1. Robotics
The material was produced under grant number SH SH7 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government. The handouts for this section are found in Section___ of the course materials.

2. Robotics Safety
Photo: Picture shows example of industrial robot doing task (placing windshield into automobile).
This is an example of a task that might be done by industrial robots to remove humans from potentially hazardous environments.

3. Previous Accidents (From OSHA Web Site)
Graphic: Slide shows a list of incidents from 2006 – 2017 involving robots.
This was taken from Go over list of event descriptions to give audience an idea of the types of accidents that can occur involving industrial robots.

4. What Can Go Wrong?
On July 21, 1984, a thirty-four-year-old male operator of an automated die-cast system went into cardiorespiratory arrest and died after being pinned between the back end of an industrial robot and a steel safety pole. The hydraulic robot had been installed in an existing production line to remove die-cast parts from a die-cast machine and to transfer these parts to a trimmer. The victim had fifteen years' experience in die-casting and had completed a one-week training course in robotics three weeks before the fatal incident.
The victim entered the working range of the operating robot presumably to clean up scrap metal that had accumulated on the floor. Despite training in the robotics course, instructions on the job, and warnings by fellow workers to avoid this dangerous practice, the victim apparently climbed over, through, or around a safety rail which surrounded two sides of the robot's work envelope. The entry point in the safety rail was interlocked. No other presence-sensing devices were operative in the system.
Slide is a detailed account of an industrial accident involving a robot. Read scenario and discuss with class. Make the point that many tragedies involving robots occur when the robot is not in production mode but in some type of maintenance or set up mode.

5. Configurations
Graphic: Various configurations of robots and the work envelopes they might have. Discuss the different types of configurations include rectangular, spherical, gantry, cylindrical, articulated arm, and SCARA.
Source:
From Section IV: Chapter 4 of OSHA’s technical manual on Industrial Robots and Robot Safety System:

6. Robots Work Envelope
Graphic: drawings of overhead and side view of robot envelopes
This slide shows an overhead and side view of robot envelopes. Stress the difference between a maximum envelope, restricted envelope, and operating envelope. Definitions will follow.
Source:
From Section IV: Chapter 4 of OSHA’s technical manual on Industrial Robots and Robot Safety System:

7. Robotics Characteristics
Programmable
Multi-Functional
Transfer/Motions programmed path
ANSI-RIA R
This slide shows characteristics of robotics and reference to ANSI/RIA Standard.

8. Definitions Maximum Space Restricted Space
Space that can be swept by the moving parts of the robot as defined by the manufacturer plus the space which can be swept by the end-effector and the workpiece
Restricted Space
Portion of the maximum space restricted by limiting devices that establish limits which will not be exceeded
Go over the definitions of maximum, and restricted space.

9. Definitions (cont.) Operating Space Safeguarded Space
Portion of the restricted space that is actually used while performing all motions commanded by the task program
Safeguarded Space
Space defined by the perimeter safeguarding
Go over the definitions of operating, and safeguarded space.

10. Limiting Device
A device that restricts the maximum space by stopping or causing to stop all robot motion and is independent of the control program and the task programs.
Go over definition of limiting device.

11. Operating Modes Program/Teaching Normal Operations Maintenance
Discuss various operating modes and once again, stress that accidents occur during program/teaching and maintenance, as well as normal operations.

12. Accidents included the following:
Robot’s arm functioned erratically during programming and struck the operator.
Operator entered the work envelope during operations and was pinned between the back end of the robot and a pole.
A fellow employee accidentally tripped the power switch while a maintenance worker was servicing a robot. The robot arm struck the maintenance worker.
This slide covers more examples of accidents involving robots.

13. Types of Accidents Include:
Impact or Collision Accidents – Unpredicted movements, malfunctions, peripheral equipment.
Crushing or Trapping Accidents
Mechanical Part Accidents – Breakdown, release of energy, failure of end- effectors
Other – Ruptured hydraulic lines, arc flash, metal spatter, dust, tripping hazards.
This slide gives more examples of accidents.

14. Loss Sources Human Factor Control Error Mechanical Environmental
Component Failure
Unexpected Energy Release
This slide discusses several sources of loss (injury). Human factor is a major source.

15. Applicable Standards 1910.212(a)(1) 1910.212(a)(2) 1910.212(a)(3)(ii)
Section 5(a)(1)
Slide lists several possible OSHA standards that could be cited related to robotics. Discuss the fact that while there is no comprehensive robot standard, these standards apply. Also discuss importance of following ANSI/RIA and 5(a)(1).

