You Must Know About the New RIA Automation Standard

Transcription

1 You Must Know About the New RIA Automation Standard AMT

2 Decoding the essentials of RIA R15.06:2012 The new Robotics Industry Association (RIA) standard for robots and robot systems (RIA R15.06:2012) will have a significant impact on all businesses using robotic automation. Here is your guide to what you need to know about the most important parts of the new safety requirements within the standard. These are the game changers that promise to have the most relevance and effect on your robotics design, construction, installation, operation, and maintenance. What s Inside: The new RIA R15.06:2012 defined The 3 Game Changers revealed that will have the greatest impact on business How they can affect your business. Putting it all together Solutions for compliance that you can implement At AMT, we are committed to providing our clients the information they need. We are conversant with the new RIA standard and relevant U.S. and global industrial automation safety standards. Whether you are an integrator or end user, this guide is designed to help you begin navigating your way through the new RIA standard in order to become compliant Applied Manufacturing Technologies All rights reserved

3 Fourteen years after the previous RIA Safety Standard, a new set of guidelines has recently been adopted. It will make automation systems even safer for workers. It also addresses the technical advancement in robotic systems that have occurred since RIA R15.06:1999, the previous version. A standard such as this is not a law; however, we recommend full compliance with it. R15.06:2012 does not take full effect until January 1, However, we recommend that starting now when modifying or implementing new systems there is little advantage to use the previous version. A complete revision According to the RIA document, the new R15.06:2012 Safety Standard is a complete revision of the previous R15.06:1999 (r2009) Safety Standard. Some of the most significant changes in the new standard include the following: 1. A total reorganization of the text presenting the ISO and ISO in their entirety. Both parts of the ISO documents are presented in one volume R Changes of selected terminology (e.g. reduced speed for slow speed, protective stop for safety stop), but not changes to functional requirements 3. Additional requirements regarding new features offered on robots and the safe integration of the features 4. Requirements for detachable and wireless pendants 5. Change in clearance requirements 6. The Operator applies to ALL persons performing tasks including maintenance and repair 7. Requirements for collaborative robot operation (new feature) 8. Functional Safety A change in requirements to define and quantify safety control circuitry 9. Safety Rated Soft Limits (SRSL) - A change in the approved control of robot motion to include newly developed safety-rated soft axis and space limiting 10. Mandatory Risk Assessment- A Risk Assessment SHALL be performed and is no longer optional The game changers We have highlighted the last three of the changes noted above as true game changers : we contend that these will have the most impact on your business in the coming months in terms of cost impact, allocation of in-house resources, and required personnel skill sets to execute the work. Robotic Industries Association (RIA) is North America s trade group serving the robotics industry. RIA now represents more than 280 robot manufacturers, system integrators, component suppliers, end user, consulting firms, research groups, and educational institutions. It hosts the ANSI/RIA National Robot Safety Standard and annual National Robot Safety Conference. As a RIA Certified integrator AMT has been identified as a specialist in safety and risk assessment saving our clients valuable time and costs from the implementation of the new standard Key Takeaway: Beginning January 1st 2015, new RIA safety standards take full effect, including several changes that will significantly affect business by changing how robotic safety is implemented in the U.S.

4 When adopting the new RIA standard, or any consensus standard, it is important to understand the content of the standard as well as how the standard could affect you. The industry leaders of the R15.06 Subcommittee worked diligently to identify specific guidelines and responsibilities for safety of industrial robots and robotic systems. Due to the complexity of the task and the language necessary to detail the standard, it is helpful to have a guide to understand the intent of the standard. Our goal in this ebook is to provide that guide and highlight the three areas that may have the greatest impact. These 3 Game Changers are highlighted because of the potential impact that they may have on your business. These are: 1. Functional Safety A change in requirements to define and quantify safety control circuitry 2. Safety Rated Soft Limits (SRSL) - A change in the approved control of robot motion to include newly developed safety-rated soft axis and space limiting. 3. Mandatory Risk Assessment - A Risk Assessment SHALL be performed and is no longer optional. *This is a big shift for our industry, especially for system suppliers who are already feeling the squeeze of tight budgets and timelines. It is paramount to your business that you have a full understanding of how these game changers can affect you. New Robotic Safety Standard How they can affect your business Require a change in the allocation of valuable time Potentially taking time away from other important tasks (size of change is process dependent) Additional Resources required Safety experts, operators, programming, controls, maintenance etc. Increased Liabilities Without the proper implementation of the new standard, there could be an increased liability. Next, we will examine each of the highlighted RIA R15.06: game changers and explore a path to compliance. Key Takeaway: The 3 Game changers from the RIA safety standard demand your attention because they can have a direct impact on your business operations.

