Robot Safety Standards Development for Mobile Robots: Where We’re At and Where We’re Going

For nearly three decades, the Robotic Industries Association (RIA) has led the development and updating of the U.S. National Standard R15.06 on Safety Requirements for Industrial Robots and Industrial Robot Systems (the “Industrial Robot Safety Standard”). Historically, and 

even today, most robots sold are of the “traditional” type: Permanently mounted, and requiring the installation of “safeguards” to keep people away from the robot’s hazardous zone (known as the “restricted space”).  An automotive welding robot is a good example of this type of robot system. People are kept safe by being kept apart from the robot system.

Meanwhile, the safety considerations around mobile industrial equipment were addressed in standards such as the Industrial Truck Standards Development Foundation’s (ITSDF) B56.5 Safety Standard for Driverless, Automatic Guided Industrial Vehicles and Automated Functions of Manned Industrial Vehicles (the “AGV Safety Standard”). 

The Problem with Today's Robot Standards

The proliferation of mobile, automated systems has complicated things. New technology has blurred the lines between R5.06- and B56.5-governed equipment, while also revealing the shortcomings of each set of safety standards.

What if you mount an industrial robot arm to an AGV? Or, what if the mobile unit has a greater degree of autonomy than a traditional AGV has?  For these types of "mobile robots," which standard should take precedence and under which circumstances?  The R5.06, the “Robot Safety Standard,” or the B56.5, the “AGV Safety Standard”? 

The R15.08 Committee and the Future of Robot Safety Standards

An exploratory group compared the two existing standards and, in the summer of 2015, recommended that a new standard be developed to describe safety requirements for mobile robots and mobile robot systems. 

The goal was to fill in gaps and resolve overlaps between the safety requirements described in the R15.06 and B56.5. The R15.08 committee was formed to carry this out.

Since then, the R15.08 committee has met several times to explore the boundaries and content of the two earlier standards (R15.06 and B56.5), agree on scope for the new work, develop an outline, and begin drafting content. 

The R15.08 group met in San Jose, CA, on November 13 – 14, 2017.  The goal of this meeting was to review and discuss a nearly complete first draft of Part 1 of the proposed R15.08 standard on Safety Requirements for Industrial Mobile Robots and Mobile Robot Systems.

Part 1 describes requirements for the Mobile Robot and as addressed to robot manufacturers. Work on Part 2 will begin next, describing safety requirements for a system of mobile robots, addressed to system integrators (installers).   

Part 1 and Part 2 will be published together, with a target publication date of early 2019. Later, Part 3 will be drafted to provide guidance to users.

Introduction to ISO 13849-1 Safety Standard

The ISO 13849-1 safety standard from the International Organization for Standardization (ISO) is a universal standard meant to help build safety systems in machinery with sufficient reliability. For machine builders and users, ISO 13849-1 is a guide for safe operations.

This safety standard replaced the older EN 954-1 standard and has made many improvements, although the categories used for defining system structure are the same. For safe operation of machinery, there are a few things you should know about ISO 13849-1, starting with “Part 1: General Principles for Design.”

What Does ISO 13849-1 Apply to?

ISO defines the first part of ISO 13849-1 as follows:

“ISO 13849-1:2015 provides safety requirements and guidance on the principles for the design and integration of safety-related parts of control systems (SRP/CS), including the design of software. For these parts of SRP/CS, it specifies characteristics that include the performance level required for carrying out safety functions. It applies to SRP/CS for high demand and continuous mode, regardless of the type of technology and energy used (electrical, hydraulic, pneumatic, mechanical, etc.), for all kinds of machinery.”

Essentially, ISO 13849-1 uses a statistical analysis to determine the probability of failure and danger over time of components and circuitry to find a performance level (PL). The PL can then be used in risk assessments to ensure the proper safety devices have been implemented.

Why is ISO 13849-1 Important?

ISO 13849-1 is important because designing safety features into machinery is one of the best ways to ensure safety over the lifetime of equipment. It is a proactive measure for maintaining a safe work environment.

Manufacturers and integrators both have a major responsibility when it comes to operational safety. A safe environment protects workers, machinery and bottom lines alike – a worthy investment for anyone in the industrial sector.

Safety has never been more important in today’s factory setting. The robotics industry has a remarkable safety track record, but robots still present unique dangers to workers. With industrial robots expanding across the globe, safety standards have helped keep the workplace safe.

Food Automation: Processing and Packaging Becomes Highly Automated

The way our food is prepared, processed and packaged has become a highly automated process. In recent years, robotic and automation equipment has steadily found its way into most food processing and packaging facilities, and this trend is expected to continue over the next few years.

