SECTION IV: CHAPTER 4

INDUSTRIAL ROBOTS AND ROBOT SYSTEM SAFETY

Contents:
I.
II.
III.
IV.
V.
VI.
Introduction
Types and Classification of Robots
Hazards
Investigation Guidelines
Control and Safeguarding Personnel
Bibliography
Appendix IV:4-1. Glossary for Robotics and Robotic Systems
Appendix IV:4-2. Other Robotic Systems Not Covered by this Chapter
I. INTRODUCTION.
Industrial robots are programmable multifunctional mechanical devices designed to
move material, parts, tools, or specialized devices through variable programmed
motions to perform a variety of tasks. An industrial robot system includes not only
industrial robots but also any devices and/or sensors required for the robot to
perform its tasks as well as sequencing or monitoring communication interfaces.
Robots are generally used to perform unsafe, hazardous, highly repetitive, and
unpleasant tasks. They have many different functions such as material handling,
assembly, arc welding, resistance welding, machine tool load and unload functions,
painting, spraying, etc. See Appendix IV:4-1 for common definitions. Most robots
are set up for an operation by the teach-and-repeat technique. In this mode, a
trained operator (programmer) typically uses a portable control device (a teach
pendant) to teach a robot its task manually. Robot speeds during these
programming sessions are slow.
This instruction includes safety considerations necessary to operate the robot
properly and use it automatically in conjunction with other peripheral equipment.
This instruction applies to fixed industrial robots and robot systems only. See
Appendix IV:4-2 for the systems that are excluded.
A. ACCIDENTS: PAST STUDIES.
1. Studies in Sweden and Japan indicate that many robot accidents do
not occur under normal operating conditions but, instead during
programming, program touch-up or refinement, maintenance, repair,
testing, setup, or adjustment. During many of these operations the
operator, programmer, or corrective maintenance worker may
temporarily be within the robot's working envelope where unintended
operations could result in injuries.
2. Typical accidents have included the following:
A robot's arm functioned erratically during a programming
sequence and struck the operator.
A materials handling robot operator entered a robot's work
envelope during operations and was pinned between the back
end of the robot and a safety pole.
A fellow employee accidentally tripped the power switch while
a maintenance worker was servicing an assembly robot. The
robot's arm struck the maintenance worker's hand.
B. ROBOT SAFEGUARDING.
1. The proper selection of an effective robotic safeguarding system
should be based upon a hazard analysis of the robot system's use,
programming, and maintenance operations. Among the factors to be
considered are the tasks a robot will be programmed to perform,
start-up and command or programming procedures, environmental
conditions, location and installation requirements, possible human
errors, scheduled and unscheduled maintenance, possible robot and
system malfunctions, normal mode of operation, and all personnel
functions and duties.
2. An effective safeguarding system protects not only operators but also
engineers, programmers, maintenance personnel, and any others
who work on or with robot systems and could be exposed to hazards
associated with a robot's operation. A combination of safeguarding
methods may be used. Redundancy and backup systems are
especially recommended, particularly if a robot or robot system is
operating in hazardous conditions or handling hazardous materials.
The safeguarding devices employed should not themselves constitute
or act as a hazard or curtail necessary vision or viewing by attending
human operators.
II. TYPES AND CLASSIFICATION OF ROBOTS.
Industrial robots are available commercially in a wide range of sizes, shapes, and
configurations. They are designed and fabricated with different design
configurations and a different number of axes or degrees of freedom. These factors
of a robot's design influence its working envelope (the volume of working or
reaching space). Diagrams of the different robot design configurations are shown in
Figure IV: 4-1.
FIGURE IV:4-1. ROBOT ARM DESIGN CONFIGURATIONS.
A. SERVO AND NONSERVO.
All industrial robots are either servo or nonservo controlled. Servo robots are
controlled through the use of sensors that continually monitor the robot's
axes and associated components for position and velocity. This feedback is
compared to pretaught information which has been programmed and stored
in the robot's memory. Nonservo robots do not have the feedback capability,
and their axes are controlled through a system of mechanical stops and limit
switches.