5 The goal of implementing functional safety is to define, as well as quantify, engineering solutions (safety measures, techniques and procedures) that need to be implemented to achieve an acceptable safety hazard level in compliance with the safety standard. What RIA R15.06:2012 says: Safety related parts of control systems shall be designed so that they comply with PL=d with structure category 3 as described in ISO :2006, or so that they comply with SIL 2 with a hardware fault tolerance of 1 with a proof test interval of not less than 20 years, as described in IEC 62061:2005. (Part 1), 5.4.2, Performance Requirements In Other Words: Supplied components and their integration into the safety-related control system must meet the required safety performance level and have the life expectancy needed to meet the system s overall functional safety. Performance Level (PL, ISO 13849) or Safety Integrity Level (SIL, IEC 62061) are calculated metrics that result from the analysis of the entire safety-related control system. What it means to you: First a risk assessment of the automation system is performed. The risk assessment identifies potential system hazards. Then, with the findings of the risk assessment, a Functional Safety Design (further engineering analysis) is conducted to identify the methods to reduce risk to a level acceptable to the end user. These methods may include system and/or operational changes. Some examples are physical guards, safeguarding devices, awareness devices, safeguarding methods, control components, operating practices. To conduct a Functional Safety Analysis, engineers must identify or calculate each independent component s Functional Safety value. They must then coordinate the accumulated value(s) of the safety system to meet an acceptable level of hazard exposure. Some calculations to consider are: 1. PFHd = probability of dangerous failure per hour (IEC/EN 62061) 2. SIL CL = SIL claim limit (IEC/EN 62061) 3. MTTFd = Mean time to dangerous failure (ISO 13849) 4. DC = Diagnostic coverage (ISO 13839) 5. Category = resistance to fault (ISO 13849) 6. = Measure against common cause failure (ISO 13849) The result of the analysis is a documented for many valuable future uses, such as certification of a reliable safety system, system validation tool, and even a scope of work document to be used through the implementation of the Functional Safety System. Key Takeaway: The new functional safety standard is highly technical and may require special expertise in assessing the efficacy of safety control systems Functional Safety provides validation of your risk assessment countermeasures to risk reduction. Finally, we have a tangible and quantifiable way to determine if the control system meets our designed acceptable risk levels as well as current safety standards. Jean-Yves Chretien, Certified TUV Functional Safety Engineer

6 Historically, robotic safety and safeguarding was all about hardware-controlled limits to a robot s movements, combined with access restrictions to the potential motion space. These limits took the form of physical hard stops on robot joints, structured walls, and columns, limit switches mounted to the robot, and non-contact safety devices. In order to keep hazards at a safe distance from operators, safeguarded areas were much larger than was required for the productive functioning of the cell. With the proper safety system design, the new standard will now allow us to use less floor space! What RIA R15.06:2012 says: Soft limits are software-defined limits to robot motion. Space limiting is used to define any geometric shape that may be used as an inclusionary or exclusionary zone, either limiting robot motion within the design space, or preventing the robot from entering the defined space. (Part 1) , Safety-rated Soft Axis and Space Limiting Robot installations SHALL be designed and integrated so as to reduce the potential exposure of personnel hazards. To reduce the safeguarded space, the maximum space can be limited by the provision of integral or external devices that restrict the movement of the robot system. (Part 2) 5.4.1, Limiting Robot Motion (General) What it means to you: The development of Safety Rated Soft Limits (SRSL) was a major innovation by robot manufacturers. They are programmable software-defined limits to robot motion within the robot s operating system. When ordering a new robot with the proper Safety Rated Soft Limit and/or manufacturer hard stop options the system can be programmed to use a smaller portion of the robot s SRSL s deliver immense flexibility compared to traditional safety limiting and can help dramatically optimize floor space while adhering to the new RIA standard maximum reach area. By doing so the restricted space can be reduced to closer match the shape of the required work envelope. Thus, less perimeter safeguarding can be used and the guarding will enclose less floor space. Now that SRSL s are safety-rated and accepted by national standards. This can be of great benefit since it allows further optimization of floor space. Your overall robotic system space requirements can be reduced by integrating the proper safeguard devices into your safety control system. The figure above represents a reduction in required floor space using SRSL s of a system with the same work envelope. With the new RIA safety requirements and the ability to purchase the SafeOperation option on our new robot, we were able to save over 120 square foot of productive floor space within our cell. In granite processing facilities, floor space is at a premium and this benefit will maximize our material processing area. - Chuck Russo, Owner Surface encounters Key Takeaway: The new RIA safety standard offers potential robotic system implementation cost savings by reducing system components and reducing the amount of floor space required