According to BCC Research, the food processing and packaging market will be valued around $31.5 billion by 2020, growing at a 4.2% compound annual growth rate (CAGR). Separately, the food processing market and the food packaging market will be worth $14.2 billion and $17.3 billion in 2020, respectively.

This steady growth marks an important shift in the way food processing and packaging plants operate, requiring new equipment and new investments as well as highly trained employees.

How Prevalent is Food Automation in Processing and Packaging?

According to a survey from the Association for Packaging and Processing Technologies, 94% of food packaging operations are using robotics already. As for food processing, approximately a third of companies are using robotics.

Robotic automation is already deployed in high volumes in the food processing and packaging industry, but the survey also revealed that half of companies in this industry plan to increase automation levels in the next three to five years.

This increase in automation will be accompanied by the hiring of new employees with more technical skills and higher spending on capital equipment.

What Effect is Food Automation Having in the Processing and Packaging Industry?

Robotic automation capabilities have expanded in recent years. Industrial robots have become more flexible and more efficient with better programming and better sensors. This increase in robotic capabilities, along with the increase in overall automation levels, is allowing processing and packaging plants to introduce new products on the same assembly lines.

In fact, four out of five packaging and processing plants already deal with more than 100 product types, with a majority expecting that number to increase in the next few years.

Food automation has had a big impact in the processing and packaging industry, and will continue to do so for the foreseeable future. But it’s still just one example of robotic automation transforming and improving the production capabilities of an entire industry.

Robot Simulation Software: The Value for Manufacturers

Robot simulation software is making robotic automation a viable option for nearly any manufacturer. It's used during the quoting and concept stage to provide proof of design, proof of process and to maximize a robot user's automation investment.

There are many reasons most robotic system integrators use some form of robot simultion software in their integration projects. But what are the benefits to manufacturers? Why should a manufacturer be interested in robot simulation software?

The Importance of Robot Simulation Software

Simply put, robot simulation software minimizes the risks associated with automation. Much of the integration process is completed before anything is assembled on your factory floor. A proper simulation helps ensure you’re receiving the best system for your application.

Computing capability is constantly improving, as well as becoming cheaper, making robot simulation more and more important to finding a system that will help you stay competitive in your industry.

3 Benefits of Robot Simulation Software

A manufacturer benefits in many ways from advanced robot simulation software. However, there are three main ways a manufacturer directly and immediately benefits:

1. Proof of Design

Often times, robotic systems are not one-size-fits-all. Robot simulation software helps fine tune and customize robotic design to ensure the system will fit seamlessly with existing production processes and equipment. If loading or unloading your automation system creates bottlenecks, it defeats the entire purpose of automation.

2. Proof of Process

Robot simulation software can prove the effectiveness of an automation system. With accurate, detailed simulation you can be sure a robotic system will meet your cycle time and efficiency goals.  Without this simulation, you're taking a big risk that the proposed system will operate correctly for your application.

3. Maximize Your Investment

Once a simulation is complete, the end result is typically downloadable software programming for your robotic application – so the real system will match the simulation exactly. Robot simulation software ensures potential flaws aren’t designed into the system and your robotic system functions precisely as anticipated. You maximize the return on your investment when you get the best possible automation system.

There are many other benefits to leveraging a system integrator with advanced robot simulation software, but the three mentioned above are some of the most important for protecting your investment and finding the highest levels of productivity.

Robots in Retail Stores are Making a Big Impact

Robots are making their way into the retail market and they're making a big splash. Their entrance into this arena marks an important era of retail defined by cost-cutting and competitiveness.

Amazon has been a major disruptor in the retail space, to say the least. And it's no secret their warehouses are full of robots increasing the speed and efficiency of their logistics operations – a key part of their ability to be so disruptive.

The use of robots – even industrial robotic arms – in the retail industry highlights their willingness to invest in automation to remain relevant and competitive in today’s fight for foot traffic, lower prices and better profit margins.

How are Robots in Retail Stores Being Used?

Robots in retail stores are typically used for customer service or logistics-related tasks, improving a customer’s in-store experience and/or improving a company’s operational efficiency.

Typical applications in use today include:

• In-store service robots to provide directions and product information to customers.
• Inventory robots track shelving stock and even grab objects for customers.
• Delivery robots bring the store to the customer autonomously.

Retail robots are relatively new and still in their early stages, but as competition heats up you can expect robots to become more and more prevalent in retail stores.

Real World Examples of Retail Robots

Walmart recently introduced shelf-scanning robots in 50 locations around the U.S. The robots check inventory, prices and misplaced items to help each individual store’s inventory practices. Additionally, these robots will be collecting data – data that Walmart claims will help them improve inventory practices across the nation.