B. TYPE OF PATH GENERATED. Industrial robots can be programmed from a
distance to perform their required and preprogrammed operations with
different types of paths generated through different control techniques. The
three different types of paths generated are Point-to-Point Path, Controlled
Path, and Continuous Path.
1. Point-to-Point Path. Robots programmed and controlled in this
manner are programmed to move from one discrete point to another
within the robot's working envelope. In the automatic mode of
operation, the exact path taken by the robot will vary slightly due to
variations in velocity, joint geometries, and point spatial locations.
This difference in paths is difficult to predict and therefore can create
a potential safety hazard to personnel and equipment.
2. Controlled Path. The path or mode of movement ensures that the
end of the robot's arm will follow a predictable (controlled) path and
orientation as the robot travels from point to point. The coordinate
transformations required for this hardware management are
calculated by the robot's control system computer. Observations that
result from this type of programming are less likely to present a
hazard to personnel and equipment.
3. Continuous Path. A robot whose path is controlled by storing a
large number or close succession of spatial points in memory during
a teaching sequence is a continuous path controlled robot. During
this time, and while the robot is being moved, the coordinate points
in space of each axis are continually monitored on a fixed time base,
e.g., 60 or more times per second, and placed into the control
system's computer memory. When the robot is placed in the
automatic mode of operation, the program is replayed from memory
and a duplicate path is generated.
C. ROBOT COMPONENTS. Industrial robots have four major components: the
mechanical unit, power source, control system, and tooling (Figure IV: 4-2).
1. Mechanical Unit. The robot's manipulative arm is the mechanical
unit. This mechanical unit is also comprised of a fabricated structural
frame with provisions for supporting mechanical linkage and joints,
guides, actuators (linear or rotary), control valves, and sensors. The
physical dimensions, design, and weight-carrying ability depend on
application requirements.
FIGURE IV:4-2. INDUSTRIAL ROBOTS:
MAJOR COMPONENTS.
2. Power Sources.
a. Energy is provided to various robot actuators and their controllers
as pneumatic, hydraulic, or electrical power. The robot's drives are
usually mechanical combinations powered by these types of energy,
and the selection is usually based upon application requirements. For
example, pneumatic power (low-pressure air) is used generally for
low weight carrying robots.
b. Hydraulic power transmission (high-pressure oil) is usually used
for medium to high force or weight applications, or where smoother
motion control can be achieved than with pneumatics. Consideration
should be given to potential hazards of fires from leaks if petroleum-
based oils are used.
c. Electrically powered robots are the most prevalent in industry.
Either AC or DC electrical power is used to supply energy to
electromechanical motor-driven actuating mechanisms and their
respective control systems. Motion control is much better, and in an
emergency an electrically powered robot can be stopped or powered
down more safely and faster than those with either pneumatic or
hydraulic power.
D. CONTROL SYSTEMS.
1. Either auxiliary computers or embedded microprocessors are used
for practically all control of industrial robots today. These perform all
of the required computational functions as well as interface with and
control associated sensors, grippers, tooling, and other associated
peripheral equipment. The control system performs the necessary
sequencing and memory functions for on-line sensing, branching,
and integration of other equipment. Programming of the controllers
can be done on-line or at remote off-line control stations with
electronic data transfer of programs by cassette, floppy disc, or
telephone modem.
2. Self-diagnostic capability for troubleshooting and maintenance
greatly reduces robot system downtime. Some robot controllers have
sufficient capacity, in terms of computational ability, memory
capacity, and input-output capability to serve also as system
controllers and handle many other machines and processes.
Programming of robot controllers and systems has not been
standardized by the robotics industry; therefore, the manufacturers
use their own proprietary programming languages which require
special training of personnel.
E. ROBOT PROGRAMMING BY TEACHING METHODS. A program consists of
individual command steps which state either the position or function to be
performed, along with other informational data such as speed, dwell or delay
times, sample input device, activate output device, execute, etc.
When establishing a robot program, it is necessary to establish a physical or
geometrical relationship between the robot and other equipment or work to
be serviced by the robot. To establish these coordinate points precisely
within the robot's working envelope, it is necessary to control the robot
manually and physically teach the coordinate points. To do this as well as
determine other functional programming information, three different
teaching or programming techniques are used: lead-through, walk-through,
and off-line.