7 A Risk Assessment is a comprehensive evaluation of the possible injury or damage to health in a hazardous situation that is done in order to eliminate or reduce hazard or to select appropriate safeguards. The new standard now mandates that a Risk Assessment is the responsibility of all involved in a robotic system s build and use. It requires them to evaluate the hazards associated with the robot system over its lifecycle. (i.e. commissioning set-up, production, maintenance, repair, decommissioning.) What RIA R15.06:2012 says: Because a robot system is always integrated into a particular application, the integrator SHALL perform a risk assessment to determine the risk reduction measures required to adequately reduce the risk presented by the integrated application. (Part 2), 4.3.1, Risk Assessment (General) What it means to you: Robotic systems must be assessed for risk. The assessment s complexity varies with the system s application and use. Previously, conducting a Risk Assessment was the end user s responsibility. With RIA R15.06:2012, a Risk Assessment must be done of all robotic systems by the system supplier and the end user. Furthermore, a Risk Assessment is recommended on all automation systems. Ultimately, this process should be used to Identify, Assess, Reduce, and Verify that all hazards are at an acceptable Risk level for operator interaction. To establish the risk level, all hazards are required to be assessed according to their SEVERITY, EXPOSURE, and AVOIDANCE. Based on these items, the following are BASIC steps that should be used during a risk assessment. 1. Identify: All Risks, All Hazards, Who could be affected, probability of occurrence and severity of the hazards) 2. Assess the risk: Use of the ANSI B11 TR: chart is the best method to describe the risk level 3. Reduce Risk to Acceptable: Create mitigation solutions that bring risks to a level that are acceptable for the systems end user 4. Validation of the mitigation action taken: Validation that the implemented hazard protection has appropriately reduced the potential harm, that all safeguard solutions are properly working, and that all hazards will be monitored and controlled through the lifecycle of the equipment Key Takeaway: Mandatory risk assessments for robotic systems are now the responsibility of the system supplier and the end user. This will require additional time and resources from both the supplier and the end use.

8 Let s recap; The new RIA R15.06:2012 Safety Standard is now complete and this long awaited set of revised guidelines has been adopted. This standard makes automation systems safer for workers, and addresses the technical advancement in robotic systems. An important question is, how does it affect you, your business and how are you going to become compliant? We identified what we consider the most impactful 3 Game Changers in the new standard: 1. Functional Safety 2. Safety Related Soft Limits (SRSL) 3. Mandatory Risk Assessment To assure compliance with the new standard you will need to adhere to these changes and possibly other changes and implement them into your future operations. To do that there are a couple of solutions: 1. Implement from within You can do it in-house with your current resources. 2. Outsource Bring a company in to consult on solutions. This may include an evaluation of your current operations, perform a Functional Safety design, or to do a Risk Assessment. When evaluating these options there are some factors you want to consider: For new cells, if I change nothing, am I exposed to increased liability? The short answer is yes. OSHA is recommending that RIA R15.06:2012 be used as a guideline. At a minimum, the RIA standard now requires a Risk Assessment. Conducting a proper risk assessment will be crucial to your operation. If not properly done, it can increase your liability Will I have the time required? Every process is different. Some assessments will require more time than others will. Do you have the additional time? Can you afford the required time and resources to complete the process? Will I have the resources I need? Do you have the in-house staff and knowledge needed to complete the compliance process? Do you have a safety expert on staff?

9 If you have determined that you may not have the time, resources, or expertise to fully comply with the new RIA standard, you may be considering outsourcing. Consider this; Some companies that provide consulting services also sell safety related hardware. They may come with a product agenda that could include purchasing their products. Make certain to verify credentials and seek out an RIA certified Robot integrator that has the experience, expertise, and successful track record to partner with. Introducing: The AMT Advantage If you are interested in complying with the new RIA standard, AMT can consult with you to find your best solution. As an industry leader, AMT specializes in robotic challenges and solutions. We offer a No Product Agenda approach to safety solution services. At AMT, we do not manufacture safety related products. This allows us to take a product-neutral look at your needs and design a solution tailored specifically for you. Whether it is a newly installed or an existing system, we ll recommend the hardware and software that best suits your situation. Among the benefits of using AMT for robotic system safety engineering: AMT employs a certified Functional Safety Engineer and other consultants. AMT has been assisting our customers with RIA specific risk assessments for the past 6 years. AMT is a RIA Certified Robot Integrator By teaming up with AMT your company will benefit from our trained, certified consultants who have the experience to identify possible hazards, determine risk reduction requirements, and then propose and validate possible solutions. Relying on AMT for advice and consultation during this period of change, you re assured of a minimum of disruption to your processes and in house resources. Press Release: The Robotic Industries Association (RIA) today announced that Applied Manufacturing Technologies (AMT) has received the prestigious RIA Certified Robot Integrator designation. In order to become certified, AMT completed a rigorous process that includes an onsite audit and testing of key personnel among other important criteria. We are delighted to welcome AMT as our eighteenth Certified Robot Integrator, said Jeff Burnstein, President of the RIA. Learn how we can help you. Timing is essential in the process and now is the time to get ahead of the competition. Get your Personal Consultation Today! Click Now To Get Started (Ctrl + Click to open new window) Our goal in this guide was to introduce you to the new RIA standards, shed some light on what you can do to be compliant in 2014 and offer you the best possible solutions. Proper implementation of the new RIA R15.06:2012 safety standard is crucial. With knowledge, the right strategic partnership and careful implementation your business can be safer and flourish in 2014 and many years beyond.