Robotics Safety: An Engineering Teaching Module Prepared by: Guohua Cui, Dan Zhang and Marc A. Rosen Faculty of Engineering and Applied Science University of Ontario Institute of Technology 2000 Simcoe Street North, Oshawa, Ontario, L1H 7K4, Canada Prepared for: Minerva Canada http://www.safetymanagementeducation.com March 2014 ii Preface and acknowledgements This document is part of an Engineering Teaching Module on robotic safety developed for Minerva Canada. It is accompanied by a powerpoint teaching aid on the topic, for which this document is intended to provide more detail and greater background. This Engineering Teaching Module is one of many health and safety engineering student teaching modules developed by Minerva Canada on various topics. This module was developed with the financial support of Minerva Canada and Mitacs Canada and with the support of General Motors of Canada, an organizational sponsor of the module. We are particularly grateful for the assistance of Ms. Lynn Smith of Engineering Operations and H&S Management at General Motors of Canada. iii Contents Preface and acknowledgements ii Contents iii 1. Introduction to robotics safety 1 2. Types of robots and industrial robots 3 2.1. Definition of robots and industrial robots 3 2.2. Classifications of robots 4 2.2.1. Classification based on design configuration 4 2.2.2. Classification based on control systems 6 2.2.3. Classification based on path generation 7 2.3. Industrial robot components 7 2.3.1. Mechanical unit 8 2.3.2. Power source 8 2.3.3. Control system 8 3. Types and sources of robotics hazards 10 3.1. Types of robot accidents 3.2 Examples of robot accidents 10 3.3. Sources of hazards 10 3.4. Case studies: Incidents and Lessons Learned 10 3.4.1. Machine Operator Crushed by Robotic Platform 12 3.4.2. Mold Setter’s Head Struck by Cycling Single-side Gantry Robot 13 3.4.3. Die Cast Operator Pinned by Robot 14 4. Robot safety requirements 16 4.1. Requirements and safety measures in normal operation 16 4.2. Demands and safety measures in special operation modes 16 4.3. Demands on safety control systems 17 5. Robot safeguards 18 5.1. Robot safeguards from design to operation 18 5.1.1. Risk assessment 18 5.1.2. Robot safety begins with the design process 18 5.2. Robot safeguards and engineering applications 20 5.2.1. Today’s safeguarding methods 20 5.2.2. Instruction to improve robot safety 26 5.2.3. Typical engineering applications 27 iv 6. Robot safety standards 31 6.1. Technology and standardization development overview 31 6.2. Current standards for robotic safety 32 References 34 1 1 Introduction to robotics safety Robots are widely used in industry. They can perform unsafe, hazardous, highly repetitive and unpleasant tasks for humans. Furthermore, industrial robots, unlike humans, can perform complex or mundane tasks without tiring, and they can work in hazardous...
