Why ISO 10218-1 and ISO 10218-2 Standards Are a Necessity, Not a Choice, in Your Robotic Cell?
When you incorporate an industrial robot into your factory, you are not just buying a machine, but a complex safety responsibility. In technical literature, robots are referred to as “partly completed machinery”; meaning they cannot perform a function on their own, but transform into a complete machine when a gripper or process equipment is added. At this point, the ISO 10218 series comes into play, guaranteeing both the safety of the system during the design phase and the integration process in your factory. If you are working with robotic arms on your production line, while ISO 10218-1 binds the robot manufacturer, ISO 10218-2 is a critical guide that directly concerns you and your system integrator. Complying with these standards is not just a legal obligation, but the fundamental set that will save your employee’s life in a potential work accident.
How Do You Ensure Category 3 and PL d Levels in Control Systems?
In control units, which are the brains of robotic systems, the word “safety” represents a technical performance level (PL) rather than an abstract concept. ISO 10218 standards require the control structure of industrial robot systems to be at a minimum of Category 3 and PL d level. This technical expression tells you: even if a single fault occurs in any safety component in the system (for example, an emergency stop button or a safety relay), the system must not lose its safety function and must not allow a dangerous movement. Safety software offered by technology providers supports these complex hardware requirements with software-based solutions, providing both flexibility and helping you meet Category 3/PL d requirements. It is not enough to just see a safety relay when you open your electrical panel; you must ensure that the circuit diagram supports this dual-channel structure.
How Should Safe Distance and Space Limitation Be Calculated in Robot Cells?
That critical gap between the robot’s maximum reach and the area where your employees are located must be based on mathematics. When calculating the Safety Distance in accordance with ISO 13855, you must take into account the total stopping performance of the system (T) and the approach speed (K). A small expert note: Since the robot’s stopping time may change over time, it is vital to repeat these measurements periodically (at least every 6 months). When placing your fences or safety barriers, you must adhere to the upper and lower limb reach tables in ISO 13857. If your fence height is 1800 mm and the distance to the robot’s danger zone is insufficient, it is only a matter of time before personnel reach over and touch the danger. In such cases, the most professional approach is to create intelligent safety zones using area scanners that gradually reduce the robot’s speed according to the operator’s proximity.
What Does ISO/TS 15066 Change When Using Collaborative Robots (Cobots)?
Unlike traditional robots, ISO 10218 is not sufficient for collaborative robots working side by side with humans; here you need to look at the ISO/TS 15066 technical specification. Automation in cobots safety is based on the principle of “force and power limiting.” These robots are designed to operate with a calibration that will not exceed the pain threshold when they hit a human. However, you must remember that even if the cobot itself is safe, a sharp blade or a heavy part at its end breaks the entire safety equation. When performing a risk analysis, you must take into account not only the movement of the robot but also the hazards created by the application (e.g., welding or screwdriving). If there is a possibility of your operator touching the robot, you must have on-site measurements taken to verify whether you remain within the biomechanical limits in ISO/TS 15066.
How Do You Prevent Unexpected Start-ups During Maintenance and Troubleshooting Processes?
A large portion of robot accidents occur during adjustment and maintenance processes, not during production. The EN ISO 14118 standard requires the LOTO (Lockout/Tagout) system to prevent the machine from restarting “unexpectedly” during maintenance. One of the most terrifying scenarios is a technical person entering the robot cell, the safety gate closing behind them, and the robot starting to operate in automatic mode. To prevent this, you should use LOTO-compatible interlocking devices or trapped key systems. The person entering the cell should not start work without attaching their padlock; this simple organizational measure provides a more reliable line of protection than the most complex sensor. You must also instill in your team that when using the robot in teach mode, the speed must not exceed 250 mm/s and that this process must only be performed with a single authorized control.