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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What are the height requirements, access hole size reqirements and height off the floor for robot safety fences?
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
These regulations are changing and it is best to reference the ANSI RIA 15.06 1999 regs. This is being revised and the new regs are avilable in draft from only but they do change stated restrictions.
Gary Bruner from WireCrafters LLC - Director of Production
gbruner [at] wirecrafters [dot] com (502) 363-6691
Using the current standard ANSI RIA 15.06 1999
Minimum Height is 55 inches
Distance from the Floor to bottom of Fence is a maximum of 12 inches
The size of the access hole depends on the distance of the fence from the hazard
The current standard is the process of being revised and my guess is the fence height and distance from the floor to bottom of the fence will be changing within the next year.
Lee Burk from Pilz Automation Safety L.P. - Manager, Training & Standards
l [dot] burk [at] pilzusa.com (734) 354-0272
Clause 11.1 f) calls out a maximum height off the floor of 0.3 m (12 inches) above adjacent walking surfaces. The minimum height to the top of the barrier can be no lower than 1.5 m, 60 inches).
For openning sizes and the rquired safe distances, refer to 10.4.2, Table 5.
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If I am replacing an obsolete robot in a cell that has single channel interlock guarding with a new robot do I have to upgrade to a two channel interlock system?
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
Reference RIA 15.06-1999. I believe the answer is the cell will need to be upgraded to current standards. Frommelt Safety would be more than willing to help. www.frommeltsafety.com
Barry Lipsman from Tapeswitch Corporation - Marketing Department
marketing [at] tapeswitch [dot] com (631) 630-0442
Please visit www.tapeswitch.com for a complete line of dual key trapped key interlocks or non-contact guards.
You can reach us directly at 1-800-234-8273. We look forward to hearing from you.
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What is a minimum fence height for a robotic cell
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
Depends on the regulatiuons in Australia. Reference AS 4024.1101—2006. These are the Australian Standard Safety of Machinery. Other codes exist for Europe and US.
Frommelt Safety offers many unique point of access guards in addition to ROBOGUARD fencing for perimeters. Please reference our web site at www.frommeltsafety.com.
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I have been involved in discussions with equipment suppliers recently regarding the requirements to limit robot motion. The discussion centers around not using any form of robot limiting device for a robot that can reach or extend beyond the perimeter fence of a working cell (maximum reach). The main argument in favor of this centers around the use of risk analysis methodology that results in the view that any fence line where no employees will be expected to be working in EXCESS of 2 hours in an 8 hour shift has an acceptable level of risk. This ruling would avoid the need to activate the Safe Robot Software or the installation of robot hardstops or axis monitoring.
Please advise if this approach would be acceptable in a US manufacturing environment.
Barry Lipsman from Tapeswitch Corporation - Marketing Department
marketing [at] tapeswitch [dot] com (631) 630-0442
We have several customers that utilize our pressure sensitive edge and bumper products for controlling physical perimeters would you be interested in visiting www.tapeswitch.com.
Lee Burk from Pilz Automation Safety L.P. - Manager, Training & Standards
l [dot] burk [at] pilzusa.com (734) 354-0272
Clause 8.2 of RIA 15.06 is very specific on this issue. "In no case shall the perimeter guarding be installed closer to the hazard than the restricted space." Unless your fencing is capable of restricting the robot motion to within its perimeter additional measures are required.
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Can more than one guard door be open at a time if I am jogging a robot with the teach pendant? Example: I open the front door and walk in with the pendant and am jogging the robot, an operator opens the back door. Does that door need to stop the robot?
John Baldiga from Eagle Automation - Service Manager
john [dot] baldiga [at] eagleautomation.com (248) 904-3802
No. The fence circuit would need to break if one, or both doors are open. Disabling the robot is not required if the fence is compromised twice.
If the operator enters the cell while you are jogging the robot, the operator would need to be holding a non-teaching enabling device.
These are simply an enabling (dead-man) switch, without the teach pendant.
Hope this helps
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We have some large workcells here with multiple entry points. At each entry point, there is a safety interlock key which can be removed and kept with the person entering. The key prevents automated motion in the event that someone else were to close the door and try to start the robot. One of our operators has questioned us on what is considered "with them". Does the key have to be in their pocket, in their hand, etc...? Can you recommend where I should look for information regarding this? Thanks!
