Robots Safety

Robotics Safety
Faculty of Industrial Technology

National University of Science & Technology
Department of Industrial & Manufacturing Engineering
M.Eng in Manufacturing Engineering/Systems & Operations
Management.
March 2018
1. Introduction to 2. Types of robots & 3. Types and 4. Robotcs safety 5. Robot 6. Robot safety
robotics safety industrial robots sources of robotics requirements safeguards standards
hazards
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 5.2. Robot safeguards and engineering
configuration applications
2.2.2. Classification based on control systems 5.2.1. Today’s safeguarding methods
2.2.3. Classification based on path generation 5.2.2. Instruction to improve robot safety
2.3. Industrial robot components 5.2.3. Typical engineering applications
2.3.1. Mechanical unit 5.3 Lessons learned from key incidents
2.3.2. Power source involving
2.3.3. Control system robots
3. Types and sources of robotics hazards 6. Robot safety standards

3.1. Types of robot accidents 6.1. Technology and standardization
3.2 Examples of robot accidents development overview
3.3. Sources of hazards 6.2. Current standards for robotic safety
4. Robot safety requirements References

4.1. Requirements and safety measures in
normal
operation
4.2.Demands and safety measures in special
operation modes
4.3. Demands on safety control systems
hazards
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
1 of 3
hazards
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
2 of 3
hazards
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.
3 of 3
hazards
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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hazards
Section 2--- Types of robots
2 of 9
hazards
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?
4 of 9
hazards
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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hazards
Section 2--- Types of industrial robots
6 of 9
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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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hazards
• 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) 8 of 9
hazards
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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hazards
Section 3---Types and sources of robotics hazards
Why are industrial robots dangerous?
1 of 13
hazards
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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hazards
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.
3 of 13
hazards
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.
4 of 13
hazards
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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hazards
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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hazards
Section 3---Sources of hazards
Human Interaction
Control Errors
Unauthorized Access
Mechanical Failures
Environmental Sources
Power Systems
Improper Installation
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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
8 of 13
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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hazards
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. 10 of 13
hazards

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.
11 of 13
hazards
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
12 support
of 13
frame. The victim was pronounced dead on arrival at the
hazards

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.
13 of 13
hazards
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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hazards
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
2 of 5
hazards
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
3 of 5
hazards
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
4 of 5
hazards
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
5 of 5
hazards
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?
1 of 16
hazards
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
2 of 16
hazards
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
3 of 16
hazards
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
5 of 16
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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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hazards
Fences and barriers
7 of 16
hazards
Interlocking devices
8 of 16
hazards
Presence sensing devices (light curtains, laser scanning devices,

pressure sensitive mats)
9 of 16
hazards
Manipulator position indication and limiting: mechanical limits and

limit switches
10 of 16
hazards
Manipulator position indication and limiting: position switch
11 of 16
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Enabling device
12 of 16
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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
13 of 16
hazards
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
14 of 16
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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

