Is a robot considered a complete machine according to the Machinery Directive? Justify your answer.

No. A pure industrial robot is considered an 'incomplete machine' because it is not assigned to a specific application according to VDI 2860. A robot system with a specific application, however, is considered a complete machine.

Name and briefly describe the three stages of safety technology for robot systems.

The three stages of safety technology are: 1. Unmittelbare Sicherheitstechnik (Direct Safety Technology): Eliminate hazards or reduce risk through design. 2. Mittelbare Sicherheitstechnik (Indirect Safety Technology): Install protective devices against remaining risks. 3. Hinweisende Sicherheitstechnik (Indicative Safety Technology): Inform users about residual risks.

Name five typical mistakes that frequently occur in robot deployment and briefly explain how they can be avoided.

Five typical mistakes in robot deployment are: 1. Underestimating load and inertia (avoid by considering all load-relevant criteria). 2. Trying to do too much at once (avoid by thorough planning and simulation). 3. Underestimating cabling issues (avoid by early definition and internal cabling). 4. Missing application definition (avoid by using 'LOSTPED' analysis). 5. Misunderstanding accuracy vs. repeatability (avoid by asking manufacturers for absolute accuracy if relevant).

Based on the DIN EN ISO 13849 risk graph, what Performance Level (PL) is required if the severity of injury is severe (S2), the frequency of exposure is frequent/permanent (F2), and the possibility of avoiding the hazard is hardly possible (P2)?

According to the risk graph, S2, F2, P2 leads to a required Performance Level 'e'.

To ensure personnel protection, 'protective devices' are often used. How can these be distinguished into two classes, and provide two examples for each class?

Protective devices can be distinguished into two classes: 1. Trennende Schutzeinrichtungen (Separating Protective Devices), e.g., safety fences, safety doors. 2. Nicht-trennende Schutzeinrichtungen (Non-separating Protective Devices), e.g., safety mats, light curtains.

Robot Systems: Legal, Safety, and Integration Cheat Sheet

This cheat sheet summarizes the essential foundations for placing robot systems on the market, focusing on legal aspects, safety standards, and integration considerations. It provides critical insights into risk assessment, safety measures, and common pitfalls in robot deployment.

Core Principles

Robot systems: Deployment aspects include legal bases, safety, and integration.
Essential foundations for placing robot systems on the market must be understood.
Further guidance on robot deployment must be considered.
Key norms and guidelines for robotics must be identified and their content outlined.
The process for safety assessment of robot systems needs to be described.
Safety functionalities of robots and safety devices must be presented.
Aspects of robot integration and workspace design are crucial considerations.
Industrial robots are recognized as potential sources of danger.
EC Declaration of Conformity and CE marking are mandatory for robot systems.
Relevant industrial robot standards must be observed.
Risk assessment is a central and mandatory process.
Safety technology is categorized into direct, indirect, and indicative measures.
Contact situations between humans and robots are classified as transient or quasi-static.
Transient contact is a dynamic impact of short duration where a body part can recoil.
Quasi-static contact involves pinching or crushing of a body part over a longer duration.
Biomechanische Belastungswerte (biomechanical load values) are based on pain threshold studies (ISO/TS 15066).
The pain onset threshold is the transition from a pressure sensation to pain.
The injury onset threshold is the development of slight swelling or a hematoma.
Every robot cell or system must have an EC Declaration of Conformity and a CE mark when placed on the EU market.
A 'machine' is an assembly of interconnected parts with a drive system for a specific application.
A pure industrial robot is considered an 'incomplete machine' as it lacks a specific application.
A robot system with a specific application is classified as a complete machine.
Norms define requirements for products, services, or processes.
Type A norms are basic safety standards (e.g., EN ISO 12100).
Type B norms are group safety standards (e.g., B1 general aspects, B2 safety devices).
Type C norms are machine-specific safety standards (e.g., EN ISO 10218).
Type C norms take precedence in cases of deviations or higher detail.
ISO 10218 (Parts 1 & 2) addresses specific hazards from industrial robots and systems.
Risk assessment can be performed using a structured risk graph (DIN EN ISO 13849).
The required Performance Level (PL) is determined by the severity, frequency, and avoidability of the hazard.
The achieved Performance Level of a safety function is calculated by summing the failure probabilities of its components.
The appropriateness of safety measures is verified by comparing the achieved PL with the required PL.
Achieving CE marking involves 8 structured steps, starting with a risk assessment.
Significant changes to a robot system after commissioning necessitate a new conformity assessment.
The totality of safety measures follows a hierarchy: direct, indirect, and indicative.
Direct safety technology eliminates hazards or reduces risks through constructive design.
Indirect safety technology involves installing separating or non-separating protective devices.
Indicative safety technology informs users about residual risks through manuals and warnings.
An approval device (Zustimmungseinrichtung) allows machine functions only when continuously actuated.
Manual setup operating modes permit reduced or high speeds under specific protective conditions.
Mechanical, electromechanical, or electronic axis limitations must be provided for main robot axes.
Collaborative robots employ specific safety mechanisms like compliance, torque measurement, and various sensors.

