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Safety Standards AGVs - Application 4
Safety Standards AGVs - Application 4
1. MMR AGV: AGV is a Powered Industrial Vehicle that transports materials by following markers or
wires on the floor, or uses vision, magnets, or lasers for navigation.
The application covered in this section is about AGV design to load or unload pallet in racks.
Note: In the near future, the standard ISO 3691-4 will become the most relevant standard,
which combines the applicable requirements of the other ISO standards.
➢ An AGV which is designed to carry a load with the forks. The AGV and the load
being carried behaves as a single unit. The AGV is designed to lift the load (AGV
Application 4).
➢ It is not designed to pull a load and should not be used for this application (see
AGV Application 2&3).
4- A documented full risk assessment must be done after install and prior to release to
manufacturing with Safety sign-off.
5- All risks that have the potential to cause injury must have an action plan implemented prior to
release to manufacturing
6- AGV design has the following MMRs:
a. Has the ability to detect 360 degrees with collision avoidance sensing on a 2d plan
(front and rear)
b. Has the ability to detect 360 degrees human intrusion in a perimeter compliant with
the safety rule in GSD 16. The objective is to maintain at least the 3 meters (10’)
space between their PIT's and any personnel when the loaded forks are at or above
the 1.5 meters (5’) level from the floor. The AGV shall be equipped with human
detection sensing on all direction around the AGV (Lateral, front and rear). The
detection is coupled with an audible signal to alert the human in the non-authorized
REAR
FRONT
h. Manual / automated mode: the AGV is designed in such a way that an authorized
operator can operate manually and drive equipment safely. The activation of the
automated mode is triggered by a human action, the AGV will only start
automatically after checking that there is no human or other obstacles in the
clearance area. The area must be clear in the direction of travel (front or back) and
lateral in case the AGV will lift a load.
i. Units have self-diagnostic verification to assure optimal sensing performance or
procedures for manual calibration and detection.
j. Visual light indicator (strobe light) active during movement.
k. For automated start, an audible signal or visual signal (example 5 second notification)
prior to start.
l. System must be “fail safe” redundancy for guidance and collision avoidance. In the
event of a sensor failure, the system will detect and prevent unit from operating (in
the same manner as if the E-stop were activated).
7- The performance criteria (PL/Cat) of the control circuit and the associated protective devices
to ensure a safe stop or other safety functions are defined in EN 1525 and would translate to
the latest version of EN ISO 13849 as:
a. Protective devices for detection travel path Cat 3 / PL d
b. Speed control that affect means of detection (e.g. size of warning and shut-off zone)
Cat 3 / PL d
c. Protective devices for side detection Cat 2 / PL c
d. Bypass of protective device for detection path Cat 2 / PL c
e. Limited speed of 0,3m/s if no means are present for detecting presence
Cat 2 / PL d
f. Speed and Steering control in general Cat 1 / PL c
g. Speed and Steering control for stability Cat 2 / PL c
h. Load handling general Cat 1 / PL c
i. Load handling for stability Cat 2 / PL c
j. Emergency stops Cat 3 / PL c
k. Control of battery charging Cat 1 / PL c
Note: In the list above the different reliability requirements are stated for the safety
functions. Next to each entry is the category and PL (achieved performance level) required
indicated. For this standard the categories itself are kept and the PL refers to the overall
reliability level which is the MMR to be reached by category.
In practice the manufacturer of the AGV will have to calculate his safety functions and prove
that the desired PL is reached using the indicated category, or if there are deviations an
equivalent level of safety has been achieved.
8- 1m rule applies (Pedestrian must maintain a minimum 1m or 3ft away from the operation of
the AGV).
9- To avoid collision with heavy PIT traffic, limit use of AGV’s inside warehouse and loading dock
area. To do so, consider the following:
a. AGV has a dedicated traffic lane marked and isolated (guarded/protected) from
PIT/PIV traffic
or
b. AGV has a dedicated traffic lane marked with a 1m clearance between max width of
unit/cart and lane dimension.
10- AGV must have a Max Load capacity label, highly visible in the local language.
11- All units are to be equipped with blue lights mounted in the direction of travel and meet the
following requirements:
a. Lights must be illuminated when the vehicle is in motion.
b. Lights must be mounted high enough to ensure unobstructed path of light to the
floor.
c. Lights to be illuminated 3meters-4meters from the end of the unit.
13- The AGV shall not be modified other than by those trained and authorized by the
manufacturer or an authorized aftermarket service integrator.
14- The site shall have an up-to-date inventory of AGVs including approved risk assessments with
completed action plans.
Note: Additional site-specific requirements may be added based on the application specific
risk assessment findings.
Pedestrian Interdiction
4. A documented full risk assessment must be done after install and prior to release to
manufacturing with Safety sign-off.
4. AGV Application 4, Operation & Maintenance
AGV checklist
(1) Blue light functioning in the direction of travel
(2) Blue or Red light mounted in 90° to direction of travel functioning
(3) E-stop visible and functioning
(4) Check Bump Force sensor (stops operation)
(5) Check visible light indicator
(6) Check unit operation, safely functioning as designed
(7) Check the human detection sensing and audible sound if someone enters the
non-authorized area (forks lifted) is functioning as designed.
(8) Check 1m rule sensing is functioning as designed.
Note: Additional pre-inspection items may be included based on the application
specific risk assessment findings.