Robot integration risk assessments

The assessment team identifies all of the tasks to be performed as part of the robot operations and maintenance, with special attention given to any tasks that may be particularly hazardous or complicated. RAs are completed for hazardous situations associated with each stage of the robot development (i.e., assembly, integration, operation, and maintenance). The potential for harm and likelihood of occurrence of each hazardous situation is identified along with the most appropriate risk reduction technique. The documented RA is distributed to and accepted by the team and all affected employees, ensuring that all personnel involved with the robot operations and maintenance understand the associated hazards and safeguarding

Furthermore, similar applications within the same plant should each have their own individual robotic system RAs, analyzed on an application-specific and site-specific level. Although the equipment may be of the same make and model, the robot applications may work on different parts or processes, be integrated into different upstream and downstream equipment, or perform unique automated functions that expose workers to particular hazards. Additionally, a robot’s end-effector, programming, or physical placement in the facility may be different from another robot with otherwise identical characteristics, which must be properly and individually analyzed for the potential for serious injury and risk mitigation.

Safeguards must be tailored specifically to protect against each hazardous situation, meeting the organization’s safety requirements and those dictated by industry consensus standards. Preferred safeguards may change based on the application and on the robot user’s risk tolerance. For example, the access frequency, orientation of the robot within a facility, and organizational disposition may dictate whether the preferred safeguard for access to the robotic cell is an interlocking gate or presence-sensing device, and whether or not the robot is designed and programmed to reset automatically. The RA defines the required safety functions and safety requirements specifications, both of which depend on the application. The RA team develops the safety system design requirements and selects the safeguards to perform each safety function. ANSI/RIA R15.06 Safety Requirements for Industrial Robots and Robot Systems provides detailed steps for conducting a task-based RA to conform with the industry consensus standards and includes examples that apply to many common robot applications.