How To Understand Robot Safety Standards

As robotics continues to advance at an exponential rate, ensuring the safety of robots and the humans interacting with them has become a critical priority. Whether robots are used in industrial environments, healthcare, autonomous vehicles, or even in consumer products, safety standards are essential to protect both operators and bystanders. This article delves into the importance of robot safety, the key standards that guide the development and use of robots, and how to navigate and implement these standards effectively.

The Importance of Robot Safety

Robots are increasingly becoming an integral part of various industries, such as manufacturing, logistics, healthcare, and even service industries. They are designed to perform tasks that are repetitive, dangerous, or require precision. While the potential benefits of robotics are immense, the safety of humans around these machines is of paramount importance. Ensuring robots do not pose a risk to human life, health, and the environment is essential to their success and acceptance in society.

Types of Robot Safety Hazards

1. Mechanical Hazards: These are the dangers posed by moving parts of the robot. They can include pinching, crushing, or being struck by parts of the robot that are in motion. These hazards are especially dangerous in industrial settings where robots work alongside human operators.
2. Electrical Hazards: Robots rely on electrical components for operation. Malfunctions, exposed wiring, or power surges can cause electrical shocks, fires, or other serious accidents.
3. System and Software Failures: Robot systems often rely on complex algorithms and software to function correctly. Software malfunctions or system crashes can lead to dangerous unintended actions, such as misinterpreting sensor data or failing to stop during an emergency.
4. Environmental Hazards: These involve conditions that could affect the robot's operation, such as extreme temperatures, wet or slippery floors, or the presence of toxic substances in the environment. These conditions could lead to robot malfunction or failure.
5. Human Interaction Hazards: Robots, particularly collaborative robots (cobots), interact directly with human operators. The risk of injury or accidents increases if the robot fails to properly detect human presence or movement, or if the human operator does not follow safety procedures.

Understanding these hazards is the first step in ensuring the safety of both robots and humans in shared environments.

Global Robot Safety Standards

The development and use of robots are guided by a set of standards that ensure the machines are designed, built, and operated safely. Various international and regional standards organizations have put forth guidelines and requirements for robot safety. Below are some of the most significant safety standards.

1. ISO 10218: Industrial Robots -- Safety Requirements

One of the most widely recognized and adopted robot safety standards is ISO 10218. This standard specifically covers the safety requirements for industrial robots, ensuring that robots can be used in manufacturing and production environments without putting workers at risk.

Key Components of ISO 10218:

• Risk Assessment: This part of the standard requires a thorough risk assessment to be conducted before a robot is introduced to a working environment. The risk assessment should consider both the potential for injury to human workers and the overall safety of the system.
• Safety Requirements for Robots: The standard outlines the minimum safety requirements that industrial robots must meet. These include ensuring that robots have adequate emergency stops, safety-rated control systems, and guarding to prevent contact with human operators.
• Human-Robot Interaction: A significant part of ISO 10218 is dedicated to human-robot interaction. It requires that robots be equipped with safety features such as sensors to detect human presence and automatic stopping mechanisms in the event of an emergency.
• Maintenance and Inspection: ISO 10218 also addresses maintenance protocols to ensure robots continue to operate safely throughout their lifecycle. Regular checks, audits, and updates to safety systems are necessary for continued compliance.

ISO 10218 is crucial for companies that employ robots in environments where human workers are present. It ensures that the robots' movements and actions are safe and predictable, reducing the risk of accidents.

2. ISO/TS 15066: Collaborative Robots -- Safety Requirements

ISO/TS 15066 is a standard specifically for collaborative robots (cobots), which work alongside humans in a shared workspace. Cobots are designed to be more flexible and safer for human interaction than traditional industrial robots, but they still pose potential risks if not properly designed or operated.

Key Components of ISO/TS 15066:

• Maximum Allowable Force: One of the critical aspects of cobot safety is the level of force exerted by the robot when making contact with a human. ISO/TS 15066 specifies maximum allowable force and pressure to minimize the risk of injury.
• Safety-rated Design Features: Cobots must be designed with safety-rated features such as soft edges, padded surfaces, and sensors that detect human presence. Additionally, the standard mandates that robots must be able to slow down or stop if they detect human contact or proximity.
• Human Protection Mechanisms: This includes both active and passive protective mechanisms, such as force-limited joints and emergency stop systems. The robot should be able to detect human presence and adjust its speed or movement accordingly.
• Environmental Considerations: The working environment for cobots must also be designed to minimize hazards. The floor should be clean and free of obstacles, and there should be no sharp objects or chemicals that could endanger the human operator.

