Robot consideration of robotic

operation
Presented by
Mohammed Amir y
110021101095

ROBOT SAFETY

OBJECTIVES:

BE ACQUAINTED WITH ROBOITIC SAFETY.

UNDERSTASND SFETY STANDARD.
RECOGNISE SAFETY RELIABILITY.
BE FAMILIAR WITH HUMAN FACTOR ISSUES.
BE AWARE OF SAFETY SENSORS AND MONITORING.
REALIZE SAFEGAURDING.
PERCEIVE THE IMPORTANT FACTORS OF TRAINING.
APPREHEND SAFETY GUIDELINES.
UNDERSTAND DEFINITIONS.

SAFETY: METHOD AND TECHNIQUE USED FOR AVOIDING ACCIDENTS.

INCLUDES THE USUAL CONSIDERATIONS OF MAN, MACHINE AND

WORKSTATIONS, ENVIRONMENT, AND THE INTERDFACE
BEHAVIOUR, BUT IT MUST ALSO CONSIDER SOFTWARE.

ROBOTS AND CONVENTIONAL MACHINERY

THREE MAJOR DIFFERENCES BETWEEN ROBOTS AND CONVENTIONAL

MACHINERY CAN BE IDENTIFIED THAT ARE CONCERN OF SAFETY PERSONNEL.
SPEED OF MOVEMENT.
PREDICTABILITY OF MOVEMENT.
HAZARD ZONES.

IN CONVENTIONAL MACHINERY HAZARD ZONES MAY BE DIFFICULT TO

RECOGNIZE, BUT ARE FIXED WITH TIME.

ALSO THE MAIN DIFFERENCE BETWEEN CONVENTIONAL MACHINERY AND

ROBOT IS THAT A ROBOT CAN BE :
PROGRAMMED TO DO DIFFERENT JOBS.
REACT TO CHANGES IN THE PROCESS, EVEN MAKING DECISIONS FROM A
LIMITED NUMBER OF CHOICES.

SAFETY ENGINEERING SHOULD BE APPLIED TO ROBOT SAFETY,

PARTICULARLY IN THE HUMAN FACTORS ASPECTS AND SYSTEMS SAFETY
APPROACHES.

ROBOT SAFETY MUST INCLUDE THE USUAL CONSIDERATIONS OF MAN,

MACHINE AND WORKSTATIONS, ENVIRONMENT, AND THE INTERFACE
BEHAVIOR, BUT IT MUST ALSO CONSIDER SOFTWARE

CAUSES OF ACCIDENTS
ENGINEERING DEFICIENCY
LACK OF PROPER PROCEDURES
INADEQUATE PROGRAMMING

EMERGENCY STOP SWITCHES MUST APPEAR ON THE

CONTROL PANEL AND ALSO BE ADDED TO THE
PENDANT USED IN THE TEACH MODE WHERE THE
OPERATOR OR PROGRAMMER MAY BE MOVING IN THE
ROBOTS WORK ENVELOPE.

COMPREHENSIVE INSTRUCTION AND OPERATION

PROCEDURES MUST ALSO BE INCORPORATED
THROUGH TRAINING PROGRAMS.

SAFETY STANDARDS

SAFETY IS AN IMPORTANT CONSIDERATION IN INSTALLING,

PROGRAMMING, OPERATING, AND MAINTAINING ROBOT SYSTEMS.

SAFETY CAN ALSO BE CONSIDERED AS A JUDGMENT OF THE

ACCEPTABILITY OF DANGER, WHERE DANGER IS THE COMBINATION
OF HAZARD AND RISK.

HAZARD IS DEFINED AS INJURY PRODUCER, AND RISK IS DEFINED AS

THE PROBABILITY THAT AN INJURY WILL OCCUR.

THE CAUSES OF EMPLOYEE INJURY IN ROBOTIC ENVIRONMENT

INCLUDES:
PARTS OF THE BODY BEING CAUGHT.
BEING STRUCK BY A PART OR ROBOT GRIPPER.
FALLING FROM THE EQUIPMENT OR STRUCTURE.
SLIPPING OR TRIPPING ON WALKING OR WORKING SURFACES.
EXPOSURE TO DANGEROUS LEVELS OF HEAT OR ELECTRICITY
EXCESSIVE PHYSICAL STRAIN

SAFETY STANDARDS ARE VERY IMPORTANT IN THE WORKPLACE. ALL

THE PROFESSIONAL ASSOCIATIONS HAVE DEFINED THE FOLLOWING
PRIORITIES FOR ELIMINATING HAZARDS.
ELIMINATE THE HAZARD THROUGH THE MACHINE DESIGN
STAGE.
APPLY SAFEGUARDING TECHNOLOGY.
USE WARNING SIGNS AND LABELS.
TRAIN AND INSTRUCT THE WORKER, PROGRAMMER, AND
MAINTENANCE PERSONNEL.
PRESCRIBE PERSONAL PROTECTIVE EQUIPMENT AND DEVICES.

