Sie sind auf Seite 1von 12

Robot Safety Consideration

Need for Safety To assure the safety of workers in and around robotic work cells, manufacturers are continually seeking to incorporate new safety features into the design of robots. This practice, however, is not enough to provide all the protection needed. In addition, the design of the work cell must be developed with an eye to providing maximum safety. Also protective devices and safety programs must be initiated by the company management. Although no machinery can ever be 100 percent safe, a conscientious safety effort that focuses on these areas should provide maximum protection against accidents and injuries. One critical rule when working with robots is to remember that they are capable of unexpected and dangerous movements. For this reason, baring robots is not a good practice. Giving the robot a name tends to make it seem more human and trustworthy. Robotics technicians must be constantly on the alert and must maintain the attitude that the robot is not a friend or companion it is a potentially deadly machine. Legal Requirements Both suppliers and users of industrial-type machinery and equipment (or whatever sort) are under a legal obligation to provide adequate safeguarding and safe working practices in respect of that equipment. Robots are industrial equipment and are thus subject to the same legal obligations and requirements. Failure to ensure safety can result in liability under both civil law, based on negligence and resulting in compensation, and criminal law, based on a breach of the law and resulting in punishment. The Factories Act covers general points such as cleanliness in the workplace, overcrowding, working conditions and other aspects of employee welfare. It covers aspects of safety in relation to work practice, guarding of machinery, materials handling equipment, fencing and other matters of access oh the shop floor. The Health and Safety at Work Act is also general, rather than specific, and imposes obligations on both employer and employee. Essential provisions for the employer include: To ensure, so far as is reasonably practicable, the health, safety and welfare at work of all employees. The provision and maintenance of equipment and systems of work that are, so far as is reasonably practicable, safe and without risks to health. The provision of such information, instruction, training and supervision as is necessary to ensure, so far as is reasonably practicable, the health and safety at work of employees.

To prepare and revise where appropriate, a written policy with respect to Health and Safety at Work. Essential provisions for the employees include:

To take reasonable care for the health and safety of themselves others who may be affected by their acts or omissions at work. To cooperate with the employer so far as is necessary, to implement the Act. Not to intentionally, or recklessly, interfere or misuse anything provided in the interest of health, safety or welfare in pursuance of the Act.

Codes of Practice A code of practice is a collection of advice, guidance, suggestions and recommendations on accepted methods of good practice and procedure on aspects to which the code relates. In general, codes of practice arc not legally enforceable. They are drawn up by collaboration between respected professional, industrial, commercial, academic and government bodies based on technical knowledge, experience, observation and historical examination. The development of industrial robotics is still in its relatively early stages. This has a number of implications for the development of codes of practice relating specifically to industrial robot installations, for the following reasons: Practical experience is at present limited; therefore definitive principles have yet to be formulated. Basic principles of existing codes of practice, relating to industrial equipment in general, may not be entirely appropriate or transferable to robotic installations. Industrial robots, and their application areas, are under such continual and rapid development that it is difficult to establish truly general guidance. Future legislation specific to industrial robots may influence the guidance tendered in any codes of practice.

Two prominent codes of practice having relevance to industrial robots are: 1. British Standard 5304:1975. Indian Standard Code of Practice: Safeguarding of Machinery, 2. Machine Tool Trades Association (MTTA): 1982. Code of Practice: Safeguarding Industrial Robots Part 1: Basic Principles Part 2: Welding and Allied Processes. BS 5304 Safeguarding of Machinery

