Safety FIRST

During FIRST Robotics

Manufacture, Assembly, Test & Operation
Greg Kirksey, OSHA General Industry Outreach Trainer
Scot Marshall, Lockheed Martin

Overview
Anatomy of Accidents
Hazard Analysis
Prevention
Training & Safeguards
Team Safety
PPE
Transportation
Abuse
Signage

Anatomy of Robotic Accidents

Higher During:
Programming
Program Touchup
Maintenance
Repair
Testing
Setup
Adjustment

Thats What Youll Be Doing Most!

Types of Accidents
Contact, Crushing, Trapping, Piercing
Movement, component malfunction, or program
changes

Failures
Components
Drive System
End Effectors
Peripheral Equipment

Power Tools
Grinding wheels, Drills, Power Screwdrivers, Nut
Runners

Tripping Hazards
Restricted Space

Risk of Injury or Damage

The risk exists to the edge the WORKING ENVELOPE
of the machine:
More than just the Robot Any machine or tool
Exists when there is energy to be released
Changes dimension when the Robot Moves

Hazardous Motions and Actions

Motions
Rotating
Reciprocating
Transversing

Actions

Cutting
Punching
Piercing
Shearing
Bending

Sources of Hazards
Human Errors
Prior to programming
Interfacing activated peripheral equipment
Connecting live devices or sensors to the
microprocessor or a peripheral
The greatest problem, however, is overfamiliarity with
the robot or tool so that an individual places himself in
a hazardous position.

Control Errors
Faults within the control system of the robot
Errors in software
interference - Electromagnetic or Radio frequency

Unauthorized Access
Entry into a robot's safeguarded area is hazardous
because the person involved may not be familiar with
the safeguards in place or their activation status.

Sources of Hazards
Mechanical Failures
Operating programs may not account for cumulative
mechanical part failure, and faulty or unexpected
operation may occur.

Environmental Sources
Electromagnetic or radio-frequency interference
(transient signals)

Power Systems
Pneumatic or electrical power sources
Electrical shock and release of stored energy from
accumulating devices

Improper Installation
The design and layout of equipment, and facilities, if
inadequately done, can lead to inherent hazards.

Energy Storage and Release

Mechanical Energy Storage
Compressed Spring
Gear
Stalled Motor
Chain Tension
Momentum

Electrical Energy Storage

Battery, Capacitor

Pneumatic Energy Storage

Charged Air Cylinders
Compressed Air in Lines

Potential Energy Storage

Extended Appendages
Bound Joints
Lifted Weights

Hazards when Powered OFF

When the tool is OFF is it Safe?
Not necessarily
Stored Energy
Potential Energy
Sharp points and edges

How do you know if it is Safe?

Only if you know all the tools systems and hazards
Learn what components can store energy
Learn how energy can be released

Learn the hazards associated with each tool

LEARN HOW TO OPERATE EACH TOOL
BEFORE YOU USE IT

Prevention Overview
System components must be designed, installed, and secured so
that the hazards associated with stored energy are minimized.
Adequate room must be provided for a robot's movement as well as
for workers. There must be a means for controlling the release of
stored energy in all the robotic systems and for shutting off power
from outside the restricted envelope.
A detailed risk assessment should be performed to ensure the safety
of workers who operate, service and maintain the robotics system.

Training
Safety training is necessary for new operators,
new or altered safeguards, or new machines or
operation
Provide instruction or hands-on training in the
following:
Describe and identify the hazards associated with each
machine
The safeguards themselves, how they provide protection,
and the hazards for which they are intended
How to use the safeguards and why
How and under what circumstances safeguards can be
removed, and by whom
What to do and what action to take if a safety incident occurs

Control & Prevention

Eliminate EXPOSURE to the hazard if at all possible
If there is NO EXPOSURE there is NO RISK of injury

Minimize the hazard if it cant be eliminated

Restrict Access to necessary personnel
Train/Educate those at risk
Personnel who program, operate, maintain, or repair robots or
robot systems should receive adequate safety training and be
able to demonstrate competency in performing their jobs safely.

