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.