Robotic systems are revolutionizing industrial environments, streamlining production, and boosting efficiency. However, these high-speed, high-power machines present significant safety risks, making robust safeguards non-negotiable. Perimeter guarding is a critical component in ensuring the safety of workers while maintaining operational productivity. Robotic guarding prevents collisions between employees and industrial robot systems operating at high speed. Learn more about its critical role here.
In this comprehensive guide, we’ll explore the concept of perimeter guarding, its importance, use cases, and best practices for implementation in environments with robotic systems.
What Is It?
Perimeter guarding refers to the use of physical barriers, sensors, and control devices to establish and secure a defined safety zone around hazardous machinery, such as robotic systems. These zones are designed to keep unauthorized personnel out of dangerous areas while allowing controlled access for authorized workers.
How It Works:
- Physical Barriers:
- Fences, walls, and interlocked gates physically prevent access to dangerous areas.
- Sensor-Based Systems:
- Devices like safety light curtains and laser scanners detect unauthorized entry and stop machines automatically.
- Access Control:
- Interlock switches and controlled entry points ensure machines cannot operate unless access points are secured.
- Pressure-Sensitive Devices:
- Safety mats detect the presence of workers in hazardous areas and trigger emergency stops.
Benefits:
- Enhanced Worker Safety: Keeps personnel away from hazardous areas while machinery is operational.
- Reduced Downtime: Quickly detects and responds to safety breaches, minimizing disruptions.
- Regulatory Compliance: Meets global safety standards, including OSHA and ISO.
- Increased Productivity: Facilitates safe and efficient workflows in automated environments.
1. Why It’s Critical for Robotic Systems
Robotic systems perform tasks with high speed, precision, and force, creating a unique set of hazards. Without proper safeguards, interactions between workers and robots can lead to serious injuries or fatalities.
Key Hazards in Robotic Systems:
- Pinch Points: Where robotic arms interact with fixed machinery.
- Crushing Zones: Areas between moving robotic parts and stationary objects.
- High-Speed Movements: Robotic systems operate faster than human reaction times, making collisions highly dangerous.
Safety Measures
Perimeter guarding mitigates these risks by restricting access to high-risk areas and ensuring machines stop immediately when breaches occur. By using a combination of barriers and sensor-based systems, facilities can protect workers while allowing robots to operate without interruption. Modular systems offer flexibility and can be easily adapted as robotic systems are reprogrammed. Learn more about these benefits in this article.
Example Application:
In a packaging facility, safety light curtains installed around robotic palletizers create an invisible barrier. If a worker enters the zone, the light curtain triggers an immediate stop, preventing potential injuries.
2. Common Use Cases
Perimeter guarding is essential in a variety of industries where robotic systems and automated machinery are used.
1. Automotive Manufacturing:
- Application: Robotic arms perform welding, painting, and assembly tasks at high speeds.
- Solution: Use physical barriers combined with safety mats to secure areas around workstations.
2. Metal Fabrication:
- Application: Robotic cutters and press brakes pose significant risks due to their force and precision.
- Solution: Install interlock gates and light curtains to prevent unauthorized access.
3. Pharmaceutical Production:
- Application: Robotic systems handle sensitive materials in sterile environments.
- Solution: Use transparent barriers and laser scanners to maintain visibility while ensuring safety.
4. Food Processing:
- Application: High-speed robotic systems package and sort food items.
- Solution: Deploy pressure-sensitive mats and fencing around robotic work cells to secure the area.
3. Components in Detail
To create an effective system, it’s essential to understand the key components and their roles.
Physical Barriers:
- Fences, walls, and interlocked gates form the backbone of a guarding system. These barriers physically block access and provide a visible reminder of restricted zones.
- Best Practice: Ensure gates are equipped with interlock switches to prevent machinery operation when access points are open.
- Effective physical barriers must prevent workers from reaching over, under, or through the guard to access dangerous machinery. For a detailed overview, refer to this guide.
Sensor-Based Systems:
- Devices like safety light curtains, laser scanners, and proximity sensors detect unauthorized entry and trigger automatic shutdowns.
- How They Work:
- Light Curtains: Emit invisible beams of light that, when interrupted, signal the system to stop.
- Laser Scanners: Map 3D zones around machinery, offering flexible detection areas.
Pressure-Sensitive Devices:
- Safety mats are placed on the floor around machinery. When stepped on, these mats stop operations instantly.
- Use Case: Ideal for areas where workers need occasional access to the guarded zone, such as robotic maintenance areas.
4. Designing an Effective System
Key Considerations for Design:
- Hazard Identification:
- Conduct a risk assessment to identify hazards posed by robotic systems.
- Accessibility Needs:
- Balance safety with operational efficiency by providing controlled access points.
- Environmental Factors:
- Choose materials and devices suitable for the facility’s environment (e.g., chemical-resistant mats for food processing).
- Integration with Existing Systems:
- Ensure that devices can communicate with existing safety systems and controllers.
Understanding the requirements for perimeter guarding of robotic cells is essential for effective safety implementation. Check out this guide for practical tips.
Customizing Solutions
Facilities often require tailored solutions to address specific challenges. For example:
- Robotic Welding Cells: Require heat-resistant barriers and smart sensors for added durability.
- High-Volume Warehousing: Use mobile laser scanners to adjust safety zones dynamically based on equipment movement.
5. The Role of Guarding in Regulatory Compliance
Safety Standards Addressed:
- OSHA Machine Guarding Standards: Requires physical barriers and safeguarding devices for hazardous machinery.
- ISO 13849: Sets performance levels for safety-related parts of control systems.
- ANSI/RIA R15.06: Focuses specifically on robotic safety requirements.
Compliance Insight: Installing perimeter guarding ensures facilities meet these standards, avoiding penalties and legal liabilities.
Why Compliance Matters:
- Legal Protection: Safeguard against workplace injury lawsuits.
- Worker Confidence: Build trust by prioritizing safety.
- Operational Continuity: Prevent unplanned shutdowns due to safety violations.
6. Future Trends for Robotic Systems
The evolution of robotic systems calls for equally advanced solutions.
Emerging Technologies:
- IoT Integration:
- Smart sensors connected to the cloud provide real-time monitoring and analytics for enhanced safety management.
- Dynamic Safety Zones:
- Laser scanners and AI-powered systems adjust safety zones based on robot movement patterns.
- Wireless Safety Devices:
- Eliminate wiring for faster installation and greater flexibility.
How These Innovations Improve Safety:
- Enable predictive maintenance by identifying system vulnerabilities early.
- Increase adaptability for facilities with frequently changing layouts.
- Provide enhanced visibility and control through centralized dashboards.
Protecting Workers and Optimizing Safety in Automation
Perimeter guarding is a vital component of any safety strategy involving robotic systems. By combining physical barriers, advanced sensors, and intelligent controls, facilities can ensure worker safety while maintaining productivity and compliance with global standards.
To learn more about solutions and how Pinnacle Systems can help secure your robotic systems, explore our range of safety products today.