1. Lead-Through Programming or Teaching. This method of
teaching uses a proprietary teach pendant (the robot's control is
placed in a "teach" mode), which allows trained personnel physically
to lead the robot through the desired sequence of events by
activating the appropriate pendant button or switch. Position data
and functional information are "taught" to the robot, and a new
program is written (Figure IV:4-3). The teach pendant can be the
sole source by which a program is established, or it may be used in
conjunction with an additional programming console and/or the
robot's controller. When using this technique of teaching or
programming, the person performing the teach function can be
within the robot's working envelope, with operational safeguarding
devices deactivated or inoperative.
FIGURE IV:4-3. ROBOT LEAD-THROUGH PROGRAMMING OR
TEACHING.
2. Walk-Through Programming or Teaching. A person doing the
teaching has physical contact with the robot arm and actually gains
control and walks the robot's arm through the desired positions
within the working envelope (Figure IV:4-4).
FIGURE IV:4-4. WALK-THROUGH PROGRAMMING OR
TEACHING.
During this time, the robot's controller is scanning and storing
coordinate values on a fixed time basis. When the robot is later
placed in the automatic mode of operation, these values and other
functional information are replayed and the program run as it was
taught. With the walk-through method of programming, the person
doing the teaching is in a potentially hazardous position because the
operational safeguarding devices are deactivated or inoperative.
Off-Line Programming. The programming establishing the required
sequence of functional and required positional steps is written on a
remote computer console (Figure IV:4-5). Since the console is
distant from the robot and its controller, the written program has to
be transferred to the robot's controller and precise positional data
established to achieve the actual coordinate information for the robot
and other equipment. The program can be transferred directly or by
cassette or floppy discs. After the program has been completely
transferred to the robot's controller, either the lead-through or walk-
through technique can be used for obtaining actual positional
coordinate information for the robot's axes.
FIGURE IV:4-5. OFF-LINE PROGRAMMING OR TEACHING.
When programming robots with any of the three techniques
discussed above, it is generally required that the program be verified
and slight modifications in positional information made. This
procedure is called program touch-up and is normally carried out in
the teach mode of operation. The teacher manually leads or walks
the robot through the programmed steps. Again, there are potential
hazards if safeguarding devices are deactivated or inoperative.
3. DEGREES OF FREEDOM. Regardless of the configuration of a robot,
movement along each axis will result in either a rotational or a
translational movement. The number of axes of movement (degrees
of freedom) and their arrangement, along with their sequence of
operation and structure, will permit movement of the robot to any
point within its envelope. Robots have three arm movements (up-
down, in-out, side-to-side). In addition, they can have as many as
three additional wrist movements on the end of the robot's arm: yaw
(side to side), pitch (up and down), and rotational (clockwise and
counterclockwise).
III. HAZARDS.
The operational characteristics of robots can be significantly different from other
machines and equipment. Robots are capable of high-energy (fast or powerful)
movements through a large volume of space even beyond the base dimensions of
the robot (see Figure IV:4-6). The pattern and initiation of movement of the robot is
predictable if the item being "worked" and the environment are held constant. Any
change to the object being worked (i.e., a physical model change) or the
environment can affect the programmed movements.
FIGURE IV:4-6. A ROBOT'S WORK ENVELOPE.
Some maintenance and programming personnel may be required to be within the
restricted envelope while power is available to actuators. The restricted envelope of
the robot can overlap a portion of the restricted envelope of other robots or work
zones of other industrial machines and related equipment. Thus, a worker can be hit
by one robot while working on another, trapped between them or peripheral
equipment, or hit by flying objects released by the gripper.
A robot with two or more resident programs can find the current operating program
erroneously calling another existing program with different operating parameters
such as velocity, acceleration, or deceleration, or position within the robot's
restricted envelope. The occurrence of this might not be predictable by maintenance
or programming personnel working with the robot. A component malfunction could
also cause an unpredictable movement and/or robot arm velocity.