Another great example is Best Buy’s Chloe robot, which was first tested in the Chelsea neighborhood of New York. The robot looks exactly like an industrial robotic arm and moves on a chassis to pick out the products that customers want.

These are just two examples of robots finding their way into retail, but they’re examples of what will likely be some of the most common robotic retail applications in the years to come.

While retail is relatively new industry for robotics, these developing technologies represent the industry’s desire to compete with Amazon and thrive in the generally declining retail marketplace. Like many industrial companies, retailers are hoping robotic automation will have a major impact on productivity and profit margins.

Medical Robots: Top 4 Applications in Use Today

In the past several decades, robots have played an increasingly important role in the healthcare industry – streamlining operations and improving the quality of patient care.

The first medical robot, the PUMA 560, was used in 1985 to place a needle for a brain biopsy using CT guidance. A few years later, robots started becoming more common in the operating room for their consistency and reliability. Now, robots are starting to take on new applications within the medical industry.

Top 4 Medical Robot Applications in the Medical Field

The following examples of robotic applications highlight some of the most fundamental ways robots are being integrated into the medical profession.

1. Disinfectant Robots

Disinfectant robots, such as those made by Texas-based Xenex, are unique robots that provide a very important function. They detect bacterial and viral growth with high intensity ultraviolet light, while moving autonomously throughout a hospital, to disinfect public spaces. Hospital-acquired infections are all too common, and these robots address this problem head on.

2. Rehabilitation Robots

Rehabilitation robots are used in a wide variety of ways, but mostly involve improving the mobility of patients with disabilities or recent accidents. These robots can be adapted to the specific condition of each patient, whether they’re recovering from a stroke, traumatic brain or spinal cord injuries, or other genetic diseases which restrict mobility.

3. IV Robots

Robots are more and more being used in the preparation of IVs and other medicines, particularly for chemotherapy. Robots, by nature, are highly repeatable. This consistency makes them highly effective at mixing chemicals to create safe drugs for patients.

4. Medical Transportation Robots

Medical transportation robots move autonomously through hospitals, delivering supplies, meals and medication to patients. This repetitive task is time consuming for nurses. Medical transportation robots enable better communication between nurses, doctors and other medical professionals, which improves the quality of care.

While there are dozens of exciting future robotics applications in the works, robots are laying the foundations of future applications today. The above robotic solutions provide fundamental services for any healthcare facility and are helping improve the overall quality of patient care.

When Do You Need a Vision System for Robotic Automation?

Vision guided robots (VGRs) open up entirely new possibilities in manufacturing and industrial automation. VGRs have functionality that their “blind” counterparts do not, but investing in a vision system for robots is a big decision.

If you don’t have a vision system when you need one, it will lead to constant failures on the part of the robot. This creates unnecessary downtime, which quickly raises operating costs, and requires regular human intervention.

On the other hand, having a vision system that you don’t need is expensive. So how do you know when you need a vision system for your robots?

Applications that Need a Vision System for Robotic Automation

Vision and robotic systems, when integrated, make a powerful combination. But how do you know when it makes sense for your application? There are a few different types of applications that call for VGRs.

Flexibility in Functionality

When robots need to perform several different functions, vision systems will be necessary. For example, if a material handling robot has to pick up parts of different sizes in the same batch, it will require vision to do this. Same goes for robots that must determine part locations. Essentially, any application where location, size and function isn’t fixed will require a vision system.

Little Operator Oversight

As mentioned, robots without vision systems that must perform flexible functions will constantly fail and require operator intervention. If your production operations won’t allow for regular operator oversight, your robotic system will need a vision system.

Collaborative Work

At the same time, if robots need to work alongside human workers, then a vision system is typically necessary for safety reasons. Collaborative robots, or ‘cobots’, are built to safely work with humans and often require vision systems to identify nearby humans and turn off or slow down to avoid injury.

Vision systems are becoming more and more common in robotic systems. VGRs have significantly more functionality than “blind” robots and can automate more than one task. While vision systems can be a big investment, often times they’re required for your application.

What is Industry 5.0 and How Will Industrial Robots Play a Role?

RIA’s Certified Robot Integrator program was created to benefit robot integrators and users alike. The program aims to establish a benchmark for evaluating technical and safety capabilities, as well as an integrator’s business acumen, in response to a lack of any other similar standards in the industry.

Certification involves a rigorous inspection process, including an on-site audit, an assessment of daily practices of key personnel, safety training and monitoring, as well as other important robotics criteria.