Key Terms

Einsatzaspekte: The overarching topic covering legal, safety, and integration aspects of robot systems.
Rechtsgrundlagen: The legal framework and regulations governing the deployment and operation of robot systems.
Sicherheit: Measures and standards designed to protect personnel and prevent damage during robot operation.
Integration: The process of incorporating robots into a larger production environment, considering all interfaces and interactions.
Endeffektoren: Devices attached to the robot arm that interact directly with workpieces or the environment, such as grippers.
Greifsysteme: Systems designed to grasp and manipulate objects, often part of a robot's end effector.
Konformitätserklärung: A formal declaration by the manufacturer stating that a product complies with all relevant EU directives.
CE-Kennzeichen: A mandatory marking on products sold within the European Economic Area, indicating conformity with health, safety, and environmental protection standards.
Risikobeurteilung: A systematic process to identify hazards, estimate risks, and evaluate the need for risk reduction measures.
Sicherheitstechnik: The application of technical measures to ensure safety, categorized into direct, indirect, and indicative.
Transienter Kontakt: A dynamic impact situation where a body part collides with a moving robot part and can recoil, typically of short duration.
Quasistatischer Kontakt: A situation where a body part is pinched or crushed between a robot system and another object, applying pressure or force over a longer duration.
Schmerzeintrittsschwelle: The level of force or pressure at which a sensation of pressure transitions into pain.
Verletzungseintrittsschwelle: The level of force or pressure at which a slight swelling or hematoma begins to form.
Maschine: An assembly of interconnected parts, at least one of which is movable, equipped with a drive system, and assembled for a specific application.
Unvollständige Maschine: A machine that cannot perform its specific application independently and requires further integration (e.g., a pure industrial robot).
Norm: A document that specifies requirements for products, services, or processes to ensure quality, safety, or interoperability.
Performance Level (PL): A discrete level specifying the ability of safety-related parts of a control system to perform a safety function under foreseeable conditions (a-e).
Restrisiko: The remaining risk after all reasonably practicable safety measures have been implemented.
Zustimmungseinrichtung: A hand-operated control device that, when continuously actuated, allows a machine function to be performed, typically used in setup modes.
Einrichtbetriebsarten: Specific operating modes for industrial robots that allow manual control, often with reduced speed and special safety conditions, for setup and programming.
Schutzeinrichtungen: Devices or systems designed to protect personnel from hazards, classified as separating or non-separating.
Trennende Schutzeinrichtungen: Protective devices that physically separate personnel from hazardous areas (e.g., safety fences, doors).
Nicht-trennende Schutzeinrichtungen: Protective devices that do not physically separate but detect presence or approach (e.g., safety mats, light curtains, laser scanners).
Singularitäten: Configurations of a robot where two or more axes become collinear, leading to loss of degrees of freedom and unpredictable movements, negatively impacting cycle time.

Quiz

Is a robot considered a complete machine according to the Machinery Directive? Justify your answer.: No. A pure industrial robot is considered an 'incomplete machine' because it is not assigned to a specific application according to VDI 2860. A robot system with a specific application, however, is considered a complete machine.
Name and briefly describe the three stages of safety technology for robot systems.: The three stages of safety technology are: 1. Unmittelbare Sicherheitstechnik (Direct Safety Technology): Eliminate hazards or reduce risk through design. 2. Mittelbare Sicherheitstechnik (Indirect Safety Technology): Install protective devices against remaining risks. 3. Hinweisende Sicherheitstechnik (Indicative Safety Technology): Inform users about residual risks.
Name five typical mistakes that frequently occur in robot deployment and briefly explain how they can be avoided.: Five typical mistakes in robot deployment are: 1. Underestimating load and inertia (avoid by considering all load-relevant criteria). 2. Trying to do too much at once (avoid by thorough planning and simulation). 3. Underestimating cabling issues (avoid by early definition and internal cabling). 4. Missing application definition (avoid by using 'LOSTPED' analysis). 5. Misunderstanding accuracy vs. repeatability (avoid by asking manufacturers for absolute accuracy if relevant).
Based on the DIN EN ISO 13849 risk graph, what Performance Level (PL) is required if the severity of injury is severe (S2), the frequency of exposure is frequent/permanent (F2), and the possibility of avoiding the hazard is hardly possible (P2)?: According to the risk graph, S2, F2, P2 leads to a required Performance Level 'e'.
To ensure personnel protection, 'protective devices' are often used. How can these be distinguished into two classes, and provide two examples for each class?: Protective devices can be distinguished into two classes: 1. Trennende Schutzeinrichtungen (Separating Protective Devices), e.g., safety fences, safety doors. 2. Nicht-trennende Schutzeinrichtungen (Non-separating Protective Devices), e.g., safety mats, light curtains.