Björn Matthias, ABB Corporate Research, 2015-10-02 Risk ...scalinon/IROS2015WS/BjoernMatthias-slides.pdf · Risk Assessment for Human-Robot Collaborative Applications Workshop IROS

© ABBSlide 1October 2, 2015

Risk Assessment for Human-Robot CollaborativeApplicationsWorkshop IROS 2015 –Physical Human-Robot Collaboration: Safety, Control, Learning andApplications

Björn Matthias, ABB Corporate Research, 2015-10-02


Risk Assessment for HRC Applications

§ Motivation for collaborative robots

§ Working situation – humans and collaborativerobots

§ Risk assessment basics

§ Requirements on a collaborative robot forpower-and-force-limited operation

§ Asimovà FRIDAà DACRà YuMi

§ Characteristics of YuMi

§ Example YuMi application – risk assessment

§ Summary and outlook

Overview


Motivation for Collaborative Robots

§ Things are going very well inestablished markets.

§ It’s tempting.

Should we simply continue with incrementalimprovements and rely on the same market?

(source: International Federation of Robotics (IFR), WorldRobotics 2015 Industrial Robots, Executive Summary)


Motivation for Collaborative Robots

§ Automotive still dominates numbers and drives industrial robottechnology requirements

§ Many other markets, e.g. 3C assembly have very low degrees ofautomation.

What applications will be important in future?

(source: International Federation of Robotics (IFR), WorldRobotics 2015 Industrial Robots, Executive Summary)


Risk Assessment for HRC ApplicationsMotivation for collaborative robots

(adapted from B. Lotter)

Number of variants lowhigh

Lot size highlow

Flex

ibilit

y

low

high

Productivity

low

high

Automatic assembly

Manual assembly

Collaborative assembly


Risk Assessment for HRC ApplicationsMotivation for collaborative robots

Conventional industrial robotsà Separate players

Collaborative industrial robotsà Team players

Safety by separationà No collaborationà No moving contact

Safety by supervision functionsà Limited collaborationà Contact under strict precautions

Harmless manipulatorsà Full collaborationà Contact OK

Robot produces according toapplication designà Limited flexibility, high cost

Human and robot share tasks,according to respective strengthsà High flexibility, moderate cost


Risk Assessment for HRC ApplicationsWorking environment – approach

Present

Future



§ Production needs§ Handle uncertain production volumes,

determined by product acceptance on themarket

§ Often batch production ranging from100s to 10,000s

§ Frequent model changes in production

§ Changeover time 1h

§ Status today§ Flexible production layouts (mostly

tables/lean cells), few conveyors

§ Assembly mostly done manually

§ Tools and fixtures are used

§ Robots only used upstream

§ Target approach§ Mixed human/robot production concept

- robots augment humans

§ Harmless robot with integrated controller

§ Multi-purpose gripper

§ Efficient programming concept

§ Competitive overall system cost

Working situation – humans and collaborative robots


Risk Assessment for HRC ApplicationsWorking situation – humans and collaborative robots



Robot Co-worker

HelperCo-existence Intrusion

Co-operation

Inspector


Human

Human

Robot



Risk Assessment for HRC ApplicationsRelevant Standards and Directives

Example EU:European Machinery Directive 2006/42/ECLaws + Directives

Type A Standards

Type B Standards

Type C Standards

IEC 61508 –Functional Safety

ISO 12100 – RiskAssessment

EN ISO 13849-1:2008

IEC 62061:2012

ISO 10218-1 – Robot

ISO 10218-2 – Robot system/cell

ISO 11161 – Integratedmanufacturing systems

ISO/TS 15066 –Collaborative Robots


Types of Collaborative OperationAccording to ISO 10218, ISO/TS 15066

ISO10218-1,clause

Type of collaborative operation Main means of riskreduction

5.10.2 Safety-rated monitored stop(Example: manual loading-station)

No robot motion whenoperator is in collaborativework space

5.10.3 Hand guiding(Example: operation as assist device)

Robot motion only throughdirect input of operator

5.10.4Speed and separation monitoring(Example: replenishing partscontainers)

