What standards or regulations define someone being locked in robot enclosure?
Mike Kunkle from MEK Consulting - Owner
mekconsulting [at] comcast [dot] net (717) 578-9875
The answer to your question can be found in the ANSI/RIA R15.06-1999 Industrial Robot Safety Standard.
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Can a panel of the cell guarding be manually removed while operating a semi-automated machine? The locating tolerance of the part being placed is within 1mm & changes with every part. Removing the panel will allow the operator to visually inspect the location while operating the controller.
Lee Burk from Pilz Automation Safety L.P. - Manager, Training & Standards
l [dot] burk [at] pilzusa.com (734) 354-0272
Hell Patrick.
I am affraid it is not possible to use a removable guard. The guard must be interlocked.
Possible alternative methods would be to install a transparent panel in the guard or to use a video camera to view the part.
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In the new R15.06-1 2012 collaborative section, it states that the robot SHALL stop when the human is in the collaborative workspace. Later there is a section on power/force limiting, but there is no specification on what the force is, nor whether that if the force is limited, will the initial "SHALL stop" statement be void. If the robot must stop when a human is near, what is the point of the safety rated power/force limiting?
Jeff Fryman from Robotic Industries Association - Director, Standards Development
jfryman [at] robotics [dot] org (734) 994-6088
The new 2012 edition of R15.06 introduces the concept of "collaborative" robot operation using new robots with special features, and lists four methods of this operation. The first, or safety-rated monitored stop, feature calls for a (safe) stop to be issued when the robot is waiting for the human to interact, or a protective stop if the human enters the collaborative work space at the wrong time. A variation of this would be to allow the robot to move in coordination with the human; similar to the second method, hand guiding. These two methods have well spelled out guidelines.
Two new methods are identified, but do not have sufficient guidance yet. That work is expected in a new ISO TS15066 to come out later this year or early next year. The tow methods are speed an separation monitoring (but we don't have adequate separation monitoring yet); and power and force limiting. Again, we do not have sufficient data for what appropriate force and power is yet. The SHALL stop statement is not applicable to these methods, but full guidance is yet to come.
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Source? Training DVD video (generic) on Industrial robot safety awareness. Could you give me vendor contacts? Could not find, via Goggle and Utube search. Limited to product Infoads.
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
Brad, I do not know of any video providing detailed information, however, there are many product videos that contain a lot of information. Our video on the Guardian DEFENDER by Frommelt Safety provides information on all the important codes and regulations and how this product can be applied.
Flossie Mohler from Miller Edge, Inc. - Vice President Sales & Marketing
fmohler [at] milleredge [dot] com (602) 738-8279
Hello Brad,
I'm not quite clear. Are you are looking for safety training video or safety product vendors.
We are based in PA and manufacture safety mats and sensitized bumper switches.
You can view more about us at www.MillerEdge.com or call.
Can we help you?
Flossie
Mike Kunkle from MEK Consulting - Owner
mekconsulting [at] comcast [dot] net (717) 578-9875
Please contact me for information.
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A turn-key equipment supplier recently gave us a proposal which had a large robot in a relatively narrow self-contained enclosure to perform finish grinding on castings. The robot must use 90%+ of its forward reach capacity to get to the part. However, as the robot spins 180 degrees for a tool change, due to the forward reach requirements, the restricted space goes well outside of the enclosure (by 20+ inches). I asked the supplier if the enclosure was designed to stop the robot and their answer was "no". In my previous experience, there was a requirement of 18" clearance between the restricted envelope and any obstruction or guarding with the hard stops on the robot. Is this still a typical industry standard?
Can electrical devices be installed on the robot to prevent that penetration of the enlcosure and possibly hit someone standing outside of it? I was always told to not trust the electrical safety devices and place the robot cell guarding 18" away from the part / end effector / robot.