Additional hazards can also result from the malfunction of, or errors in, interfacing
or programming of other process or peripheral equipment. The operating changes
with the process being performed or the breakdown of conveyors, clamping
mechanisms, or process sensors could cause the robot to react in a different
manner.
I. TYPES OF ACCIDENTS. Robotic incidents can be grouped into four
categories: a robotic arm or controlled tool causes the accident, places an
individual in a risk circumstance, an accessory of the robot's mechanical
parts fails, or the power supplies to the robot are uncontrolled.
1. Impact or Collision Accidents. Unpredicted movements,
component malfunctions, or unpredicted program changes related to
the robot's arm or peripheral equipment can result in contact
accidents.
2. Crushing and Trapping Accidents. A worker's limb or other body
part can be trapped between a robot's arm and other peripheral
equipment, or the individual may be physically driven into and
crushed by other peripheral equipment.
3. Mechanical Part Accidents. The breakdown of the robot's drive
components, tooling or end-effector, peripheral equipment, or its
power source is a mechanical accident. The release of parts, failure
of gripper mechanism, or the failure of end-effector power tools
(e.g., grinding wheels, buffing wheels, deburring tools, power
screwdrivers, and nut runners) are a few types of mechanical
failures.
4. Other Accidents. Other accidents can result from working with
robots. Equipment that supplies robot power and control represents
potential electrical and pressurized fluid hazards. Ruptured hydraulic
lines could create dangerous high-pressure cutting streams or
whipping hose hazards. Environmental accidents from arc flash,
metal spatter, dust, electromagnetic, or radio-frequency interference
can also occur. In addition, equipment and power cables on the floor
present tripping hazards.
II. SOURCES OF HAZARDS. The expected hazards of machine to humans can
be expected with several additional variations, as follows.
1. Human Errors. Inherent prior programming, interfacing activated
peripheral equipment, or connecting live input-output sensors to the
microprocessor or a peripheral can cause dangerous, unpredicted
movement or action by the robot from human error. The incorrect
activation of the "teach pendant" or control panel is a frequent
human error. The greatest problem, however, is overfamiliarity with
the robot's redundant motions so that an individual places himself in
a hazardous position while programming the robot or performing
maintenance on it.
2. Control Errors. Intrinsic faults within the control system of the
robot, errors in software, electromagnetic interference, and radio
frequency interference are control errors. In addition, these errors
can occur due to faults in the hydraulic, pneumatic, or electrical
subcontrols associated with the robot or robot system.
3. Unauthorized Access. Entry into a robot's safeguarded area is
hazardous because the person involved may not be familiar with the
safeguards in place or their activation status.
4. Mechanical Failures. Operating programs may not account for
cumulative mechanical part failure, and faulty or unexpected
operation may occur.
5. Environmental Sources. Electromagnetic or radio-frequency
interference (transient signals) should be considered to exert an
undesirable influence on robotic operation and increase the potential
for injury to any person working in the area. Solutions to
environmental hazards should be documented prior to equipment
start-up.
6. Power Systems. Pneumatic, hydraulic, or electrical power sources
that have malfunctioning control or transmission elements in the
robot power system can disrupt electrical signals to the control
and/or power-supply lines. Fire risks are increased by electrical
overloads or by use of flammable hydraulic oil. Electrical shock and
release of stored energy from accumulating devices also can be
hazardous to personnel.
7. Improper Installation. The design, requirements, and layout of
equipment, utilities, and facilities of a robot or robot system, if
inadequately done, can lead to inherent hazards.
INVESTIGATION GUIDELINES.
. MANUFACTURED, REMANUFACTURED, AND REBUILT ROBOTS.
1. All robots should meet minimum design requirements to ensure safe
operation by the user. Consideration needs to be given to a number
of factors in designing and building the robots to industry standards.
If older or obsolete robots are rebuilt or remanufactured, they should
be upgraded to conform to current industry standards.
2. Every robot should be designed, manufactured, remanufactured, or
rebuilt with safe design and manufacturing considerations. Improper
design and manufacture can result in hazards to personnel if
minimum industry standards are not conformed to on mechanical
components, controls, methods of operation, and other required
information necessary to insure safe and proper operating
procedures. To ensure that robots are designed, manufactured,
remanufactured, and rebuilt to ensure safe operation, it is
recommended that they comply with Section 4 of the ANSI/RIA
R15.06-1992 standard for Manufacturing, Remanufacture, and
Rebuild of Robots.
