Robot Safety Standard Independent Study Cory Grant Spring

Robot Safety Standard Independent Study Cory Grant Spring

Robot Safety Standard Independent Study Cory Grant Spring 2011 Illinois State University Objectives

Study ANSI/RIA R15.06 Safety Standard Develop Risk Assessments Per Standard Design Physical/Electrical Safety System Implement Designed Safety System Check Implemented Safety System Against Standard Present Project to Illinois State

University (Employer) Present Project to Heartland Community College (Customer) Logical Flow SMC FMS-200

HCC Fanuc/SMC Workstation Robot Primary Function Screw/Torque Screws into Base Robot Secondary Function

Load Shaft and Cover from Table Mounted Inventory Stand HCC Fanuc/SMC Workstation

Robot Functions Assemblies Arrive on Conveyor Table Mounted Inventory Stand Robot Auxiliary Functions

Additional functions for external projects Ex: Using robot for SIT Conference to write student participants names

May use table area, conveyor area, area in front of table, or any combination. Workstation Model Workstation Model

Workstation Model Current User Position Current Student Position Initial Risk Assessment

Created risk assessment chart based on RIA standard and ISUs ABB risk

assessment Station currently does not include any safety equipment Used standard set of safety equipment to predict risk reduction Planned Safety Solutions

Presence sensing devices (curtain/mat) Barriers (fencing) Programming requirements (PLC/robot) Standard procedure training (classroom) Properly designed safety circuits (per NEC)

Awareness Signal on Fencing Station Controls Moved to Fencing Light Curtain Values

Allen Bradley PAC T4H 3400N 3 Beams 23mm Beam Width 400mm Beam Center to Center

Min Os=Beam C2C-Beam Width Min Os=400mm-23mm Min Os=377mm (14.85in) Therefore, Dpf=178mm (7.5in) Per Figure B.2 Light Curtain Values

Allen Bradley PAC T4H 3400N

3 Beams 23mm Beam Width 400mm Beam Center to Center Min Os=Beam C2C-Beam Width Min Os=400mm-23mm Min Os=377mm (14.85in) Therefore, Dpf=178mm (7.5in) Per Figure B.2

Fencing Opening 1.5in Square Openings Per Figure B.1

Per Figure B.1 1.25in Opening =6.5in Distance from Hazard 1.875in Opening=17.5in Distance from Hazard

1.875in-1.25in=0.625in (Opening) 17.5in-6.5in=11in (Distance) 11in/0.625in=17.6 (Distance Ratio) 1.5in>1.25in by 0.25in (Opening Increase) 17.6*0.25in=4.4in (Additional Distance)

6.5in+4.4in=10.9in (Total Distance) Therefore Fence to Envelope11in Cell Model With Safety Solution 5 Foot Fencing 1.5 Square Openings

Awareness Signal to Be Added Station Controls Moved to Fencing AB Light Curtain Cell Model With Safety Solution

19>Require d Figure-A.2 And Figure B.1 48=Require d

Figure-B.2c 12=Require d Figure-B.2c Cell Model With Safety Solution 11>Require d

Figure-B.2 12=Require d Figure-A.3 Light Curtain Recalculation

Cell Model With Safety Solution 53>Require d Figure-B.2 12=Require d Figure-A.3

Real Distance25 Initial Risk Assessment Risk Solutions

Post Risk Assessment Safety System Conditions And Outcomes Safety Circuit Truth Table

Basic Safety Circuit Layout Circuit Layout Circuit Layout Concerns

Fencing Interferes With Robot Envelope Possible Solutions: -Axis Limits -Additional Hard

Stops Concerns Student Checking PLC Panel Without Safety Mat Robot Could

Be Reset and Motion Started Possible Solutions: -Add Safety Mat Under Student Concerns

Possibly Unprotected Area Inside System -Gaps at 4 Corners -Crawl Through Access to Inside

Possible Solutions: -Safety Chains at 4 Corners -Barriers -Safety Mat Inside

Concerns Accessing Center of System No Presence Sensing Devices Inside System

Possible Solutions: -Add Safety Chains Over Gaps -Add Safety Mat Inside

Solution-Soft Stops Two proximity sensors added to the base to detect J1 movement towards fencing

Solution-Gap Chains Gap chains added to prevent entry into center of the system without setting off light curtain Solution-Standard Procedures

Standard procedures for safe operation booklets added to outside fencing for operator reference Solution-Fencing

Solution-PLC Panel Relocation Student technician outside of fencing while troubleshooting Solution-Robot E-Stop Board

Solution-Robot E-Stop Board Solution-Light Curtain Solution-Op Panel Relocation

Unable to reach reset button from inside fencing Appendix A-Figure A.2 Back

Appendix A-Figure A.3 Back Appendix B-Figure B.1 Back

Appendix B-Figure B.2 Back Appendix B-Figure B.2c Back

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