interaction

Common causes:
• lack of employee training
• improper use of safety guards

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Section 1---Introduction to robotics safety

Effective robot safety systems

Note: Robots, depending on the task, may generate paint mist, welding fumes,
plastic fumes, etc. In general, the robot, on occasion is used in environments
or tasks too dangerous for workers, and as such creates hazards not specific to
the robot but specific to the task.
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Section 2--- Types of robots & industrial robots

What is a robot?

A robot is a machine built for real-

world functions that is computer-
controlled

Some types:
• Industrial Robots
• Military Robots
• Medical Robots
• Mobile Robots
• Service Robots
• Nano Robots

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Section 2--- Types of robots

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Section 2---What are industrial robots?

• Industrial robots are, multifunctional, mechanical devices,

programmable in 3 or more axes, designed to move material, parts,
tools or specialized devices through variable programmed motions to
perform a variety of tasks.

• Industrial robots perform many functions, e.g., material handling,

assembly, arc welding, resistance welding, machine tool load and
unload functions, painting and spraying.

• An industrial robot system includes not only industrial robots but also
any devices and/or sensors required for the robot to perform its tasks
as well as sequencing or monitoring communication interfaces.

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Section 2---What are industrial robots?

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Section 2---Types of industrial robots

Seven types of robot design configurations exist:

• Cartesian Coordinate Robots

• Cylindrical Robots
• Spherical Robots
• SCARA Robots
• Delta Robots
• Articulated Robots
• Snake Arm Robots

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Section 2--- Types of industrial robots

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Section 2--- Types of industrial robots

Two types of control systems exist:

• Servo robots
• Nonservo robots

Three types of paths generated exist:

• point-to-point path
• controlled path
• continuous path

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Section 2--- Types of industrial robots

• Manipulators: the most commonly used robots in the industrial

environment
• Mobile Robots: unmanned vehicles capable of locomotion
• Hybrid Robots: mobile robots with manipulators

(Images from AAAI and How Stuff Works, respectively)

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Section 2--- Robot Components

Body Industrial robots have four

main components:
Effectors
Actuators • Mechanical unit
Sensors • Power source
Controller • Control system
Software • Robot tool

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Section 3---Types and sources of robotics hazards

Why are industrial robots dangerous?

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Section 3---Types of robot accidents

Typical types of robot accidents:

1. A robotic arm or controlled tool causes an accident
2. A robot places an individual in a risk circumstance
3. An accessory of the robot's mechanical parts fails
4. The power supplies to the robot are uncontrolled
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Section 3---Examples of robot accidents

Example 1: First fatal robot-related

accident in the U.S.

On July 21, 1984, a die cast operator was

working with an automated die cast
system utilizing a Unimate Robot, which
was programmed to extract the casting
from the die-cast machine, dip it into a
quench tank and insert it into an
automatic trim press.

A neighboring employee discovered the victim pinned between the

right rear of the robot and a safety pole in a slumped but upright
position. The victim died five days later in the hospital.
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Section 3---Examples of robot accidents

Example 2:

A material handling robot was operating in its automatic mode and a

worker violated safety devices to enter the robot work cell. The worker
became trapped between the robot and a post anchored to the floor,
was injured and died a few days later.

Example 3:

A maintenance person climbed over a safety fence

without turning off power to a robot and
performed tasks in the robot work zone while it
was temporarily stopped. When the robot
recommenced operation, it pushed the person
into a grinding machine, killing the person.
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Section 3---Examples of robot accidents

Details of some other reported robot-related accidents:

• 2000: The head of a person was crushed between a conveyor and a

robot. The task of the robot was to feed cows at a farm.

• 2005: A person was crushed between a manipulator (resembling a

gantry type robot) and a conveyor. The task of the manipulator was
to move bricks from one conveyor to another at a brick factory.

• 2006: A person was crushed between a robot and a conveyor. The

task of the robot was to move trays to a conveyor, in an application
in the dairy industry.

