Industrial Robots: Safe Robotic Workstations for Modern Manufacturing

Industrial robots are advanced automated devices designed to perform tasks related to manufacturing, assembly, and material handling. With their precision, speed, and efficiency, these robots play a crucial role in modernizing and optimizing industrial processes. In today’s rapidly evolving technological landscape, industrial robots have become indispensable across various industries, from automotive to electronics and pharmaceuticals.

Types of Industrial Robots and Application Possibilities

Industrial robots can be categorized into several basic types based on their design and intended use:

• Cartesian Robots: These robots feature three linear movements along the X, Y, and Z axes. They are commonly used in pick and place processes, assembly, and CNC applications.
• SCARA Robots: With four degrees of freedom, these robots excel in assembly, packaging, and material handling tasks.
• Cylindrical Robots: Characterized by cylindrical movement, these robots are used in welding, casting, and assembly operations.
• Spherical Robots: These robots have spherical movements and are used in assembly and manipulation processes where precise positioning is required.
• Delta Robots: Known for their lightweight design, delta robots are used in fast pick and place applications, packaging, and sorting.

Industrial robots find applications in various sectors such as automotive, electronics, food, and pharmaceuticals. Their versatility and ability to perform complex tasks make them invaluable in modern industry.

Leading Manufacturers of Industrial Robots

The industrial robotics industry is dominated by several leading manufacturers with significant market shares both in Europe and Poland. Here is an overview of the key players:

These data are derived from the latest market reports and analyses, highlighting the dominance of key players in the industrial robotics market. ABB, KUKA, FANUC, and Yaskawa stand out for their innovation and wide range of products tailored to various industrial needs.

Industrial Robots: Safe Robotic Workstations

Safe robotic workstations are specially designed work areas equipped with industrial robots to perform specific tasks. These workstations can be used in various applications, such as welding, assembly, machining, and packaging. The introduction of robotic workstations offers numerous benefits, including increased efficiency, precision, and workplace safety.

Benefits of Using Robotic Workstations

1. Increased Efficiency: Industrial robots can operate 24/7, significantly boosting production efficiency. Automation allows companies to achieve higher product quality in less time.
2. Precision and Repeatability: Robots perform tasks with high precision and repeatability, minimizing production errors and ensuring consistent product quality.
3. Worker Safety: Introducing robots to perform hazardous tasks, such as welding or material processing, significantly reduces the risk of workplace accidents. Robots can work in harsh conditions where human presence would be dangerous.
4. Flexibility: Robotic workstations can be easily adapted to various tasks and production processes, enhancing production flexibility and enabling quick responses to market changes.

Examples of Robotic Workstation Applications

• Welding: Robotic welding is widely used in the automotive industry, where precision and speed are crucial. Advanced technologies, such as laser welding, enable high-quality welds.
• Assembly: Assembly robots are used to assemble electronic, mechanical, and other components. Precise manipulators allow for quick and accurate assembly of even the smallest parts.
• Packaging: Packaging robots automate the product packaging process, speeding up the entire production line. Advanced vision systems enable robots to recognize and sort products of various shapes and sizes.
• Machining: Robots can be equipped with various machining tools, such as milling, turning, or grinding. Automating these processes increases precision and production efficiency.

Industrial Robots: Key Requirements of the PN-EN ISO 10218-1 Standard

The PN-EN ISO 10218-1:2011 standard outlines a series of requirements and guidelines aimed at ensuring the safe use of industrial robots. Below are ten key aspects of this standard:

1. Hazard Identification and Risk Assessment

Identifying potential hazards associated with industrial robots and assessing risk are fundamental steps in ensuring safety. The standard requires that all hazards be identified, and risk assessed. Based on this assessment, appropriate protective measures are implemented to minimize risk to operators and other employees.

The risk assessment process should include identifying all potential hazards, assessing associated risks, and implementing appropriate protective measures.

2. Designing Safe Robotic Systems

Designing robotic systems in accordance with the standard must consider risk minimization at the design stage. This includes power transmission components, electrical equipment, and control systems. All these elements must be designed to ensure maximum safety in use.

3. Protective Measures

The PN-EN ISO 10218-1:2011 standard specifies requirements for protective measures, such as physical barriers, locks, and emergency switches. These measures aim to prevent accidental access to dangerous robot work areas and ensure that robots can be quickly and safely stopped in emergencies.

4. Safety-Related Control Systems

Robot control systems must meet specific performance criteria to ensure that any failure leads to a safe state. The standard requires these systems to be designed to minimize the risk of failure and provide appropriate protective mechanisms in case of technical problems.

5. Safe Robot Operation

The standard specifies requirements for safe robot operation, including start-up, shutdown, and mode-switching procedures. It is crucial that operators are adequately trained and aware of potential hazards associated with robot use.

6. Operating Instructions and Documentation

Each robot must be supplied with complete documentation, including operating instructions, safety warnings, and maintenance guidelines. This documentation is a key element in ensuring safety and must be easily accessible to all robot users.

