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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We just installed a paint robot in our new lab. We have followed RIA guidlines for install and use in a Lab environment. Is there a agency that inspects an d will certify that we are in compliace operating in a lab using the robot?
Wade Hickle from Motoman Robotics - Sr. Manager Project Solutions Group
wade [dot] hickle [at] motoman.com (937) 440-2615
The robot standard addresses robot installation and safeguarding or the robot, but does not address hazardous environments. NFPA70 addresses Class 1 Division 1 enrionments, and there are can be addtional local government requirements associated with this type of install.
I would recommend contacting the local electrical inspector for guidance.
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I'm a student writing a paper for school on robot safety devices and what I really need is information on applications of robot safety devices in industry. For example John Deere uses safety mats on all machines and has reduced injuries by 50%. Do you guys have any information like that?
Wade Hickle from Motoman Robotics - Director Project Solutions Group
wade [dot] hickle [at] motoman.com (937) 440-2615
This type of data is generally held within the organizations themselves. I would recommend that you contact safety product companies such as Banner, Sick, ... etc. for this type of data. While they may not be able to provide specific, they may be able to share industry trends.
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
Jacob:
Please visit www.frommeltsafety.com and navigate to Light Curtain Alternatives under the Machine Guarding Header. By the way John Deere uses our Automated Barrier Doors on their robotic work cells becasue it increases productivity creates an inherently safer environment for the operator/technician and saves floor space.
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What speed do you recommend for robot teaching?
James Perlberg from Terra Community College - Professor of Robotics/Mechatyronics
jperlberg01 [at] terra [dot] edu (419) 559-2415
Whatever speed provides the safest control of the robot path/position. There is no one universal speed for all applications.
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com (937) 847-6200
The safety standard limits slow speed control to 250 mm/sec (10 in/sec). Robot manufactures limit to this slow speed and you often have slower speed settings when you are jogging close to obstables.
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Do robotic security fences have to be yellow? If not, what colors are acceptable?
Jason Jamiel from KC Robotics, Inc. - Service Manager & Senior Applications Engineer
jjamiel [at] kcrobotics [dot] com (513) 860-4442
No, the color of a fence should'nt matter unless the facility it is in requires it. If you are welding, then the shading of the weld drapes should be an approved shade for the process.
Neil Wiebe from Automation Guarding Systems - Partner
neil [at] ags [dot] us.com (586) 991-6138, x103
you can have any color you like we do it all the time
Mark Lewandowski from Procter & Gamble - Machine Controls Technology Leader
lewandowski [dot] ml [at] pg.com (516) 634-9011
There is no requirement for the color of the barrier guards in the robot or ANSI guarding standards. You can find the specific barrier guard requirements in section 11.1 of the RIA 15.06-1999 standard.
Also, in the ANSI B11.19 standard for safeguarding it states that guards should be constructed to provide visibility of the hazard area. In the comments section they state the the color of the guarding should be darker than the area being observed to enhance visibility. In most cases, using yellow for guard fencing does not provide the required visibility to the area.
Frank Claude from Dunwoody College of Technology - Principle Instructor
fclaude [at] dunwoody [dot] edu (612) 374-5800, x8206
The RIA Safety Standard does not specify a color for fences. It is a matter or choice and may come down to the illusion of visibility. Taking the same situations, it seems as though objects inside of a yellow fence are more visible. Objects inside an identical installation using a black fence seem more difficult to see.
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
The color as specified by the RIA 15.06 1999 states black panels and yellow posts but this is not a requirement rather a suggestion. So long as it meets and/or exceeds the specification sset forth for imapctability and size requirements you should be fine. Frommelt Safety would be happy to help you through the process. Please call 800-553-5560 for more information or visit frommeltsafety.com
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If a Robot Cell is modified by adding a new load station, does the safety for the entire cell need to be updated to the latest standards?
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
As the rules are written, yes - the entire safety system would have to be updated. Our Regional Sales Manager would be happy to help. If you would like, please go to frommeltsafey.com and either call 800-553-5560 or send us an e.mail safetyinfo@ritehite.com.
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I have a Motoman k6sb robot. After progamming, when I change the mode to play, under the screen it shows "UNDER SAFETY SPEED". What does it mean? How can I solve it?
