How to keep your workers safe with collaborative applications

Collaborative robots have changed the manufacturing industry. Allowing machines and humans to work next to each other safely on the factory floor.  

Safety and compliance are critical as we move closer to Industry 5.0 - where man and machine work together on a smart factory floor. Especially when 85 per cent of manufacturers expect 'human-machine-centric environments' will be commonplace by 2020. 

Collaborative applications, which are essential tools of advanced automation, are what you can consider adopting to keep your workers safe.  

What is a collaborative application? 

A collaborative application is where your workers have the ability to engage directly with a robot as part of a process they have to complete. Think of the robots as work tools that are there to support your employees. For example, you could deploy a collaborative robot into your production to support your workers with product assembly to increase quality, consistency and production speed.  

In most cases, collaborative robots don’t require safety fencing (subject to a risk assessment). They can complete tasks alongside your worker's safely and the robots themselves are flexible and they can be easily moved around the factory floor. 

Their easy programming and flexibility mean they can automate virtually anything from assembly and painting to labelling, packing and small-batch and mixed-product assembly.  

To keep up with the changing manufacturing landscape, businesses must adopt new technologies and integrate collaborative applications to remain competitive. Joe Gemma, President of the International Federation of Robotics believes “robots offer high levels of precision and their connectivity will play a key role in new digital manufacturing environments”. 

Customising your collaborative application 

When considering your collaborative application, you will need accessories or products that work with your robot. 

There are many types of cutting-edge products and software you can use with a UR robot to customise an application specifically to your needs. There are end-effectors, accessories and software for all types of applications including: 

?   Pick and place 

?   CNC 

?   Screw driving 

?   Lab analysis and testing 

?   Machine tending 

?   Polishing 

?   Injection molding 

?   Packaging and palletising 

?   Assembly 

?   Gluing, dispensing and welding 

?   Quality inspection 

The robot accessories you use will depend on the type of process you want to automate and the type of application you want to create. Have a look at the Universal Robots+ (or UR+) online showroom. Here you will find tested and approved products (i.e. end-effectors, vision cameras and software) that work with UR robots. Our showroom will provide you with a better understanding of what is possible for your business. Learn more about Universal Robots+ HERE. 

Servo-electric grippers, for example, are products that work well with UR robots because they have the ability to sense when an object comes in contact with the fingers of the gripper. Servo-electric grippers easily control the gripping force by controlling the current applied to the electric motor. This allows your task to be completed safely and effectively. Other end-effectors like milling tools, screwdrivers, or welding torches can be used however they do require careful consideration during the risk assessment of a collaborative application. 

Servo-electric grippers are recommended for many handling applications with collaborative robots because they add value in certain production processes where collaborative operation with workers and a robot is required. 

Whippany Actuations Systems in the US makes electro-mechanical actuation systems for the aerospace and defence industries. They have deployed a collaborative application that uses a servo-electric gripper on a CNC machine. Watch the collaborative application in progress and learn about the benefits Whippany Actuations Systems has received HERE. 

To find out how you can develop a collaborative application for your business contact us and we will connect you with a channel partner in your region. Call +65 6635 7270 or click HERE to access our online contact form taking just 1 minute to complete. 

Protecting your company's greatest asset 

Your employees are your greatest asset and safety must come first. 

In February 2016, guidelines on how to ensure the safety of workers in collaborative robot systems were published by the International Organisation for Standardisation (ISO). ISO/TS 15066 shows System Integrators how to safely implement collaborative robots into a production environment. 

Collaborative robots are safe. UR robots, for example, have a patented safety system featuring seven fixed safety functions: emergency and safeguard stopping mechanisms to protect workers from being exposed to a hazard in the workspace as well as digital output safety signals that can be sent to other safety equipment within the installation to report the status of the robot system in a safe and reliable manner. 

There are also eight adjustable safety functions present: join positions and speeds, TCP positions, orientation, speed, and force, as well as the momentum and power of the robot. Each of these can be set according to requirements deemed necessary in risk assessments based on the ISO/TS 15066 guidelines. You can read more about the guidelines HERE. 

Risk assessments are essential for safety 

The UR robot patented safety system, is TüV-certified and in most cases, these robots can be deployed without the need for safety fencing (unlike traditional robots), however, this is subject to a risk assessment. 

Collaborative robots work alongside people safely yet it's the way you use the robots in your business and the type of application you create that must be assessed to ensure the health and safety of your workers. 

Risk assessments are essential and must be completed as part of the deployment process. How will you know if the application you're integrating your robot into is safe if you haven’t completed a risk assessment? How will you know if there are potential risks? 

In most cases, the Systems Integrator completes the risk assessment. They will assess the application to ensure its safety in the workplace. Most Systems Integrators will have an internal policy detailing how these assessments are conducted. In some cases, end users will have their own internal risk assessment policy, which they will implement. 

Either way, a risk assessment must be completed. If you don't have a policy in place in your business, talk to your Systems Integrator to ensure they have one and talk to them about what is involved. Or, you can contact a third party organisation such as TüV Rheinland for advice on how to carry out a risk assessment. The more informed you are, the safer your workers will be. 

It's paramount that a risk assessment is carried out to determine whether the way you're using the collaborative robot in your application is safe. A risk assessment is essential for ensuring the safety of your greatest asset, your employees. 

It is important to note, safety guidelines for traditional robots are completely different to safety guidelines for collaborative robots. If you have safety guidelines based on traditional industrial robot deployments, you will need to update them. You can read more about the ISO/TS 15066 guidelines HERE. 

About the author: 

Shermine Gotfredsen is the General Manager Universal Robots Pte Ltd (Southeast Asia and Oceania). Shermine is committed to working in partnership with companies across the SEAO region to help them make the right decisions on how to improve productivity through automation.