This is a Standard giving general guidance on methods of safeguarding industrial machinery. It indicates criteria to be observed in the design, construction and application of such safeguards, and how they should be used. The standard offers the guiding principle that, unless a danger point or area cannot be reached, then the machine should be provided with an appropriate safeguard which eliminates or reduces the danger, before access to the danger area can be achieved. Since it dates back to 1975, the standard does not specifically address the safeguarding of industrial robots. In this respect British standards accepts that it is often impractical to apply the basic principles to the entire work area of, for example, robots. Complementary standards offering advice on specific applications are in the course of preparation. MTTA Safeguarding Industrial Robots The Machine Tool Trades Association is a central national organization charged with the task of furthering the interests of those companies who manufacture or import machine tools and allied equipment. The code of practice is published in two parts. Part 1: Basic Principles describes the basic principles of safeguarding industrial robots other than mobile robots and master-slave manually controlled manipulators. It includes a systematic examination of the foreseeable safety problems which could arise as a result of introducing robots into the workplace. Part 2: Welding and Allied processes describes the additional hazards likely to be encountered using robots in welding related tasks including spot welding, gas-shielded arc welding, thermal spraying and cutting, hardening and welding by laser. This code of practice is just one of a large number of similar publications concerning safeguarding and safe working practice published by the MTTA. In addition, the Health and Safety Executive (HSE) are very active and provide a number of useful working papers and guidance notes relating to specific aspects of safety across all disciplines. Potential Safety Hazards Following are the main potential safety hazards: () Fires: Fires are one of the most potential hazards of high pressure hydraulics. High pressure hydraulic oil when atomized through a leak the size of a pinhole, can create an explosive environment. It is a good idea to minimize the number of flexible hose lines used in hydraulic installations. If specifying a hydraulic robot, considers. Each installation should consider the fire hazard in a flammability study. Procedures and fire prevention systems should be part of the planning. If properly handled, hydraulic robots can operate safely. (b) Electrical Hazards: Electrical systems can present different hazards. Grounding and shock prevention must be considered when evaluating at electrical system.

Safety Planning Check List The following list of what, if it is a checklist for safety planning what if: () (b) (c) (d) (e) (f) (g) A person is in an unauthorized area Power fails The robot fails The robot is caught in a press Hydraulic fluid is leaking The robot drops or hurts a part The robot is in a hazardous environment where i. ii. iii. iv. Fire Nuclear leaks Contaminated atmosphere or Vacuum

is a safety hazard (h) (i) (j) The control fails The machinery around robot fails The robot mounting fails ... etc.

For every "what if", there must be an answer. Fail safe devices screens, guards, proximity detectors, alarms etc. can be used to answer each safety need. Safety Guide Lines The following guidelines can help to remove hazardous solutions to robot personnel, factory workers, visitors and to the robot itself. (1) Use of Barriers: The robot working area should be closed by permanent barriers (e.g., fences, rolls and chains), to prevent people from entering the area while the robot is working. The robot's reach envelope diagram should be used in planning the barriers. The advantage of a fence type barrier is that it is also capable of stopping apart being replaced in the robots gripper while in motion.

(2) Use of Sign Boards: An illuminated working sign, stating, "Robot at work" should be automatically turned on when the robot is switched on. This lighted sign warns visitors not to enter into the closed area when the robot is switched on, even if it does not move. (3) Use of Automatic Doors in Robot Work Place: Access to gate the closed working area of the robot and should be interlocked with the robot control. Once such a gate is opened, it automatically shuts down the robot system. (4) Provision of Emergency Stop Buttons: Emergency stop buttons must be provided in easily accessible locations as well as on the robots teach box and control console. (5) Provision of Pressure Sensitive Pads: Pressure sensitive pads can be put on the floor around the robot that, when stepped, on, turn the robot controller off. (6) Use of Standards in Design: The robot's electrical and hydraulic installation should meet proper standards. This includes efficient grounding of the robot body. Electrical cables must be located where they cannot be damaged by the movement of robot. (7) Use of Sensors & Interlockers: Mechanical stoppers interlocks and sensors should be used to limit the robot's reach envelope when the maximum range is not required. (8) Power cables and signal wires should be designed such that they must not create hazards if they are accidently cut during the operation of the robot. (9) Great care must be taken during programming with the manual reaching mode. The teach box must be designed so that the robot can move as long as switch is pressed by the operator's finger. Removing the finger must cease all the operations. Hazard Analysis The safeguarding of an industrial robot, installation should be preceded by a thorough analysis of potential hazards and the source of those hazards within the workplace. When the likelihood and consequences of the potential hazard conditions have been assessed, the appropriate safeguards can be designed and applied. In many cases the assessment or risk and the identification of hazard conditions will be a matter of judgement and experience coupled with guidelines available within various legislative standards and codes of practice. Hazard analysis should encompass those extraordinary conditions that may arise during periods when the robot installation is not working under normal production conditions. For example, surveys have highlighted that almost 90% of accidents concerning industrial robots occur during periods of programming and maintenance. Additionally those, often unpredictable, conditions that could arise due to loss of power or malfunction must also be very carefully considered and taken into account when designing safeguard systems. Another potential source of hazards may involve equipment necessary to the installation, but peripheral to the robot itself.

