Pilz Robotics Safety Application Series II: Manual Handling

The Risks of Manual Tasks

In many industrial settings, human involvement is still necessary when operating robots, especially during tasks such as manual loading, unloading, and handling. These activities often require workers to interact with fixtures, turntables, and jigs, which can be dangerous due to the close proximity of moving robotic components.

When humans and robots share the same workspace, there's a high risk of accidents. Tooling systems are often equipped with jaws, cylinders, and other actuators that can move unpredictably, leading to hazards like crushing, shearing, or entanglement. This makes it crucial to implement proper safety measures to protect workers from these risks.

To ensure operator safety, targeted protective measures must be in place. These can range from physical barriers to advanced control systems designed to detect and respond to potential dangers in real time.

Human Interaction with Robots

Key Protective Measures

According to ISO 12100, interlocking devices and mechanical guards are among the most effective ways to reduce risk. These solutions are also widely used in robot safety applications to prevent accidental access to hazardous areas.

For example, fixed guards must meet specific standards, such as:

• Being removable only with special tools (e.g., Allen keys)
• Keeping fasteners attached to the guard or machine body even when removed
• Having a minimum height of 1,400 mm above the floor

These requirements come from international standards like ISO 14120 and ISO 13857 and are included in the robot safety standard ISO 10218-2.

Primary Safety Device for Robots

Additional Protective Measures

In situations where manual operations occur frequently, physical barriers may not always be practical. In such cases, additional safety measures should be considered after assessing all potential risks—like flying parts or sparks from welding.

Three common additional protection methods include:

- Stop Time Limit: The control system must have enough time to stop the robot before an operator enters a danger zone. This involves using interlocks, delays, speed monitoring, and position detection to ensure the robot is in a safe state.

- Light Curtain Activation: Light curtains can detect the presence of an operator and trigger an immediate stop of the machine, preventing collisions or injuries.

- Collaboration Space Restrictions: When a robot and worker share the same space, the workflow and control system must be designed so they never occupy the area at the same time. If both are present, the robot automatically stops to avoid danger.

Using Light Curtains to Stop the Machine

Limiting Collaborative Workspaces

Restricting the Area Where Humans and Robots Work Together

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