The Risks of Manual Tasks in Industrial Robotics
In many industrial robotic applications, manual intervention is often required for tasks such as turning, loading, unloading, and handling. These activities typically involve the use of fixtures and other tooling that are operated manually. This interaction between human workers and robot movements can lead to serious safety concerns.
When operators work in close proximity to robots, there is a risk of injury due to moving parts like grippers, cylinders, and rotating components. Common hazards include crushing, shearing, and entanglement, which can occur if proper precautions are not taken.
To ensure the safety of personnel, it's crucial to implement effective protective measures. This includes both physical barriers and control systems designed to prevent access to dangerous areas during robot operation.
Operator Interaction
Primary Safety Measures
According to ISO 12100, interlocks and mechanical guards are among the most effective ways to reduce risks. These methods are also widely used in robotic applications to protect workers from potential dangers.
For example, fixed guards must meet certain standards, such as:
- Being removable only with a specific tool, like an Allen key;
- Remaining attached to the machine or guard when removed;
- Having a minimum height of 1400 mm from the ground.
These requirements are based on international standards like ISO 14120 and ISO 13857, and they are also referenced in ISO 10218-2 for robotic safety.
Main Guard for the Robot
Additional Protective Solutions
In scenarios where frequent manual interventions are necessary, physical barriers may not always be practical. After assessing potential risks—such as flying debris or welding sparks—three additional protective strategies can be considered:
Stop Time Limit
The control system should allow enough time for the robot to stop safely before an operator enters the hazardous area. This involves using interlocking systems with locking mechanisms and implementing delay, speed monitoring, and static detection to ensure the equipment is in a safe state.
Light Curtain to Trigger Machine Stop
Collaborative Space Limitation
When humans and robots share the same workspace, the workflow and control system should be designed so that they do not occupy the space simultaneously. If both are present at the same time, the robot should automatically stop to prevent accidents.
Limiting Collaborative Space
To address the various risks associated with human-robot interaction, Pilz has developed a new course focused on human-machine collaboration and safety, aligned with ISO/TS 15066. This training is ideal for engineers working with industrial robots across different industries.
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