HUMAN FACTOR ISSUES

HUMAN FACTOR(ERGONOMICS) ISSUES OR ENGINEERING IS THE STUDY OF THE

HUMAN-MACHINE INTERACTION AND IS DEFINED AS AN APPLIED SCIENCE THAT
COORDINATES THE DESIGN OF DEVICES, SYSTEMS AND PHYSICAL WORKING
CONDITIONS WITH THE CAPACITIES AND REQUIREMENTS OF THE WORKER.

A MACHINE OR ROBOT SYSTEM DESIGNED WITH POOR ERGONOMICS WILL BE

UNCOMFORTABLE AND TIRING TO USE, MAY EVEN BE DANGEROUS.

BESIDES THE SIZE OF A ROBOTS WORK ENVELOPE, ITS SPEED, ITS PROXIMITY
TO HUMANS, AND INTERACTION WITH OTHER MACHINERY, MANY OTHER
FACTORS SHOULD BE CONSIDERED AND INVESTIGATED SUCH AS:
THE LAYOUT OF CONTROL PANELS.
TEACH-PENDANT ACCURACY.
PERSONNEL TRAINING
BARRIER GUARDS.
SAFETY DEVICES.
INTERLOCKS.
WARNINGS

IN ADDITION HUMAN FACTOR ISSUES SHOULD INCLUDE EVALUATION OF A

ROBOT WORKSTATIONS WHEN AN OPERATOR ENTERS THE WORKSTATIONS
FOR MAINTENANCE, PROGRAMMING, AND THE LIKE.

SAFETY SENSORS AND MONITORING

SAFETY MONITORING INVOLVES THE USE OF SENSORS TO INDICATE

CONDITIONS OR EVENTS THAT ARE UNSAFE OR POTENTIALLY
UNSAFE.

THE OBJECTIVE OF SAFETY MONITORING INCLUDES NOT ONLY THE

PROTECTION OF HUMANS WHO HAPPEN TO BE IN THE CELL, BUT
ALSO THE PROTECTION OF THE EQUIPEMENT IN THE CELL.

THE SENSORS USED IN THE SAFETY MONITORING RANGE FROM THE

SIMPLE LIMIT SWITCHES TO SOPHISTICATED VISION SYSTEM THAT
ARE ABLE TO SCAN THE WORKPLACE FOR INTRUDERS AND OTHER
DEVIATIONS FROM THE NORMAL OPERATING CONDITIONS.

GREAT CARE MUST BE TAKEN IN WORKCELL DESIGN TO

ANTICIPATE ALL POSSIBLE MISHAPS THAT MIGHT OCCUR DURING
THE OPERATION OF THE CELL, AND TO DESIGN SAFEGAURDS TO
PREVENT OR LIMIT THE DAMAGE RESULTING FROM THESE
MISHAPS.

LEVELS OF ROBOT SAFETY

THE NATIONAL BUREAU OF STANDARDS DEFINES THREE LEVELS OF

SAFETY SENSOR SYSTEMS IN ROBOTS.

LEVEL 1 --- PERIMETER PENETRATION DETECTION.

LEVEL 2 --- INTRUDER DETECTION INSIDE THE WORKCELL

LEVEL 3 --- INTRUDER DETECTION IN THE IMMEDIATE VICINITY

OF THE ROBOT.

LEVEL 1 SYSTEMS ARE INTENDED TO DETECT THAT AN INTRUDER

HAS CROSSED THE PERIMETER BOUNDARY OF THE WORKCELL
WITHOUT REGARD TO THE LOCATION OF THE ROBOT.

LEVEL 2 SYSTEMS ARE DESIGNED TO DETECT THE PRESENCE OF AN

INTRUDER IN THE REGION BETWEEN THE WORKCELL BOUNDARY
AND THE LIMIT OF THE ROBOT WORK VOLUME.

LEVEL 3 SYSTEMS PROVIDE INTRUDER DETECTION INSIDE THE

WORK VOLUME OF THE ROBOT.

