Making Robotics Safety Job One

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To reap the benefits of robots, you must first ensure they are safe.

Contributor: MHI’s TRG (The Robotics Group)

Robots offer warehouses enormous efficiencies, and thanks to that promise—improved accuracy, cost savings, improved inventory management—the demand for robots is exploding. According to Statista, the annual growth rate over the next several years will be in the range of 15 percent, reaching $41 billion in 2027.¹ From automated guided vehicles (AGVs) to autonomous mobile robots (AMRs), articulated arms, and more, the robotics options are plentiful for making improvements to your operations.

Despite all that, robots are a moving object, no matter what form they come in. And when those moving objects are on a warehousing floor working alongside humans, safety is always going to be of top concern. “I’d say that 80 percent of the concerns I hear surround robots,” says Jacob Gross, application engineer at Sumitomo Corporation of America. “Most of that concern surrounds human and robot collision, but there are also concerns about damage to products, components and equipment.”

But robotics manufacturers have gone to great lengths to ensure their products have built in design features. When you add in thorough training and a consistent approach to safety, robots can deliver on their promises. “There are literally hundreds of ways to make robots safe,” says Gross.

Here’s what you need to know.

ASSESSING RISK

To understand the methods, you can use to protect your employees and equipment when robots on are the floor, the first thing you must do is determine what task you’re asking it to do. “Once you know that, a risk assessment is the best place to start,” says Dean Elkins, senior director of robotics and vision at GrayAES. “This will ensure that once you’ve deployed robots, you’ll be following the best safety practices.”

The American National Standards Institute (ANSI) and other regulatory organizations have developed several safety standards related to both stationary and mobile robots. It’s important to learn what those are and stay abreast of new standards the organization may develop. For instance, this year ANSI is releasing a new collaborative robot application safety standard that is worth knowing about.

When performing your risk assessment, you’ll want to work with your systems integrator and/or OEM to ensure each box is checked. “This is generally a two-part assessment that involves both machine safety and operational safety,” explains Elkins. “This isn’t a document driven by law, but a set of best practices. The safety of workers should always be the paramount concern in any manufacturing environment.”

DESIGN PHASE

After you’ve completed a risk assessment, you’ll be entering the design phase with your integrator partner. This will help you determine where to add safety features, such as fencing, a safety PLC system, how far to space out your robots and their reach to ensure safe operation, and more. Once you’ve built out your system, as part of factory acceptance, you will test your barriers and physical boundaries. “Ideally, your robots will slow down or stop when an object or person encroaches on their operating space” says Elkins. “You’ll also test the interlocks on the doors—you need to use common sense in the design and then do a test and final check off before launching.”

Your robot systems or AMR’s will come equipped with a host of safety features, including LIDAR sensing, emergency stop mechanisms, light curtains, “human-in-the-loop” systems, control algorithms to ensure the stability and robustness of robots, and more. It’s important to check all these systems before launching your robots onto the floor.

PUTTING IT ALL TOGETHER

Increasingly, AGVs and AMRs are working in a collaborative relationship with your employees. This means not just installing guarding like fences and interlocks but also training your staff to work safely in the robots’ presence. You should conduct this training at the outset, and then again on a regular, routine basis. “At the end of the day, if your training isn’t correct, then nothing else matters,” says Gross. “Training should be a top-of-the-line consideration.”

Your robotics partner can provide a “train the trainer” approach on safety, and you can then roll out your learnings to the entire warehouse staff. “Everyone on the floor should go through training,” says Gross.

Beyond live training on the floor, you can supplement the robot safety training with your staff through online tutorials and send your staff to conferences that address safety. “Appointing a champion of safety on the floor is a smart move,” says Elkins, “so that someone is ensuring the entire staff is up-to-speed with training.”

At the end of the day, your risk assessment should serve as your guide for “safety hardening,” says Elkins. “Follow all the guidelines for protective fencing and devices, understand the machine’s sensing systems, and provide training. Keeping your employees safe is the most important thing you can do.” WMHS

The Robotics Group (TRG) of MHI are leading manufacturers, integrators, consultants, and component suppliers of robotic solutions designed specifically for warehousing and distribution applications. Technology advancements are creating opportunities for robots and automated machinery in a wide variety of applications, including warehousing and distribution center activities. TRG conducts education and outreach with the goal of fostering technology adoption in this rapidly changing industry sector. Visit: https://www.mhi.org/trg