MiR - MiR500 and MiR1000 Risk Analysis Guide

MiR500 and MiR1000
Risk Analysis Guide
Release date: 2019.06.18

MiR500 and MiR1000 Risk Analysis Guide
Table of contents
1 Introduction ......................................................................................................................................................3
2 Terminology ......................................................................................................................................................3
3 Assumptions .....................................................................................................................................................4
4 Safety Components Overview ..........................................................................................................................4
4.1 Safety Laser Scanners ...............................................................................................................................4
4.2 Awareness Indicators ...............................................................................................................................5
5 Use Cases and Risk Identifications ...................................................................................................................6
6 Safety Design and Residual Risks ......................................................................................................................7
6.1 Docking to charging station - Risk 1 to 3 ..................................................................................................7
6.2 Undocking from charging station - No residual risk .............................................................................. 11
6.3 Placement of pallet on pallet rack - Risk 4 to 12 ................................................................................... 13
6.4 Pickup of pallet from pallet rack - Risk 14 – 19 ..................................................................................... 26
6.5 Impact with robot when passing narrow passages - Risk 20 - 22.......................................................... 36
6.6 Impact with robot during entering and exiting small enclosures - Risk 23 - 26 .................................... 40
7 Appendix A: Resources .................................................................................................................................. 45
8 Appendix B: Illustrations Documentation ..................................................................................................... 45
9 Changelog ...................................................................................................................................................... 47
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1 Introduction
This document describes scenarios in which the safety level of the MiR500/MiR1000 safety system is reduced.
First an introduction to the terminology, assumptions, safety- and awareness indicator components are given.
This is followed by a section describing normal use case scenarios.
The individual phases of each scenario are described in chronological order. Based on the phases, the residual
risks are highlighted. For each residual risk, the compensating safety features are highlighted, and based on this
a conclusion is made on the significance of the residual risk.
This document does not provide an exhaustive list of scenarios in which the MiR500/MiR1000 can be used with
a reduced safety level of the safety system. However, it describes the most common scenarios for the intended
use. The scenarios provided in this document can also be used as a template for making risk analysis of similar
scenarios during the commissioning phase.
2 Terminology
• Awareness indicator: Light and/or acoustic signals, see section 4.2.
• Charging station: Unit connected to a factory power outlet, which enables a robot to autonomously
charge its batteries.
• Docking: Precision maneuvering to a relative marker.
• Entry position: Coordinate on the robot’s map that must be reached before initiating a docking
sequence.
• Goal position: Coordinate on the robot’s map that the robot moves to.
• Relative marker: Object with specific physical dimensions and shape used for precision positioning of
the robot. Examples are pallet rack, charging station, V-, VL- and L-marker.
• Operating hazard zone: Marked area according to standard EN 1525:1997 clause A.3.2. No obstacles
other than those specified by each scenario can be placed inside this zone.
• Pallet lift: Top module that enables the MiR 500 robot to carry pallets on the load surface.
• Pallet rack: Delivery station for pallets. Dimensions L1300 x W1182 x H352 mm.
• PLd: Performance level d as defined by ISO 13849-1.
• Protective field: Area in which protective stop is automatically triggered if a person or object enters
the area.
• Relative move: When driving using a relative move, the robot relies only on wheel encoders for
navigation and the robot will only move in the specified direction, e.g. straight forward.
• Software collision avoidance: Software using safety scanner data to detect persons or obstacles to
avoid these or stop the robot before protective stop is triggered. This works regardless of the
protective field active but filters out expected obstacles such as a charging station or pallet rack. The
software collision avoidance is not safety rated.

3 Assumptions
• Throughout this document it is assumed that the products are used within the specifications and the
guidelines for correct commissioning has been followed according to the product manuals, see
appendix A.
• When illustrating normal driving operation, the largest protective field will be used. However, the size
of the protective field depends on the speed of the robot, see section 4.1.
• When placing and picking up pallets from the pallet rack it is assumed that the robot always enters and
exits from the same side of the pallet rack.
• When the robot drives through a narrow passage not connected to an enclosure it is assumed that the
passage is not required as an escape zone.
• When the robot drives into an enclosure it is assumed that the passage into the enclosure is required
as an escape zone.
4 Safety Components Overview

4.1 Safety Laser Scanners
• 360° protective field
• Two safety laser scanners (PLd’s) placed diagonally in two corners:
o One front safety laser scanner 20 cm off the ground
o One rear safety laser 20 cm off the ground
• Four emergency stop buttons, two on each side
Emergency stop
SICK microScan3 safety laser (PLd)
• Size of protective fields depending on robot speed and driving direction

When active, the size of the protective field will always be adjusted such that the robot stops before a
collision with a person during maneuvering.

