ROBOTICS- IMPLEMENTATION AND ROBOT ECONOMICS

WELCOME
UNIT 5 - IMPLEMENTATION AND ROBOT ECONOMICS
ME8099 – ROBOTICS
(Professional elective-III)
Mr. TAMIL SELVAN M, A/P, MECH, KIT.

UNIT 5 - IMPLEMENTATION AND ROBOT
ECONOMICS
RGV, AGV; Implementation of Robots in Industries-Various
Steps; Safety Considerations for Robot Operations - Economic
Analysis of Robots.

RGV (Rail Guided Vehicle)
 Rail Guided Vehicle (RGV) is a flexible transportation vehicle developed
by SMC's own technology.
 It can link multiple destinations and be a good & economic alternative of
conveyor by its characteristic that it can eliminate complex and fixed
layout of conveyors.
 which enables simple and easily maintainable transportation system.

 In a system multiple vehicles can be operated according to the
transportation requirement.
 RGV system constitutes of transportation rail, vehicles and controller.
RGV rail can be installed linear or circular.
 RGV is controlled by distribution control system and can be expanded
easily as the system parameter changes.
 This characteristic cannot be obtained in normal conveyor system.

FEATURES
 Independent operation of vehicle by individual controller on each
vehicle
 Low noise & vibration
 Modular design of drive unit to enable less parts and easy
maintenance
 Relatively accurate positioning by an encoder
 Distribution control system

APPLICATION
 Super high speed-RGV application
 Driving speed 265m/min, C/V loading speed 30m/min
 Inactivity server motor & S-curve urgent acceleration/deceleration
 Installation of absolute encoder in external timing belt

“Automated guided vehicle”.(AGV)
 AGV is a material handling system that uses independently
operated, self-propelled vehicles guided along defined pathways.

INTRODUCTION
 AGVs increase efficiency and reduce costs by helping to automate a
manufacturing facility or warehouse.
 AGVs can carry loads or to objects behind them in trailers.
 The trailers can be used to move raw materials or finished product.
 The AGV can also store objects on a bed.
 some AGVs use fork lifts to lift objects for storage.
 AGVs are employed in nearly every industry, including, paper, metals,
newspaper and general manufacturing.

 An AGV can also be called a laser guided vehicle(LGV) or self-
guided vehicle (SGV).
 In Germany the technology is also called Fahrerlose Transport
system (FTS) and in Sweden Forarlosa trucker.
 AGVs are available in a variety of models and can be used to move
products on an assembly line, transport goods throughout a plant or
warehouse.

SYSTEM FEATURES
 High dynamic operation
 Innovative steering method
 Robust design
 CAN Bus system communication
 Speed control separately for each wheel
 Angular position control separately for each axle
 Low energy consumption by self charging

SYSTEM CONCEPT
 4 drive units - 4 steering axles
 2 motors for each unit
 1 Controller for each motor
 Communication with CAN Bus
 Host computer gets
 speed-position information and
determines the drive path

TYPES OF AGV’S
 Driverless trains
 AGV’s pallet trucks
 Unit load carriers

DRIVERLESS TRAINS:-
 It consists of a towing vehicle that pulls one or more trailers to form
a train.
 This type is applicable in moving heavy pay loads over large
distance in warehouses or factories with or without intermediate
pickup and drop off points along the route.
 It consists of 5-10 trailers and is an efficient transport system.
 The towing capacity is up to 60,000 pounds (27,000 kilos) approx.

AGV PALLET TRUCKS:-
 Pallet trucks are used to move palletized loads along
predetermined routes.
 The capacity of an AGV pallet truck ranges up to several thousand
kilograms and some are capable of handling two pallets.
 It is achieved for vertical movement to reach loads on racks and
shelves.

UNIT LOAD CARRIERS:-
 These are used to move unit loads from one station to another.
 It is also used for automatic loading and unloading of pallets by means
of rollers.
 Load capacity ranges up to 250 kg or less.
 Especially these vehicles are designed to move small loads.

TYPES OF NAVIGATION IN AGV’S
 Wired navigation
 Guide tape navigation
 Laser target navigation

WIRED NAVIGATION
 The wired sensor is placed on bottom of the AGV’S and is placed
facing the ground.
 A slot is cut in the ground and a wire is placed approximately 1 inch
below the ground.
 The sensors detects the radio frequency being transmitted from the
wire and follows it.