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Section 3---Types of robot accidents

Robotic incidents can be grouped into four categories:

1. Impact or collision accidents
2. Crushing and trapping accidents
3. Mechanical part accidents
4. Other accidents

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Section 3---Sources of hazards

Human Interaction
Control Errors
Unauthorized Access
Mechanical Failures
Environmental Sources
Power Systems
Improper Installation

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Section 3---Sources of hazards

• Human Interaction: Hazards from human interaction associated

with programming, interfacing activated peripheral equipment, or
connecting live input-output sensors to a microprocessor or a
peripheral device, can cause dangerous, unpredicted movement or
action by a robot
• Control Errors: Intrinsic faults within the control system of the robot,
errors in software, and electromagnetic interference are possible
control errors
• Unauthorized Access: Entry into a robot's safeguarded area is
generally potentially hazardous
• Mechanical Failures: Operating programs may not account for
cumulative mechanical part failure, which can allow faulty or
unexpected operation to occur
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Section 3---Sources of hazards

• Environmental Sources: Electromagnetic interference (transient

signals) can exert an undesirable influence on robotic operation and
increase the potential for injury to any person working in the area
• Power Systems: Pneumatic, hydraulic or electrical power sources that
have malfunctioning control or transmission elements in the robot
power system can disrupt electrical signals to the control and/or
power-supply lines
• Improper Installation: The design, requirements, layout of equipment,
utilities, and facilities of a robot or robot system, if inadequate, can
lead to inherent hazards

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Section 3---Case studies: incidents and lessons learned

Machine Operator Crushed by Robotic Platform (Nebraska, 1999)

• Incident:
– A 23-year-old carousel operator at a meat packing plant was killed
when his foot tripped a light sensor causing a computer controlled
robotic platform to descend, crushing his skull.
– He had been watching a technician work on a conveyor and
apparently stepped on the conveyor for a better view.
– The conveyor the mechanic was working on had been shut off but
the entire system had not been locked out. Power still remained to
the light sensors and the robotic platform.
– When the platform descended it pinned the victim between it and
the conveyor. The victim was pronounced dead at the scene.
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Section 3---Case studies: incidents and lessons learned

Machine Operator Crushed by Robotic Platform (Nebraska, 1999)

• Lessons learned:
– Ensure all equipment is properly locked out/tagged out prior to
performing maintenance on it.
– Consider implementing a spot inspection program to ensure all
employees are complying with safety requirements.
– Develop procedures to ensure individuals not involved in
maintenance activities are not in the immediate area of the
maintenance being performed.
– Consider installing a protective grate around access areas to the
robotic platform.

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Section 3---Case studies: incidents and lessons learned

Mold Setter’s Head Struck by Cycling Gantry Robot (Michigan, 2001)

• Incident:
– A 29-year old male was struck on the head by a cycling single-side
gantry robot. He had recently changed a mold on a 1500-ton
horizontal injection-molding machine.
– The victim climbed on top of the purge guard and leaned over the
top of the stationary platen of the machine to see if the tools were
left in the mold area, and placed his head beneath the robot’s
gantry frame. His position placed him between the robot’s home
position and the robot’s support frame on the stationary platen.
– The robot cycled, and the victim’s head was struck from the side
and crushed between the robot and the robot’s support frame.
The victim was pronounced dead on arrival at the local hospital.
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Section 3---Case studies: incidents and lessons learned

Machine Operator Crushed by Robotic Platform (Nebraska, 1999)

• Lessons learned:
– The robot and the point of operation should be safeguarded to
prevent entry during automatic operation.
– Users should conduct a risk assessment of the robot/robot system
to identify equipment, installation, standards, and process hazards
so adequate employee safeguards are provided.
– Users should ensure that personnel who interact with the robot or
robot system, such as programmers, teachers, operators and
maintenance personnel are trained on the safety issues associated
with the task, robot and robot system.