I. INSTALLATION.
1. A robot or robot system should be installed by the users in
accordance with the manufacturer's recommendations and in
conformance to acceptable industry standards. Temporary
safeguarding devices and practices should be used to minimize the
hazards associated with the installation of new equipment. The
facilities, peripheral equipment, and operating conditions which
should be considered are:
Installation specifications;
Physical facilities;
Electrical facilities;
Action of peripheral equipment integrated with the robot;
Identification requirements;
Control and emergency stop requirements; and
Special robot operating procedures or conditions.
2. To ensure safe operating practices and safe installation of robots and
robot systems, it is recommended that the minimum requirements of
Section 5 of the ANSI/RIA R15.06-1992, Installation of Robots and
Robot Systems be followed. In addition, OSHA's Lockout/Tagout
standards (29 CFR 1910.147 and 1910.333) must be followed for
servicing and maintenance.
CONTROL AND SAFEGUARDING PERSONNEL.
For the planning stage, installation, and subsequent operation of a robot or robot system,
one should consider the following.
0. RISK ASSESSMENT. At each stage of development of the robot and robot
system a risk assessment should be performed. There are different system
and personnel safeguarding requirements at each stage. The appropriate
level of safeguarding determined by the risk assessment should be applied.
In addition, the risk assessments for each stage of development should be
documented for future reference.
1. SAFEGUARDING DEVICES. Personnel should be safeguarded from hazards
associated with the restricted envelope (space) through the use of one or
more safeguarding devices:
Mechanical limiting devices;
Nonmechanical limiting devices;
Presence-sensing safeguarding devices;
Fixed barriers (which prevent contact with moving parts); and
Interlocked barrier guards.
2. AWARENESS DEVICES. Typical awareness devices include chain or rope
barriers with supporting stanchions or flashing lights, signs, whistles, and
horns. They are usually used in conjunction with other safeguarding devices.
3. SAFEGUARDING THE TEACHER. Special consideration must be given to
the teacher or person who is programming the robot. During the teach mode
of operation, the person performing the teaching has control of the robot
and associated equipment and should be familiar with the operations to be
programmed, system interfacing, and control functions of the robot and
other equipment. When systems are large and complex, it can be easy to
activate improper functions or sequence functions improperly. Since the
person doing the training can be within the robot's restricted envelope, such
mistakes can result in accidents. Mistakes in programming can result in
unintended movement or actions with similar results. For this reason, a
restricted speed of 250 mm/ or 10 in/ should be placed on any part of the
robot during training to minimize potential injuries to teaching personnel.
Several other safeguards are suggested in the ANSI/RIA R15.06-1992
standard to reduce the hazards associated with teaching a robotic system.
4. OPERATOR SAFEGUARDS. The system operator should be protected from
all hazards during operations performed by the robot. When the robot is
operating automatically, all safeguarding devices should be activated, and at
no time should any part of the operator's body be within the robot's
safeguarded area.
For additional operator safeguarding suggestions, see the ANSI/RIA R15.06-
1992 standard, Section 6.6.
5. ATTENDED CONTINUOUS OPERATION. When a person is permitted to be
in or near the robots restricted envelope to evaluate or check the robots
motion or other operations, all continuous operation safeguards must be in
force. During this operation, the robot should be at slow speed, and the
operator would have the robot in the teach mode and be fully in control of
all operations.
Other safeguarding requirements are suggested in the ANSI/RIA R15.06-
1992 standard, Section 6.7.
6. MAINTENANCE AND REPAIR PERSONNEL. Safeguarding maintenance
and repair personnel is very difficult because their job functions are so
varied. Troubleshooting faults or problems with the robot, controller, tooling,
or other associated equipment is just part of their job. Program touchup is
another of their jobs as is scheduled maintenance, and adjustments of
tooling, gages, recalibration, and many other types of functions.
