Critical Safety Standards for Robotics in Industrial Environments

 As robotics continues to make its mark in industrial environments, safety has become one of the primary concerns. The integration of robots into manufacturing, assembly lines, and warehouses has revolutionized the industry, improving efficiency, reducing costs, and performing dangerous tasks. However, these advancements come with the responsibility of ensuring that robots operate safely, especially when they work alongside human operators. A breach in safety standards can lead to severe injuries or even fatalities, making it essential for robotics systems to adhere to rigorous safety protocols.

In this blog, we will discuss the critical safety standards for robotics in industrial environments, how they ensure the protection of workers, and what manufacturers and developers must consider when deploying robotic systems in the workplace.

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1. International Organization for Standardization (ISO) Standards for Robotics

The International Organization for Standardization (ISO) plays a significant role in setting standards that govern the safe operation of robots in industrial environments. Two primary ISO standards that focus on robot safety are:

a. ISO 10218-1:2011 - Robots and Robotic Devices — Safety Requirements for Industrial Robots

ISO 10218-1 outlines the safety requirements for the design, construction, and integration of industrial robots. This standard provides guidelines to ensure that robots are safe to operate in environments where human workers may be present. Some of the key aspects of ISO 10218-1 include:

• Safety Risk Assessment: This standard emphasizes conducting thorough risk assessments before deploying robots. The assessment must account for potential hazards associated with the robot’s interaction with the environment and human workers.

• Safe Operating Conditions: It provides requirements for establishing safe working conditions, including limits on robot speeds, force, and range of motion to prevent accidents.

• Physical Barriers and Safeguarding: The standard recommends installing barriers or safety-rated systems (e.g., light curtains, protective enclosures) around robots that work in close proximity to human operators to reduce the risk of injury.

• Emergency Stops and Emergency Shutdowns: Robots must be equipped with easily accessible emergency stop mechanisms that allow workers to stop the robot immediately in case of an emergency.

b. ISO 10218-2:2011 - Robots and Robotic Devices — Safety Requirements for Industrial Robot Systems and Integration

ISO 10218-2 complements the first part of the standard and deals with the integration and use of industrial robotic systems. It focuses on the safety protocols when robots are part of a larger system, ensuring they work in harmony with other equipment in the industrial environment. Key aspects include:

• Risk Assessment for Integration: The standard calls for a comprehensive risk assessment before robots are integrated into existing production lines or other systems. It considers the interaction between the robot, other machines, and human workers.

• Functional Safety: It outlines requirements for functional safety, ensuring that robots, control systems, and sensors operate reliably and fail safely.

• Collaborative Systems: In environments where robots collaborate directly with humans, the standard provides additional guidance on minimizing collision risks, energy absorption in case of a mishap, and appropriate robot behaviors during human interaction.

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2. European Union (EU) Safety Standards

The European Union has established several safety standards that regulate robotics in industrial environments. These standards are designed to ensure that robots operate safely while complying with EU directives and regulations.

a. EN ISO 13482:2014 - Safety Requirements for Personal Care Robots

EN ISO 13482 provides safety requirements specifically for personal care robots that might work closely with humans in industrial or domestic settings. Although primarily designed for robots used in healthcare, the principles from this standard are applicable to industrial environments where robots may have direct human interaction. Key considerations include:

• Low-Impact Design: Personal care robots should be designed with low-impact, low-speed movements to reduce the risk of harm to individuals they assist.

• Human Monitoring: The robot’s sensors must detect human presence and adjust operations accordingly to ensure safe interaction.

b. Machinery Directive (2006/42/EC)

This directive governs the safety of machines in the EU, including industrial robots. The Machinery Directive ensures that manufacturers meet the necessary safety requirements when designing and producing robotic systems. The core elements of this directive include:

• Risk Assessment: Manufacturers must conduct a thorough risk assessment to identify hazards associated with the robot’s design, installation, operation, and maintenance.

• CE Marking: The directive requires that all robotic systems sold in the EU have a CE marking, which indicates conformity with EU safety standards.

• Guarding and Safety Devices: Robots must have physical barriers, interlocking systems, or safety-rated devices to prevent contact with humans during operation.

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3. Occupational Safety and Health Administration (OSHA) Standards (USA)

In the United States, the Occupational Safety and Health Administration (OSHA) is responsible for setting and enforcing standards that ensure workplace safety, including the safe use of robots in industrial environments. Key OSHA standards related to robotics include:

a. OSHA Standard 1910.333 – Electrical Safety

This standard outlines the safety requirements for electrical systems in industrial environments. Robots, especially those used in automation, rely heavily on electrical components. Proper grounding, insulation, and disconnection mechanisms must be in place to prevent electrical hazards.

b. OSHA Standard 1910.212 – Machine Guarding

Under this standard, robots must have appropriate guards, barriers, and interlocks to prevent workers from coming into contact with moving parts. It is crucial to prevent injury from pinch points, moving arms, and other hazardous components.

c. OSHA’s Robotics Safety Guidelines

In addition to the general safety regulations, OSHA has developed guidelines specifically for robotic systems used in industrial environments. The guidelines focus on risk assessments, hazard mitigation strategies, and the proper training of workers to handle robots safely.

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4. ISO 13849-1 – Functional Safety of Control Systems

ISO 13849-1 addresses the functional safety of control systems, including those used in robots. Robots must be equipped with safety-rated control systems that meet the highest reliability standards. This standard specifies:

• Safety-Related Control Systems: Robots must have control systems that function reliably under normal and fault conditions. This includes fail-safe mechanisms in case of a component failure.

• Performance Levels (PL): The standard introduces the concept of performance levels, which classify the safety requirements of control systems based on their reliability. For example, robots designed for hazardous tasks must meet higher performance levels.

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5. Safety for Collaborative Robots (Cobots)

Collaborative robots (cobots) are designed to work alongside human operators, requiring additional safety measures to ensure both parties can work safely together. Some safety guidelines for cobots include:

a. ISO/TS 15066:2016 - Collaborative Robots Safety Requirements

ISO/TS 15066 sets guidelines specifically for the safe operation of collaborative robots in industrial settings. The standard addresses:

• Collaborative Operation: Cobots must be designed to operate safely in close proximity to humans. This includes considerations for robot force and power limits to prevent injury in case of contact.

• Speed and Force Monitoring: Cobots should have sensors that monitor the speed and force of movement, ensuring that robots adjust their behavior when interacting with humans to minimize risk.

• Safety-rated Monitors and Sensors: Cobots must have safety-rated sensors and monitors, such as vision systems and force sensors, to detect human presence and prevent accidents.

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6. Conclusion: Ensuring Robot Safety in Industrial Environments

Incorporating robots into industrial environments is a transformative step toward enhancing productivity, efficiency, and safety. However, with these advancements comes the responsibility to ensure that robots operate without posing risks to human workers. Adhering to established safety standards like ISO 10218, ISO 13849-1, EN ISO 13482, and OSHA guidelines is essential to minimize the risk of accidents, injuries, and fatalities.

By implementing these standards, manufacturers can create robots that are not only effective in their tasks but also safe to work alongside humans in complex industrial settings. Ongoing training, regular audits, and continuous improvements in robotic safety will ensure that robotics continues to play a critical role in creating safer and more efficient workplaces for the future.