RIA intentionally sets the bar high with the Certified Robot Integrator program. The purpose is to identify the most talented, reliable and experienced integrators. All certified integrators will have already achieved a high level of success before being considered for certification.

3 Ways the Certified Robot Integrator Program Helps Your Business

RIA’s Certified Robot Integrator program can help robot integrators grow their business. There are several benefits of the program that lead directly to acquiring more business, but three in particular benefit integrators the most.

1. Distinguish Yourself from the Competition

RIA Certified Robot Integrators set themselves apart from other robot integrators. RIA’s rigorous standards for awarding certifications allows robot users to see the most qualified integrators for their facility. RIA’s certification is the most authoritative way to show you’ve achieved high standards of excellence.

2. Access Valuable Safety Training for You and Your Staff

Robot safety is a primary consideration in all integration projects. It’s a key component of what integrators do on a daily basis. When you undergo RIA’s certification process, you’ll receive exclusive safety training to keep you up to date with the latest standards and keep your team acquainted with best practices. Integrators with impeccable safety records are more likely to acquire new customers and gain repeat business.

3. Put Your Company in Front of Potential Customers

Robot integration is a major investment for robot users. Understandably, they’re cautious about who they choose. Robot users come to RIA to find the most reliable integrators to work on their facilities. By becoming a certified integrator, you put yourself exactly where potential customers are going to look for a qualified service provider.

RIA’s Certified Robot Integrator program helps your business in many different ways, but mainly by allowing you to distinguish yourself from the competition, access valuable safety training and getting in front of potential customers.

The certification program, through its rigorous standards, aims to help both integrators and users create lasting business relationships that prove profitable for everyone involved.

To learn more about RIA’s certification program, sign up for our free archived webinar, “Becoming a Certified Robot Integrator.”

Robotics in Agriculture: Types and Applications

Agriculture is quickly becoming an exciting high-tech industry, drawing new professionals, new companies and new investors. The technology is developing rapidly, not only advancing the production capabilities of farmers but also advancing robotics and automation technology as we know it.

At the heart of this phenomenon is the need for significantly increased production yields. The UN estimates the world population will rise from 7.3 billion today to 9.7 billion in 2050. The world will need a lot more food, and farmers will face serious pressure to keep up with demand.

Agricultural robots are increasing production yields for farmers in various ways. From drones to autonomous tractors to robotic arms, the technology is being deployed in creative and innovative applications.

Agricultural Robot Applications

Agricultural robots automate slow, repetitive and dull tasks for farmers, allowing them to focus more on improving overall production yields. Some of the most common robots in agriculture are used for:

• Harvesting and picking
• Weed control
• Autonomous mowing, pruning, seeding, spraying and thinning
• Phenotyping
• Sorting and packing
• Utility platforms

Harvesting and picking is one of the most popular robotic applications in agriculture due to the accuracy and speed that robots can achieve to improve the size of yields and reduce waste from crops being left in the field.

These applications can be difficult to automate, however. For example, a robotic system designed to pick sweet peppers encounters many obstacles. Vision systems have to determine the location and ripeness of the pepper in harsh conditions, including the presence of dust, varying light intensity, temperature swings and movement created by the wind.

But it still takes more than advanced vision systems to pick a pepper. A robotic arm has to navigate environments with just as many obstacles to delicately grasp and place a pepper. This process is very different from picking and placing a metal part on an assembly line. The agricultural robotic arm must be flexible in a dynamic environment and accurate enough not to damage the peppers as they’re being picked.

Harvesting and picking robots are becoming very popular among farmers, but there are dozens of other innovative ways the agricultural industry is deploying robotic automation to improve their production yields.

The demand for food is outpacing available farmland and it’s up to farmers to close this gap. Agricultural robots are helping them do just that.

Robot Safety Standards: A Brief Overview

As industrial robots continue to become more advanced, more capable and more popular on the international stage, the need for comprehensive robot safety standards increases exponentially.

Robots can be dangerous to operate – especially when safety protocols aren’t followed. While standards for operation are important, safety standards have a far larger impact than safe operation of industrial robots.

Robots are a relatively new technology and still gaining widespread adoption, so you may be wondering, what is a robot safety standard? Why do they matter?

What is a Robot Safety Standard?

A robot safety standard is a collection of guidelines for robot specifications and safe operations in which all involved in the manufacture, sales and use of robots must follow. Often, standards are created by a diverse group of industry interests to ensure the standards benefit everyone.

Some common standards organizations include:

• American National Standards Institute (ANSI)
  • U.S. Standards Body including CSA, BSI, DIN, AFNOR, JISC and more
• International Organization for Standardization (ISO)
  • International Standards Body
• International Electrotechnical Commission (IEC)
  • International Standards Body

Much of the work of robot safety standards organizations is involved in making international robot standards. This is where robot safety standards begin to have a much larger impact on the global market.