GUIDE TAPE NAVIGATION
 The AGV’S (some known as automated guided carts or AGC’S) use
magnetic tape for the guide path.
 The AGC’S is fitted with the appropriate guide sensors to follow the path
of the tape.
 It is considered a “passive” system since it does not require the guide
medium to be energized as wire does.

LASER TARGET NAVIGATION
 The AGV’S carry’s a laser transmitter and receiver on a rotating
turret.
 The laser is sent off then received again the angle and distances are
automatically calculated and stored into AGV’S memory.
 The AGV’S has reflector map stored in memory and can correct its
position based on errors between the expected and received
measurements.
 It can then navigate to a destination target using the constantly
updating position.

Laser target navigation AGV’S

COMMON AGV APPLICATIONS
 Automated Guided Vehicles can be used in a wide variety of
applications to transport many different types of material including
pallets, rolls, racks, carts, and containers.
RAW MATERIAL HANDLING:-
 AGVs are commonly used to transport raw materials such as
paper, steel, rubber, metal, and plastic.

WORK-IN-PROCESS MOVEMENT:-
 Work-in-Process movement is one of the first applications where
automated guided vehicles were used, and includes the repetitive
movement of materials throughout the manufacturing process.
PALLET HANDLING:-
 Pallet handling is an extremely popular application for AGVs as
repetitive movement of pallets is very common in manufacturing and
distribution facilities.

 FINISHED PRODUCT HANDLING:-
 Moving finished goods from manufacturing to storage or shipping is the
final movement of materials before they are delivered to customers.
 These movements often require the gentlest material handling
because the products are complete and subject to damage from rough
handling.

Pallet handling Finished goods handling

IMPLEMENTATION OF ROBOTS IN INDUSTRIES

STEPS TO BE FOLLOWED BY THE COMPANY IN ORDER TO
IMPLEMENT ROBOT PROGRAMS IN ITS OPERATION:

TYPES OF INDUSTRIAL ROBOTS
 Cartesian Robot
 Cylindrical Robot
 Spherical / Polar Robot
 Scara Robot
 Articulated Robot
 Parallel robot

CARTESIAN ROBOT
 A type of robotic arm that has
prismatic joints only.
 The linear movement of the joints
gives the Cartesian robot a highly
rigid structure that allows it to lift
heavy objects.

CYLINDRICAL ROBOT
 Used for assembly operations,
handling at machine tools, spot
welding, and handling at die-
casting machines.
 It's a robot whose axes form a
cylindrical coordinate system.

SPHERICAL / POLAR ROBOT
 Used for handling at machine tools,
spot welding, die-casting, fettling
machines, gas welding and arc
welding.
 It's a robot whose axes form a polar
coordinate system.

SCARA ROBOT
 Used for pick and place work,
application of sealant, assembly
operations and handling machine
tools.
 It's a robot which has two parallel
rotary joints to provide compliance
in a plane.

ARTICULATED ROBOT
 Used for assembly
operations, die- casting, fettling
machines, gas welding, arc
welding and spray painting.
 It's a robot whose arm has at
least three rotary joints

PARALLEL ROBOT
 One use is a mobile platform
handling cockpit flight simulators.
 It's a robot whose arms have
concurrent prismatic or rotary
joints.

USES OF ROBOT FOR INDUSTRIAL
APPLICATION

MATERIAL HANDLING
It is further classified into two types :
1.Machine loading and unloading
2.Material transfer
We use material handling robots to transfer parts from one machine to
another.
Material handling is the combination of art and science of:
 Moving
 Storing
 Protecting
 Controlling the material

TYPES OF MATERIAL HANDLING ROBOTS
 Palletizing Robots: Automating the stacking of bag, cases, boxes,
and other containers with an industrial robot arm increases
productivity and saves workers from injury.
 Pick and Place Robots: Like manual palletizing, manual pick and
place is a tedious process.
 Part Transfer Robots

MACHINE LOADING AND UNLOADING
 In machine loading and unloading process, a robot will be used to
move the work parts to or from the production machine.
 This application comes under the category of material handling
operations.
 The machine loading and unloading application includes the following
three processes:
Machine loading
Machine unloading
Machine load and unload

MACHINE LOADING
 In this operation, the robot loads raw work parts in the
machine, and some other systems are used to unload the finished
work parts from the machine.
 Example: In a press working process, a robot is used to load the
sheet metal in the press, and the finished work parts are removed
from the press with the help of gravity.