16. Safeguarding Stages Risk Assessment
Safeguarding Devices (limiting devices, presence-sensing, fixed barriers, interlocked barrier guards)
Awareness Devices
Safeguard the Teacher
Operator Safeguards
Attended Continuous Operation
Maintenance and Repair
Safety Training
General Requirements
This slide from the OSHA web site ( covers some steps that can be taken to safeguard robots. Discuss each one.

17. Robot Safeguarding Devices
Mechanical limiting devices
Non-mechanical limiting devices
Presence-sensing safeguarding devices
Fixed barriers
Interlocked barrier guards
This slide covers options for safeguarding. Discuss each.

18. NIOSH Recommendations (Publication 85-103)
Include physical barriers that incorporate gates equipped with electrical interlocks so that operation of the robot stops when the gate is opened.
Include, as a backup to electrical interlocks,
motion sensors, light curtains, or floor sensors that stop the robot whenever a worker crosses the barrier.
Provide barriers, as may be appropriate, between robotic equipment and any freestanding objects such as
posts limiting robot arm movement so that workers cannot get between any part of the robot and the "pinch points."
Provide adequate clearance distances around all moving components of the robotic system.
This slide covers NIOSH recommendations from publication regarding the design of robotic systems. Discuss.
Source:

19. NIOSH Recommendations (continued)
Include remote "diagnostic" instrumentation as much as possible so that the maximum amount of troubleshooting of the system can be done from areas outside the operating range of the robot.
Provide adequate illumination in the control and operational areas of the robotic system so that written instructions, as well as buttons, levers, etc., are clearly visible.
Include on floors or working surfaces clearly visible marks that indicate the zones of movement of the robot.
Continuation of NIOSH Recommendations. Discuss.

20. Hierarchy of Controls (In Order of Priority)
Elimination or Substitution
Engineering Controls
Awareness Means
Training and Procedures – Administrative
Personal Protective Equipment
This slide covers hierarchy of controls. Discuss.
Graphic: The hierarchy of controls, upside down pyramid, showing the order of priority—most effective (on top) to least effective (on bottom).

21. Elimination or Substitution
Eliminate human interaction in envelope
Eliminate pinch points
Automated material handling
This slide begins detailed discussion of hierarchy of controls with elimination or substitution. Discuss.

22. Engineering Controls Mechanical hard stops Barriers Interlocks
Presence sensing devices
Two hand controls
Engineering Controls. Discuss.

23. Awareness Means Lights, beacons, strobes Computer warnings Signs
Restricted space painted on floor
Beepers
Horns
Labels
Awareness Means. Discuss fact that these are only to supplement engineering controls.

24. Training and Procedures
Safe job procedures
Safety equipment inspections
Training
Lockout/tagout
Training and procedures. Discuss administrative controls.
Photo: A red lock with a key in it and a red hasp for multiple people to apply locks. Source: Google Images

25. Personal Protective Equipment
Safety Glasses
Ear Plugs
Face Shields
Gloves
PPE. Discuss this as a last resort.
Graphic: graphic of a safety checklist with a red checkmark in the first check box and the words safety glasses written next to it.
Photo: Safety Gloves

26. Teaching Protection Slow Moving Emergency Stops Under Control
Slide discusses protections during teaching. Discuss each point and stress “control.”

27. Maintenance Lock-Out and Tag-out Slow Moving Mode
Slide covers maintenance. Stress lockout/tagout.

28. Robot Safety Standards
Current National Standards
ANSI/RIA R
CSA Z (Canadian)
Current International Standards
ISO :2011 Industrial robots
ISO :2011 Industrial robot systems and integration
Technical Reports
RIA TR R – Task-based risk assessment
RIA TR R – Safeguarding
RIA TR R – Existing Applications
Slide gives overview of consensus standards for robot safety.

29. Definitions Industrial robot (Must answer yes to all 5 bullet points)
Automatically controlled
Reprogrammable multipurpose manipulator
Programmable in 3 or more axes
Can be either fixed in place or mobile
For use in industrial automation applications
If not yes to all 5, not industrial robot and R15.06 not required
For example, warehouse retrieval systems are not industrial robots because they don’t have a multipurpose manipulator
Definitions. Stress that all 5 bullets must be “yes” for device to be considered industrial robot.

30. Definitions Industrial robot system – System comprising:
End-effector(s)
Any machinery, equipment, devices, external auxiliary axes or sensors supporting the robot performing its task.
Industrial robot cell
One or more robot systems including associated machinery and equipment and the associated safeguarded space and protective measures
Slide covers more definitions. Cover.