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Section 4---Robotcs safety requirements

Requirements and safety measures in normal operation

Demands and safety measures in special operation modes

Demands on safety control systems

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Section 4---Requirements and safety measures in normal operation

The use of robot technology necessitates hazard analysis, risk

assessment and safety measures

The following can serve as guidelines:

• Prevent physical access to hazardous areas

• Prevent injuries as a result of the release of energy

• Apply interfaces between normal operation and special operation

to enable the safety control system to automatically recognize the
presence of personnel

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Section 4---Demands and safety measures in special operation modes

Certain special operation modes (e.g., setting up, programming) of an

industrial robot require movements which must be assessed directly
at the site of operation

The movements should be:

• only of the scheduled type and speed

• prolonged only as long as instructed

• performed only if it can be guaranteed that no parts of the human

body are in the danger zone

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Section 4---Demands on safety control systems

Suggested measures to provide reliable safety control systems :

• Redundant and diverse layouts of electro-mechanical control

systems including test circuits

• Redundant and diverse set-ups of microprocessor control systems

developed by different teams (this modern approach is considered
state-of-the-art, and often includes safety light barriers)

• Redundant control systems that take into account mechanical as

well as electrical failures

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Section 4---Robot controller

Controllers direct a robot how to

move

Two controller paradigms exist:

1. Open‐loop controllers execute

robot movement without
feedback

2. Closed‐loop controllers execute

robot movement and judge
progress with sensors; they can
thus compensate for errors

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Section 5---Robotic safeguards from design to operation

Topics to consider for robot safeguards:

• What are the potential hazards of the robotic cell?

• What safeguarding technologies are available?

• How can unnecessary personnel be keep out, and necessary

personnel protected?

• How much panel space must be used for relays?

• How difficult or easy will the troubleshooting of the system be?

• What is the overall reliability and safety of the system?

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Section 5---Robotic risk assessment

The first step in designing a safe robot system is to understand the

hazards that exist in the system

At each stage of the robot and robot system development, a risk

assessment should be performed

Assessment criteria:

• severity
• potential injury
• frequency of access to the hazard
• possibility of avoidance

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Section 5---Robot safety begins with the design process

Safeguards should be designed into and

around the robotic cell early in the design
process

Perimeter Guarding
Hard-guarding and optical perimeter
guards

Protection on the inside

Area safety scanners and light curtains

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Section 5---Safeguarding considerations for other stages

The following should be considered in the planning, installation and

subsequent operation of a robot or robot system:
• Safeguarding devices
• Awareness devices
• Safeguarding the teacher
• Operator safeguards
• Attended continuous operation
• Maintenance and repair personnel
• Safety training

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Section 5---Robot safeguard measures

Measures taken to safeguard a robot depend on the circumstances of

its operation and surrounding environment

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Section 5---Today’s safeguarding methods

• Perimeter fencing
• Interlocking devices
• Presence sensing devices (light curtains, laser scanning devices,
pressure sensitive mats)
• Audible and visible warning systems
• Manipulator position indication and limiting (mechanical limits,
position switches, limit switches)
• Enabling devices
• Other safeguard devices

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Section 5---Today’s safeguarding methods

Fences and barriers

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Section 5---Today’s safeguarding methods

Interlocking devices

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Section 5---Today’s safeguarding methods

Presence sensing devices (light curtains, laser scanning devices,

pressure sensitive mats)

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Section 5---Today’s safeguarding methods

Manipulator position indication and limiting: mechanical limits and limit

switches

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Section 5---Today’s safeguarding methods

Manipulator position indication and limiting: position switch

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Section 5---Today’s safeguarding methods

Enabling device

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Section 5---Instruction to improve robot safety

• Use boundary warning devices, barriers and interlocks around
robot systems
• Offer annual robot safety training for employees working on the
floor with robots
• Provide work cell operators with training geared toward their
particular robot
• Create and implement a preventive maintenance program for
robots and work cells
• Ensure operators read and understand robot system
documentation, including material on robot safety
• Ensure that only capable employees who know the safety
requirements for working with a robot operate robot systems
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Section 5---Typical engineering applications

ABB SafeMove - the next generation in robot safety

SafeMove is an electronics and software based safety approach that

ensures safe and predictable robot motion; it allows leaner more
economic and flexible operation

video\ABB_Safemove__The_Next_Generation_in_Robot_Safety_-_YouTube.mp4

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Section 5---Example 1

Example 1: Monitor and increase safety of tool zones

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Section 5---Examples 2 and 3

Example 2: Safe stand Example 3: Safe axis ranges with

still/direct loading of a robot track motions

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Section 6---Robot safety standards

