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What are effective strategies for reducing human injury from industrial robots?

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Industrial robots are powerful and versatile machines that can perform complex tasks with precision and speed. However, they also pose potential risks to human workers who share the same workspace or interact with them. According to the International Federation of Robotics, there were 2,722 robot-related accidents reported worldwide between 1993 and 2019, resulting in 34 fatalities and 2,688 injuries. How can control engineers design and implement effective strategies for reducing human injury from industrial robots? Here are some key aspects to consider.

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Aaron Prather

Director, Robotics & Autonomous Systems Program at ASTM International
Marco Antonio Escalona

Business strategist | Business growth expert | CXM | Inspirational leader of commercial teams | Sales | Retail | P&L |…

1 Safety standards

The first step to ensure robot safety is to follow the relevant standards and regulations that apply to your industry and region. For example, the ISO 10218-1 and ISO 10218-2 standards provide general requirements and guidance for the design, integration, and validation of industrial robots and robot systems. The ISO/TS 15066 standard specifies safety requirements for collaborative robots that work directly with humans. The ANSI/RIA R15.06 standard covers safety requirements for industrial robots in North America. By complying with these standards, you can avoid common hazards and ensure the quality and reliability of your robot systems.

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Marco Antonio Escalona

Business strategist | Business growth expert | CXM | Inspirational leader of commercial teams | Sales | Retail | P&L | Mentor | Disruptive | Coach | Altruistic | Speaker | Author of the book "Crece Feliz" | 28K
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Siempre he pensado que llegará el gran momento de convivir en una línea de producción con los robots y estoy seguro que debe haber una nueva carrera que prepara a cierto tipo de personas para que ayuden a crear un ambiente de convivencia y esta se logre de la mejor manera, por el momento, solo se me ocurre que se debe de incluir a los equipos que van a convivir para que sean ellos los que definan la mejor manera de hacer este proceso.

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2 Risk assessment

The second step to ensure robot safety is to conduct a thorough risk assessment of your robot system and its environment. A risk assessment is a systematic process of identifying, analyzing, and evaluating the potential hazards and harms that may arise from the interaction between the robot and the human, as well as the measures to eliminate or reduce them. A risk assessment should consider factors such as the robot's speed, force, shape, motion, function, location, accessibility, and emergency stop. A risk assessment should also involve the participation of the workers who will operate or maintain the robot, as they can provide valuable feedback and suggestions.

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Aaron Prather

Director, Robotics & Autonomous Systems Program at ASTM International
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It is critical that a risk assessment is performed on your robot application. One should start with the part that the robot is going to be handle, because the part is one of the items that makes up your application. Then work up through the rest of the application, look at the end effector, then the robot itself. Take into account all of the points in the application and how they impact safety. Then look at the different categories of the people that may interact with the robot. This can be everyone from the employee that will work with the application daily, to the maintenance people, the clean crew, and even visitors. Training may be part of your risk mitigation per the assessment. Are you going to train visitors to your facility?

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3 Safety features

The third step to ensure robot safety is to incorporate safety features into your robot system that can prevent or mitigate human injury. Safety features can be classified into three categories: hardware, software, and human-robot interface. Hardware features include sensors, guards, barriers, interlocks, brakes, and limit switches that can detect or stop the robot's movement in case of danger. Software features include safety functions, modes, and parameters that can control or modify the robot's behavior according to the situation. Human-robot interface features include indicators, warnings, signals, displays, and controls that can inform or instruct the human operator about the robot's status and actions.

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Aaron Prather

Director, Robotics & Autonomous Systems Program at ASTM International
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Safety features can run the gamut from physical items on the robot application to workers themselves. There can also be things like required training or access limitations based on job roles. The goal of any feature is to mitigate risk and get the risk to an acceptable level. Now everyone's definition of acceptable risk could be different. However, if one can not mitigate the risks to acceptable levels, one has to wonder if the application should even be deployed. It should be noted that a Risk Assessment can and will be used by regulatory and potentially lawyers if there is an incident. A good rule of thumb is if you are not willing to put one of your loved ones in the application, then you should put no one in that application.

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4 Safety training

The fourth step to ensure robot safety is to provide safety training to the workers who will interact with the robot. Safety training is essential to educate and inform the workers about the potential risks and hazards of working with robots, as well as the proper procedures and precautions to follow. Safety training should cover topics such as the robot's capabilities and limitations, the safety features and functions, the emergency response and recovery, and the maintenance and inspection. Safety training should also include practical demonstrations and simulations that allow the workers to gain hands-on experience and confidence with the robot.

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5 Safety culture

The fifth step to ensure robot safety is to foster a safety culture within your organization that values and promotes the well-being of the workers and the robots. A safety culture is a set of beliefs, attitudes, and behaviors that influence how safety is perceived and practiced in the workplace. A safety culture can be enhanced by establishing clear and consistent safety policies and procedures, providing regular and constructive feedback and communication, encouraging reporting and learning from incidents and near-misses, recognizing and rewarding good safety performance, and involving the workers in safety decisions and improvements.

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6 Safety evaluation

The sixth step to ensure robot safety is to conduct periodic and systematic safety evaluations of your robot system and its performance. A safety evaluation is a process of measuring and monitoring the effectiveness and efficiency of the safety strategies and features that you have implemented, as well as identifying and addressing any gaps or weaknesses that may arise. A safety evaluation can involve methods such as testing, auditing, reviewing, surveying, and analyzing data and feedback. A safety evaluation can help you to verify and validate your robot system's compliance with the safety standards and regulations, as well as to improve and optimize your robot system's safety and reliability.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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What are effective strategies for reducing human injury from industrial robots?

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1 Safety standards

2 Risk assessment

3 Safety features

4 Safety training

5 Safety culture

6 Safety evaluation

7 Here’s what else to consider

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