According to the International Federation of Robotics (IFR), global manufacturing averaged 74 robot units per 10,000 employees in 2017. As industrial automation intensifies, ensuring worker safety amid robotic integration becomes paramount. Traditional industrial robots—confined to safety cages—handled hazardous, repetitive, or precision-critical tasks ("dirty, dull, dangerous"). However, tasks demanding both robotic repeatability and human dexterity necessitated a paradigm shift.
Evolution of Human-Robot Collaboration
The 1990s witnessed the emergence of collaborative robots (cobots). Designed with reduced mass, compact footprints, and inherent safety features, cobots operate without physical barriers. Modern facilities deploy them for material handling, assembly, quality inspection, and hazardous material operations. Yet, uncaged operation doesn’t equate to inherent safety. As cobot density increases, proactive risk management is non-negotiable.
ISO/TS 15066: The Cobot Safety Framework
The ISO/TS 15066 technical specification (2006) defines safety requirements for collaborative operations. Compliance mandates at least one core safety feature:
Safety-rated monitored stop (halts operation upon human intrusion)
Hand guiding (human-directed motion control)
Speed and separation monitoring (SSM, dynamic distance-based speed regulation)
Power and force limiting (PFL, intrinsic torque/force constraints)
These ensure incidental human-robot contact prevents injury or pain
Comprehensive Risk Assessment Protocol
Deploying cobots requires exhaustive risk assessment:
Collaborative workspace analysis: Map human-robot interaction points
Task-specific hazard identification: Evaluate all potential contact scenarios (transient vs. quasi-static)
ALARA principle (As Low As Reasonably Achievable): Mitigate all identified risks, not just critical ones
Hazard-control linking: Pair each hazard (e.g., pinch points, impact zones) with engineered/administrative controls
Operator transparency: Disclose residual risks and safety protocols post-assessment
Critical Safety Considerations Beyond the Cobot
While cobots reduce workplace hazards, ancillary risks persist:
End-of-arm tooling (EOAT) hazards: Sharp, hot, or heavy EOAT (e.g., knives, welding torches) requires separate safeguarding
Peripheral equipment: Conveyors, presses, or automated guided vehicles (AGVs) in shared spaces need revalidation
Dynamic risk reevaluation: Safety protocols must evolve with task modifications or workspace reconfiguration
Conclusion
Cobots revolutionize productivity by merging human ingenuity with robotic precision, but their safety hinges on rigorous adherence to ISO/TS 15066 and proactive risk governance. Manufacturers must treat every cobot application as unique—validating not just the robot’s safety features, but the entire integrated system. Remember: True collaboration demands that safety engineering precedes operational efficiency. Only through meticulous planning, continuous risk assessment, and operator education can we ensure that cobots deliver more good than harm.