THERE ARE TWO COMMON MEANS OF IMPLEMENTING A

ROBOT SAFETY SENSING SYSTEM
1. PRESSURE SENSITIVE FLOOR MATS --- ARE AREA PADS
PLACED ON THE FLOOR AROUND THE WORKCELL THAT
SENSE THE WEIGHT OF SOMEONE STANDING ON THE
MAT. THESE CAN BE USED FOR EITHER LEVEL1 OR
LEVEL2 SENSING SYSTEMS.

2. LIGHT CURTAIN --- CONSISTS OF LIGHT BEAMS AND

PHOTSENSITIVE DEVICES PLACED AROUND THE
WORKCELL THAT SENSE THE PRESENCE OF AN
INTRUDER BY AN INTRRUPTION OF THE LIGHT BEAM.
USE OF LIGHT CURTAINS WOULD BE MORE
APPROPRIATE AS LEVEL1 SYSTEMS.

PROXIMITY SENSORS LOCATED ON THE ROBOT ARM COULD BE

UTILIZED AS LEVEL 3 SENSORS.

THE SAFETY MONITORIN STRATEGIES THAT MIGHT BE FOLLOWED

BY THE WORKCELL CONTROLLER WOULD INCLUDE THE FOLLOWING
SCHEMES.
1.
2.
3.
4.
5.

COMPLETE SHUTDOWN OF THE ROBOT UPON DETECTION OF AN

INTRUDER.
ACTIVATION OF WARNING ALARMS.
REDUCTION OF THE SPEED OF THE ROBOT TO SAFE LEVEL.
DIRECTING THE ROBOT TO MOVE ITS ARM AWAY FROM THE
INTRUDER TO AVOID COLLISION.
DIRECTING THE ROBOT TO PERFORM TASKS AWAY FROM THE
INTRUDER.
NOTE: THERE IS ANOTHER SAFETY MONITORING CALLED A FAILSAFE HAZARD DETECTOR. THE CONCEPT OF THIS DETECTOR IS
BASED ON THE RECOGNITION THAT SOME COMPONENT OF BASIC
HAZARD SENSOR SYSTEM MIGHT FAIL AND THAT THIS FAILURE
MIGHT NOT BE FOUND OUT UNTIL SOME SAFETY EMERGENCY
OCCURRED. THE FAIL-SAFE HAZARD DETECTOR IS DESIGNED TO
OVERCOME THIS PROBLEM.

SAFEGUARDING

MOST INDUSTRAIL ACCIDENTS OCCUR ARE THE RESULTS OF UNSAFE

ACTS BY THE WORKER. UCH ACTS CAN OCCUR DUE TO:

IMPROPERLY TRAINED OPERATORS.

CARELESS PROGRAMMERS ACTIVATING THE WRONG CONTROLS.

COMPONENT FAILURE OR OTHER UNSAFE CONDITIONS IN THE

PLANT.

MAJOR CONCERN IN SAFETY OF ALL PERSONNEL INVOLVED WITH

INDUSTRIAL ROBOTS IS VERY IMPORTANT.

ACCORDING TO THE NATIONAL SAFETY COUNCIL(1991) THE

PRINCIPAL HAZARDS ASSOCIATED WITH ROBOTS ARE AS FOLLOWS:
1.

BEING STRUCK BY A MOVING ROBOT WHILE INSIDE THE WORK

ENVELOPE.

2.

BEING TRAPPED BETWEEN A MOVING PART OF A ROBOT AND

ANOTHER MACHINE, OBJECT, OR SURFACE.

3.

BEING STRUCK BY A WORKPIECE, TOOL, OR OTHER OBJECT

DROPPED OR EJJECTED BY A ROBOT.

SAFEGUARDING (CONTD.)

ROBOT SAFEGUARD:
TO ERECT A PHYSICAL BARRIER AROUND THE ENTIRE
PERIMETER OF A ROBOTS WORK ENVELOPE.
A GUARD CONTAINING A SENSING DEVICE THAT
AUTOMATICALLY SHUTS DOWN THE ROBOT IF ANY
PERSON OR OBJECT ENTERS ITS WORK ENVELOPE CAN BE
EFFECTIVE.
TO PUT SENSITIZED DOORS OR GATES IN THE PERIMETER
BARRIER THAT AUTOMATICALLY SHUT DOWN THE
ROBOTS MOVEMENT WHEN THEY ARE OPENED.