Many robot actions may be determined or influenced by information feedback from external sensors or equipment. The disoperation of sensory or external equipment must not be allowed to cause disoperation of the robot itself to the extent that a hazard situation results. The hazard situations that may be encountered within a robot environment will include the following: Hazards due to human failings, acts or omissions, including during periods of programming and maintenance. Hazards due to designed robot operation and workplace layout. Hazards due to hardware failure or disoperation including loss of power supply. Hazards due to control system failure or malfunction including software and data transmission errors. Hazards due to the malfunction of external sensors, equipment and safety devices.

In all cases the provision of easily accessible emergency stop controls and the adoption of safe working practices and procedures should be prerequisite and regarded as of paramount importance as part of a continuing philosophy of review, re-assessment and improvement. Full documentation should be raised and maintained. Such documentation should include details of the analysis, decisions and systems of work finally implemented together with an on-going log recording any maintenance, additions, modification, malfunctions and other relevant incidents. Safety Hazards Human consideration: The human groups at risk in a robot environment include operators, programmers, maintenance personnel, casual observers and others outside the assumed safety zone. Many potential hazard situations present themselves because of the failure of human personal to appreciate the nature of robot behavior within its working environment. The reasons identify and include the following: Personnel tend to assume that the robot will operate and move correctly according to its programmed task. Malfunctions can cause serious departures from programmed operation, sometimes resulting in complete loss of control. Personnel tend to assume that a working robot will continuously repeat an observed sequence of movements. Different programmed sequences may be activated dependent on the feedback from external sensors and equipment. There is thus a very real possibility and danger of inexperienced personnel being caught unaware if they are allowed uncontrolled access into the immediate robot workplace. Personnel tend to assume that a stationary robot is a safe robot. There are many occasions when robots are programmed to remain stationary. Examples include waiting for external

feedback or performing a timed delay or dwell. This can be signaled by means of (flashing) indicator warning lamps. Since the extent of robot movement is usually well beyond its base dimensions, and is three dimensional, it is often difficult to visualize the safe zone around a particular robot configuration. The type and extent of robot movements and the shape of many working envelopes are often difficult for human personnel to visualize. The speed of robot operation may well be greater than human reaction time, thus giving little time for evasive action to be taken. Safe working practices and procedures may not be established, communicated or adhered to by all groups of personnel having cause to enter the robot workplace. Similarly, due to inexperience or unfamiliarity with equipment or otherwise, human operators are prone to errors or error in judgement.

A number of factors can be brought into play in order to reduce the risks outlined by, they include: Physical guarding and fencing: Perhaps the most obvious outward sign that access to a robotised workplace is either restricted or prohibited is the presence of extensive guarding and fencing. The principle is that of demarcating and denying access to unsafe positions within the workplace. When such guarding is installed it highlights just how large the potential danger zone is. Guards or fences constructed especially to permit access (i.e. doors or gates) will commonly are interlocked to ensure their closure before correct operation can be initiated. An abundance of safety guarding must not promote a false sense of security. Intrusion monitoring to prevent unauthorised access: In cases where it is impractical to erect physical barriers to prevent access, or as a double safeguard, intrusion monitoring is often employed. Intrusion monitoring means the detection of intruders. Various techniques are available Photo-electric beams or light curtains, Pressuresensitive mats, infra-red and ultrasonic range sensors and mechanical interlock systems operating on conventional guards or fences, can detect unauthorised access into the workplace the systems are configured such that, if an intrusion monitoring device is tripped, the robot and associated equipment is halted in a safe manner. Resumption of system operation is done by restoring the intrusion monitoring system and consciously activating a re-start cycle. The choice of device will be determined by the extent of risk ascribed to the likelihood and type of access. Obviously, designs should be fail-safe and designed such that they cannot be bypassed either intentionally or otherwise. Safety control devices: Devices such as pause/hold, dead mains control and emergency stop trip controls are

