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Robot Safety Standard Independent Study

Robot Safety Standard Independent Study. Cory Grant Spring 2011 Illinois State University. Objectives. Study ANSI/RIA R15.06 Safety Standard Develop Risk Assessments Per Standard Design Physical/Electrical Safety System Implement Designed Safety System

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Robot Safety Standard Independent Study

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  1. Robot Safety Standard Independent Study Cory Grant Spring 2011 Illinois State University

  2. Objectives Study ANSI/RIA R15.06 Safety Standard Develop Risk Assessments Per Standard Design Physical/Electrical Safety System Implement Designed Safety System Check Implemented Safety System Against Standard Present Project to Illinois State University (Employer) Present Project to Heartland Community College (Customer)

  3. Logical Flow

  4. SMC FMS-200

  5. HCC Fanuc/SMC Workstation

  6. Robot Primary Function Screw/Torque Screws into Base

  7. Robot Secondary Function Load Shaft and Cover from Table Mounted Inventory Stand

  8. HCC Fanuc/SMC Workstation

  9. Robot Functions Assemblies Arrive on Conveyor Table Mounted Inventory Stand

  10. Robot Auxiliary Functions • Additional functions for external projects • Ex: Using robot for SIT Conference to write student participants names • May use table area, conveyor area, area in front of table, or any combination.

  11. Workstation Model

  12. Workstation Model

  13. Workstation Model

  14. Current User Position

  15. Current Student Position

  16. Initial Risk Assessment Created risk assessment chart based on RIA standard and ISU’s ABB risk assessment Station currently does not include any safety equipment Used standard set of safety equipment to predict risk reduction

  17. Planned Safety Solutions Presence sensing devices (curtain/mat) Barriers (fencing) Programming requirements (PLC/robot) Standard procedure training (classroom) Properly designed safety circuits (per NEC) Awareness Signal on Fencing Station Controls Moved to Fencing

  18. Light Curtain Values Per Figure B.2 Allen Bradley PAC T4H 3400N 3 Beams 23mm Beam Width 400mm Beam Center to Center Min Os=Beam C2C-Beam Width Min Os=400mm-23mm Min Os=377mm (14.85in) Therefore, Dpf=178mm (7.5in)

  19. Light Curtain Values Per Figure B.2 Allen Bradley PAC T4H 3400N 3 Beams 23mm Beam Width 400mm Beam Center to Center Min Os=Beam C2C-Beam Width Min Os=400mm-23mm Min Os=377mm (14.85in) Therefore, Dpf=178mm (7.5in)

  20. Fencing Opening Per Figure B.1 • 1.5in Square Openings • Per Figure B.1 • 1.25in Opening =6.5in Distance from Hazard • 1.875in Opening=17.5in Distance from Hazard • 1.875in-1.25in=0.625in (∆Opening) • 17.5in-6.5in=11in (∆Distance) • 11in/0.625in=17.6 (Distance Ratio) • 1.5in>1.25in by 0.25in (Opening Increase) • 17.6*0.25in=4.4in (Additional Distance) • 6.5in+4.4in=10.9in (Total Distance) Therefore Fence to Envelope≈11in

  21. Cell Model With Safety Solution Awareness Signal to Be Added 5 Foot Fencing 1.5” Square Openings Station Controls Moved to Fencing AB Light Curtain

  22. Cell Model With Safety Solution 19”>Required Figure-A.2 And Figure B.1 48”=Required Figure-B.2c 12”=Required Figure-B.2c

  23. Cell Model With Safety Solution 11”>Required Figure-B.2 12”=Required Figure-A.3

  24. Light Curtain Recalculation

  25. Cell Model With Safety Solution Real Distance≈25” 53”>Required Figure-B.2 12”=Required Figure-A.3

  26. Initial Risk Assessment

  27. Risk Solutions

  28. Post Risk Assessment

  29. Safety System Conditions And Outcomes

  30. Safety Circuit Truth Table

  31. Basic Safety Circuit Layout

  32. Circuit Layout

  33. Circuit Layout

  34. Concerns Fencing Interferes With Robot Envelope Possible Solutions: -Axis Limits -Additional Hard Stops

  35. Concerns Student Checking PLC Panel Without Safety Mat Robot Could Be Reset and Motion Started Possible Solutions: -Add Safety Mat Under Student

  36. Concerns Possibly Unprotected Area Inside System -Gaps at 4 Corners -Crawl Through Access to Inside Possible Solutions: -Safety Chains at 4 Corners -Barriers -Safety Mat Inside

  37. Concerns Accessing Center of System No Presence Sensing Devices Inside System Possible Solutions: -Add Safety Chains Over Gaps -Add Safety Mat Inside

  38. Solution-Soft Stops Two proximity sensors added to the base to detect J1 movement towards fencing

  39. Solution-Gap Chains Gap chains added to prevent entry into center of the system without setting off light curtain

  40. Solution-Standard Procedures Standard procedures for safe operation booklets added to outside fencing for operator reference

  41. Solution-Fencing

  42. Solution-PLC Panel Relocation Student technician outside of fencing while troubleshooting

  43. Solution-Robot E-Stop Board

  44. Solution-Robot E-Stop Board

  45. Solution-Light Curtain

  46. Solution-Op Panel Relocation Unable to reach reset button from inside fencing

  47. Appendix A-Figure A.2 Back

  48. Appendix A-Figure A.3 Back

  49. Appendix B-Figure B.1 Back

  50. Appendix B-Figure B.2 Back

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