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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Can a Safety Light curtain be used to initiate cycle start of a machine after hand is removed from the light curtain? Machine will be located in Ontario Canada.
Lee Burk from Pilz Automation Safety L.P. - Manager, Training & Standards
l [dot] burk [at] pilzusa.com (734) 354-0272
CSA Z434-03 does not allow the use of presence-sensing devices (PSDI) for initiation. Refer to clause 10.9.3.
Roberta Nelson Shea from Safety Compliance Services, LLC - President
robertanelson [at] shea [dot] us (248) 719-8242
At the present time, CSA Z434 prohibits PSDI.
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Is it possible to safely have a person welding on the robot at the same time it is operating? Could the robot be programmed to stop while a smaller weld is completed and then operator could restart?
Lee Burk from Pilz Automation Safety L.P. - Manager, Training & Standards
l [dot] burk [at] pilzusa.com (734) 354-0272
Yes, it is but you cannot rely simply on the robot program for the stop. Power must be removed from the robot and end of arm tooling during the process. In the case the stop must meet the requirements of "Control Reliable" performance.
Roberta Nelson Shea from Safety Compliance Services, LLC - President
robertanelson [at] shea [dot] us (248) 719-8242
Please clarify the situation. You want a person to be welding on/at the robot while it is welding? Or, you want a person to be manually welding near the robot while it is welding? If so, how close? Is there a perimeter guard that separates the person and the robot?
Please describe the scenario better, so that a complete response can be provided.
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I am working on my Masters in Advanced Safety Engineering and was writing a paper on hazard analysis and risk assessments. Where would I find information on robotic incidents due to improper setup or safety system failures with robotic systems or human error? I wanted to make a case toward the benefit of risk reduction using the Preferred Method and the Risk Assessment Methodologies.
Jeff Fryman from Robotic Industries Association - Director, Standards Development
jfryman [at] robotics [dot] org (734) 994-6088
I probably can't help you out here. There is no tracking of robot incidents. The OSHA website does have reports of industrial accidents, but not categorized by type of machine, or cause of the accident. If you were to find some information, the major cause of the incidents is failure to follow established requirements for safety, including the error of the person injured. Failures of the safety system are extremely rare, as are errors in setting them up.
If you mean "prescribed" method in your statement about making a case, you need to know that it is NOT the preferred method (risk assessment is) and that it will not be in the next edition of R15.06. Risk Assessment will be required, by whatever methodology you choose.
Roberta Nelson Shea from Safety Compliance Services, LLC - President
robertanelson [at] shea [dot] us (248) 719-8242
Are you in the UAB program?
I do not know of any data that would be helpful in your paper. I am not aware of any incidents where either the prescribed method (not preferred) or the risk assessment method have been used.
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Section 4.11 refers to hard stops on the major axis. For large warerhousing gantry robots in the 50 meter length catagory this is impractical and unsafe. What are the exceptions allowed? The one listed, refering to major rotary axis of 360 degrees seems to excuse any and all articulated robots.
Jeff Fryman from Robotic Industries Association - Director, Standards Development
jfryman [at] robotics [dot] org (734) 994-6088
The requirement for hard stops is to provide a means for the user to establish the "restricted space"; that area where the robot's motion is physically restricted. Perimeter guarding (fence) may not be placed any closer to the hazard than the restricted space. This assures the safety of anyone outside this area from injury due to robot motion. The example you cite is the case where a rotary axis is designed to move 360 degrees (or more). In this instance placing a hard stop on the axis would prevent the normal operation of the robot and the the total or maximum area swung by the robot at the full (or restricted) extension must be safeguarded, i.e. inside the "restricted space".
Lee Burk from Pilz Automation Safety L.P. - Manager, Training & Standards
l [dot] burk [at] pilzusa.com (734) 354-0272
I am not sure why you are indicating that mechanical stops on the major axis are impractical or unsafe. They are necessary if obstructions to a full 360 degree rotation would crate pinch points or entrapment. If guarding or other structures prohibit 360 degrees of motion, articulated robots are not exempt.