4.2 Awareness Indicators

• Light signals:
two lights on each corner giving a total of 8 light indicators
visible 360 degrees around the robot
blink yellow during maneuvering
Light indicators
• Acoustic signals:
Optional feature
1 speaker placed in front of the robot
The sound is a beeping sound, like a vehicle
motion alarm/back-up beeper

5 Use Cases and Risk Identifications

Use cases Risks No.
Docking to charging station No residual risk 1
Docking to charging station Risk of being crushed 2
Dock to charging station
Docking to charging station Risk of being crushed 3
Localization failure Risk of being crushed 4
Undock from charging NA NA NA
station
Raising of pallet Risk of being crushed 5
Docking to pallet rack Risk of being crushed 6
Placement of pallet on
pallet rack
Docking to pallet rack No residual risk 11
Lowering of pallet Risk of being crushed 12
Incorrect docking to pallet rack Risk of being crushed 13
Pickup of pallet from Incorrect docking to pallet rack Risk of being crushed 16
pallet rack Incorrect pallet position before pickup Risk of being crushed 17
Incorrect pallet position on robot after pickup Risk of being crushed 18
Lowering of pallet Risk of being crushed 19
Impact with robot when Passing through passage Risk of being crushed 20
passing narrow passages Passing through passage Risk of being crushed 21
Unfavorable path planning NA 22
Entering and exiting Entering/exiting enclosure Risk of being crushed 23
small enclosures Entering/exiting enclosure Risk of being crushed 24
Unfavorable path planning NA 25
Blockage of escape route NA 26

6 Safety Design and Residual Risks

6.1 Docking to charging station - Risk 1 to 3
Description of docking sequence:
Phase 1: Approaching entry position Phase 2: Marker detection
Maximum speed [m/s] 1.2 Maximum speed [m/s] 0.0

Awareness indicator No Awareness indicator No
Software collision avoidance Yes Software collision avoidance Yes
Front Yes Front Yes
Protective fields Sides Yes Protective fields Sides Yes
Rear Yes Rear Yes
Operating hazard zone No Operating hazard zone Yes

Phase 3: Long range docking Phase 4: Mid-range docking

Awareness indicator Yes Awareness indicator Yes
Front Yes Front Yes
Rear Yes Rear Yes
Operating hazard zone Yes Operating hazard zone Yes
Phase 5: Close range docking Phase 6: Final position reached

Awareness indicator Yes Awareness indicator No
Front No Front No
Rear Yes Rear Yes

Residual risks:
1. A person is staying between the charging station while the robot is

docking to the charging station (phase 5).  Risk of being crushed.
But:
• Phase 3 and 4 protective fields will detect the person
and trigger protective stop.
Conclusion: No residual risk.
2. A person is standing close to the charging station and robot while

the robot is docking to the charging station (phase 5).  Risk of
getting crushed.
But:
• Phase 4 protective field will trigger protective stop if
a person is staying in the area of the front protective
field.
• Software collision avoidance (not PLd) will detect the
person and stop the robot.
• Awareness indicators during docking sequence will
warn the person.
• Risk only if the person does not move.
• Due to the size of the charging station at least 0.19
meters of space will always be free between the
robot and the wall. See MiRCharge 48V Operating
guide.
Note! Users must receive proper safety training.
Conclusion: Residual risk extremely low.

3. A person enters during near range docking (phase 5)  Risk of

being crushed.
But:
• The robot is less than 0.15 meters from the charging
station during this phase  No reasonable space to
enter between the charging station and the robot.
• Person must enter during phase 5  Hazard occurs for a
very limited time.
• Awareness indicators during docking sequence will warn
the person.
• Very improbable behavior  Staff and visitors need to be trained.
4. Localization fault: The robot is not well localized and docks to a marker/object
different than the desired charging station, and a person is staying between the
marker/object and the robot  Risk of being crushed.
But:
• Localization fault is improbable.
• The robot must detect a shape similar to the characteristic shape of a
charging station before initiating docking sequence.
• Phase 4 protective field will trigger protective stop if a person is staying
in the area.
• Software collision avoidance (not PLd) will detect the person and stop
the robot.
• Awareness indicators during docking sequence will warn the person.

