5 - Safety requirements and protective measures

5.2 The Standard provides the Performance Level required for the safety-related control systems.
5.3 The Standard provides the design and installation requirements for robotic systems.  

• The Standard specifies the robot system and the protective measures shall be designed taking into account environmental conditions [5.3.1]. 
• The Standard specifies where operational controls and equipment shall be located [5.3.2]
• The Standard provides requirements regarding power sources. The Standard specifies that all electrical installation shall meet the requirements of IEC 60204-1, while hydraulic power installation shall meet the requirements of ISO 4413 and pneumatic power installation shall meet those of ISO 4414. [5.3.4]. 
• The Standard provides requirements related to isolation of the energy sources. Means shall be provided to isolate hazardous energy sources without exposing personnel to hazard [5.3.6]. 
• The Standard provides requirements for the control of stored energy [5.3.7].

5.4 The Standard provides requirements for limiting robot movements. 

• Robot installations shall be designed so as to reduce the potential exposure of personnel to hazards [5.4.1].
• The safeguarded space shall be established by perimeter guards. The restricted space of the robot system shall be established by means which limit the motion of the robot. The restricted space shall be made smaller than the maximum space. The restricted space shall be within the safeguarded space and should match the operating space as close as is reasonably practicable [5.4.2]. 
• The Standard describes the means for limiting motion. Limiting means are used to restrict the space in which a robot may perform its task. Limiting devices fall into two categories: mechanical and non-mechanical limiting devices. Mechanical limiting devices physically restrain the robot from moving beyond a designed limit. Non-mechanical limiting devices do not limit the robot motion themselves, but rather initiate a stop through the robot control system. Non-mechanical limiting devices require the integrator to take the robot stopping distance into account when establishing the restricted space of the robot. When non-mechanical limiting devices are used, the restricted space shall be determined based on the robot with actual load. The restricted space shall be based on the maximum speed of the robot (unless the speed is limited by a monitoring system) [5.4.3]

5.5 The Standard provides requirements regarding perimeter safeguarding design. 

• The protective devices selection shall consider: 

            a)    The expected operating stresses; 
            b)    The influence of the processed material;
            c)    Other relevant external influences 
           For the choice of protection devices, it is necessary to perform a risk analysis [5.5.1].

• The layout shall be designed to allow operator tasks to be performed from outside the safeguarded space. Where it is necessary to perform tasks within the safeguarded space there shall be safe and adequate access to the task locations. Access paths and means shall not expose operators to hazards [5.5.2].
• The hazard associated with the material handling shall be considered in the risk assessment. Measures shall be taken to prevent persons entering undetected into the hazard zone [5.5.3]. 

5.6 The Standard provides requirements related to robot system operational mode. 
5.6.3 Automatic mode

• Entering the safeguarded space in automatic mode shall lead to a protective stop of all equipment that could present a hazard or hazardous situation [5.6.3.1]
• Selection of automatic mode of the robot system shall not override or reset any protective stop or emergency stop condition [5.6.3.2];
• Automatic operation shall be initiated from outside the safeguarded space. Initiation of automatic operation shall only be possible when all associated safeguards are active [5.6.3.3]
• Personnel shall be protected from start and restart of the robot cell when they are inside the safeguarded space, in accordance with ISO 14118 [5.6.3.4]. 

5.6.4 Manual mode

• When manual intervention is required, local control shall be effected by a single pendant [5.6.4.1]
• In manual mode, the velocity shall not exceed to a standard limited value (250 mm/s). It shall be possible to select speed lower than the limited value. The risk analysis shall determine if it necessary to use speed lower than the limited value.  In manual mode, motion of the robot or any part of the robot system shall be possible only in conjunction with an enabling device [5.6.4.2]

5.7 The Standard provides requirements regarding pendants
 

• Pendants used inside the safeguarded space shall conform to the requirements in ISO 10218-1. 
• Teach pendants equipped with a cable shall have a cable that is of sufficient length to allow the teacher to perform expected tasks in a safe manner [5.7.1]
•  A single pendant may control simultaneous motion of a system with multiple robots. Each robots shall be selected before it can be activated. Only the selected robots shall be activated. Any robots in the system not selected shall not move and shall not move [5.7.3]

5.8 The Standard provides requirements regarding maintenance and repair.

• It shall be possible to carry out inspection and maintenance operations on the robotic system.  The inspection and maintenance programme shall take into account the manufacturer’s recommendations. 
• Information for use shall include requirements for periodic functional testing of the safety-related parts of equipment to ensure proper operation [5.8.1].
• The robot system shall be designed and constructed in such a way as to allow safe access to all areas where intervention is necessary during operation, adjustment and maintenance. Maintenance shall be performed from outside the safeguarded space. The Standard provides requirements in order to perform maintenance within the safeguarded space [5.8.2].

5.9 The Standards provides requirements for the integrated manufacturing system interface. 

• Hazards associated to machinery and equipment that are inside the safeguarded space shall be taken into account [5.9.1]; 
• The span of control may include multiple zones. Information for use shall include information on the span of control of each emergency stop device [5.9.2]; 
• Operational requirements shall determine the need for local control. When local control is selected, the integrated manufacturing system shall be notified of this condition and shall not be able to override the local control. The emergency and protective stop functions shall remain operational during local control [5.9.4].