SAFEGUARDING (CONTD.)

EVEN THOUGH IT IS DIFFICULT TO GO TO A RISK-FREE

ENVIRONMENT BECAUSE THER IS ALWAYS THE
POSSIBILITY OF A MALFUNCTION OR THE VIOLATION OF
GOOD SAFETY PRACTICES. HOWEVER, THERE ARE WAYS
TO MINIMIZE THE POTENTIAL OF THESE ERRORS:
1.
2.
3.
4.
5.
6.
7.
8.

SAFETY TRAINING
DEPENDABLE MACHINE DESIGN
HIGH-RELIABILITY CONTROLS
PROPER LAYOUT WORK AREA.
SAFE POSITION AND CLEAR VISIBILITY FOR
PROGRAMMING.
ESTABILISHING PROPER MAINTENANCE PROCEDURES.
ADEQUATE INSTALLATION PERFORMED IN THE
PRESENCE OF SAFETY PERSONNEL.
OBEYING SAFETY RULES AND REGULATIONS OF
AUTHORITATIVE ORGANIZATIONS.

SAFETY GUIDLINES

THE UNEXPECTED ROBOT MOVEMENTS ARE THE CONCERN OF

EMPLOYEES FOR OBTAINING FURTHER GUIDELINES ON ROBOTICS
SAFETY.

RESEARCHERS HAVE DEVELOPED MANY GUIDELINES PERTAINING

TO SAFETY ISSUES IN ROBOTS.

FOLLOWING GUIDELINES ARE FOR SAFE USE OF ROBOTS IN A

PRODUCTION ENVIRONMENT:
1.

IF THE ROBOT IS NOT MOVING, DO NOT ASSUME IT IS NOT

GOING TO MOVE.

2.

IF THE ROBOT IS REPEATING PATTERN, DO NOT ASSUME IT

WILL CONTINUE.

3.

ALWAYS BE AWARE OF WHERE YOU ARE IN RELATIONSHIP TO

THE POSSIBLE POSITIONS THAT THE ROBOT MAY REACH.

SAFETY GUIDELINES (CONTD.)

4.

BE AWARE IF THERE IS POWER ACTUATORS. INDICATOR

LIGHTS WILL BE ON WHEN THERE IS POWER TO THE
ACTUATORS.

5.

TEACHING, PROGRAMMING, SERVICING, AND MAINTENANCE

ARE THE ONLY AUTHORIZED REASONS FOR ENTRY INTO THE
WORK ENVELOPE.

6.

BEFORE ACTIVATING POWER TO THE ROBOT, EMPLOYEES

SHOULD BE AWARE OF WHAT IT IS PROGRAMMED TO DO, THAT
ALL SAFEGUARDS ARE IN PLACE, AND THAT NO FOREIGN
MATERIALS ARE PRESENT WITHING THE WORK ENVELOPE.

7.

NOTIFY SUPERVISION IMMEDIATELY WHEN AN UNEXPECTED

INTERRUPTION TO THE NORMAL ROBOT WORK CYCLE OCCURS.

8.

REPORT ANY MISSING OF DEFECTIVE SAFEGUARD TO

SUPERVISION IMMEDIATELY. CHECK ALL SAFEGUARDS AT THE
BEGINNING OT EACH SHIFT.

SUMMARY

SAFETY IS AN IMPORTANT COMPONENT IN INDUSTRIAL

AUTOMATION.

ROBOT SAFETY DEPENDS ON THE SIZE OF THE ROBOTS WORK

ENVELOPE, ITS SPEED, AND ITS PROXIMITY TO HUMANS.

SAFETY SENSORS AND MONITORING PROVIDE THE CAPABILITY OF

THE WORKCELL CONTROLLER AND ITS SENSORS TO MONITOR THE
OPERATION DURING UNSAFE CONDITIONS IN THE CELL.

SAFEGUARDING IS THE PREVENTION OF INJURY OR ACCIDENT IN

THE WORKPLACE.

TRAINING IS A MAJOR FACTOR IN THE SUCCESSFUL

IMPLEMENTATION OF ANY ADVANCED TECHNOLOGY IN A COMPANY
OR OPERATION.

SAFETY GUIDELINES HAVE BEEN DEVELOPED BY RESEARCHERS

PERTAINING TO SAFETY ISSUES IN ROBOTS TO REDUCE OR
ELIMINATE ACCIDENTS IN A PRODUCTION ENVIRONMENT.