6.2 Undocking from charging station - No residual risk

Description of undocking sequence:
Phase 1: Close range undocking Phase 2: Mid-range undocking

Front No Front Yes
Rear Yes Rear Yes

Phase 3: Long range undocking Phase 4: Normal operation

Awareness indicator Yes Awareness indicator No
Software collision avoidance Yes Software collision
Yes
Front Yes avoidance
Protective fields Sides Yes Front Yes
Rear Yes Protective fields Sides Yes
Operating hazard zone Yes Rear Yes
Operating hazard zone No
Residual risks:
No residual risks as the robot is always covered by protective fields in the directions of movement.

6.3 Placement of pallet on pallet rack - Risk 4 to 12

Description of pallet placement sequence:

Pallet position Lowered Pallet position Lowered
Front Yes Front Yes
Rear Yes Rear Yes

Phase 3: Raise pallet Phase 4: Long range docking 1

Pallet position Raising Pallet position Raised
Front Yes Front Yes
Rear Yes Rear Yes

Phase 5: Long range docking 2 Phase 6: Close range docking 1

Pallet position Raised Pallet position Raised
Front Yes Protective fields Front Yes
Protective fields Sides No Sides No
Rear Yes Rear Yes

Phase 7: Close range docking 2 Phase 8: Lower pallet

Pallet position Raised Pallet position Lowering on rack
Front No Front No
Protective fields Sides No Protective fields Sides No
Rear Yes Rear Yes

Phase 9: Initial undocking 1 Phase 10: Initial undocking 2

Pallet position On rack Pallet position On rack
Front No Front Yes
Rear Yes Rear Yes

Phase 11: Long range undocking 1 Phase 12: Long range undocking 2

Front Yes Front Yes
Protective fields Sides No Protective fields Sides Yes
Rear Yes Rear Yes

Phase 13: Normal driving operation
Maximum speed [m/s] 1.2

Pallet position On rack
Awareness indicator Yes
Software collision avoidance Yes
Front Yes
Protective fields Sides Yes
Rear Yes
Operating hazard zone Yes

Residual risks:
5. Pallet is lowered onto the robot top surface

during docking procedure and a person is
touching the surface (phase 3-7)  Risk of
getting crushed.
But:
• Pallet is only in raised position during
docking procedure.
• Awareness indicators will warn the
person.
• Very improbable behavior  Staff and
visitors need to be trained.

6. The robot is maneuvering toward the pallet rack and a person

is in close proximity (phase 5-7)  Risk of collision
But:
• Phase 1-4 protective field will trigger protective stop if a
person stands in the area during these phases.
• Awareness indicators will warn the person.
Note! Users must receive proper safety training
7. The robot is docking into the pallet rack while a person is

staying inside the pallet rack (phase 5-7 & 9-10)  Risk of
being crushed
But:
• Phase 4 protective field will trigger protective stop if a
person stands in the area during phase 5-7.
• Rear protective field will trigger protective stop if a person
stands in the area during phase 9-10.
Note! Users must receive proper safety training

8. The robot docks to the pallet rack with the pallet in the
lowered position. The pallet falls off the robot while a person
is in close proximity of the pallet rack (phase 5-7)  Risk of
being crushed.
But:
9. An undetected pallet is already placed on the

pallet rack, and this pallet or the pallet on the
robot is pushed off the rack while the person is
staying near the pallet rack (phase 5-7)  Risk of
being crushed.
But:
person.