Protect against the damage or injury

Personnel Protective Equipment (PPE)
Barriers and Safeguards

Eliminate the Hazard

Release stored energy before power-down
Return it to its home position
Power the equipment OFF

Safeguard Requirements
Prevent Contact
The safeguard must prevent hands, arms, and any other part
of a worker's body from making contact with moving parts.

Secure
Workers should not be able to easily remove or tamper with
the safeguard

Protect from falling objects

The safeguard should ensure that no objects can fall into
moving parts.

Create no new hazards

A safeguard defeats its own purpose if it creates a hazard of
its own.

Create no interference
Any safeguard which impedes a worker from performing the
job quickly and comfortably might soon be overridden or
disregarded.

Allow safe maintenance if possible.

Safeguards
RISK ASSESSMENT. At each stage of development of the robot
and robot system a risk assessment should be performed.

SAFEGUARDING DEVICES. Personnel should be safeguarded

from hazards associated with the restricted envelope (space)
through the use of one or more safeguarding devices:
Mechanical limiting devices
Nonmechanical limiting devices
Presence-sensing safeguarding devices
Fixed barriers (which prevent contact with moving parts)
Interlocked barrier guards

AWARENESS DEVICES
Chain or rope barriers
Supporting stanchions or flashing lights
Signs, whistles, and horns

Moving Part Safeguarding

Point of operation:
That point where work is performed on the material, such as
cutting, shaping, boring, or forming of stock.

Power transmission apparatus:

All components of the mechanical system which transmit
energy to the part of the machine performing the work. These
components include flywheels, pulleys, belts, connecting
rods, couplings, cams, spindles, chains, cranks, and gears.

Other moving parts:

All parts of the machine which move while the machine is
working. These can include reciprocating, rotating, and
transverse moving parts, as well as feed mechanisms and
auxiliary parts of the machine.

General Safety
Comply with final inspection requirements as
soon as possible to prevent accidents
Arena Safety/Operation
Essential personnel only
Stay behind barriers
Enter when authorized
Energize when approved

Pit Safety Not just at competition

Eye protection at a minimum
Assume you are at risk
Scan for hazards

Chemical Safety
Material Safety Data Sheets (MSDS)

Team Safety
Safety Captain
Independent monitor of operations during concept, manufacturing
process, shipping / receiving, field trip, and competition
Uninvolved in the proceedings while observing
Answers only to Coach & Mentors
Identifies safety hazards and prevents safety incidents

Spotters
Used during every movement of a tool or equipment
Eliminate hazards for the transportation team
Ensures clearances, accessibility, coordination

Disciplinarian Consequences of Safety Infractions

Verbal
Documentation
Cumulative documentation
Disciplinary action up to and including:
Being relieved of you job on the team
Exclusion from travel to the regional
Dismissal from the team

Team Safety Discipline Consequences

All students wishing to be a part of FIRST ROBOTICS competition must
avoid receiving 10 or more checks on the following check list
Students that collect 10 checks or more will not be able to go to the
Regional and will lose all possible recognition for participation.
Checks 1 thru 9 can result in lost of participation at the Regional and or
Championship. In some cases, careless action while on school grounds and
field trip activities may invoke school administrative discipline.
First offense - Verbal warning with check box on check list circled
Two (2) or more circled check points will be considered a check for each.

Second offense - Check made in check box

Third offense Additional checks, invoke appeal process, consequences

Students are either returned to team assignment, reassigned, placed on

suspension, or dismissed from the team.
Academic Probation, failing a class, school suspension or expulsion are
considered severe and may result in immediate expulsion from FIRST
ROBOTICS
Court of Appeals: Teacher / Mentors. Students will have a right to explain
their complaints or differences.