Jeff Fryman from Robotic Industries Association - Director, Standards Development
jfryman [at] robotics [dot] org (734) 994-6088
One absolute in robot safeguarding is that the perimeter guarding (establishing the safeguarded space) may not be placed any closer to the hazard than the restricted space. Further, no one may be able to reach over, under, around or through (an opening) and reach the hazard. This means that the robot may NOT reach out beyond the perimeter guarding in any circumstance. The restricted space must be established using limiting devices (usually hard stops). While considered bad design, the enclosure, as you inquired, could be the restricting device if strong enough. You were informed correctlya about ordinary electrical devices.
There is a new optional feature available on some new robots called "safety-rated soft axis and space limiting". The various manufacturers have their own names for this optional feature; but it is a safety-rated software feature that limits robot travel and can be used as the limiting device to establish the restricted space (but again this has to be inside the perimeter guarding). In the new R15.06 (2012) the clearance requirement is changed to 20 inches instead of 18, but is now applicable only in areas where there are required tasks and the hazard of a pinch point from an obstruction not supporting the robot task, such as a perimeter guard (fence).
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In a multiple robot cell. When two people are required for a teaching operation (1 teaching,1 spotter). If a second tm is holding another robot teach pendant with an E-stop does this satisfy the requirement for an enabling device or does it have to be a three position deadman switch? This is provided that the second robot teach pendant E-stop will stop the robot being taught as well.
Mike Kunkle from MEK Consulting - Owner
mekconsulting [at] comcast [dot] net (717) 578-9875
Chad,
The second person must have an active three position secondary enabling device in his/her position. There are wireless secondary enabling switches and e-stops now available.
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ANSI-RIA R15.06-1999, page 29, letter B, states: "Barrier openings shall not be greater than 132.00mm (5.0 inches) unless a risk assessment is performed." Does this apply to the opening underneath permeter guarding, sometimes referred to as a "sweep space"?
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
Everybody will interpret this document slightly different. After selling robot guarding for Frommelt Safety Products for over 12 years I always recommended no more than 3" of sweep space. With that said later in that same document you will find a specification stateing that the gap from the walking surface to the bottom of the fixed barrier fencing be no greater than 12" . You are probably safe but if you would like, I could arrange to have our Regional Manager visit your facility. Please give me a call or visit our webwite at frommeltsaefty.com
Mike Kunkle from MEK Consulting - Owner
mekconsulting [at] comcast [dot] net (717) 578-9875
Kyle,
The "sweep space" you speak about is 7" in the R15.06-1999 standartd, but has changed to 5" in the R15.06-2012. The barrier openings of 132.00mm are areas where you may reach through the perimeter guarding as long as the robot work envelope is out of reach.
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We have set up a robot cell with pure mechanical interlocks. All doors will be locked and keys pulled off the locks and keys need to stay with the controller to activate the robot. Just realised that somebody will be locked during programming because of this safety system. Is there any other way to solve this and still comply with safety regulations?
Flossie Mohler from Miller Edge, Inc. - Vice President Sales & Marketing
fmohler [at] milleredge [dot] com (602) 738-8279
You could use safety mats inside the robot cell to prevent the robot from moving while a person is standing inside the cell.
Please visit our web site at www.MillerEdge.com to learn more about your options and feel free to contact us.
Best Regards,
-Flossie
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We are designing a HMI Screen that is currently mirroring our robots Teach Pendant program. The only way to manually jog the robot is still through the Teach Pendant. We do, however, have a "home" button on the HMI screen and on the Teach Pendant to send the robot into a safe position before anyone can enter the robotic cell. What can be done to prevent both devices from being "active" at the same time in order to be in compliance with with 10218-1 (single point of control)?
Lee Burk from Pilz Automation Safety L.P. - Manager, Training & Standards
l [dot] burk [at] pilzusa.com (734) 354-0272
For the "home" button on the pendant to be active you must be in teach mode. When in teach mode, the "home" button on the HMI should no longer be active.