Robot motion only whenseparation distance aboveminimum separationdistance

5.10.5

Power and force limiting by inherentdesign or control(Example: ABB YuMi® collaborativeassembly robot)

In contact events, robot canonly impart limited static anddynamics forces



§ Use case identification

§ Hazard identification

§ Risk estimation

§ Risk reduction

§ Iterate until acceptable residual risk

Risk Assessment Basics


ISO 12100 – Safety of Machinery – Risk Assessment


Risk Assessment for HRC ApplicationsRisk Estimation

Source: ISO 12100:2010 – Safety of machinery – General principles fordesign – Risk assessment and risk reduction


Risk Assessment for HRC ApplicationsHazards

vrel

F

Transient Contact Quasi-Static ContactDescription • Contact event is “short” (< 50 ms)

• Human body part can usually recoil• Contact duration is “extended”• Human body part cannot recoil, is

trapped

Limit Criteria • Peak forces, pressures, stresses• Energy transfer, power density

• Peak forces, pressures, stresses

Accessiblein Design orControl

• Effective mass (robot pose,payload)

• Speed (relative)• Contact area, duration

• Force (joint torques, pose)• Contact area, duration

ISO / TS 15066 – clause 5.5.4 “Power and force limiting”



§ Fits in a workspace intended for human worker

§ Can easily be moved from one location to another andrecommissioned

§ Has human-like reach and payload

§ Is inherently safe for collaborative operation

Requirements on Collaborative Robot for PFL


Concept for Scalable Automation“Friendly Robot for Industrial Dual-arm Assembly”