MACHINE UNLOADING
 In machine unloading, the finished work parts are
unloaded from the machine by a robot, while the loading of raw
materials are done without any robot support.
 Example: Plastic modeling and die casting.

MACHINE LOADING & UNLOADING
 In this process, a robot performs both loading and
unloading of work parts in and from the machine.
 Example: Machining operation

ASSEMBLY
 When it comes to putting parts
together, assembly line robots occupy
a sweet spot between humans and
dedicated or “hard” automation.
 An assembly robot moves faster and
with greater precision than a human.

 Assembly tasks are typically those which involve insertion of a
peg into a hole. See Figure

APPLICATION
Robot find applications in assembly areas involving
 screwing of studs and screws in threads holes
 screwing and unscrewing of nuts
 insertions of shafts in holes
 insertion of electronics components in electric
assemblies.
 assemblies of small electric motors , plugs, switches,
etc

INSPECTION
The inspection of robots will involve some of the sensors to calculate
the worth of a manufactured part.
It uses mechanical probe experiments to inspect the finished parts.
A robot arm with a vision camera can also be used for non-destructive
testing and 3D measurements.
It can objectively identify and pinpoint defects or faulty parts before
they are packed.

WELDING
•The large bulk of materials that are welded are metals and their
alloys although welding is also applied to the joining of other
materials such as thermoplastics.
•Welding joins different metals or alloys with help of a number of
processes in which heat is supplied either electrically or by means of
a gas torch.

FEATURES OF ARC WELDING ROBOTS
 work volume and degrees of freedom
 motion control system precision of motion programming
 interface with other system

FEATURES OF SPOT-WELDING ROBOTS
The robot must be able to position and orient the welding gun in
places on the product that might be difficult to access.
This might result in need for an increased number of freedoms.
The controller memory must have enough capacity to accomplish
the many positioning steps required for the spot-welding cycle.

SPRAY PAINTING
 Every metallic material will be painted at the final stage of production
in order to protect it from corrosion.

MOBILE ROBOTS
Robots that move around on legs, tracks or wheels from one
place to another.
 Eg-In 1979 a nuclear accident in the USA caused a leak of
radioactive material which led to Production of special robot –
which Can handle the radioactive materials.

TASKS
I. Obtaining and measuring data by sensing
II. Collecting samples
III. Recording and
IV. Transferring images to a Central Control Station.
 A Microbot is also contain a mobile communication module
by means of which it can receive commands from the control
centers and send responses.

SUBSYSTEMS
 A microbot system is composed of four fundamental subsystems
1) Mobility
2) Power
3) Communication
4) Control and Computation
5) Sensors.

Robots in Space
NASA Space Station

Robots in Hazardous Environments
TROV in Antarctica operating
under water
HAZBOT operating in atmospheres
containing combustible gases

SAFETY CONSIDERATIONS
FOR ROBOT OPERATIONS

2. Types of robots &
industrial robots
3. Types and sources
of robotics hazards
4. Robotcs safety
requirements
1. Introduction to
robotics safety
5. Robot safeguards 6. Robot safety
standards
Contents
1. Introduction to robotics safety
2. Types of robots and industrial robots
2.1. Definition of robots and industrial robots
2.2. Classifications of robots
2.2.1. Classification based on design configuration
2.2.2. Classification based on control systems
2.2.3. Classification based on path generation
2.3. Industrial robot components
2.3.1. Mechanical unit
2.3.2. Power source
2.3.3. Control system
3. Types and sources of robotics hazards
3.1. Types of robot accidents
3.2 Examples of robot accidents
3.3. Sources of hazards
4. Robot safety requirements
4.1. Requirements and safety measures in normal
operation
4.2.Demands and safety measures in special
operation modes
4.3. Demands on safety control systems
5. Robot safeguards
5.1. Robot safeguards from design to operation
5.1.1. Risk assessment
5.1.2. Robot safety begins with the design process
5.2. Robot safeguards and engineering applications
5.2.1. Today’s safeguarding methods
5.2.2. Instruction to improve robot safety
5.2.3. Typical engineering applications
5.3 Lessons learned from key incidents involving
robots
6. Robot safety standards
6.1. Technology and standardization
development overview
6.2. Current standards for robotic safety