While maintenance and repair is being performed, the robot should be
placed in the manual or teach mode, and the maintenance personnel
perform their work within the safeguarded area and within the robots
restricted envelope. Additional hazards are present during this mode of
operation because the robot system safeguards are not operative.
To protect maintenance and repair personnel, safeguarding techniques and
procedures as stated in the ANSI/RIA R15.06-1992 standard, Section 6.8,
are recommended.
7. MAINTENANCE. Maintenance should occur during the regular and periodic
inspection program for a robot or robot system. An inspection program
should include, but not be limited to, the recommendations of the robot
manufacturer and manufacturer of other associated robot system equipment
such as conveyor mechanisms, parts feeders, tooling, gages, sensors, and
the like.
These recommended inspection and maintenance programs are essential for
minimizing the hazards from component malfunction, breakage, and
unpredicted movements or actions by the robot or other system equipment.
To ensure proper maintenance, it is recommended that periodic
maintenance and inspections be documented along with the identity of
personnel performing these tasks.
8. SAFETY TRAINING. Personnel who program, operate, maintain, or repair
robots or robot systems should receive adequate safety training, and they
should be able to demonstrate their competence to perform their jobs
safely. Employers can refer to OSHA's publication 2254 (Revised), "Training
Requirements in OSHA Standards and Training Guidelines."
9. GENERAL REQUIREMENTS. To ensure minimum safe operating practices
and safeguards for robots and robot systems covered by this instruction, the
following sections of the ANSI/RIA R15.06-1992 must also be considered:
Section 6 - Safeguarding Personnel;
Section 7 - Maintenance of Robots and Robot Systems;
Section 8 - Testing and Start-up of Robots and Robot Systems; and
Section 9 - Safety Training of Personnel.
Robots or robotic systems must comply with the following regulations:
Occupational Safety and Health Administration, OSHA 29 CFR 1910.333,
Selection and Use of Work Practices, and OSHA 29 CFR Part 1910.147, The
Control of Hazardous Energy (Lockout/Tagout).
BIBLIOGRAPHY.
American National Standards Institute (ANSI) American National Safety Standard ANSI/
RIA R15.06-1992. Industrial Robots and Robot Systems - Safety Requirements. American
National Standards Institute, Inc., 1430 Broadway, New York, New York 10018
National Institute for Occupational Safety and Health (NIOSH) Alert Publication No. 85103.
Request for Assistance in Preventing the Injury of Workers by Robots. National Institute for
Occupational Safety and Health, Division of Safety Research, 944 Chestnut Ridge Road,
Morgantown, West Virginia 26505
National Institute for Occupational Safety and Health (NIOSH) Technical Report Publication
No. 880108. Safe Maintenance Guidelines for Robotic Workstations. National Institute for
Occupational Safety and Health, Division of Safety Research, 944 Chestnut Ridge Road,
Morgantown, West Virginia 26505
National Safety Council Data Sheet 1-717-85. Robots. National Safety Council, 444 N.
Michigan Avenue, Chicago, Illinois 60611
Occupational Safety and Health Administration Publication No. 2254 (Revised). Training
Requirements in OSHA Standards and Training Guidelines. Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C. 20210
Occupational Safety and Health Administration Publication No. 3067. Concepts and
Techniques of Machine Safeguarding. U.S. Department of Labor, 1980 (reprinted 1983).
Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20210
OSHA Instruction Publication No. 8-1.3. 1987. Guideline for Robotics Safety. Occupational
Safety and Health Administration, Washington, D.C.
Robotic Industries Association, 900 Victors Way, P.O. Box 3724, Ann Arbor, Michigan 48106
Underwriters Laboratories, Inc. 1996. Standard for Industrial Robots and Robotic
Equipment. ANSI/UL1740. Northbrook, Illinois
APPENDIX IV:4-1. GLOSSARY FOR ROBOTICS AND ROBOTIC SYSTEMS.
Actuator A power mechanism used to effect motion of the robot; a device that converts
electrical, hydraulic, or pneumatic energy into robot motion.
Application Program The set of instructions that defines the specific intended tasks of
robots and robot systems. This program may be originated and modified by the robot user.
