Top Safety Considerations for Robotic Systems Integration
When planning a robot or automation integration project, most businesses focus on the anticipated productivity gains; however, because robots and automated equipment are fast-moving machines and are often located in the busiest areas of the facility, industrial robot safety should receive equal attention in order to keep the workplace as efficient and safe as possible.
Because there are several aspects to robot safety, this blog will provide general information about and links to the relevant regulatory standards and guidelines and provide best practices and top considerations for safe and compliant robot integration.
Industrial Robot Safety Standards
Although automation integration can bring greater levels of efficiency, productivity and quality to industry, the addition of these high-speed workhorses can create safety hazards for the employees of the facility. As a result, several organizations have put forth standards and guidelines to ensure robot safety.
ISO 10218 is the most recognized guideline for industrial robot safety. Following a recent update, this standard from the International Organization for Standardization (ISO) provides parameters regarding the safe design, installation and use of robots.
Previous iterations of ISO 10218 have been adopted as part of the ANSI R15.06 standard from the American National Standards Institute (ANSI), which outlines safety requirements for the use of industrial robots, as well as robotic integration into work cells. As the updated ISO 10218 is expected to be adopted by ANSI, a new version of ANSI R15.06 is likely to be released later in 2025, according to the Association for Advancing Automation (A3).
The updated version of ISO 10218 consists of two parts. Part 1 discusses the safety requirements for industrial robots for manufacturers. Part 2 covers safety requirements for industrial robot applications and is aimed at automation integrators.
Both parts address current safety challenges and advances in technologies and include functional safety requirements with more precise guidelines around compliance and risk mitigation. Integrated safety requirements for collaborative robots that consolidate the previously separate ISO 15066 are also included in the update.
Other updates focus around the following:
- Safety guidance for manual load/unload procedures and end of arm tooling have been incorporated from previously separate technical reports, TR 20218-1 and TR 20218-2.
- New robotic classifications with corresponding functional safety requirements and test methodologies.
- Cybersecurity requirements relevant to industrial robot safety.
It should be noted that while the Occupational Safety and Health Administration (OSHA) has no specific standards for the robotics industry or robotics and automation integration, the agency does rely on ISO, ANSI and other relevant industry standards regarding risk assessments, safeguarding and other related hazards.
Identifying Risks to Enhance Robot Safety
While navigating and complying with the plethora of standards can be a complex and confusing process, there are several commonalities between them, including conducting risk and hazard assessments and the use of safety barriers.
Risk assessments identify hazards that are specific to each robot installation and often pinpoint the need for safeguarding such as barriers, sensors and emergency stops during robotic integration projects.
Risk assessments, which should occur during the earliest stages of the robotic systems integration project, focus on identifying potential hazards associated with the use of robots based on the tasks that will be performed, the type and level of robot/human interaction and the specific work environment in which the robot will be placed.
Following a thorough risk assessment, specific hazards must be noted and recorded and then safeguards intended to prevent potential accidents should be implemented as part of the automation integration project.
Best Practices for Industrial Robot Safety
When done properly, risk assessments almost always reveal the need to include safety barriers as part of the robotic systems integration project.
Key practices for robot safety will likely include the use of the following:
| Physical barriers | Physical blockades such as guardrails, safety fencing, walls, machine guarding and other barriers designed to prevent human workers from getting too close to high-speed robots are one of the best solutions and serve as a visual reminder to help prevent accidents on the manufacturing floor. These can be purchased off the shelf or can be custom designed using T-slot framing solutions from reputable companies such as 80/20. Designing physical barriers and guards allows users to customize safety barriers to their unique requirements. |
| Sensors and devices | In addition to physical barriers, it may be necessary to ensure safety with floor sensors that slow down or stop a moving robot if an employee ventures too close. Light curtains, electric safety mats, shutoff sensors and door interlocks will interrupt the robot’s operation if a worker enters the area. In many processes, there are specific times when interruptions should not occur. Safety interlocks function as safety door switches but come equipped with a built-in electromagnet that “locks” the door. This mechanism prevents individuals from opening the door when the system is not ready for interruption. Electronic barriers will need to be linked with the robot’s programming during the automation integration process. |
| Lockout/Tagout devices | Lockout/Tagout devices assure that any potential energy in the machine is neutralized to prevent unintentional start ups during repair and maintenance. These mechanisms are available in several versions. Locks use a padlock to enforce manual locking/unlocking routines. Tags feature coded colors and written details to provide visual indicators of machine status. Hasps are available for isolation points where multiple people may be required to restart the equipment. |
| Emergency stop devices | Emergency stop buttons, switches, chains and ropes can be integrated into the robotic installation to override other controls and instantly cut off power to the robot to prevent injury or material loss. These devices are usually brightly colored and placed in easy-to-access areas. |
Understanding the regulatory mandates and guidelines, conducting a thorough risk assessment and using safety barriers and devices will help ensure industrial robot safety in the workplace. However, these must be considered during the earliest stages of project planning and automation integration to provide the highest levels of safety in the application. Experienced automation integrators will be well versed in these safety practices and can provide guidance. Contact the automation and robotics experts at JHFOSTER for assistance today.
