New requirements for force- and power-limited robots are supposed to enhance security. Supply: IDEC
Industrial automation continues as a fast-growing market, with producers and finish customers of all kinds wanting to reap the advantages of dependable and speedy execution for a lot of kinds of duties. Some folks consider autonomous automobiles, remote-controlled drones, and software program “bots” as robots, however industrial robots and cobots are characterised as programmable manipulators of three or extra axes.
Many industries use conventional robots, which have skilled a 7% compound annual development price (CAGR) over the previous 5 years, in accordance with the Worldwide Federation of Robotics (IFR). Nevertheless, the marketplace for force- and power-limited robots — generally known as collaborative robots or cobots — in its infancy, and the IFR predicted that its development price might be a lot stronger.
Whereas each robots and cobot arms embrace provisions to guard staff, cobots are designed to work side-by-side with plant personnel. Varied security requirements have been established for each kinds of programs, and every class has been independently acknowledged (Determine 1).
Determine 1: Robots and cobot requirements are evolving, and this can have an effect on how designers and unique gear producers adjust to security necessities. Supply: IDEC
The security necessities for all sorts of robots are evolving. Designers, unique gear producers (OEMs), and finish customers must know what the brand new requirements imply for his or her implementations, as defined beneath.
Requirements differentiate for industrial robots and cobots
The traditional industrial robotic most individuals consider is giant, highly effective, and quick. It’s best for functions which can be tough or harmful for folks, akin to manipulating giant payloads, repetitively performing correct duties, and/or working in difficult environments.
There are various variations of those robots and the instruments/grippers they use, however frequent examples of the duties they carry out are welding, portray, meeting, and materials dealing with. These robots are usually positioned inside safety-fenced work cells to maintain plant personnel away from them when in operation.
Cobots are a subcategory of robots which can be comparatively light-weight and designed to collaborate with people. As a result of pace and power are restricted, such programs can function in shared workspaces to securely to help with, or utterly carry out, many duties.
As well as, cobots are designed to be simply configured or programmed to allow them to be regularly re-deployed for a number of functions. Cobot makers say this function democratizes the implementation of those programs.
Customers usually configure these robots by manually directing the manipulator arm via the specified operation. These traits allow cobots to be launched into guide work environments the place no such automation beforehand existed.
Beforehand, the ISO 10218 sequence customary utilized to industrial robots and robotic programs, whereas the ISO/TS 15066 customary addressed collaborative programs. A revised ISO 10218 sequence was printed in 2025, with ISO 10218-1 addressing industrial robots, and ISO 10218-2 masking industrial robotic programs, robotic functions, and robotic cells.
Successfully, all robotic varieties are built-in into one customary sequence, with out the earlier robotic/cobot distinction and differentiation. The identical guidelines apply to all industrial robots, and the time period “collaborative robotic” is eradicated. As a substitute, the brand new ISO 10218 requirements now emphasize that when an operator and a robotic coexist or collaborate in the identical area, then your complete system should be handled as a collaborative utility.
Notice that the commercial robotic class consists of the manipulator—consisting of a number of arms—and the related controller and train pendant. An industrial robotic system consists of the robotic finish effector or software, work merchandise, related equipment, safeguards and sensing gadgets, and guard {hardware}.
A brand new class of robotic is outlined
With the brand new customary, two lessons of robots are outlined:
- Robotic Class I: Outlined as robots designed for a complete manipulator mass of 10 kg (22 lb.) and underneath, with a most power of 50N and fewer, and a most pace of 250mm/s (0.5 mph) and underneath.
- Robotic Class II: Outlined as robots designed for a complete manipulator mass, a most power, and/or a most pace exceeding any of the values for a Robotic Class I.
Due to this fact, Robotic Class I entails smaller, lighter robots extra more likely to work round people, whereas Class II are bigger, heavier robots. The usual permits Class I robots to do sure collaborative duties with none security options.
For Class II robots for use in collaborative functions, a number of of the next safety-oriented applied sciences should be added, relying on the appliance:
- Velocity and separation monitoring (SSM): Ensures a minimal distance between robotic and human is maintained throughout operation; this may be completed by integrating a security laser scanner into the appliance, which makes use of mirrored laser beams to detect if a human or different object is current.
- Energy and power limiting (PFL): Ensures that even when a robotic and human come into contact, the human is unhurt.
- Hand-guided controls (HGC): Employees management the robotic movement for a collaborative portion of the duty, and the robotic executes an automatic process as soon as the employee presses a hold-to-run button.
Each lessons of robots will want sure frequent security performance, akin to hardwired emergency cease (estop) buttons. The bigger Class II robots may have a higher want for protected/restricted zone security gadgets, which may embrace cage door interlock switches, gentle curtain sensors, security laser scanners, and different types of a presence-sensing system (PSD). These measures are crucial to detect staff within the protecting/restricted zone of a robotic.