still/direct loading of a robot with track motions
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Section 6---Robot safety standards
Overview of the technology and standardization development
1 of 6
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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 /
(robot) ANSI/RIA/ISO 10218 / RIA TR
Robot safety
ISO 10218-2:2011 R15.206
standard
(robot systems and CAN/CSA-Z434-03 (R2013)
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)
2 of 6
hazards
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
3 of 6
hazards
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 4 of 6
hazards
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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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 6 of 6
• Synchronous robots
References
[1] B. S. Dhillon. “Robot safety analysis methods”, in Proceedings of the 11th
National Conference on Machines and Mechanics. Delhi, India, pp. 86-93,
2003.
[2] ANSI/RIA R15.06-1999, American National Standard for Industrial Robots
and Robot Systems —Safety Requirements, American National Standards
Institute, Inc.
[3]
http://thebreakthrough.org/index.php/voices/roger-pielke-jr/its-not-about-the-ma
chines/. 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=me
dical+robots. Accessed October, 2013.
[7] http://www.looptechnology.com/robotic-robot-types.asp. Types of Robots, in:
Loop Technology, Robotics, Accessed October, 2013.
[8] https://www.osha.gov/dts/osta/otm/otm_iv/otm_iv_4.html . Industrial robots
References
[9] http://www.osh.net/articles/archive/osh_basics_2002_may24.htm. Maureen
Alvarez, working safely around industrial robots, in: Gateway for Safety &
Health Information Resources, Accessed August, 2013.
[10]
http://www.ilo.org/oshenc/part-viii/safety-applications/item/972-safety-principles-
for-industrial-robots?tmpl=component&print=1. Marty Albert, Retsch Toni,
Schmitter Guido, safety principles for industrial robots, in: 58. Safety
Applications, Encyclopedia of Occupational Health and Safety, International
Labor Organization, Geneva. 2011. Accessed August, 2013.
[11]http://www.robotics.org/content-detail.cfm/Industrial-Robotics-Featured-Artic
les/Robot-Safety-Begins-with-the-Design-Process/content_id/1120. S. Kelly,
Robot safety begins with the design process, in: Robotics Online. Accessed
August 2013.
[12] K. Behnisch. White paper: Safe collaboration with ABB robots electronic
position switch and SafeMove.
[13] http://www.looptechnology.com/robotic-robot-safety.asp. Robot Safety, in:
Loop Technology, Robotics. Accessed October, 2013.
[14]https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=DIR
ECTIVES&p_id=1703. Guidelines for Robotics Safety, in: Occupational Safety
References
[15] K. Okada, I. Maeda and Y. Sugano. “Risk assessment of robot cell
production system that achieved high productivity and safety in HMI
environment,” Proc. Int. Conf. on Safety of Industrial Automated Systems, pp.
181–186, Tokyo, Japan, 2007.
[16] http://www.robots.com/articles/viewing/robot-safety. Robot Safety, in:
RobotWorx, Accessed August, 2013.
[17]
http://www.abb.com/product/seitp327/ec6cfad87f69dd2dc12572d300775f5b.aspx.
SafeMove - Next generation in robot safety, in: ABB, Accessed August 2013.
[18] S. Kock, J. Bredahl, P.J. Eriksson. Taming the robot - Better safety without
higher fences. ABB Review 4, 2006.
[19] J. Fryman, B. Matthias. Safety of industrial robots: from conventional to
collaborative applications. Proceedings of ROBOTIK 2012; 7th German
Conference on Robotics, Munich, Germany, pp. 51-55, 2012.
[20] ISO 10218 “Robots and robotic devices – safety requirements for industrial
robots”, with parts 1 (“Robots”) and 2 (“Robot systems and integration”),
International standard for robot safety, Geneva, 2011.
[21] CAN/CSA-Z434-03 (R2008) - Industrial Robots and Robot Systems -
General Safety Requirements, Canadian Standard Association.
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Robotics Safety

Faculty of Industrial Technology

3. Types and sources of robotics hazards 6. Robot safety standards

4. Robot safety requirements References

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

6. Robot safety standards

Section 1---Introduction to robotics safety

Robot safety is extremely important

Most accidents with robots occur during programming,

Section 1---Introduction to robotics safety

Effective robot safety systems

Section 2--- Types of robots & industrial robots

A robot is a machine built for

Section 2--- Types of robots

Section 2---What are industrial robots?

• Industrial robots are, multifunctional, mechanical devices,

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

• An industrial robot system includes not only industrial robots but

Section 2---What are industrial robots?

Section 2---Types of industrial robots

Seven types of robot design configurations exist:

• Cartesian Coordinate Robots

Section 2--- Types of industrial robots

Section 2--- Types of industrial robots

Two types of control systems exist:

Three types of paths generated exist:

Section 2--- Types of industrial robots

• Manipulators: the most commonly used robots in the

(Images from AAAI and How Stuff Works,

Section 2--- Robot Components

Body Industrial robots have four

Section 3---Types and sources of robotics hazards

Why are industrial robots dangerous?

Section 3---Types of robot accidents

Typical types of robot accidents:

Section 3---Examples of robot accidents

Example 1: First fatal robot-related

On July 21, 1984, a die cast operator

Section 3---Examples of robot accidents

A material handling robot was operating in its automatic mode

A maintenance person climbed over a safety

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

• 2005: A person was crushed between a manipulator

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

Section 3---Types of robot accidents

Robotic incidents can be grouped into four categories:

Section 3---Sources of hazards

Section 3---Sources of hazards

• Human Interaction: Hazards from human interaction

Section 3---Sources of hazards

• Environmental Sources: Electromagnetic interference

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

Machine Operator Crushed by Robotic Platform (Nebraska,