The Latest in Sensors, Programming, and Risk Assessment for Safe Collaborative Deployment

Collaborative robots—or cobots—are revolutionizing industrial automation by working harmoniously alongside human employees. Unlike traditional industrial robots, which typically operate within barred confines, cobots are built for direct interaction, promoting more flexible and efficient workflows.

As their integration into various industries accelerates, the demand for sophisticated safety systems, enhanced programming environments, and thorough risk assessment frameworks has never been greater. In this article, we delve into the latest advancements in human-robot collaboration, highlighting how evolving safety standards, cutting-edge sensor technologies, and innovative software solutions are paving the way for safer and scalable cobot deployments.

The Changing Regulatory Landscape

Cobot safety is governed by a comprehensive array of international standards. Among these, ISO 10218 and ISO/TS 15066 stand out as pivotal frameworks that outline essential requirements for robot system safety and human-robot interactions.

• ISO 10218 generally outlines safety measures for industrial robots, while ISO/TS 15066 specifically addresses collaborative applications, setting guidelines for permissible contact forces and types of human-robot collaboration—such as hand-guiding and speed/separation monitoring.

These standards evolve continuously to accommodate emerging technologies and diverse use cases. Recent updates to ISO/TS 15066 have laid a foundation for newer guidelines, including RIA TR R15.806 and EN ISO 13849, which elaborate further on functional safety and the performance levels for safety-critical control system components.

Such regulatory frameworks compel manufacturers and integrators to prioritize safety in both hardware and software design.

Advanced Safety Sensors: From Vision to Proximity

Central to cobot safety is real-time environmental awareness. Recent innovations in sensor technology enable robots to detect and react to human presence with unprecedented speed and precision. Let’s explore some key sensor advancements:

1. Vision-based Systems

AI-powered 3D vision cameras now possess the capability to distinguish between humans, objects, and the surrounding environment. These systems facilitate dynamic zone mapping, allowing cobots to modify their behavior—such as slowing down, halting, or rerouting—upon detecting a person entering their workspace.

2. Force-Torque Sensors

Integrated into the joints or end-effectors of cobots, force-torque sensors provide crucial tactile awareness. When a cobot encounters unforeseen resistance or impact, it can react almost instantly—either by stopping or recalibrating its motion.

3. Proximity and Ultrasonic Sensors

These sensors establish virtual safety zones, akin to automotive collision-avoidance mechanisms. When utilized alongside vision systems, they deliver layered safety measures.

4. Wearable Safety Devices

Innovations extend to wearable transponders or haptic belts that alert workers to unsafe proximities, offering feedback when in shared zones with cobots. This innovation places an additional layer of safety directly on the user.

Smarter Programming for Safer Collaboration

Low-code and no-code programming environments are empowering individuals without extensive technical expertise to configure cobots, embedding safety constraints from the outset.

• Graphical safety programming tools allow integrators to create safety zones, set velocity limits, and determine toolpaths with clarity and visual confirmation, significantly enhancing user-friendliness.

• Teach pendant systems now often come equipped with safety override features and soft stops, allowing operators to physically guide robots through tasks, ensuring instinctive and cautious path planning.

Moreover, AI and machine learning are beginning to play a role in dynamic safety adaptation. By learning from past data and human feedback, certain cobots can autonomously modify speed, path, or tool pressure according to the specific context of a task.

Risk Assessment: A Critical Pillar of Safe Deployment

Prior to embarking on any cobot deployment, a robust risk assessment is essential, as mandated by ISO/TS 15066 and EN ISO 12100. This process involves identifying potential hazards, estimating their severity and likelihood, and implementing effective mitigation strategies.

Key Elements of a Comprehensive Cobot Risk Assessment:

• Task Analysis: Understanding the physical interactions required, frequency of human involvement, and complexity of robot movements.

• Workspace Mapping: Identifying collaborative zones, restricted areas, and safe egress paths to enhance overall safety.

• Force and Pressure Limits: Guaranteeing that any potential contact remains within predetermined human-safe thresholds.

• Emergency Response Planning: Establishing redundant stop buttons and safe robot recovery protocols while providing extensive training for all personnel involved.

Modern software tools, such as SISTEMA (developed by IFA Germany), assist in calculating safety performance levels based on the intended use and architecture of the system.

Leading Companies in Safety Systems for Cobots

A number of leading technology providers are at the forefront of developing components and systems dedicated to ensuring safe human-robot interaction. Here’s a rundown of ten noteworthy companies:

1. Sick – A market leader in vision-based safety systems and LiDAR technology for automated setups.

2. Pilz – Known for programmable safety controllers and modular safety relay systems.

3. Keyence – Provides compact, high-resolution safety sensors and zone scanners.

4. Cognex – Specializes in advanced machine vision technologies with AI-based safety systems.

5. ABB – Combines motion control with safety through platforms such as SafeMove and OmniCore.

6. Universal Robots – Offers built-in force limiting and user-friendly configurations for safety.

7. Kuka – Produces the LBR iiwa cobots equipped with torque sensors and integrated safety features.

8. OnRobot – Develops end-effectors with in-built sensing capabilities and compliant gripping technologies.

9. Fanuc – Features Dual Check Safety (DCS) systems with adaptable safety parameters.

10. Omron – Provides integrated safety platforms incorporating adaptive motion controls and vision systems.

A Safer, Smarter Cobot Future

With cobots increasingly deployed across warehouses, manufacturing plants, and laboratories, safety has become a fundamental aspect, rather than an afterthought. Through advancements in sensor technology, intuitive programming solutions, and rigorous international standards advocating for best practices, the future of human-robot collaboration looks promising.

However, the responsibility for ensuring safe deployment rests with integrators, manufacturers, and end-users alike. Safety is not merely a specification—it’s a shared accountability, integral to the successful integration of collaborative robots into our workplaces.