industrial robots
of robotics hazards
4. Robotcs safety
requirements
1. Introduction to
robotics safety
standards
Section 1---Introduction to robotics safety
1. Introduction to robotics safety
2. Types of robots and industrial robots
3. Types and sources of robotics hazards
4. Robot safety requirements
5. Robot safeguards
6. Robot safety standards
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Robot safety is extremely important
Most accidents with robots occur during programming, maintenance,
repair, setup and testing, all of which involve human interaction
Common causes:
• lack of employee training
• improper use of safety guards
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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Effective robot safety systems
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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Note: Robots, depending on the task, may generate paint mist, welding
fumes, plastic fumes, etc. In general, the robot, on occasion is used in
environments or tasks too dangerous for workers, and as such creates hazards
not specific to the robot but specific to the task.

Section 2--- Types of robots & industrial robots
What is a robot?
A robot is a machine built for real-
world functions that is computer-
controlled
Some types:
• Industrial Robots
• Military Robots
• Medical Robots
• Mobile Robots
• Service Robots
• Nano Robots
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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Section 2--- Types of robots
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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Section 2---What are industrial robots?
• Industrial robots are, multifunctional, mechanical devices,
programmable in 3 or more axes, designed to move material, parts,
tools or specialized devices through variable programmed motions to
perform a variety of tasks.
• Industrial robots perform many functions, e.g., material handling,
assembly, arc welding, resistance welding, machine tool load and
unload functions, painting and spraying.
• 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.
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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Section 2---What are industrial robots?
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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Section 2---Types of industrial robots
Seven types of robot design configurations exist:
• Cartesian Coordinate Robots
• Cylindrical Robots
• Spherical Robots
• SCARA Robots
• Delta Robots
• Articulated Robots
• Snake Arm Robots
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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Section 2--- Types of industrial robots
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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Two types of control systems exist:
• Servo robots
• Nonservo robots
Three types of paths generated exist:
• point-to-point path
• controlled path
• continuous path
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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
• Manipulators: the most commonly used robots in the industrial
environment
• Mobile Robots: unmanned vehicles capable of locomotion
• Hybrid Robots: mobile robots with manipulators
(Images from AAAI and How Stuff Works, respectively)

Section 2--- Robot Components
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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Body
Effectors
Actuators
Sensors
Controller
Software
Industrial robots have four
main components:
• Mechanical unit
• Power source
• Control system
• Robot tool