Nicole Allison from Tapeswitch Corporation - Marketing Department
nallison [at] tapeswitch [dot] com (631) 630-0442
Safety interlock keys range in size and weight which might constrict the placement or way they are carried on aperson but our keys are durable heavy weight and strong. Would you like to visit www.tapeswitch.com to review their features.
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We are wondering what is the right way to label and incorporate cell entry loto to our robot cells. Have you seen anything that might help us out? Right now we place a lock on our safety switches at the door entry and that keeps the robot from starting in auto. We would appreciate any ideas on how to identify this information for our operators.
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com (937) 847-6200
Your current method sounds like you are locking out the control. The standard specifies that personnel enter the cell with the pendant or enabling device. Modern pendants have mode switches on the pendant which would prevent personnel other than the teacher from placing the system in auto. The safeguards should be interlocked so that the system can not operate in auto while the safeguard is active. Your lock out method would work for older controls which have teach/auto mode switch outside the cell.
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If I have a welding operation that is completely enclosed with interlocks, what should the distance be from the robatic arm + the part to the safety barrier? No teaching of the robot needs to be done.
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
That is dependent on many factors. 18" for a fixed barrier in the US.
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com (937) 847-6200
The 18 inch clearance is meant to avoid a pinch point between the robot and the barrier. The 18 in. distance is referenced between the operating space (programmed path) in slow speed control and between the resticted space in high speed APV. If the teacher can program from outside the safeguarded space and barrier, then the 18 in. is not necessary. The safety barrier should be sufficient to stop the robot if the restriced space extends beyond the barrier in order to safeguard the operator.
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Though I have asked this question before, I believe it deserves another round of attention. Currently in a workplace in Ontario Canada there are a variety of automation cells and Lifts that have no light curtains/safety matting/ to prevent access to the cell. Following teh train of thought that due diligence is proved by actions not words I have again asked the company to bring this Older architecture of robotic cell into compliance. Their response I believe, should be forthwith and the cells should be made to be brought into compliance. They will ( I am sure) provide the rehearsed speech about " grandfathering". Your thoughts and opinions are greatly appreciated.
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
Best practices would dictate that the Grandfathered cells while compliant to the standards from that time period should be brought into current standards as a matter of best practice. To my knowledge there are no regulations stating any differnt however I am not as familiar with the Canadian regulations/laws/rules and company specifications regarding this subject. If proper Guarding is required I hope you would consider Frommelt Safety Products line of automated barrier doors for these applications.
Nick Hunt from ABB Inc. - Product Support Manager
nick [dot] j.hunt [at] us.abb.com (248) 391-9000
Hello Andy,
Unfortunately, sometimes safety is only given visibility when something happens. If I understand your question, you are looking for consensus regarding the updating to current standards of old technology running in production. If that is the case then you certainly have my vote. After all, an injury from old equipment is still an injury; the person is still injured, and it affects the the company in the same way with the same liability.
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Is the norm ISO 13857 valid in the US?
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
RIA 15.06-1999 references safe distances which is similar if not the same as 13857. There are better ways to save space using different devices. See www.frommeltsafety.com
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In guarding robotic welding cells ANSI states, "Shall be constructed to withstand operational forces and environmental conditions." At a previous employer, only canvas material was used to cover outer cell. Is this considered to be adequate or is a solid (fencing or hard sheet material) required?
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (414)-362-3736
Mark:
I would say best practices would indicate that canvas is not an adequate means of standing up to "operational forces" due to the fact that an individual could easily push canvas out of the way to gain access to robot movement. Other sections of the document clearly define the specifications for perimeter guarding in regard to height distance etc. I would be willing to discuss my interpretation of the RIA 15.06 at your conveninece. I can be reached at eesson@ritehite.com
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (414)-362-3736
Mark:
I would say best practices would indicate that canvas is not an adequate means of standing up to "operational forces" due to the fact that an individual could easily push canvas out of the way to gain access to robot movement. Other sections of the document clearly define the specifications for perimeter guarding in regard to height distance etc. I would be willing to discuss my interpretation of the RIA 15.06 at your conveninece. I can be reached at eesson@ritehite.com
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Can we deploy an RJ2 Fanuc Robot w/single channel circuitry and still comply with RIA/ANSI standard? (ex. monitor robot estop and auto chain with safety PLC, conduct risk assessment)
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com (937) 847-6200
This is dependent on your Risk Assessment and the Risk Reduction Determination. Clause 9.5 of the Safety Standard outlines the circut performance required for the different risk reduction categories.
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