Safety and risk management

Whether you're new to working with industrial robots or a seasoned worker, safety is always the top priority in any manufacturing setting.

Automation Safety
Whether you're new to working with industrial robots or a seasoned worker, safety is always the top priority in any manufacturing setting.
Image: Factory automation with industrial robots for palletizing food products.


It's better to be cautious and safe than to be caught off guard, and be involved in an accident.


According to the Bureau of Labor Statistics (US), there was a 2% increase in fatal work related injuries in 2018 when compared to the previous year.
**Fatal work injuries **
2018 – 5,250 accidents
2017 – 5,147 accidents
Of the 5,250 accidents, 786 cases (14.9%) involved contact with objects and equipment.


Maximum Envelope
(Image: OSHA Technical Manual)


Restricted Envelope
(Image: OSHA Technical Manual)


Operating Envelope
(Image: OSHA Technical Manual)


Hazards

Physical Barriers
Interlocked Barrier Guard
A physical barrier is installed around the robot and access can only be permissible through the electrical interlocks that will stop the robot when the gate is opened.
Restarting the operation requires closing the gate and reactivating the control switch located outside the barrier
Pictured: Metal barricades surrounding the robotic arms used in an automobile manufacturing plant.


Awareness Barrier Guard
These are typically only used in work cells were there are minimal hazards. Examples include: low railings, or suspended chains around the perimeter that can prevent inadvertent entry but can still be easily climbed over, under or around.


Presence Sensing Devices
Floor sensors & Motion sensors
Pressure sensitive flooring can be used to detect forces that are stationery or moving, this is usually combined with machine programming which slows down the operating speed of the robot when movement is detected.
Similarly motion detectors using infrared beams can be implemented to do the same.
Image: Pressure Sensitive Mat. WireCrafters / CC BY-SA 4.0 (via Wikimedia Commons)


Emergence of Collaborative Robots (Cobots)
Cobots are designed to work safely around humans. The robotic arms are designed to be lighter weight and far more responsive to their environment, as they have more sensors built in.
Pictured: Sawyer the Cobot by Rethink Robotics


A coworker of yours, a metal die-cast worker sees scrap metal that had accumulated on the floor, he climbs over the safety rail which surrounds the work envelope of an active traditional robot.


What should have been done in this scenario?


What do you need to before you begin working with an new robot?


Risk Control & Safeguarding

Routine Safety Check
This lesson will cover the key things to keep in mind when performing a routine safety check.


Make it a habit to perform these daily checks before operating any machinery:
Safeguards secure in place before turning on the power to the machine
Check that you know where the emergency stop button is located and that it's unobstructed
Check that the machine isn't 'locked out' for maintenance, if it is then it shouldn't be used.
Make sure you're wearing the correct PPE for the task
Check that you're confident in operating this machine, if it's been a while, don't hesitate to ask for a quick refresher training
Never use machinery you haven't been trained to use or don't understand


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