Moreover, most robots embrace some choice for a train pendant, which is a kind of human-machine interface (HMI) often cable-connected in such a manner as to permit the consumer to maneuver about with it a bit.
Educating pendant necessities for protected cobots
Robotic train pendants could have digital components but in addition would possibly want some particular hardwired gadgets, relying on the functions. Security capabilities for these functions are required to be hardwired, versus touchscreen controls. A key instance of a hardwired perform aside from an e-stop is an enabling change.
Determine 2: The IDEC HExB sequence of three-position enabling switches adjust to IEC 60947-5-8, allowing robots to function solely when customers are consciously holding the change in a mid-position. Gear will cease if the operator squeezes too laborious or releases the change. Supply: IDEC
An enabling change—generally colloquially often known as a “lifeless man’s change” or extra formally as a three-position enabling (3PE) system—is a hardwired change organized on the instructing pendant the place it’s handy for the consumer to grip it. When the operator wishes the robotic to run, they have to positively maintain the allow change in a mid-position to allow hold-to-run management performance.
Letting go of the enabling change for any motive, or gripping the change too tightly akin to in a panic or electrical shock state of affairs, instantly stops robotic operation. These switches are specified by IEC 60947-5-8 (Determine 2).
For Class II robots, it’s necessary for the instructing pendant to incorporate a 3PE system because of the hazard concerned if an operator is in proximity to the robotic in guide mode. For Class I robots, a threat evaluation should be carried out to see if that is essential.
For Class I robots, if adequate threat discount is achieved via a threat evaluation, the usage of 3PE change just isn’t required.
Nevertheless, underneath the brand new customary for Class I robots, if a train pendant is used to provoke movement for frequent guide duties akin to upkeep or troubleshooting, then integrating a 3PE change is probably going one of the best ways to realize compliance.
Or, if the robotic is operated utilizing HGC, then a 3PE change could also be choice.
How interface designs can adjust to the brand new customary
Robotic OEMs usually create their very own train pendants, whether or not absolutely personalized, or assembled from different industrial off-the-shelf (COTS) parts, or a mix of the 2. Smaller robots with fewer axes simply want fundamental pendants, however bigger and extra succesful robots usually have pendants with touchscreen HMIs.
Shifting ahead, these OEMs could must adapt their designs to incorporate 3PE switches that adjust to IEC 60947-5-8. This might contain expensive revisions to customized {hardware}. Nevertheless, there’s an alternative choice available on the market that may assist OEMs ship a whole and protected answer, whereas profiting from the most recent COTS interface know-how.
Trendy consumer-grade tablets already provide the show dimension and computing energy wanted to offer a wealthy consumer interface and visualization expertise for a lot of kinds of automation. These might be helpful for industrial applicaitons, however that is solely potential if the pill might be bodily protected, provided with energy, related to networking, and incorporate the mandatory hardwired security/management parts.
Determine 3: The IDEC HT4P Security Commander can be utilized by OEMs to include digital HMI capabilities utilizing tablets, whereas complying with ISO 10218 sequence requirements for security. Supply: IDEC
A brand new cellular system holder is offered to fulfill all these necessities (Determine 3). Key options embrace:
- Incorporates wired energy and networking, a hardwired estop with LED indicator and retrofittable guard, and a hardwired 3PE change
- Functionality to combine different hardwired gadgets akin to a guide/computerized customary or keyed mode selector change, begin/restart change/ reset change, and/or a traditional cease change
- Adjustable grippers to carry tablets as much as 33 cm (13 in.)
- Skill to lock the holder in vertical/portrait or horizontal/panorama orientation.
- Will be handheld by left- and right-handed customers, with a hand or shoulder strap to reduce fatigue.
- Rated IP54, with a large working temperature vary, and drop resistance examined to 1.2 m (3.9 ft.)
- Out there cable lengths of 5 via 20 m (16.4 to 65.6 ft.), and a wall-mount bracket.
Utilizing this cellular system holder for robotics functions, OEMs can shortly and economically develop and deploy train pendants compliant with the ISO 10218 sequence requirements whereas utilizing cheap tablets to offer a complete HMI.
Requirements change to maintain robots protected
Robotic security requirements are altering and are anticipated to influence the quickly rising market share of cobots. Nevertheless, OEMs can method this evolution as a possibility to offer safer gear, with higher options that differentiate their choices.
Requirements-compliant 3PE switches and cellular system holders are cost-effective COTS merchandise that may add important flexibility and functionality to robotic designs, whereas making certain compliance with related security requirements.
Concerning the creator
Luiz Shida is a advertising specialist at IDEC Corp. and liable for security product advertising. Since becoming a member of IDEC Japan headquarters greater than seven years in the past, he has change into licensed as a security sub-assessor in Japan. Shida can also be a specialist in security merchandise.