Section 3---Types and sources of robotics hazards
Why are industrial robots dangerous?
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
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Section 3---Types of robot accidents
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Typical types of robot accidents:
1. A robotic arm or controlled tool causes an accident
2. A robot places an individual in a risk circumstance
3. An accessory of the robot's mechanical parts fails
4. The power supplies to the robot are uncontrolled
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Section 3---Examples of robot accidents
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Example 1: First fatal robot-related
accident in the U.S.
On July 21, 1984, a die cast operator was
working with an automated die cast
system utilizing a Unimate Robot, which
was programmed to extract the casting
from the die-cast machine, dip it into a
quench tank and insert it into an
automatic trim press.
A neighboring employee discovered the victim pinned between the
right rear of the robot and a safety pole in a slumped but upright
position. The victim died five days later in the hospital.
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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Example 2:
A material handling robot was operating in its automatic mode and a
worker violated safety devices to enter the robot work cell. The worker
became trapped between the robot and a post anchored to the floor,
was injured and died a few days later.
Example 3:
A maintenance person climbed over a safety fence
without turning off power to a robot and
performed tasks in the robot work zone while it
was temporarily stopped. When the robot
recommenced operation, it pushed the person
into a grinding machine, killing the person.
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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Details of some other reported robot-related accidents:
• 2000: The head of a person was crushed between a conveyor and a
robot. The task of the robot was to feed cows at a farm.
• 2005: A person was crushed between a manipulator (resembling a
gantry type robot) and a conveyor. The task of the manipulator was
to move bricks from one conveyor to another at a brick factory.
• 2006: A person was crushed between a robot and a conveyor. The
task of the robot was to move trays to a conveyor, in an application
in the dairy industry.
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Section 3---Types of robot accidents
Robotic incidents can be grouped into four categories:
1. Impact or collision accidents
2. Crushing and trapping accidents
3. Mechanical part accidents
4. Other accidents
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
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Section 3---Sources of hazards
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Human Interaction
Control Errors
Unauthorized Access
Mechanical Failures
Environmental Sources
Power Systems
Improper Installation
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• Human Interaction: Hazards from human interaction associated
with programming, interfacing activated peripheral equipment, or
connecting live input-output sensors to a microprocessor or a
peripheral device, can cause dangerous, unpredicted movement or
action by a robot
• Control Errors: Intrinsic faults within the control system of the robot,
errors in software, and electromagnetic interference are possible
control errors
• Unauthorized Access: Entry into a robot's safeguarded area is
generally potentially hazardous
• Mechanical Failures: Operating programs may not account for
cumulative mechanical part failure, which can allow faulty or
unexpected operation to occur
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
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• Environmental Sources: Electromagnetic interference (transient
signals) can exert an undesirable influence on robotic operation and
increase the potential for injury to any person working in the area
• 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
• Improper Installation: The design, requirements, layout of equipment,
utilities, and facilities of a robot or robot system, if inadequate, can
lead to inherent hazards
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
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Machine Operator Crushed by Robotic Platform (Nebraska, 1999)
• Incident:
– A 23-year-old carousel operator at a meat packing plant was killed
when his foot tripped a light sensor causing a computer controlled
robotic platform to descend, crushing his skull.
– He had been watching a technician work on a conveyor and
apparently stepped on the conveyor for a better view.
– The conveyor the mechanic was working on had been shut off but
the entire system had not been locked out. Power still remained to
the light sensors and the robotic platform.
– When the platform descended it pinned the victim between it and
the conveyor. The victim was pronounced dead at the scene.
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Section 3---Case studies: incidents and lessons learned
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• Lessons learned:
– Ensure all equipment is properly locked out/tagged out prior to
performing maintenance on it.
– Consider implementing a spot inspection program to ensure all
employees are complying with safety requirements.
– Develop procedures to ensure individuals not involved in
maintenance activities are not in the immediate area of the
maintenance being performed.
– Consider installing a protective grate around access areas to the
robotic platform.
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
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Mold Setter’s Head Struck by Cycling Gantry Robot (Michigan, 2001)
• Incident:
– A 29-year old male was struck on the head by a cycling single-side
gantry robot. He had recently changed a mold on a 1500-ton
horizontal injection-molding machine.
– The victim climbed on top of the purge guard and leaned over the
top of the stationary platen of the machine to see if the tools were
left in the mold area, and placed his head beneath the robot’s
gantry frame. His position placed him between the robot’s home
position and the robot’s support frame on the stationary platen.
– The robot cycled, and the victim’s head was struck from the side
and crushed between the robot and the robot’s support frame.
The victim was pronounced dead on arrival at the local hospital.
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
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• Lessons learned:
– The robot and the point of operation should be safeguarded to
prevent entry during automatic operation.
– Users should conduct a risk assessment of the robot/robot system
to identify equipment, installation, standards, and process hazards
so adequate employee safeguards are provided.
– Users should ensure that personnel who interact with the robot or
robot system, such as programmers, teachers, operators and
maintenance personnel are trained on the safety issues associated
with the task, robot and robot system.
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
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Section 4---Robotcs safety requirements
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Requirements and safety measures in normal operation
Demands and safety measures in special operation modes
Demands on safety control systems
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Section 4---Requirements and safety measures in normal operation
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The use of robot technology necessitates hazard analysis, risk
assessment and safety measures
The following can serve as guidelines:
• Prevent physical access to hazardous areas
• Prevent injuries as a result of the release of energy
• Apply interfaces between normal operation and special operation
to enable the safety control system to automatically recognize the
presence of personnel

