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Enhancing Worker Safety with Collaborative Robots in the Manufacturing Industry
In recent years, the integration of robotics in manufacturing has rapidly transformed the industry. According to the International Federation of Robotics, in 2017, the global average of robots in the manufacturing sector stood at 74 robot units for every 10,000 employees. This number continues to increase as manufacturers explore the efficiency and precision that robotics can bring to production lines. However, as robotics becomes a staple in modern manufacturing, ensuring worker safety becomes more crucial than ever before.
Understanding Collaborative Robots
Traditionally, industrial robots were seen as dangerous machines that could only operate in isolated environments, locked behind safety cages to protect human workers. These robots performed repetitive, dangerous, or physically demanding tasks, making them invaluable in certain manufacturing processes. However, as industries evolve, the demand for robots that can work directly alongside humans has increased.
This need led to the development of collaborative robots (cobots) in the 1990s. These robots are designed to be smaller, lighter, and safer than their industrial counterparts, enabling them to work in close proximity to humans without the need for cages or barriers. Today, cobots are integral to tasks such as assembly, inspection, and material handling, offering a level of flexibility that enhances productivity.
Ensuring Safety Standards for Collaborative Robots
While cobots are designed with safety in mind, manufacturers must still ensure that their use aligns with strict safety regulations. One such regulation is the ISO/TS 15066, introduced in 2006, which sets safety standards for collaborative robots. The regulation mandates that cobots must include at least one safety feature, such as speed and separation monitoring, power and force limiting, hand guiding, or a safety-rated monitored stop.
These safety features are critical in preventing injuries if a robot accidentally comes into contact with a human. By adhering to these standards, manufacturers can significantly reduce the risk of accidents and ensure that cobots are safe to operate in human-robot collaborative environments.
Conducting Thorough Risk Assessments
Before integrating cobots into a manufacturing setting, manufacturers must carry out comprehensive risk assessments. This involves evaluating the entire collaborative workspace, considering how humans will interact with robots, and identifying potential hazards. A thorough risk assessment ensures that every possible scenario is considered, reducing the likelihood of injuries caused by unexpected interactions.
It's essential for engineers to analyze every movement the robot will make, assessing not only the risks associated with the machine itself but also those posed by its surroundings. The safety concept of ALARA (As Low As Reasonably Achievable) is a useful approach during risk assessments. It emphasizes the need to evaluate all risks in the robot's application, ensuring that every potential hazard is addressed.
Additionally, once the risk assessment is completed, it’s important that the findings are shared with the workers who will interact with the cobot. They need to be aware of the potential dangers and how to mitigate them, ensuring a collaborative approach to workplace safety.
Addressing Potential Hazards Beyond the Robot
While cobots are generally safer than traditional industrial robots, manufacturers should remain vigilant about the tools and equipment attached to them. For example, the end-of-arm tooling (such as welding tools or knives) can pose additional risks if not properly designed or handled. Although the cobot itself may be safe to operate around humans, its tooling might present unforeseen dangers.
Manufacturers must thoroughly assess any potential risks introduced by these tools and ensure that they are safely integrated into the cobot’s operation. Taking extra precautions when selecting and testing end-of-arm tools is essential to prevent injuries.
Conclusion
As the manufacturing industry continues to embrace collaborative robots, worker safety must remain a top priority. By adhering to safety standards, conducting comprehensive risk assessments, and carefully evaluating the tools used with cobots, manufacturers can significantly reduce the potential for accidents. With the right safety measures in place, collaborative robots can enhance productivity while ensuring the well-being of the workforce.
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