Lacking a mechanical stop, how would you prevent overtravel of the robot and associated hazards?
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The case is for a robot with three axis, and the average speed of the axis is 2m/s The length of movement outside the machine is 1m horizontal, and 950mm vertical from 2300mm to 1350mm from the floor.
Why is necessary to ensure that the robot motion area is completely guarded off from human interference?
Lee Burk from Pilz Automation Safety L.P. - Manager, Training & Standards
l [dot] burk [at] pilzusa.com (734) 354-0272
2 m/s is a fairly high speed. Anyone struck by a robot moving at such speed is likely to be seriously injured, especially so if there are sharp edges or protrusions moving at the end of the arm. The range of motion you specified would easily strike an individual in the upper body or head.
The issue is human injury, not interference.
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I have been given robot risk assessments by an integrator using a methodology that varies from the method found in ANSI/RIA R15.06-1999. The methodology has an estimation of risk. However, the outcome of the estimation of risk is a numeric number that does not prescribe any safeguarding. Does a methodology have to prescribe safeguarding based on estimation of risk to meet Clause 9 requirements? How do I test the methodology to ensure it meets ANSI/RIA R15.06-1999?
Jeff Fryman from Robotic Industries Association - Director, Standards Development
jfryman [at] robotics [dot] org (734) 994-6088
The R15.06 standard says that any methodology of risk assessment that gives "equivelent" results as the method suggested in Annex C is ok. Others who have faced this question run a comparative risk assessment using both methodologies and compare the results. Of course you will have to make some decisions on what appropriate safeguarding is for the number you obtain. That is the advantage of the R15.06 methodology, we equate it to safety control system performance.
Lee Burk from Pilz Automation Safety L.P. - Manager, Training & Standards
l [dot] burk [at] pilzusa.com (734) 354-0272
The Hazard Rating Number (HRN) system provides a numeric value representing severity of risk. This is useful for determining relative risk for a number of hazards and prioritization of the application of protective measures. The result cannot be directly converted to the risk categories of R15.06.
The criteria from the HRN method can be evaluated to determine the required robot risk reduction category. Severity and frequency of exposure are directly translatable. In the HRN method, likelihood of occurrence (LO) must be translated to provide the possibility of avoidance factor used in the robot assessment. You can approximate possibility of avoidance, for instaqnce, by assuming that an LO less than 50 / 50 is equivalent to P1.
The method described above was used to select EN ISO 13849-1 perfromance levels, PLr in the examples you were provided.
Roberta Nelson Shea from Safety Compliance Services, LLC - President
robertanelson [at] shea [dot] us (248) 719-8242
It is the responsibility of the entity performing the risk assessment to ensure that the methodology arrives at the same results as would happen if the R15.06 methodology were used. Your integrator needs to explain how their method has been validated to be equivalent to R15.06.
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What are the differences between ANSI RIA R15.06 - 1999 and R2009?
Jeff Fryman from Robotic Industries Association - Director, Standards Development
jfryman [at] robotics [dot] org (734) 994-6088
None! The document was simply "reaffirmed" to keep it current under the ANSI procedures.
A new version is expected out later this year, preliminary drafts are available on the website.
Lee Burk from Pilz Automation Safety L.P. - Manager, Training & Standards
l [dot] burk [at] pilzusa.com (734) 354-0272
The standards was simply reaffirmed in 2009. There are no differences.
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What materials can robot hard stops be made from?
Jeff Fryman from Robotic Industries Association - Director, Standards Development
jfryman [at] robotics [dot] org (734) 994-6088
Any material that has the strength sufficient to physically stop the robot at full rated load and speed. Typically steel has been the choice.
Lee Burk from Pilz Automation Safety L.P. - Manager, Training & Standards
l [dot] burk [at] pilzusa.com (734) 354-0272
Stops can be made of any material that possesses the mechanical strength, rigidity, and durability to physically stop the robot motion.
Roberta Nelson Shea from Safety Compliance Services, LLC - President
robertanelson [at] shea [dot] us (248) 719-8242
Hard stops also must not create a hazard. So if the robot impacts the hard stop, the hard stop must stop the robot and must also not shatter. If the hard stop were to shatter, these flying pieces would be dangerous.