1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Section 4---Demands and safety measures in special operation modes
Certain special operation modes (e.g., setting up, programming) of an
industrial robot require movements which must be assessed directly
at the site of operation
The movements should be:
• only of the scheduled type and speed
• prolonged only as long as instructed
• performed only if it can be guaranteed that no parts of the human
body are in the danger zone
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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Section 4---Demands on safety control systems
Suggested measures to provide reliable safety control systems :
• Redundant and diverse layouts of electro-mechanical control
systems including test circuits
• Redundant and diverse set-ups of microprocessor control systems
developed by different teams (this modern approach is considered
state-of-the-art, and often includes safety light barriers)
• Redundant control systems that take into account mechanical as
well as electrical failures
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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Section 4---Robot controller
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Controllers direct a robot how to
move
Two controller paradigms exist:
1. Open‐loop controllers execute
robot movement without
feedback
2. Closed‐loop controllers execute
robot movement and judge
progress with sensors; they can
thus compensate for errors

Section 5---Robotic safeguards from design to operation
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1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Topics to consider for robot safeguards:
• What are the potential hazards of the robotic cell?
• What safeguarding technologies are available?
• How can unnecessary personnel be keep out, and necessary
personnel protected?
• How much panel space must be used for relays?
• How difficult or easy will the troubleshooting of the system be?
• What is the overall reliability and safety of the system?

Section 5---Robotic risk assessment
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The first step in designing a safe robot system is to understand the
hazards that exist in the system
At each stage of the robot and robot system development, a risk
assessment should be performed
Assessment criteria:
• severity
• potential injury
• frequency of access to the hazard
• possibility of avoidance
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Section 5---Robot safety begins with the design process
3 of 16
Safeguards should be designed into and
around the robotic cell early in the design
process
Perimeter Guarding
Hard-guarding and optical perimeter
guards
Protection on the inside
Area safety scanners and light curtains
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Section 5---Safeguarding considerations for other stages
4 of 16
The following should be considered in the planning, installation and
subsequent operation of a robot or robot system:
• Safeguarding devices
• Awareness devices
• Safeguarding the teacher
• Operator safeguards
• Attended continuous operation
• Maintenance and repair personnel
• Safety training
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Section 5---Robot safeguard measures
5 of 16
Measures taken to safeguard a robot depend on the circumstances of
its operation and surrounding environment
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Section 5---Today’s safeguarding methods
6 of 16
• Perimeter fencing
• Interlocking devices
• Presence sensing devices (light curtains, laser scanning devices,
pressure sensitive mats)
• Audible and visible warning systems
• Manipulator position indication and limiting (mechanical limits,
position switches, limit switches)
• Enabling devices
• Other safeguard devices
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Fences and barriers
7 of 16
1. Introduction to
robotics safety
industrial robots
standards
of robotics hazards
4. Robotcs safety
requirements

Interlocking devices
8 of 16
1. Introduction to
robotics safety
industrial robots
standards
of robotics hazards
4. Robotcs safety
requirements

Presence sensing devices (light curtains, laser scanning devices,
pressure sensitive mats)
9 of 16
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Manipulator position indication and limiting: mechanical limits and limit
switches
10 of 16
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Manipulator position indication and limiting: position switch
11 of 16
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Enabling device
12 of 16
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Section 5---Instruction to improve robot safety
• Use boundary warning devices, barriers and interlocks around
robot systems
• Offer annual robot safety training for employees working on the
floor with robots
• Provide work cell operators with training geared toward their
particular robot
• Create and implement a preventive maintenance program for
robots and work cells
• Ensure operators read and understand robot system
documentation, including material on robot safety
• Ensure that only capable employees who know the safety
requirements for working with a robot operate robot systems
13 of 16
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Section 5---Typical engineering applications
ABB SafeMove - the next generation in robot safety
SafeMove is an electronics and software based safety approach that
ensures safe and predictable robot motion; it allows leaner more
economic and flexible operation
videoABB_Safemove__The_Next_Generation_in_Robot_Safety_-_YouTube.mp4
14 of 16
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Section 5---Example 1
Example 1: Monitor and increase safety of tool zones
15 of 16
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Section 5---Examples 2 and 3
Example 2: Safe stand
still/direct loading of a robot
Example 3: Safe axis ranges with
track motions
16 of 16
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

Section 6---Robot safety standards
1 of 6
Overview of the technology and standardization development
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