Attended Continuous Operation The time when robots are performing (production)
tasks at a speed no greater than slow speed through attended program execution.
Attended Program Verification The time when a person within the restricted envelope
(space) verifies the robot's programmed tasks at programmed speed.
Automatic Mode The robot state in which automatic operation can be initiated.
Automatic Operation The time during which robots are performing programmed tasks
through unattended program execution.
Awareness Barrier Physical and/or visual means that warns a person of an approaching
or present hazard.
Awareness Signal A device that warns a person of an approaching or present hazard by
means of audible sound or visible light.
Axis The line about which a rotating body (such as a tool) turns.
Barrier A physical means of separating persons from the restricted envelope (space).
Control Device Any piece of control hardware providing a means for human intervention
in the control of a robot or robot system, such as an emergency-stop button, a start
button, or a selector switch.
Control Program The inherent set of control instructions that defines the capabilities,
actions and responses of the robot system. This program is usually not intended to be
modified by the user.
Coordinated Straight Line Motion Control wherein the axes of the robot arrive at their
respective end points simultaneously, giving a smooth appearance to the motion. Control
wherein the motions of the axes are such that the Tool Center Point (TCP) moves along a
prespecified type of path (line, circle, etc.)
Device Any piece of control hardware such as an emergency-stop button, selector switch,
control pendant, relay, solenoid valve, sensor, etc.
Drive Power The energy source or sources for the robot actuators.
Emergency Stop The operation of a circuit using hardware-based components that
overrides all other robot controls, removes drive power from the robot actuators, and
causes all moving parts to stop.
Enabling Device A manually operated device that permits motion when continuously
activated. Releasing the device stops robot motion and motion of associated equipment
that may present a hazard.
End-effector An accessory device or tool specifically designed for attachment to the
robot wrist or tool mounting plate to enable the robot to perform its intended task.
(Examples may include gripper, spot-weld gun, arc-weld gun, spray- paint gun, or any
other application tools.)
Energy Source Any electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or
other source.
Envelope (Space), Maximum The volume of space encompassing the maximum
designed movements of all robot parts including the end-effector, workpiece, and
attachments.
Restricted Envelope (Space) That portion of the maximum envelope to which a robot is
restricted by limiting devices. The maximum distance that the robot can travel after the
limiting device is actuated defines the boundaries of the restricted envelope (space) of the
robot.
NOTE: The safeguarding interlocking logic and robot program may redefine the restricted
envelope (space) as the robot performs its application program. (See Appendix D of the
ANSI/RIA R15.06-1992 Specification).
Operating Envelope (Space) That portion of the restricted envelope (space) that is
actually used by the robot while performing its programmed motions.
Hazard A situation that is likely to cause physical harm.
Hazardous Motion Any motion that is likely to cause personal physical harm.
Industrial Equipment Physical apparatus used to perform industrial tasks, such as
welders, conveyors, machine tools, fork trucks, turn tables, positioning tables, or robots.
Industrial Robot A reprogrammable, multifunctional manipulator designed to move
material, parts, tools, or specialized devices through variable programmed motions for the
performance of a variety of tasks.
Industrial Robot System A system that includes industrial robots, the end-effectors,
and the devices and sensors required for the robots to be taught or programmed, or for the
robots to perform the intended automatic operations, as well as the communication
interfaces required for interlocking, sequencing, or monitoring the robots.
Interlock An arrangement whereby the operation of one control or mechanism brings
about or prevents the operation of another.
Joint Motion A method for coordinating the movement of the joints such that all joints
arrive at the desired location simultaneously.
Limiting Device A device that restricts the maximum envelope (space) by stopping or
causing to stop all robot motion and is independent of the control program and the
application programs.
Maintenance The act of keeping the robots and robot systems in their proper operating
condition.
Mobile Robot A self-propelled and self-contained robot that is capable of moving over a
mechanically unconstrained course.
Muting The deactivation of a presence-sensing safeguarding device during a portion of
the robot cycle.
Operator The person designated to start, monitor, and stop the intended productive
operation of a robot or robot system. An operator may also interface with a robot for
productive purposes.
Pendant Any portable control device, including teach pendants, that permits an operator
to control the robot from within the restricted envelope (space) of the robot.
