Industrial Robot Safety: Preventing Packaging Line Hazards
Using industrial robots in packaging has revolutionized the manufacturing industry by boosting productivity and efficiency. Adopting this innovative technology also creates safety challenges and dangerous risks for employees. Identifying and mitigating these risks is crucial to protecting your staff at the worksite.
We sat down with Jeff Squires from SMC Electric, Magnum Systems’ controls vendor, to discuss common industrial robot safety issues and how they can be avoided. With his extensive background in the field, Squires provided valuable insights into the main hazards and precautions necessary to mitigate these risks effectively.
“Even when robots are used for the application, there's still a human aspect involved. In scenarios like palletizing, people still need to move items, making considerations for hard guarding essential,” Squires emphasized. “This all begins with a physical risk assessment when we sell a robot."
Common Safety Incidents
Ensuring workplace safety is paramount in industrial automation. Many safety incidents involving industrial robots can pose significant risks to workers, machinery and overall operational efficiency. These incidents range from collision accidents and pinch points to electrical hazards and programming errors. In these instances, people's health and lives are at risk if strict safeguards are not in place.
"At some point, a robot is bound to fail, so you need a way to shut it off to prevent accidents,” Squires stressed. “Having multi-layered safety shut-off mechanisms is crucial to prevent potentially tragic events."
Understanding and addressing these risks through accurate programming, regular maintenance and stringent safety protocols can significantly mitigate the potential for accidents. Here are several common safety concerns associated with industrial robots and practical measures for preventing these hazards.
Collision Accidents
Industrial robots can collide with other machinery, equipment or even workers if they are not correctly programmed or malfunction. Ensuring accurate programming and regular maintenance can help minimize this risk.
Pinch Points and Entrapment
Workers can get caught in the robot's moving parts or between the robot and other objects, leading to injuries. Safety guards and barriers around moving parts are vital to protect workers from these hazards.
Falling Objects
Improperly secured or stacked items being handled by the robot can fall and injure nearby workers. Proper stacking and securing protocols should be established and monitored regularly.
Electrical Hazards
Malfunctioning electrical components or improper wiring can lead to electric shocks or fires. Regular electrical inspections and proper wiring practices are necessary to prevent such risks.
Unauthorized Access
Workers entering the robot's workspace without proper training or authorization are at risk of accidents, especially if the robot is in operation. Access should be restricted and monitored to prevent unauthorized entry.
Material Jams
Objects stuck in the robot's mechanisms can cause sudden movements or malfunctions, potentially leading to injuries. Clear procedures for dealing with material jams should be established and followed.
Programming Errors
Incorrect programming or failure to update the robot's software can result in unexpected movements or actions, posing a risk to workers. Keeping software up-to-date and ensuring accurate programming is critical.
Lack of Maintenance
Neglected maintenance can lead to mechanical failures or malfunctions, increasing the risk of accidents. Regular and thorough maintenance schedules should be adhered to.
Mitigating Safety Risks The good news is that risks associated with robotic palletizing can be reduced or altogether alleviated by implementing training and various safety measures. Squires urges businesses to use proper training and industry-standard safety protocols, such as lockout/tagout procedures. He also recommends regular safety assessments to help identify and address risks, ensure compliance with relevant safety standards and foster a secure workplace.
Training and Protocols
Training personnel and implementing safety protocols, such as lockout/tagout procedures, are crucial. To ensure worker safety, safety guards and barriers around the robot's workspace should be installed.
Safety Assessments
As already mentioned, conducting regular safety assessments is critical for the well-being of workers and the efficient operation of the system.
"Safety assessments should also consider hard guarding, which you can think of as a fence,” explains Squires. “However, sometimes physical hard guarding can reduce productivity, so integrating technologies like laser scanners or safety PLCs can be more efficient. Your goal should always be to increase productivity while maintaining the highest safety standards."
Here are several critical guidelines for conducting safety assessments:
Risk Assessment: Identify potential hazards associated with the industrial robot system, including moving parts, pinch points, electrical components, programming errors and environmental factors.
Safety Standards Compliance: Ensure that the robot system complies with relevant safety standards and regulations, such as ISO 10218 (for robot safety) and ISO 13849 (for safety-related parts of control systems).
"Organizations like TUV Rhineland guide the overarching rule for machine automation safety,” Squire says. “They establish safety levels and performance standards, which organizations like Rockwell Automation apply to real-world applications.”
Workspace Analysis: Evaluate the robot's workspace to identify potential risks to nearby workers, considering factors such as the robot's reach, speed, payload and workspace layout.
Safety Measures Implementation: Implement safety measures to mitigate identified risks. This may include installing safety guards, barriers and interlocks and incorporating safety features like emergency stop buttons and safety mats.
Emergency Procedures: Develop and communicate emergency procedures for dealing with accidents or malfunctions involving the industrial robot. Ensure that workers are trained in these procedures and have access to emergency stop devices.
Operator Training: Provide comprehensive training for operators and maintenance personnel on the safe use and maintenance of the industrial robot system, always emphasizing the importance of following safety protocols and procedures.
Regular Inspections and Maintenance: Establish a schedule for regular inspections and maintenance of the industrial robot system, including checking for wear and tear, verifying the proper functioning of safety features and addressing any issues promptly.
Documentation and Record-Keeping: Maintain detailed documentation of safety assessments, procedures and maintenance activities. Keep records of training sessions and any incidents or near misses that occur.
Continuous Improvement: Regularly review and update safety assessments and procedures to address any changes in the robot system or work environment. Solicit feedback from workers and incorporate lessons learned from incidents or near misses.
“Collaborating with your engineering team is essential to ensure that the safety standards outlined by ISO, TUV Rhineland and Rockwell Automation are met,” Squires concludes.
By following these guidelines, engineers can help ensure that industrial robots are designed, implemented and operated safely, minimizing the risk of accidents and injuries in the workplace.