10. A person enters the pallet rack during close range docking 2
(phase 7) Risk of being crushed.
But:
• Software collision avoidance (not PLd) will detect
the person and stop the robot.
• Awareness indicators during docking sequence will
warn the person.
• Pallet rack is 0.352 meters high  Difficult to enter
pallet rack from sides.
• Very improbable behavior  Staff and visitors need
to be trained.
11. A person is standing in the pallet rack while the robot docks to
the pallet rack (phase 7)  Risk of being crushed
a. No obstacle behind the pallet rack.
But:
person is standing in the area.
Conclusion: No residual risk.

b. Obstacle behind the pallet rack.
But:
person is standing in the area.
Conclusion: No residual risk

12. The pallet is lowered onto the pallet rack, and a

person is touching the pallet rack Risk of
being crushed.
But:
person
visitors need to be trained
• Pallet rack is marked with crushing
hazard risk
13. The robot performs an incorrect docking (too short/too

far) and the pallet falls off the pallet rack (phase 9-11)
Risk of being crushed.
But:
• Awareness indicators will warn the person

6.4 Pickup of pallet from pallet rack - Risk 14 – 19

Description of pallet pick up sequence:

Front Yes Front Yes
Rear Yes Rear Yes

Phase 3: Long range docking 1 Phase 4: Long range docking 2

Front Yes Front Yes
Protective fields Sides Yes Protective fields Sides No
Rear Yes Rear Yes

Phase 5: Close range docking 1 Phase 6: Close range docking 2

Front Yes Front No
Rear Yes Rear Yes

Phase 7: Raise Pallet Phase 8: Close range undocking 1

Pallet position Raising Pallet position Raised
Front No Front No
Rear Yes Rear Yes

Phase 9: Close range undocking 2 Phase 10: Long range undocking 1

Pallet position Raised Pallet position Raised
Front Yes Front Yes
Rear Yes Rear Yes

Phase 11: Long range undocking 2 Phase 12: Lower pallet

Pallet position Raised Pallet position Lowering
Front Yes Front Yes
Rear Yes Rear Yes

Phase 13: Normal driving operation
Maximum speed [m/s] 1.2

Pallet position Lowered
Awareness indicator Yes
Software collision avoidance Yes
Front Yes
Protective fields Sides Yes
Rear Yes
Operating hazard zone Yes

Residual risks:
14. A pallet is already placed on the robot, and this

pallet or the pallet on the pallet rack is pushed off
the rack while the person is staying near the pallet
rack (phase 4-6)  Risk of being crushed.
But:
15. The robot docks to the pallet rack with the pallet lift in the raised
position and pushes off the pallet on the pallet rack while a person
is standing near the pallet rack (phase 4-6)  Risk of being crushed.
But:

16. The robot performs an incorrect docking (too

short/too far), and the pallet falls off the robot
during undocking sequence (phase 9-11) Risk of
crushing.
But:
• Risk only if rear and/or side protective fields
sets does not detect the person.
17. The robot performs a correct docking to the pallet

rack with a pallet placed incorrectly on the pallet
rack. The pallet falls off during undocking sequence
(phase 9-11) Risk of being crushed.
But:
• Risk only if rear and/or side protective fields
sets does not detect the person.
18. The pallet is placed incorrectly on the load surface of

the robot but does not fall off during undocking
sequence. The robot enters normal driving
operation with the pallet, and the pallet falls off the
robot (phase 13) Risk of being crushed.
But:
• Risk only if…

19. Part of a person’s body is situated between the

raised pallet on the robot and the robot top
surface while the pallet is being lowered (phase
9)  Risk of being crushed
But:
• Awareness indicators during lowering
will warn the person
visitors need to be trained
Conclusion: Residual risk extremely low

6.5 Impact with robot when passing narrow passages - Risk 20 - 22

Description of passing narrow passage sequence:
Phase 1: Approaching entry position Phase 2: Enter reduced safety mode

Front Yes Front Yes
Rear Yes Rear Yes

Phase 3: Pass passage using straight Phase 4: Approach goal position

forward relative move

Front Yes Front Yes
Rear Yes Rear Yes

Phase 5: Return to normal safety mode Phase 6: Normal driving operation

Front Yes Front Yes
Rear Yes Rear Yes
Operating hazard zone Yes Operating hazard zone No

Residual risks:
20. A person is staying in passage while the robot drives

through (phase 3-4)  Risk of being crushed.
But:
• Risk only if the front protective field does not detect
the person.
• The person can escape to both sides of passage.
21. A person enters passage while the robot drives through

(phase 3-4)  Risk of being crushed.
But:
• Risk only if the front protective field does not detect
the person.
• Very improbable behavior  Staff and visitors need
to be trained.