Wade Hickle from Motoman Robotics - Sr. Manager Project Solutions Group
wade [dot] hickle [at] motoman.com (937) 440-2615
That's a special run mode on ERC:
Safety speed mode keeps robot velocity to no more than 25% of maximum speed
and tool instructions are executed. This mode is recommended when testing new
jobs.
1.) Press PLAY.
2.) Press SPEED ADJ (F1).
3.) Press SAFETY SPD (F5).
4.) Press START.
To release:
Note: Releasing a special playback mode returns the system to normal playback.
The CRT will display "all reserved modes have been released".
1.) Press PLAY.
2.) Press RELEASE (F5).
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Is there a simple print calling out the specific protection requirements for a welding robot? We have a customer with a free standing unit with no protection at all!
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
Rick: Please reference the RIA 15.06 standards. It may not be simple but it is the best place to start.
Frommelt Safety also has a Regional Sales Manager that would be able to come in and provide some guidence as well. He is located in St Louis MO. Please check out our web site and let us know if you would like us to contact you by filling out a request for more information or sending us an e.mail.
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An employee goes into a welding robot w/ both interlocked doors open and teach pendant in his exclusive control at all times. Pendant is not turned "on" or E-stopped, but simply is in his control. If he is doing things inside like changing weld tips, clearing jammed weld wire, cleaning the weld nozzle, changing wire, etc. is this adequate from a lockout standpoint?
Jason Jamiel from KC Robotics, Inc. - Service Manager & Senior Applications Engineer
jjamiel [at] kcrobotics [dot] com (513) 860-4442
As long as your employee is doing "general" maintenance or programing, and he is the only one in the robots maximum envelope, all that is required is a single point of control (teach pendant). If someone else is in with him, then a remote e-stop will be needed. Hope this helps!
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With regards to robotic guarding, there are the ANSI R15.06-2012 standards (American), the CSA Z432-03-2008 standards (Canadian), and the ISO 10218-2 standards (International). ANSI requires a max opening of 7" from floor and a minimum height of 55". CSA requires a maximum opening of 6" from floor and a minimum height of 72". ISO requires a max opening of 7" from floor and a minimum height of 55". Would you know if these are correct statements? I am looking to ensure that our standard guard will meet safety requirements anywhere in the world.
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
The best bet is to reference the EN ISO 10218 1&2 as the new RIA code (US) is heavily basing its regs on that document as is the CSA standards. You should also use your own common sense and internal corporate standards as checks and balances. Please feel free to contact Frommelt Safety for any of your requirements.
Mike Kunkle from MEK Consulting - Owner
mekconsulting [at] comcast [dot] net (717) 578-9875
Anthony,
Those statements are correct. If you want to make sure that your fencing meets world wide requirements you would need to meet the CSA requirements, as the ANSI and ISO requirements are max and min. 6" max and a minimum height of 72" will satisfy all requirements.
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Do I have to use clear lexan to guard a robot or can I use a mesh metal (e.g. 1"x1" mesh) to do the same thing?
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
An approved wire mesh adhering to the RIA specifications is allowed.
Gary Bruner from WireCrafters LLC - Director of Production
gbruner [at] wirecrafters [dot] com (502) 363-6691
Woven or Welded mesh are both acceptable and widely used in the robotics industry. There are several factors that would come into play to determine what would be the best fit for your application... such as Height of Hazard area, Height of Protective Structure, Horizontal Safety Distance to Hazard.. to name a few.
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Can a robotic machine be unjammed or cleaned without being locked out if the interlocked access doors are kept open during this process?
Eric Esson from Frommelt Safety Products - National Sales & Marketing Manager
eesson [at] ritehite [dot] com (262) 574-1126
Best practices would indicate that you lock out for maintenance purposes. The door could be inadvertently closed allowing the process to start during the dejamming or cleaning process.
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Do I still need to provide 18" of restricted space between the max. travel of the robot/EOA tooling and the plexiglass guarding?
Chris Anderson from Motoman Robotics - Technology Leader - Thermal Products
chris [dot] anderson [at] motoman.com (937) 847-6200
The 18 inches of cleanance between max. travel and guarding is required when personnel have to be in the inside the safeguarded space for teaching (10.7.7) and the robot supports high speed APV (10.8.5).
If your robot is limited to slow speed, then the 18 in clearance applies to the operating space which is the volume used by the robot during its program.
If the plexiglass is clear and personel do not enter the safeguarded space to program, then the clearance requirement does not apply.
You should set soft limits of the arm to stop before contacting the guarding.
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