2 of 6
Present status of safety standards for robots in Europe and North America
Type of safety
standard
Europe North America
Robot safety
standard
ISO 10218-1:2011
(robot)
ISO 10218-2:2011
(robot systems and
integration)
ANSI/RIA R15.06 / ANSI/RIA/ISO
10218 / RIA TR R15.206
CAN/CSA-Z434-03 (R2013)
(robots and robot systems)
Machinery
safety
standard
ISO 12100:2010
(risk assessment)
ISO 13849-1:2006
(functional safety)
IEC 62061:2005
(functional safety)
CSA-Z432-04 (R2009)
ANSI B11.0-2011
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards

3 of 6
Current standards for robotic safety:
• ANSI/RIA R15.06 / ANSI/RIA/ISO 10218 / RIA TR R15.206
• CAN/CSA-Z434-03 (R2013)
• ISO 10218-1:2011 and ISO 10218-2:2011
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Notes:
• In the U.S., ISO 10218 and ANSI RIA 15.06.1999 are both valid
• The Robotic Industries Association (RIA) and the Canadian Standards
Association now are cooperating to publish a single harmonized standard
for the U.S. and Canada
• The new standard—ANSI/RIA R15.06 in the U.S. and CAN/CSA Z434 in
Canada—will be a “four-in-one” document that includes ISO 10218-1:2011,
ISO 10218-2:2011, and the unique requirements of both countries

4 of 6
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Standard: ANSI/RIA R15.06 / ANSI/RIA/ISO 10218 / RIA TR R15.206
The ANSI/RIA R15.06 / ANSI/RIA/ISO 10218 / RIA TR R15.206 -
Industrial Robots Safety Package provides the fundamentals for
industrial robots and systems as it pertains to the safety requirements
The safety requirements are applicable to manufacturers, integrators,
installers and personnel
The ANSI/RIA R15.06 / ANSI/RIA/ISO 10218 / RIA TR R15.206 -
Industrial Robots Safety Package includes:
• ANSI/RIA R15.06-2012
• ANSI/RIA/ISO 10218-1-2007
• RIA TR R15.206-2008

5 of 6
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Standard: CAN/CSA-Z434-03 (R2013)
CAN/CSA-Z434-03 (R2013) - Industrial Robots and Robot Systems -
General Safety Requirements
This safety standard applies to the manufacture, remanufacture,
rebuild, installation, safeguarding, maintenance and repair, testing and
start-up, and personnel training requirements for industrial robots and
robot systems
Publish date: 2003-02-01
Supersedes: CAN/CSA-Z434-94
Reaffirmed: 2013-05-09

6 of 6
1. Introduction to
robotics safety
industrial robots
of robotics hazards
4. Robotcs safety
requirements
standards
Standard: ISO 10218-1:2011 and ISO 10218-2:2011
The ISO 10218-1 standard for the robot, and the ISO 10218-2 standard
for robot systems and integration, were both published 1 July 2011
ISO 10218-1: For robot (an approved standard and adopted as an ANSI
standard)
ISO 10218-2: For robot system and integration (an approved standard )
New features in ISO 10218:
• Cable-less pendants – wireless operation
• Collaborative robots
• Simultaneous motion control
• Synchronous robots

 Introduction
Type of Robot Installation
Cost Data Required for the Analysis
Investment Costs
Operating Costs
 Life Cycle of Cash Flow
 Methods of Economic Analysis
Payback (or payback period) Method
Equivalent Uniform Annual Cost (EUAC) Method
Return on Investment (ROI) Method
ECONOMIC ANALYSIS OF ROBOTS

 The economy is an important issue while setting up a new automated
firm.
 An economic analysis of the proposed engineering project must be
done.
 On the basis of this analysis, the management usually decides the
feasibility of the project.
 To perform the economic analysis of the proposed robot project, we
require certain basic information about the project.
INTRODUCTION

 This information includes the following:
1. Type of robot installation.
2. Cost of robot installation.
3. Production cycle time.
4. Savings and benefits resulting from the project.

 There are two basic categories of robot installation:
New application:
Here we have to begin from the scratch.
So we are in a need for new facilities, and the robot installation is
the only facility to satisfy that need.
In this case, the best alternative is selected after comparing various
alternatives and the selected alternative should meet the
investment criteria of the firm.
TYPE OF ROBOT INSTALLATION

Existing application:
Here, the robot is employed as a substitute for the human
labour.
In this scenario, the economic justification of the robot
installation depends on how inefficient and costly the manual
method is, rather than the absolute merits of the method.
 In either of these situations, certain basic cost information is
needed in order to perform the economic analysis.