The aim of ISO/TS 15066 is to ensure that cobots are designed with both efficiency and safety in mind, making them a viable and safe option for workplaces where human interaction is frequent.

3. IEC 61508: Functional Safety of Electrical/Electronic/Programmable Electronic Systems

IEC 61508 is an international standard for the functional safety of electrical, electronic, and programmable electronic systems. It is applicable to robots that rely on electronic control systems to function. The standard ensures that these systems are safe and capable of handling faults without causing harm to human operators or the environment.

Key Components of IEC 61508:

• Safety Integrity Levels (SILs): The standard defines different levels of safety, referred to as SILs, ranging from SIL1 to SIL4. SIL4 represents the highest level of safety and is required in applications where failure could result in significant harm to humans or the environment.
• Redundancy and Fault Tolerance: The standard emphasizes the importance of redundancy and fault-tolerant design. In the case of a system failure, the robot's control system must be able to take corrective action to prevent harm.
• Safety Lifecycle: IEC 61508 outlines a safety lifecycle that includes the development, operation, maintenance, and decommissioning of robotic systems. Each phase of the lifecycle must consider safety, and the robot's safety features must be validated at each step.
• Risk Reduction: IEC 61508 requires that risks associated with robot operations be reduced to an acceptable level. This involves identifying hazards, assessing risks, and implementing safety measures to mitigate those risks.

This standard is particularly important for robots used in critical applications, such as medical robots, autonomous vehicles, and industrial robots in hazardous environments.

4. ANSI/RIA R15.06: Robot Safety in Industrial Settings

The American National Standards Institute (ANSI) and the Robotic Industries Association (RIA) developed the R15.06 standard for robot safety in industrial environments. This standard is commonly used in the United States to ensure that industrial robots operate safely.

Key Components of ANSI/RIA R15.06:

• Safety Requirements for Robot Systems: Similar to ISO 10218, R15.06 covers the safety requirements for robot systems, including hazard analysis, risk assessment, and safety features such as emergency stops and protective barriers.
• Robot System Performance: This part of the standard specifies the performance requirements for robot systems, ensuring that they operate within defined safety parameters and can handle various contingencies.
• Training and Procedures: R15.06 requires that operators and maintenance personnel be adequately trained in the safe use and maintenance of robots. It also includes guidelines for developing safety protocols and emergency procedures.

This standard is vital for manufacturers and companies in the United States that rely on robots in production lines, assembly plants, and other industrial settings.

Implementing Robot Safety Standards

Understanding and implementing robot safety standards can be a complex process, but it is essential for minimizing risk and ensuring a safe working environment. Here are some practical steps to follow:

1. Conduct a Risk Assessment: Before introducing robots into a workplace, perform a thorough risk assessment to identify potential hazards and determine the necessary safety measures. This includes assessing both physical and environmental risks, as well as potential system failures.
2. Design and Select Robots with Built-in Safety Features: Choose robots and systems that meet or exceed relevant safety standards. Ensure that they are equipped with sensors, emergency stops, and other protective mechanisms.
3. Establish Safety Protocols and Training: Develop and implement safety protocols that address the operation, maintenance, and emergency procedures for robots. Additionally, ensure that all employees are properly trained on these protocols.
4. Regularly Inspect and Maintain Robots: Robot safety requires continuous monitoring and maintenance. Conduct regular inspections to ensure that robots are operating safely and that all safety features are functioning correctly.
5. Stay Updated with Evolving Standards: As technology advances, robot safety standards will continue to evolve. It's crucial to stay informed about updates and revisions to relevant safety standards to ensure compliance and safety.

Conclusion

Robot safety is an essential consideration for industries that integrate robots into their operations. By adhering to recognized safety standards like ISO 10218, ISO/TS 15066, IEC 61508, and ANSI/RIA R15.06, companies can reduce risks and ensure a safe working environment for both humans and robots. Understanding these standards and their implications is key to creating a culture of safety and achieving the full potential of robotic technology.

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