Overview of the technology and standardization development

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Section 6---Robot safety standards

Present status of safety standards for robots in Europe and North America

Type of safety Europe North America

standard
ISO 10218-1:2011 ANSI/RIA R15.06 / ANSI/RIA/ISO
(robot)
Robot safety ISO 10218-2:2011 10218 / RIA TR R15.206
standard CAN/CSA-Z434-03 (R2013)
(robot systems and
integration) (robots and robot systems)

ISO 12100:2010
(risk assessment)
Machinery ISO 13849-1:2006 CSA-Z432-04 (R2009)
safety
(functional safety) ANSI B11.0-2011
standard
IEC 62061:2005
(functional safety)

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Section 6---Robot safety standards

Current standards for robotic safety:

• ANSI/RIA R15.06 / ANSI/RIA/ISO 10218 / RIA TR R15.206

• CAN/CSA-Z434-03 (R2013)
• ISO 10218-1:2011 and ISO 10218-2:2011

Notes:
• In the U.S., ISO 10218 and ANSI RIA 15.06.1999 are both valid
• The Robotic Industries Association (RIA) and the Canadian Standards
Association now are cooperating to publish a single harmonized standard
for the U.S. and Canada
• The new standard—ANSI/RIA R15.06 in the U.S. and CAN/CSA Z434 in
Canada—will be a “four-in-one” document that includes ISO 10218-1:2011,
ISO 10218-2:2011, and the unique requirements of both countries

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Section 6---Robot safety standards

Standard: ANSI/RIA R15.06 / ANSI/RIA/ISO 10218 / RIA TR R15.206

The ANSI/RIA R15.06 / ANSI/RIA/ISO 10218 / RIA TR R15.206 -

Industrial Robots Safety Package provides the fundamentals for
industrial robots and systems as it pertains to the safety requirements

The safety requirements are applicable to manufacturers, integrators,

installers and personnel

The ANSI/RIA R15.06 / ANSI/RIA/ISO 10218 / RIA TR R15.206 -

Industrial Robots Safety Package includes:
• ANSI/RIA R15.06-2012
• ANSI/RIA/ISO 10218-1-2007
• RIA TR R15.206-2008

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Section 6---Robot safety standards

Standard: CAN/CSA-Z434-03 (R2013)

CAN/CSA-Z434-03 (R2013) - Industrial Robots and Robot Systems -

General Safety Requirements

This safety standard applies to the manufacture, remanufacture,

rebuild, installation, safeguarding, maintenance and repair, testing and
start-up, and personnel training requirements for industrial robots and
robot systems

Publish date: 2003-02-01

Supersedes: CAN/CSA-Z434-94

Reaffirmed: 2013-05-09
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Section 6---Robot safety standards

Standard: ISO 10218-1:2011 and ISO 10218-2:2011

The ISO 10218-1 standard for the robot, and the ISO 10218-2 standard
for robot systems and integration, were both published 1 July 2011

ISO 10218-1: For robot (an approved standard and adopted as an ANSI
standard)
 
ISO 10218-2: For robot system and integration (an approved standard )
 
New features in ISO 10218:
• Cable-less pendants – wireless operation
• Collaborative robots
• Simultaneous motion control
• Synchronous robots
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 References
[1] B. S. Dhillon. “Robot safety analysis methods”, in Proceedings of the 11 th National
Conference on Machines and Mechanics. Delhi, India, pp. 86-93, 2003.
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Robot Systems —Safety Requirements, American National Standards Institute, Inc.
[3] http
://thebreakthrough.org/index.php/voices/roger-pielke-jr/its-not-about-the-machines/.
Roger Pielke Jr, how leading economists misunderstand productivity and jobs, in: The
Breakthrough, Accessed October, 2013.
[4] http://commons.wikimedia.org/wiki/File:KUKA_Industrial_Robots_IR.jpg. From
Wikimedia Commons, the free media repository, Accessed October, 2013.
[5] http://hopetotheend.com/robots.html. ROBOTS, Accessed October, 2013.
[6]https://www.google.ca/?
gws_rd=cr&ei=WttSUsDBIMTgrQHUx4DYAQ#q=medical+robots. Accessed October,
2013.
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Questions?