examples of safety control devices. A pause/hold control stops operation of the robot whilst maintaining power to all axis and end effector functions. A dead mains control requires that it is held in a set position by an operator. If released the control reverts to its original position and deactivates robot operation until it is again depressed. Emergency stop trips are similar to the type found in normal factory and workshop environments and on common machine tools and equipment. They should be prominently identified and within easy access of potential danger zones. Their action should be fail-safe and such as to disable operation in a safe manner. Safe systems of work: Safe systems of work, including access into, and manual operation or programming of, robot environments, will minimize all types of hazard. They should be prominently displayed, thoroughly observed and meticulously documented. Oral instructions, requests or promises can be misheard, misinterpreted, misunderstood or forgotten and cannot be relied upon. A written permit-to-work system will exert control over those persons requiring access. Such permits must also be correctly cancelled by an agreed procedure. In the event of an accident; such documentation will form important evidence in discovering the cause of the accident and be instrumental in preventing a re-occurrence. Restrict mechanisms on robot operation: In conjunction with point above, teach-restrict and reduced speed and torque settings may have to be invoked to safely contain robot motion. This is especially important during programming, setting and maintenance operations and status information. The re-connection of power may thus cause unpredictable operation of the robot in an attempt to re-orientate itself or to resume a particular task where it left off. Hydraulic and pneumatic systems are prone to immediate loss of pressure if fluid lines are severed or connecting unions damaged by collision. This can cause rapid movement of the robot structure and its cargo under the influence of gravity. Servo valves blocked or jammed due to a contaminated fluid supply can cause erratic and unpredictable behaviour. Mechanical failure can occur through overloading, corrosion or fatigue failure. Whilst it is difficult to predict the failure of physical components, certain precautions can be implemented to lessen the likelihood of catastrophic failure : regular planned checking and maintenance procedures ; the use of fail-safe devices ; the use of duplicate systems ; the use of physical safety elements such as steel wires to limit movement; and of course extensive emergency stop facilities. Control System Failure and Malfunction Any computer controlled system can suffer either electronic or software failures and malfunctions. Digital electronic control systems are inherently reliable since they are

predominantly solid state (electronic with no moving parts) systems. However, excess heat, humidity or voltage overload can cause damage or disoperation. Feedback signals from position and velocity feedback transducers, and environment sensors, can become corrupted either by failure of the transducers themselves or by electrical interference. This latter point is important in those applications where external currents arid electrical radiations are likely to be significant, for example in arc welding applications. The other prime source of electrical interference concerns an unstable mains voltage supply. Supply spikes and troughs can result from momentary surges and overloads in the mains circuit where demands are being made by other equipment. Software malfunctions are likely to arise from or more of the following sources: () Data corruption due to transmission errors. (b)Inherent program or operating system faults (bugs). (c)Electrical loss or interference. (d) Electronic component malfunction causing inadvertent loss or corruption, of memory contents. It is for many of the above reasons that software interlocks are not recognised as being entirely safe. They are also difficult to check thoroughly since there may be a large number of possibilities and problems may only occur under a combination of unique conditions. Safety inspectors cannot verify and certify them during on-site inspections. A number of methods are available for combatting control system failures, in addition to routine checking, and maintenance procedures. Many systems have resident diagnostic checking routines that can be invoked at any time; data transmission can be checked by a variety of means; battery back-up systems maintain the contents of volatile memory through a power loss situation; and system status and operation can be monitored by a computer system by continually applying signals to various points and receiving them back on a time-out basis. Data checking and verification during transmission is vitally important. It is possible/for example, for the process of data transmission to occur seemingly without error. However, without software checks during transmission, it would be equally possible dimensional and/or command values to become altered during transmission. Ways to prevent Accidents and Injuries The efforts made to avoid accidents and injuries in and around work cell of the robot include the following:

Design of Robots Today robots are designed with built-in safety devices. One device is the sensor. Sensors come in many types, light, microwave, infrared, and ultrasonic. All of these sensors are designed to detect an unknown obstruction in the work cell and shut down the operation of the robot. For example, a light sensor might be a light curtain that surrounds the robot. When an object or person moves into the horizontal beam of the curtain, the light beam is broken and the robot shuts down. Another safety feature that is very important is the power switch to the robot. First of all, all power switches must be clearly marked. These switches should be located in the work cell so that the technician working in the work cell has access to shut down from any place inside the work envelope. In addition, a manual switch to cut the power should be located outside the work cell. While both these switches are essential for the prevention of possible accidents, they do not solve one crucial problem: the technician must have the power on in order to troubleshoot problems. To solve this dilemma, "dead man switch", such as the one used on the IBM systems, is needed. This switch stops the machine but doesn't cut of the power to the robot. In this way, the technician can work on the machine without the possibility of its suddenly moving and crushing him or her. Design of the Work Cell Coupled with safety features of the robot are safety features in the design of the work cell. Before a robotics unit is installed, engineers must carefully lay out plans that define human interface. Ideally, there should be no interspersion of humans and robots, so that there are no chances that humans will be injured during their daily work routine. One technique that aids in establishing safer work cells is the use of computer simulation. Stephen Derby at Rensselaer Polytechnic Institute has written programs for the computer that illustrates the movements of general-purpose robot arms. By using such a program, the work cell designer can establish the paths of motion and the limits of the robot arm before the robot is ever put into actual use in industry. When the designers have this type of information to work form, they can more accurately set up a work evil that provides maximum protection for employees. Protective Devices The perimeter of the work cell is an area that must be well defined and protected. An ideal way to do this is to place the robot inside a fence or cage with belts running in and out to carry parts to and from the robot. Another way to delineate the perimeter is to use bright yellow lines. In addition to these lines, warning signs should be posted around the area. If these signs are to be effective, they should not only provide clear indications of danger, but also should describe for employees the types of dangers and injuries to which they could be

subjecting themselves. Still and other good practice is to have lights in the cell that flash whenever the robot is in operation. The safety practices that apply to any moving equipment should be followed. These would include painting equipment according to federal and/or state safety standards and providing protective equipment for employees. In all cases, tool boxes should be left outside the work cell. A robot gone away could easily grasp one of these tools and turn it into a lethal weapon. Finally, workers should be advised never to enter the work cell alone. A pair of workers has a much better chance of avoiding potential hazards. Safety Programs Every company using robots should provide extensive, ongoing safety programs for employees. One aspect of these programs should be developing respect for the robot. Employees should be made to realize that no one can predict when a robot might fail. Therefore, constant vigilance is required when working with these machines. In order to be effective, the program must do more than just list the possible hazards: it should provide graphic demonstrations of the types of problems that can occur. Another aspect of the program should be thorough training in the operation of robots. This training can be carried out in house or at a local college or vocational school. The best solution is for the company using robots to have a contract with the company supplying the robots wherein the robotics company must train each employee, both current and future, who will have contact with the equipment. As a part of robotics training, the program should focus on potential trouble spots. The instructor in such a program should carefully identify possible hazards and suggest ways that these trouble spots can be avoided. Finally, the safety program needs to include periodic inspection of equipment. This preventive maintenance program will be useful in locating problems and preventing their occurrence. Another advantage of these inspections is that they will assure that only proper equipment and replacement parts have been used. Treatment of Accident Victims While safety precautions are stressed in every phase of the robotics operation accidents and injuries are still a very real possibility. In case an accident should occur, the robotics technician needs to know what to do. Robotics technicians face many hazards, including the possibility of electrical shock, wounds, and broken bones.

Because company policies and procedures vary, all employees must be thoroughly trained and informed of their company's practices. Some large companies may have doctors and nurses present whenever the plant is in operation. Other companies may have specially trained personnel who are to be called in when an accident occurs.

Das könnte Ihnen auch gefallen