Why Are Robot Safety Standards Important?

Robot safety standards are beneficial to the global robotics industry in many ways, which is why so many experts from various fields divert time and energy into developing effective standards.

Every country has different robot safety standards. International standards organizations work to unify and assimilate these separate sets of robot standards into a more cohesive whole. This allows for easier use and sales of industrial robots – stabilizing markets and incentivizing the further growth of robotics as a whole.

Robot safety standards are still evolving and will continue to evolve as the global market for industrial robots grows and inevitably changes. They play an important role in the international adoption of industrial robots, even if you may not have heard of them before.

To get a deeper dive into robot safety standards, the organizations that create these standards and what the future may hold, watch our free archived webinar, "Robot Safety Standards Update."

IIoT In Your Factory: The Role of Robotics

The Industrial Internet of Things (IIoT) is poised to
revolutionize manufacturing as we know it. The concept refers to the ability of different devices to be connected to each other and to a centralized system of one form or another. This enables many different things.

In theory, IIoT-connected devices can do anything from provide in-depth data, optimize operations, or teach a machine how to optimize its own performance without stopping production.

In practice, why is this significant to industrial robots? What role do industrial robots have to play in IIoT?

IIoT and the Role of Robotics

Industrial robots are perfectly positioned to be equipped with IIoT devices as they are at the heart of the production process. Additionally, robots are inherently connected, when compared to manual processes.

It’s because of their connectivity and proximity to production processes can take measurements and record data about their own performance as well as overall throughput and a number of other things. They provide a perfect opportunity for the deployment of IIoT initiatives.

IIoT and Robotics in the Workplace Today

IIoT may seem more fictional than real, but there are a few trailblazers in the manufacturing sector that are beginning to see the true benefits of doubling down on IIoT initiatives. Unsurprisingly, General Motors (GM) is one of these trailblazers.

In 2014, they teamed up with FANUC and Cisco to launch their Zero Down Time (ZDT) solution. The goal was to build a connected network of robots for painting, dispensing and welding that would be smart enough to know when they needed maintenance so that they wouldn’t break down. As the technology evolves, the system will transform into more of an in-process adaptive tool, where robots can monitor and automatically adjust their own performance for maximum productivity.

Nearly 8,500 connected robots later, with more being implemented and connected to the cloud every day, the program has been a huge success. GM has been able to avoid over 100 significant unscheduled downtimes since the program began. That’s a massive savings considering 60 seconds of downtime can cost them as much as $20,000.

IIoT is just beginning to take hold in some of the largest, most automated factories in the world. Robots are playing a crucial role in this automation. Their proximity to production processes and inherent connectivity have made them an important part of integrating IIoT concepts from the ground up.

Connecting Industrial Robotics with IIoT in Your Factory

The industrial internet of things (IIoT) presents enormous productivity potential for manufacturers, but the true benefits can be difficult to realize. Industrial robotics inherently promote connectivity and are proving to be a great starting point for broader IIoT initiatives.

Industrial robots are increasingly integrated with the IIoT in manufacturing facilities across the world. Some of the world's largest manufacturers have already seen big profits, but most manufacturers are just starting to implement robotic connectivity in their facilities.

Industrial Robotic Connectivity is a Quickly Maturing Technology

General Motors (GM), perpetually a leader in automation technology, was one of the first to invest heavily in robotic connectivity and have established a framework for success.

GM has over 7,500 connected robots in their facilities with the goal of collecting real-time data on robotic performance. Currently, this helps productivity by avoiding unnecessary downtime. They're able to see when a robot needs maintenance and proactively address performance issues before the entire assembly line shuts down. In the future, though, they plan to adjust robotic accuracy and repeatability in real time to improve product quality.

While GM is a leader in robotic connectivity, the technology is becoming widely available across the industrial sector.

The State of Robotic Connectivity in Today's Factories

A recent panel of experts weighed in on today's robotic connectivity technology in an RIA webinar. One of the main conclusions reached was that most businesses leveraging industrial robotics technology are now highly interested in mining more data from these robots.

Typically, robots feature an Ethernet or wifi connection. Most manufacturers want their robots to connect to the cloud with no PLC in the middle for easier data collection and mining. When robot data is brought into the cloud, it can more cleanly be brought into plant production networks or local ERP systems for process analysis.

In general, we're in the early stages of connected robot technology, but the desire for greater connectivity exists. For many facilities, it simply comes down to making the investment at the right time.