 The cost data required for the economic analysis
involves the following:
Investment costs
Operating costs
COST DATA REQUIRED FOR THE ANALYSIS

INVESTMENT COSTS
Robot purchase cost
Engineering cost
Installation cost
Special tooling cost
Miscellaneous cost
OPERATING COSTS
 Direct labour cost
 Indirect labour cost
 Maintenance cost
 Utilities cost
 Training cost

INVESTMENT COSTS:
1. Robot purchase cost
 The basic price of the robot equipped from the manufacturer with the
proper options (excluding end effector) to perform the application.
2. Engineering costs
 The costs of planning and design engineering staff to install the robot.

3. Installation costs
 This includes the labor and materials needed to prepare the
installation site (provision for utilities, floor preparation, etc.).
4. Special tooling
 This includes the cost of the end eflector, parts position and other
fixtures and tools required to operate the work cell.
5. Miscellaneous costs
 This covers the additional investment costs not included by any of
the above categories (e.g., other equipment needed for the cell).

OPERATING COSTS
6. Direct labor cost
 The direct labor cost associated with the operation of the robot cell.
 Fringe benefits are usually included in the calculation of direct labor
rate, but other overhead costs are excluded.
7. Indirect labor cost
 The indirect labor costs that can be directly allocated to the operation
of the robot cell.
 These costs include supervision, setup, programming, and other
personnel costs not included in category 6 above

8. Maintenance
 This covers the anticipated costs of maintenance and repair for the
robot cell.
 These costs are included under this separate heading rather than
in category 7 because the maintenance costs involve not only
indirect labor (the maintenance crew) but also materials
(replacement parts) and service calls by the robot manufacturer.
 A reasonable of thumb‖ in the absence of better da robot
will be approximately 10 percent of the purchase price (category I).

9. Utilities
 This includes the cost of utilities to operate the robot cell (e.g.,
electricity, air pressure, gas).
 These are usually minor costs compared to the above items.
10. Training
 Training might be considered to be an investment cost because much
of the training required for the installation will occur as a first cost of
the installation.
 However, training should he a continuing activity, and so it is included
as an operating cost.

LIFE CYCLE OF CASH FLOW
Net Annual Cash flow (NACF) = Revenues – Operating cost

 The methods of economic analysis are listed below:
Payback (or payback period) Method
Equivalent Uniform Annual Cost (EUAC) Method
Rate on Investment (ROI) Method
METHODS OF ECONOMIC ANALYSIS

 Payback period means the period of time that a project requires to recover the money invested On
it.
 The payback period of a project is expressed in years and is computed using the following
formula:
𝒏 =
𝑰𝑪
𝑵𝑨𝑪𝑭
PAYBACK PERIOS METHOD
Where n = Payback period
IC = Investment cost
NACF = Net Annual Cash Flow
Assumptions:
 NACF is + ve. [Revenues > Operating Cost]
 All cash flows occur at the end of the year.
 All the investments are done at beginning of the
year.
 NACF is calculated at the end of the year.
 Most of the companies require a payback period of not more than two to three years.

 The equivalent uniform annual cost (EUAC) is the annual cost of owning an asset over its entire
life. Equivalent uniform annual cost is often used by firms for capital budgeting decisions.
Equivalent uniform annual cost is calculated as:
 This method converts all of the present, future investments and the cash flows into their equivalent
uniform cash flows over the anticipated life of the project. This is accomplished by using various
interest factors associated with engineering economic calculations.
 When the company is to be started it must select the minimum attractive rate of return (MARR).
This is used to decide whether funding is to be made or not.
 If the sum of EUAC > 0 then the company is attractive. If the sum of EUAC < 0 then the
company is non attractive.
EUAC METHOD

 This method determines the rate of returns on the proposed work based on estimated cost and
revenues.
 To calculate ROI, the benefit (or return) of an investment is divided by the cost of the investment,
and the result is expressed as a percentage or a ratio.
 The return on investment formula:
 This rate of return is compared with company’s MARR to determine whether the investment is
justified or not.
ROI METHOD

ROBOTICS- IMPLEMENTATION AND ROBOT ECONOMICS

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