7. Operator Training

Industrial robot operators must be adequately trained in the safe use of equipment. Training should cover both theoretical and practical aspects of robot operation, as well as emergency procedures.

8. Maintenance and Technical Inspections

Regular maintenance and technical inspections are essential to keeping robots in a safe operational state. The standard specifies requirements for the frequency and scope of inspections and maintenance procedures, which must be carried out by qualified personnel.

9. Conformity Assessment and Certification

Industrial robots must meet the requirements of the PN-EN ISO 10218-1:2011 standard and other relevant safety standards. Conformity assessment and certification are crucial elements in ensuring that robots meet all required safety criteria before being marketed.

10. Post-Implementation Control

After implementing robots in the work environment, regular controls and monitoring of their operation are necessary. The goal is to ensure that robots continue to meet safety requirements and identify and eliminate potential hazards that may arise during operation.

Industrial robots and robotic workstations play a key role in modern industry, providing increased efficiency, precision, and safety. Implementing safety standards, such as PN-EN ISO 10218-1:2011, is essential to minimizing risk and protecting workers. As robotic technology continues to evolve, we can expect further growth in its significance and application across various industrial sectors. The future of industrial robotics is promising, with many new applications and innovations that could revolutionize production and other industries.

Industrial Robots and the CE Mark

Industrial robots, although often part of larger integrated systems, must meet specific requirements to obtain the CE mark. The CE mark is a mandatory designation on many products sold in the European Economic Area (EEA), indicating that the product meets European health, safety, and environmental standards.

Incomplete Machines

Industrial robots are considered incomplete machines because they usually require integration with other systems as part of larger production lines. According to the Machinery Directive (2006/42/EC), incomplete machines cannot be independently CE marked. However, they must meet certain requirements:

1. Declaration of Incorporation:
   • The manufacturer of the incomplete machine must provide a declaration of incorporation stating that the machine is intended for integration into other machines or systems and cannot be used independently until integrated and assessed according to the Machinery Directive.
2. Assembly Instructions:
   • The manufacturer must provide detailed assembly instructions specifying how to safely integrate the incomplete machine with other equipment.

Final CE Certification Process

When an industrial robot is integrated with other systems as part of a larger machine, the responsibility for obtaining full CE marking lies with the final manufacturer. The CE certification process includes:

1. Conformity Assessment:
   • The entire integrated system must undergo a conformity assessment according to relevant directives, including the Machinery Directive (2006/42/EC), EMC Directive (2014/30/EU), and other applicable directives, such as the Low Voltage Directive (LVD).
2. Technical Documentation:
   • The final manufacturer must prepare complete technical documentation, including information on all integrated components, risk assessment, and compliance tests.
3. EC Declaration of Conformity:
   • The final manufacturer must issue an EC declaration of conformity stating that the entire integrated system meets all the requirements of the relevant directives.
4. CE Marking:
   • After completing the conformity assessment process and issuing the EC declaration of conformity, the final manufacturer can affix the CE mark to the entire integrated system (note: the CE mark on the robot itself does not apply to the Machinery Directive).

Industrial Robots: Practical Aspects

Example

A company integrating industrial robots provides its products as parts of larger production automation systems. Each robot is supplied with a declaration of incorporation and assembly instructions. The integrator, who incorporates these robots into the production line, is responsible for ensuring that the entire system meets EU directive requirements and obtaining the CE mark for the entire system.

Industrial Automation and Industrial Robots

Industrial automation and industrial robots are two key elements of modern manufacturing that work closely together to optimize processes and increase efficiency. Their intersections are numerous and encompass various aspects, from design and programming to implementation and maintenance of systems.

1. Automation of Production Processes:
   • Industrial automation uses industrial robots to automate various stages of production, allowing for increased efficiency and cost reduction. These robots can be programmed to perform precise tasks, such as assembly, welding, or packaging.
2. PLC Programming:
   • PLC (Programmable Logic Controllers) programming plays a crucial role in integrating industrial robots with other automation systems. PLCs control robot operations, ensuring synchronization and seamless operation of the entire production system.
3. Design Offices and Machine Design:
   • Design offices are responsible for creating machines that work with industrial robots. Machine design involves creating components and systems compatible with robots, which is essential for effective automation.
4. Machine Safety and Harmonized Standards:
   • Ensuring machine safety is one of the most important aspects of integrating industrial automation and robots. Harmonized standards, such as PN-EN ISO 10218-1:2011, define safety requirements that must be met for systems to operate safely and effectively.
5. Outsourcing Engineers:
   • Outsourcing engineers allows companies to hire specialists for designing, programming, and implementing automation and robotics systems. This enables businesses to leverage the latest technologies and expertise without maintaining a large team of engineers permanently.
6. Construction of Industrial Machines:
   • The construction of industrial machines takes into account the integration of robots and automation systems. Machine construction must be adapted to work with robots, requiring careful planning and coordination between different engineering teams.

Industrial automation and industrial robots create complex, integrated systems that require collaboration at many levels, from design and programming to implementation and maintenance. Harmonized standards and machine safety are crucial to ensuring these systems operate efficiently and safely.

FAQ: Industrial Robots