Presence-Sensing Safeguarding Device A device designed, constructed, and installed
to create a sensing field or area to detect an intrusion into the field or area by personnel,
robots, or other objects.
Program
1. (noun) A sequence of instructions to be executed by the computer or robot
controller to control a robot or robot system.
2. (verb) to furnish (a computer) with a code of instruction.
3. (verb) to teach a robot system a specific set of movements and instructions to
accomplish a task.
Rebuild To restore the robot to the original specifications of the manufacturer, to the
extent possible.
Remanufacture To upgrade or modify robots to the revised specifications of the
manufacturer and applicable industry standards.
Repair To restore robots and robot systems to operating condition after damage,
malfunction, or wear.
Robot Manufacturer A company or business involved in either the design, fabrication, or
sale of robots, robot tooling, robotic peripheral equipment or controls, and associated
process ancillary equipment.
Robot System Integrator A company or business who either directly or through a
subcontractor will assume responsibility for the design, fabrication, and integration of the
required robot, robotic peripheral equipment, and other required ancillary equipment for a
particular robotic application.
Safeguard A barrier guard, device, or safety procedure designed for the protection of
personnel.
Safety Procedure An instruction designed for the protection of personnel.
Sensor A device that responds to physical stimuli (such as heat, light, sound, pressure,
magnetism, motion, etc.) and transmits the resulting signal or data for providing a
measurement, operating a control, or both.
Service To adjust, repair, maintain, and make fit for use.
Single Point of Control The ability to operate the robot such that initiation or robot
motion from one source of control is possible only from that source and cannot be
overridden from another source.
Slow Speed Control A mode of robot motion control where the velocity of the robot is
limited to allow persons sufficient time either to withdraw the hazardous motion or stop the
robot.
Start-up Routine application of drive power to the robot or robot system.
Start-up, Initial Initial drive power application to the robot or robot system after one of
the following events:
Manufacture or modification;
Installation or reinstallation;
Programming or program editing; and
Maintenance or repair.
Teach The generation and storage of a series of positional data points effected by moving
the robot arm through a path of intended motions.
Teach Mode The control state that allows the generation and storage of positional data
points effected by moving the robot arm through a path of intended motions.
Teacher A person who provides the robot with a specific set of instructions to perform a
task.
Tool Center Point (TCP) The origin of the tool coordinate system.
User A company, business, or person who uses robots and who contracts, hires, or is
responsible for the personnel associated with robot operation.
APPENDIX IV: 4-2. OTHER ROBOTIC SYSTEMS NOT COVERED BY THIS CHAPTER.
Service robots are machines that extend human capabilities.
Automatic guided-vehicle systems are advanced material-handling or conveying
systems that involve a driverless vehicle which follows a guide-path.
Undersea and space robots include in addition to the manipulator or tool that actually
accomplishes a task, the vehicles or platforms that transport the tools to the site. These
vehicles are called remotely operated vehicles (ROV's) or autonomous undersea vehicles
(AUV's); the feature that distinguishes them is, respectively, the presence or absence of an
electronics tether that connects the vehicle and surface control station.
Automatic storage and retrieval systems are storage racks linked through
automatically controlled conveyors and an automatic storage and retrieval machine or
machines that ride on floor-mounted guide rails and power-driven wheels.
Automatic conveyor and shuttle systems are comprised of various types of conveying
systems linked together with various shuttle mechanisms for the prime purpose of
conveying materials or parts to prepositioned and predetermined locations automatically.
Teleoperators are robotic devices comprised of sensors and actuators for mobility and/or
manipulation and are controlled remotely by a human operator.
Mobile robots are freely moving automatic programmable industrial robots.
Prosthetic robots are programmable manipulators or devices for missing human limbs.
Numerically controlled machine tools are operated by a series of coded instructions
comprised of numbers, letters of the alphabet, and other symbols. These are translated into
pulses of electrical current or other output signals that activate motors and other devices to
run the machine.
Occupational Safety & Health Administration
OSHA Technical Manual
http://www.osha.gov/dts/osta/otm/otm_iv/otm_iv_4.html