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Is the Risk Assessment in ANSI R15.06-2012 going to be the same as the Risk Assessment in ISO 10218? Is the draft copy of ANSI R15.06-2012 available?
Wade Hickle from Motoman Robotics - Sr. Manager Project Solutions Group
wade [dot] hickle [at] motoman.com (937) 440-2615
There is currently a working group creating a technical report on this subject. While the release date has not been defined, I would expect the document will be publish this year.
Overall look and feel is the similar.
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Can an employee enter a work envelope by locking the gate open to mop floors or perform set up on a machine not associated with the robot, e.g, a lathe, etc.. The interlock is wired in safe mode and requires the gate to be closed and two start up buttons to be engaged prior to the robot engagement.
Frank Claude from Dunwoody College of Technology - Principle Instructor
fclaude [at] dunwoody [dot] edu (612) 374-5800, x8206
Sounds like this question is related to OSHA's Control of Hazardous Energy LOTO rather than the safety systems on the robot. Anyone who needs to be in the workcell, but is not working specifically with the robot, should have a lock on the primary power to the workcell.
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Safety Standards - Is EN ISO 13849-1 relevant in North America, specifically the U.S.?
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
Yes. Effective January 1, 2012, machine builders and integrators must use EN ISO 13849-1:2008 to prove presumption of conformity with the Machinery Directive. On January 1, 2012, EN 954-1:1996 and EN ISO 13849-1:1999 may no longer be used for this purpose.
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Is there an International and European standard that addresses the minimum clearance from the operating space such as specified in the R15.06 section 10.7.7?
from Robotic Industries Association
No, there currently is not. Several European Norms offer safe distance and reach information, but not in the same context that R15.06 calls out. The international robot standard, ISO 10218-1 presently only addresses the robot. The information about clearance will be in the Part 2 which is currently in development. The 1992 edition of ISO 10218 was withdrawn.
from Pilz Automation Safety L.P.
There is information that coorelates a dimension of 20" or 1/2 meter as needed to prevent crushing. CSA Z434 uses 20" (1/2 meter) for clearance. It is expected that the ISO 10218-2 will also state 20" (1/2 meter) when clearance is required.
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What is the frequency of Fanuc robots damaged by hitting the e- stop? I ask because at work today I was told to never hit the e-stop on a Fanuc robot because of possible damage to the robot.
from Robotic Industries Association
I believe the advice about hitting the e-stop was a little mis-leading, and certainly not limited to Fanuc robots. Please DO hit the e-stop if you see something unsafe! E-stop devices are not designed for repetitive use. They have a singular purpose - stopping machinery when a hazard exists. The damage comment has to do with issues of torque and how quickly the robot stops. The robot stops VERY quickly in an emergency and repetitive activations of the high torque stops could affect wear on bearings and other internal components and ultimately (not immediately) result in deterioration of accuracy and repetitiveness.
This is one of the reasons why the R15.06 requires that all safeguarding devices, including the gate switches, be connected to a safety or "protective" stop circuit rather than the e-stop circuit.
from Pilz Automation Safety L.P.
Emergency Stopping is meant for emergencies. So if it is an emergency, YES "hit the e-stop".
Machine damage is not tracked by the safety standard committee, and technically, it is not a safety issue. However there are safety implications of machinery damage. (1) if personnel think that an action will harm the machine, they may hesitate when the action is needed, thereby increasing the risk to personnel. (2) damage to the equipment may not be visible, and such damage may affect the machine's ability to respond as expected when needed for safety issues.
I suggest that you contact Fanuc, as they will be able to give you specific information and guidance about appropriate use of the robot.
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com
Hitting the E-stop during program motion can result in an abrupt stop. The Motoman robots are equipped with a HOLD button which is meant to stop program execution in a non-emergency condition.
If the robot is not moving, then hitting the E-Stop is a way to remove drive power and keep the controller in automatic operation. It can be restarted by simply applying servo power and starting the program again. This will not damage the robot.