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Scenario: 6 axis robot mounted on a X direction base axis/ servo track. Will the safety spec allow linear motion of the servo track to exceed 1600mm/sec considering that the robot itself will not be moving; only the track will move?
Lee Burk from Pilz Automation Safety L.P. - Manager, Training & Standards
l [dot] burk [at] pilzusa.com (734) 354-0272
There is nothing in the standards to prevent this. You must perform a risk assessment to determine the hazards and risk and apply appropriate safeguards in the cell.
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What is the standard for safety fencing on a robotic cell. Is 6'8" fencing 1 foot off the ground meeting the safety standard?
Steve Diebold from WireCrafters LLC - President
sdiebold [at] wirecrafters [dot] com (800) 626-1816
Compliance with standard depends on size of openings in the mesh, and distance between the guard and the equipment.
What size are the openings in the guard?
How far away from the equipment (especially movign parts) is the guard?
Lee Burk from Pilz Automation Safety L.P. - Manager, Training & Standards
l [dot] burk [at] pilzusa.com (734) 354-0272
R15.06 requires a barrier guard to be no more than 0.3 m (12 inches) above adjacent walking surfaces with the top of the guard no more than 1.5 m (60 inches) above the walking surfaces unless additional safeguarding devices are installed to prevent access to the hazards. - Clause 11.1 f)
Roberta Nelson Shea from Safety Compliance Services, LLC - President
robertanelson [at] shea [dot] us (248) 719-8242
The standard states the minimum requirement with also a condition. Perimeter guarding must start no higher than 12" above the ground or adjacent walking surface. From what you wrote, your perimeter guard complies with this requirement. Next, the height of the guard must be at least 60" (five feet) above the ground or adjacent walking surface. It sounds like your perimeter guard meets this requirement.
One last condition... The perimeter guard must be higher if there is a possibility of parts (or other) to fly. This can happen if there is a problem with the end effector or if suction is being used and there is a loss of air. If the perimeter guard needs to retain parts, then it is required to be as high as needed to "capture" that part and it must be strong enough to stop the part. I do not know if your perimeter guard meets these requirements.
There are issues about the opening sizes in the guarding & distances to hazards, but insufficient information to comment.
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Thank you for your services. I will suggest you are saving lives with this service!
Do the Robotics Cell CAN/CSA Z434-94 (reaffirmed 2000 ) Industrial Robots and Robot systems General safety Requirements have any "Grandfather" clause anywhere that would negate a corporation from having to adhere to 6.2.4?
Thank you in advance
Lee Burk from Pilz Automation Safety L.P. - Manager, Training & Standards
l [dot] burk [at] pilzusa.com (734) 354-0272
The current standard is Z434-03. Clause 2.3 contains the provisions for exclusion.
"Robots that are rebuilt or re-deployed shall comply with the Standard in effect on the date of original manufacture. This does not preclude the addition of safety enhancements of this Standard. Rebuilt robots are those that are overhauled and repaired to their original condition and to the manufacturer’s original or current specifications for that model robot, including software changes. This includes overhaul and repair, reconditioning, refurbishment, or restoration. Re-deployed robots are those that are physically moved and only undergo changes to the task program and end-effector (EOAT)."
Roberta Nelson Shea from Safety Compliance Services, LLC - President
robertanelson [at] shea [dot] us (248) 719-8242
There are no "grandfathering" clauses in either R15.06 or Z434. There are requirements about applicability and descriptions of changes that are required for existing robots and/or robot systems.
There is no clause 6.2.4 in CSA Z434.
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Do we have to isolate the power to the servo motors while we are in the robot cell work area?
Lee Burk from Pilz Automation Safety L.P. - Manager, Training & Standards
l [dot] burk [at] pilzusa.com (734) 354-0272
Without more detailed information the answer is yes, unless doing so would create a hazard. The robot can only move at slow speed, 250 mm/sec., and an enable pendant must be used.
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