Team Safety Discipline Checklist

Horseplay during construction, manufacturing, shipping, field
trip, competition
Disregard for posted signs and set safety rules in place
Lack of Gracious Professionalism or respect among fellow
students and mentors
Operating tools or equipment unsafely
Careless handling or a hazard to self or others
Abuse or playing with equipment or tools
Irresponsible to team duties or no participation in work activity
Disrespect of rules set forth by Team Captain, Safety Captain,
Mentors, or Coaches
Theft of school, robot, or team members property
Absent, late, or unexcused early departure from Robotics
program activity
Failing a class, academic probation, suspension or expulsion

Team Safety Operations Checklist

Personnel in working area without Safety Briefing
Visitors
Nonessential Personnel
Authorized and qualified personnel on break
Equipment Location
Equipment Configuration
Improper fixturing of parts
Misplaced Tools
Damaged Tools
Hazardous Situations
Eye, Ear, Face, Hand, Body, Foot, Trip,

Typical Personal Protective Equipment (PPE)

Hand
Gloves

Face
Face Shield

Eye
Glasses, Goggles

Ear
Ear Plugs, Ear Muffs

Lung
Mask, Respirator

Head
Hard Hat

Before PPE
No Loose Clothing
Unnecessary risk around moving or rotating
machinery
Tripping Hazard
Can catch on nearby equipment

Lift properly to avoid injury

Head Up, Straight Back, Bend at Hips
Load close to body and directly in front
Lift with Legs, shift feet to turn, elbows in

PPE Selection - Survey

Conduct a walk-through to identify sources
of hazards to workers and co-workers from
the basic hazard categories:
Impact
Penetration
Compression (roll-over)
Chemical
Heat
Harmful dust
Light (optical) radiation

PPE Selection Hazard Sources

Motion
Machinery or processes where movement of tools, machine elements or
particles could exist, or collision with stationary objects

High Temperatures
Burns, eye injury or ignition of protective equipment, etc.

Chemical Exposures
Harmful Dust
Light Radiation
Welding, brazing, cutting, furnaces, heat treating, high intensity lights, etc.

Falling objects or potential for dropping objects

Sharp objects
Pierce the feet or cut the hands

Rolling or pinching objects which could crush the feet

Layout of workplace and location of co-workers
Electrical hazards
Review injury/accident data to help identify problem areas

Safety During Transportation

Transportation-related risks for drivers, vehicles,
and passengers:
Drivers of vehicles should be properly licensed,
insured, be adequately trained to drive the kind of
vehicle used.
Drive prudently and not be under the influence of
alcohol or drugs.
Vehicles should be in good condition, and have
required safety equipment, insurance, and
inspections, and not be overloaded.
Passengers should act safely, refrain from
distracting the driver, and take proper safety
precautions (i.e., use seat belts in vehicles so
equipped).

Abuse
Abuse and harassment may be emotional, physical, or sexual.
FIRST now has eligibility procedures for volunteer selection,
training and supervision for FIRST Robotics Competition
(FRC) regional events and all components of the FIRST
Championship similar to those being used by many other
youth-serving organizations.
Staff and volunteers at FIRST events are easily
distinguishable.
Participants are expected to be in pairs or larger groups at all
times going to, coming from, and during FIRST events.
Volunteers and participants should avoid isolated situations
where incidents or allegations are more likely to occur.
Report any suspicions of harassment or abuse immediately.
FIRST will follow up on all reports, and will take appropriate
action.

Examples of Safety Signs

Training Project
1. Have Students create their own version of Robotic Safety
2. Use the following slide to get students involved with making
safety signage
3. Discuss what causes accidents between man and machines
4. With Coaches, Mentors and Team members.

FIRST asks everyone involved in FIRSTs programs to

place the highest priority on safety, looking out not only
for ones own safety but also the safety of others. Do
not hesitate to speak up or act in the interest of safety.
FIRST particularly wants to highlight safety measures
in the areas of transportation, equipment and work
safety, and guarding against abuse.

http://www.osha.gov/SLTC/robotics/solutions.html