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Hello,
I am a Board Member of the Iowa Illinois Safety Council. We are looking for a speaker to present a Robotic Safety lecture at our professional development conference on April 23, 2009. Please call me at 319-390-2190 for details. Thank you.
from Maverick Technologies, LLC
Patrick,
I left a message for you on your voicemail, but feel free to call me and we can discuss when you return at 630-213-0308 or cell 630.728.0910 Bob Iossi. bob.iossi@mavtechglobal.com
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Does the latest version of ANSI allow an extra person in the cell without an enabling device when training?
What is the latest on Human/Robot Interaction. Is there a set standard on robot required performance, category?
We need an alternative way of viewing the path of the paint robot in our paint booth. We view now through the window of the paint booth, which is not good enough. We have interlocks on the paint booth, but we need to get the into paint booth to view the spray path of the robot. There is room behind the robots to view. We are reviewing numerous guarding methods. We do have hard pins on the robots. What method do you suggest?
from Applied Manufacturing Technologies
Some plants are using video cameras mounted in the upper corner of the booth, near the ceiling to monitor their robot paths. These cameras are even controlled by a joystick in the “control room” to monitor different robots.
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When will R15.06 be modified to address new products such as ABB Robotics SafeMove and Fanuc Robotics DCS?
from Robotic Industries Association
The R15.06 which addresses the complete robot installation will not be revised until the work on the International Standard ISO10218-2 is complete (maybe late next year).
In the meantime, the committee has addressed using the new features allowed in the ANSI/RIA/ISO 10218-1-2007 standard with the publication of the Technical Report RIA TR R15.206-2008. The TR is available through the bookstore on this website.
The message is - if you are buying a new robot with some of the optional features offered it is ok to use them.
This will be a principle topic of discussion at next week's Robot Safety Conference in Indianapolis. I hope you can join us.
from ABB Inc.
There has been a Technical Report written by the RIA an registered with ANSI July 13, 2008 that addresses this technology and gives guidance for use until the 15.06 is updated. The document is named RIA TR R15.206-2008.
This document covers parts of the new safety technology available, some applications were not addressed in this Technical Report and will be addressed more completely in the upcoming revision of 15.06
If you have any questions please feel free to contact us.
Robin Schmidt ABB Inc.
robin.r.schmidt@us.abb.com
from Pilz Automation Safety L.P.
There is a short answer and a long answer. However please be assured that some of these new features can be used now. However there are capabilities that will not be addressed until ISO 10218-2 is completed, & rolled into R15.06.
SHORT: There is a technical report that will help with this: ANSI RIA TR R15.206. This document addresses using robots that meet ISO 10218-1 and complying with R15.06. ISO 10218-1 includes such new technology and the guide helps to make use of this new and optional robot technology.
LONG: The R15.06 committee is very active now. First we are addressing (and providing input to) ISO 10218-2 Integration of Robot Systems. Once ISO 10218-2 is adopted, the R15.06 committee will be taking both part 1 and part 2 of ISO 1018, to turn it all into the new R15.06. There are formatting issues, packaging issues, and even the possibility of providing a guide. These open issues will be addressed by the committee.
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I'm working on a project and need industrial robotics injury and fatality statistics. I'm having a hard time finding them, could you help me please.
from Robotic Industries Association
You are having a hard time finding them because they are not tracked separately from general industrial accidents. The good news is there are not that many. Industry, for the most part, does an excellent job of safeguarding industrial robots. Statistically speaking, they would be insignificant to the total number of industrial accidents each year, i.e. significantly less than 1 %.
from ABB Inc.
If I remember correctly OSHA keeps track of all the work related incidents.
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I'm looking at a Joint 1 safety limit system, in particular a retractable hard stop system. Was wondering if you knew of a company - or several - that makes these for a variety of robots - say for Nachi... Thanks!
from Robotic Industries Association
Adrian, have you tried "Find a Product"? There is a safety equipment category that brings up numerous listings and you can probably find something there. Or type "safety limit" in the box for "Search Our Site." I saw a few come up that way, too.