31. Risk Assessment Give particular consideration to:
Intended operations of the robot including teaching, maintenance, setting, and cleaning
Unexpected start-up
Access by personnel from all directions
Reasonably foreseeable misuse
Effect of failure in the control system
Hazards associated with the specific robot application
Slide talks about risk assessment. Go over points and stress that risk assessment is now required under current ANSI Standard.

32. Risk Assessment – Hierarchy of Controls
Risks eliminated or reduced first by design or substitution, then by safeguarding and other complementary measures.
Residual risks then reduced by other measures
warnings,
signs,
training
Slide ties Risk Assessment to Hierarchy of Controls

33. Design requirements and protective measures
Robot designed in accordance with principles for relevant hazards
Power transmission components guarded
Fixed guards attached
Moveable guards interlocked
Loss or variation of power not result in a hazard
Re-initiation of power not lead to motion (2-step process)
Components designed so hazards of breaking, loosening, or releasing stored energy are minimized
Slide taken from ANSI standard and covers protective measures. Discuss.

34. Functional Safety
Single fault in any of these parts does not lead to the loss of safety function
Single fault detected at or before the next demand upon the safety function whenever possible
When single fault occurs, safety function is always performed and safe state maintained until the detected fault is corrected
All reasonably foreseeable faults shall be detected
Slide discusses functional safety. Discuss.

35. Functional Safety Continued
Comprehensive risk assessment performed on the robot and its intended application may determine an alternate performance is warranted
Selection of other performance criteria specifically identified and appropriate limitations and cautions included in the information for use provided with the affected equipment
Slide continues with functional safety. Cover.

36. Single point of control
When robot placed under local control, initiation of motion or change of local control selection from any other source is prevented
Manual control using the pendant
Other teaching devices
Pendant is in charge
Pendant Controls must have 3-position enabling device
Continuously held in center to permit motion
Release or fully-depressing stops motion
Must be fully released before re-initiation of motion
Slide discusses single point of control as in the use of a pendant or motion enabling device. Discuss 3-position enabling device.

37. Risk Assessment Needed
Integrator perform a risk assessment to determine the risk reduction measures required to adequately reduce the risks presented by the integrated application
Risk assessment enables systematic analysis and evaluation of the risks associated with the robot system over its whole lifecycle
Risk assessment included
Determination of the limits of the robot system
Hazard identification
Risk estimation
Risk evaluation
The user shall be consulted to ensure that all reasonably foreseeable hazardous situations are identified
Slide discusses more risk assessment.

38. Safeguarding
Required when design does not remove hazards or adequately reduce risks
Guards and protective devices can (See RIA TR R15.406):
Prevent access to the hazard(s)
Cause hazard(s) to cease before access
Prevent unintended operation
Contain parts and tooling
Limit other process hazards
Guards or sensitive protective devices used for perimeter safeguarding
Selection take into account all the hazards within the safeguarded space
Safeguarding taken from technical report from ANSI Standard. Discuss.

39. Requirements for Guards
Only removable by the use of a tool
Perimeter safeguarding not installed closer to the hazard than the restricted space
Openings in any fixed guard shall not allow a person to reach over, under, around or through any opening or gap and access a hazard
Max opening at bottom 7 inches
Minimum height at top 55 inches
Moveable guards shall open laterally or away from the hazard, and not into the safeguarded space and bring any hazards to a safe state before an operator can gain access
Slide covers additional requirements for guards from Technical Report. Discuss.

40. Task Based Risk Assessment Methodology
RIA TR R – 2014
Information and guidance only. Not only method of doing.
Integrates hierarchy of control methodology
Slide covers additional Risk assessment Methodology. Stress that TR R covers methodology.

41. Barrier Protected Area
Photo: An example of an industrial robot inside a barrier protected area.

42. Example of Barrier Protection
Photo: A robot behind another type of barrier protection. Stress gap at bottom must be less than 7 inches and top must be at least 55 inches.

43. Barrier Protection
Graphic: Illustration shows barrier protection for robotic work cell. Stress the need for interlocked gates and scanners inside work cell to detect presence of workers.

44. Resources RIA, www.roboticsonline.com
STD – Guidelines for Robotics Safety-
OSHA Technical Manual – Industrial Robots and Robot System Safety -
Preventing Injury of Workers by Robots – NIOSH Publication
Slide covers resources.
RIA,
STD – Guidelines for Robotics Safety-
OSHA Technical Manual – Industrial Robots and Robot System Safety -
Preventing Injury of Workers by Robots – NIOSH Publication

45. Questions?
Ask audience if there are any questions or discussion points.
Graphic: Lightbulb with yellow question mark inside.