6.6 Impact with robot during entering and exiting small enclosures - Risk 23 - 26
Description of entering and exiting small enclosure sequence:
Phase 1: Approaching entry position Phase 2: Enter reduced safety mode

Front Yes Front Yes
Rear Yes Rear Yes

Phase 3: Enter enclosure Phase 4: Approach entry goal position

Front Yes Front Yes
Rear Yes Rear Yes

Phase 5: Initiate exit move Phase 6: Approach exit goal position

Front Yes Front Yes
Rear Yes Rear Yes

Phase 7: Return to normal safety mode Phase 8: Normal driving operation

Front Yes Front Yes
Rear Yes Rear Yes
Operating hazard zone Yes Operating hazard zone No

Residual risks:
22. A person is staying in entry passage while the robot drives

But:
• Risk only if the front protective field does not
detect the person.
23. A person enters entry passage while the robot drives

But:
• Risk only if front protective field does not detect
the person.
• Very improbable behavior  Staff and visitors
need to be trained.

7 Appendix A: Resources
• MiR500: MiR500 User Guide v. 1.1
• MiR1000: MiR1000 User Guide v. 1.0
• MiRCharge 48V: MiRCharge 48V Operating Guide v.1.0
• MiR500 EU Pallet Lift: MiR500 EU Pallet Lift Operating Guide v1.0
• MiR EU Pallet Rack: MiR EU Pallet Lift Operating Guide v1.0
• MiR500 Lift: MiR500 Lift Operating Guide v1.0
• MiR Lift Pallet Rack: MiR500 Lift Operating Guide v1.0
8 Appendix B: Illustrations Documentation

1. Robot
Robot
2. Protective field (PLd)
3. Direction of movement Direction of movement
Protective field (PLd)
4. Operating hazaard zone

5. Charging station
6. Robot positions
7. Palletrack
8. Pallet

9. Person
9 Changelog
Version Date Changes
1.0 2019.06.18 First version

MiR - MiR500 and MiR1000 Risk Analysis Guide

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4 Safety Components Overview

SICK microScan3 safety laser (PLd)

• Size of protective fields depending on robot speed and driving direction

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4.2 Awareness Indicators

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5 Use Cases and Risk Identifications

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6 Safety Design and Residual Risks

Phase 1: Approaching entry position Phase 2: Marker detection

Maximum speed [m/s] 1.2 Maximum speed [m/s] 0.0

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Phase 3: Long range docking Phase 4: Mid-range docking

Maximum speed [m/s] 0.25 Maximum speed [m/s] 0.25

Phase 5: Close range docking Phase 6: Final position reached

Maximum speed [m/s] 0.25 Maximum speed [m/s] 0.0

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1. A person is staying between the charging station while the robot is

Conclusion: No residual risk.

2. A person is standing close to the charging station and robot while

Note! Users must receive proper safety training.

Conclusion: Residual risk extremely low.

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3. A person enters during near range docking (phase 5)  Risk of

Conclusion: Residual risk extremely low.

Conclusion: Residual risk extremely low.

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6.2 Undocking from charging station - No residual risk

Phase 1: Close range undocking Phase 2: Mid-range undocking

Maximum speed [m/s] 0.25 Maximum speed [m/s] 0.25

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Phase 3: Long range undocking Phase 4: Normal operation

Maximum speed [m/s] 0.25 Maximum speed [m/s] 1.2

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6.3 Placement of pallet on pallet rack - Risk 4 to 12

Phase 1: Approaching entry position Phase 2: Marker detection

Maximum speed [m/s] 1.2 Maximum speed [m/s] 0.0

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Phase 3: Raise pallet Phase 4: Long range docking 1

Maximum speed [m/s] 0.0 Maximum speed [m/s] 0.25

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Phase 5: Long range docking 2 Phase 6: Close range docking 1

Maximum speed [m/s] 0.25 Maximum speed [m/s] 0.25

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Phase 7: Close range docking 2 Phase 8: Lower pallet

Maximum speed [m/s] 0.25 Maximum speed [m/s] 0.0

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Phase 9: Initial undocking 1 Phase 10: Initial undocking 2

Maximum speed [m/s] 0.25 Maximum speed [m/s] 0.25

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Maximum speed [m/s] 0.25 Maximum speed [m/s] 0.25

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Phase 13: Normal driving operation

Maximum speed [m/s] 1.2

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5. Pallet is lowered onto the robot top surface

Conclusion: Residual risk extremely low.

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6. The robot is maneuvering toward the pallet rack and a person