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Where can I find the governing document that determines what is an acceptable barrier, (conveyor, fencing, cabinets…) and protection level within the cell area but beyond the robot reach (including EOAT with load)?
from Reis Robotics USA, Inc.
A good source for this is our partner www.robotunits.com , 732-438-0500 asked for Juergen Roth They do safety fencing and specialized systems for robot barriers. if you need additional info please ask to sales@reisrobotics.com
from Pilz Automation Safety L.P.
The safety standard is ANSI RIA R15.06 - 1999. Although a revision will be starting soon, the existing standard contains details and useful information. If you need further assistance regarding safety requirements or in understanding safety standards, please feel free to contact Pilz Automation Safety, L.P. (www.Pilz.us) 734-354-0272, select technical support.
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I have been tasked with producing a procedure for "extracting a human that is pinned by a robot." Is there a best practice for this procedure? Anyone have guidelines or procedures that they are willing to share?
Thank you
Bob
from Stäubli Robotics
Most Staubli robot arms, as well as arms made by other companies, have a brake release selector switch and push button on the arm that can be used to release the brake on any single joint so that it can be moved by hand. A few models, such as our new Striclean arms, have the manual brake controls on a separate pendant which is typical attached outside of the robot enclosure.
from Banner Engineering Corp.
I'd start by dialing 911, also contact Fire and Rescue services to get some guidance as there may be instances where you may not want to remove the pinned person until professional help is available. For moving the robot contact the OEM.
Regardless I'd be interested in reviewing your final procedures.
from Reis Robotics USA, Inc.
Bob,
Most robot manufacturers have a brake release button, but you must be careful not to release the brake until it is 100% CLEAR as the arm weight could cause more damage if released in a "wrong position". Reis Robots have a 6D mouse option that is moveable from the teach pendant to the robot arm. As you know during duress the operator can move the robot in the wrong way, the 6D mouse lets the arm follow the motion of the operator taking away the "guess factor" as to +/- . See more at: direction.http://www.reisrobotics.de/us/ROBOTS/Robot+control.html
By the way it is very important to ensure complete safety perimeter guarding to reduce the possibility the operator can enter under auto run mode!
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I am looking at using color tinted UV filtering Plexiglas or Lexan in place of the standard wire cage with vinyl screens for our welding robots. The cage we want to replace with the Plexiglas or Lexan would be the same layout, height, gates, interlocks, light curtains maintained etc. Does section 5.1a of ANSI/RIA R15.06 restrict this or any other section. We have questions about 5.1a "be constructed to withstand operational forces" .
from Robotic Industries Association
ANSI/RIA R15.06 5.1a does not restrict this. The referenced clause simply means the guarding device must be correct for it's intended use. If it is meant to keep a person out, it has to be strong enough and secure enough to do that. If it is meant to keep parts in, it has to be strong enough, tall enough, etc. As for the environment, you might not want to use steel fencing in a highly salt corrosive atmosphere, or a photo-optic device where the sensing element is subject to being obstructed by overspray and the like.
from Pilz Automation Safety L.P.
I agree with Jeff's response. It may be used for guarding applications. If there is a possibility of a part, parts, scrap, or other potential impact to the guard, then it must be designed to contain these objects and still function properly. For example, shattering would be inappropriate and subject personnel to added hazards. The operational forces may be chemical in nature, such that the "cage" is subjected to fumes or other sources that may degrade the performance of the "cage".
Over the past few years, there have been studies about the use of polycarbonate type materials and their effective life. Increasingly machine providers / integrators are requiring inspection of such guards & their replacement if there is any damage. They also require replacement within X (differs) years, regardless of any visible damage.
If you select the guard and its materials, you are responsible to check, test, and ensure that the selection will work as anticipated throughout it lifecycle.
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