Robotics - Safety

Review
Use/Goal

 An industrial robot is a device used for moving a

tool or gripper into position so it can do its job

 The goal is to use the cheapest, easiest means to

position and orient the end-effector
What continents/countries have the most robotics?

What industries utilize it the most?

Number of Robots in Industry
Number of Robots in Industry
What Comprises a Robot?

 ?
 ?
 ?
 ?
 ?
 Industrial Robot is Composed of:

 Jointed manipulator arm

 Controller
 Teach pendant
 End effector (grip, welder, paint sprayer, etc.)
 External power
 electric
 Pneumatic
 hydraulic
Robot Characteristics

 Servo controlled robot arms

 Position/speed feedback
 Similar to closed loop cruise control on car
 Revolute coordinate
 Rotates about the axes
 Continuous Path
 Can move to any point within work envelope
How many axis do the Kuka robots have?

What are the different coordinate systems that the

Kuka robots use?
 6 Rotational Joints/Axis
Basic Terms

Axis 1 = Waist

Axis 2 = Shoulder

Axis 3 = Elbow

Axis 4,5, and 6 often

called the Wrist
Positional Axes

 These are the major movement axes

 Axis 1, 2, and 3
 They correspond with a human with waist
turning movement, shoulder movement,
and elbow movement.
 They are responsible for getting the tool
from position to the next.
Orientation Axes

 These are the axes at the end of the arm and

are similar to movements of the human wrist.
 Axis 4, 5, and 6
 They are often labeled roll, pitch, and yaw.
 They are responsible for orientating the tool
into the proper position to interact with the
object.
Continuous Path
Teach Stations: Consists of teach pendants,
programming units, software.
 Teach pendants support 3 activities:
 Robot power up and preparation.
 Entry and editing the programs.
 Execution of programs in the work cell.
End Effector

 The part that actually interacts with the object being

manipulated or of the process being undertaken.

 End effector
 End of arm tooling – EOAT
 Gripper
 Tool
Robot Coordinate Systems

 Axis/Revolute/Joint coordinate system

 Single joint movement

 World/Linear coordinate system

 XYZ origin is at base of robot

 Tool coordinate system

 XYZ origin is at Tool/end effector
 Joint/Axis Coordinate System
 Faster
 Used to position robot near object of work
 Most commonly use Joint 1-3 for large motion
 Rotational movement only
 World/Linear Coordinate System
 Used to bring end effector to object
 Moves the TCP linear relative to the XYZ axis

 Most common to use

XYZ movement
 All joints/motors in use
World Coordinates – Right Hand
Rule
 Tool Coordinate System – video link

 Used to properly orientate end effector for use on object

 Moves the TCP linear relative to TCP position
 All joints/motors in use
What does TCP stand for?

How many calibration points are required to

calibrate the TCP?
 Tool Center point: point of action for the tool mounted to
the robot tool plate is called offset or TCP.
 Precise identification of the TCP is critical for accuracy
and repeatability.
 Tool Center point calibration method.
 Types of Motion: Non-Linear
 Kuka – PTP (Point to Point)
 ABB – MoveJ
 Fanuc – J
 Motoman – MOVJ

 Moves to the point the fastest

 Path is non-linear
 Types of Motion: Linear
 Kuka – LIN
 ABB – MoveL
 Fanuc – L
 Motoman – MOVL

 Moves to the point in a straight line

 Slower than non-linear motion
 Types of Motion: Circular
 Kuka – CIRC
 ABB – MoveC
 Fanuc – C
 Motoman – MOVC

 Uses an auxiliary midpoint and

endpoint to create an arc
Motion Command Lines

 Kuka 1. Type 2. Name 3. Accuracy 4. Speed

• ABB 1.Type 2.Name 3.Speed 4.Accuracy 5. Tool#

• Fanuc 1.Type 2.Name 3.Speed 4.Accuracy

• Motoman 1. Type 2. Speed

Kuka Program Example
Fanuc Program Example
 Safety

Workcell Safety Devices??

Robotic Safety Devices??

 Guarding – Z432
 Physical barriers:
 Chains
 Safety rails
 Wire mesh fencing
 Equipment within work cell.
 Presence sensing devices:- light curtains, pressure sensing pads,
proximity sensing devices.
 E-Stop devices: Mushroom push buttons.
 Interlock Devices: switches that interlock a guard door with power
source of the hazard.
 Safety control units: Intelligent controllers that integrate the safety to
rest of the automated cell.
 Robot Safety – Z434

 Power Lock-out
 Dead man switch
 Speed lockout
 Teach Mode
 E-stops – dual chain
 Power failure protection

*must Fail *OFF* - no power, brakes engaged

 Contact and Non- contact gate interlocks:

• Magnetic
• Proximity
• RFID
Light
Curtains
 Proximity Laser - Video Link

• Presence sensing devices:

• Proximity laser sensor: Called a PLS system
Robotics Fundamentals

Risk Assessment steps

 Zone Indicators

 Zone 1 – signs/yellow lights.

 Zone 2 – continuous barrier w/
electrical interlocks.
 Zone 3 – outline on floor indicating
robots maximum reach
Risk Assessment – 3 Steps

1. Determine the severity of the potential injury.

2. Determine the frequency of exposure.

3. Determine the probability of injury

 R15.06 Matrix

RISK REDUCTION
SEVERITY OF INJURY EXPOSURE AVOIDANCE
CATEGORY

E2 Frequent
A2 Not Likely R1
S2 Serious Injury exposure
A1 Likely R2A
More than
First-aid E1 Infrequent
A2 Not Likely R2B
exposure
A1 Likely R2B

E2 Frequent
A2 Not Likely R2C
exposure
S1 Slight Injury A1 Likely R3A
First-aid
E1 Infrequent
A2 Not Likely R3B
exposure
A1 Likely R4
Table 2 – Risk reduction decision matrix prior to safeguard selection
 Safety Risk Assessment

 R1 – unacceptable – redesign required

 R2 – interlocked gates, light curtain, mats etc

 R3 – simple barriers, awareness chain

 R4 – lights, labels, or floor markings