§ Harmless robotic co-worker for industrial assembly

§ Human-like arms and body with integrated IRC5 controller

§ Agile motion based on industry-leading ABB robot technology

§ Padded dual arms safely ensure productivity and flexibility

§ Complements human labor for scalable automation

§ Light-weight and easy to mount for fast deployment

§ Multi-purpose lightweight gripper for flexible material handling

FRIDA / ABB Dual-Arm Concept Robot (DACR) / ABB YuMi®


Risk Assessment for HRC ApplicationsYuMi Development History

FRIDAà Dual-Arm Concept Robot

Red dotdesign award

YuMi® - Hannover Fair 2015

FRIDA – Hannover Fair 2011

Pilot projectsfor verificationand testing

Shipping tocustomers

Initial ideas andtechnologystudies, simplerprototypes

https://www.youtube.com/user/ABBRobotics

https://www.youtube.com/user/ABBRobotics


Participation in Academic ResearchEU-FP7 project ROSETTA

§ Simulation based safetyapproval for DACR

§ Visual operator tracking

§ Human centric robotmotion

§ Task orientedoffline programmingof assembly tasks

§ Networked, learningassembly robots

§ Semantic productionknowledge-base onnetwork

www.fp7rosetta.org

http://fp7rosetta.org/

http://www.fp7rosetta.org/


Level 1

Level 2

Level 3

Level 4

Robot system – mechanical hazards

Low payload andlow robot inertia

Injury-avoiding mechanicaldesign and soft padding

Power and speedlimitation

Software-based collision detection,manual back-drivability

Level 5 Personal protectiveequipment

AB

Bco

llabo

rativ

ein

dust

rialr

obot

conc

ept

Mea

sure

sfo

rris

kre

duct

ion

and

ergo

nom

ics

impr

ovem

ent

Level 6 Perception-based real-timeadjustment to environment

Oth

er,a

pplic

atio

n-sp

ecifi

c

Qua

si-s

tatic

cont

act

Tran

sien

tcon

tact

ABB YuMi® Safety ConceptProtection Levels


YuMi® - IRB 14000 0.5/0.55Overview IRB 14000 – 0.5/0.55

Payload 0.5 kg per arm

Reach 559 mm

Repeatability 0.02 mm

Footprint 399 mm x 497 mm

Weight 38 kg

Controller IRC5 integrated in torso

Programming Lead-through or RAPID

Gripper Servo, 2x suction, integratedvision

Application supplies Ethernet, 24 V, air to flanges

Connections Ethernet, digital I/O 8in/8out, air

Temperature 5 °C – 40 °C

IP Protection IP 30

ESD Protection Certified

Clean room / food grade No

Speed Supervision Configurable up to 1.5 m/s

Safety Performance PL b, cat. B (ISO 13849-1)

www.abb.com/yumi

http://www.abb.com/yumi


§ Collaborative Assembly(Plastic parts etc.)

§ Packaging of small goods

§ Multifunction hand for addcomponents

Small Parts Assembly Consumer Products Toy Industry

§ Collaborative Assembly§ Camera-based inspection

and assembly§ Accurate and fast

assembly§ Testing and packaging

§ Collaborative Assembly(toys)

§ Use of feeding and visionoptions

YuMi®Target growth markets



§ Internal application example

§ ABB Busch-Jaeger, Lüdenscheid

§ Pick-and-place operation

§ Co-existence in production

§ Customer application example

§ Continental

§ Packaging operation

§ Co-existence in production

Example YuMi Application – Risk Assessment


Collaborative Applications at ABB

§ Application profile

§ Pick component 1 from in-conveying 1, left arm

§ Pick component 2 from in-conveying 2, rightarm

§ Place component 1 to fixture in press

§ Assemble component 2 to component 1

§ Cycle press to clip together

§ Pick finished sub-assembly and place to out-bin(hole in table)

§ Running since Feb. 2015

§ Integrated in to factory information system

§ Phoebus robot waiting to be replaced by YuMi robot

§ More applications envisioned esp. for single-armcollaborative robots

Busch-Jaeger (BJE) Lüdenscheid – Pick’n’Place


Collaborative Applications at ABBBusch-Jaeger (BJE) Lüdenscheid – Gripper Padding

§Protectivepadding ongripper


Risk Assessment – Use CasesUse case Activity Person FrequencySetup andprogramming

Build, program, commissionapplication

Typically speciallytrained personnel

Rare, only before SOP

Normal productionoperation

Use robot system to runproduction application

Typically simplytrained personnel

High

Manual interventionin production

Reach into robot work spaceto clear error situation

Typically simplytrained personnel

Low

Foreseeable misusein production

Non-authorized colleague orvisitor entering work space

Typically untrainedpersonnel

Unknown, assumedrare

Maintenance Repair, service, modify,optimize application

Typically speciallytrained personnel

Rare to moderate,depending onproduction changes

Cleaning Clean surfaces, does notinclude servicing machinery


Moderate

Dismounting Dismount, pack, ship, disposecomponents of application


Rare, only afterproduction lifetime


Risk Assessment – Hazard Identification

Use case Human-robotwork spaceoverlap

Free impacthazard

Crushing hazard

Setup andprogramming Y Y Y

Normal productionoperation N N N

Manual interventionin production Y Y Y

Foreseeable misusein production Y Y Y

Maintenance Y Y YCleaning n.a. N NDismounting n.a. N N


Risk Assessment – Risk Estimation and Reduction

Use case Unprotected risk

Severityof hazard(S)

Exposureto hazard(F)

Avoidanceof hazard(P)

Risk reduction measures

Setup,programming,maintenance

Too high S1*à S0† HighF2

P2à P1 • Training to reduce P• Speed supervision to reduce S

Normalproductionoperation

Too high S1*à S0† F1 P1 • Speed supervision to reduce S

Manualintervention

Too high S1*à S0† HighF2

P2à P1 • Training to reduce P• Speed supervision to reduce S

Foreseeablemisuse

Too high S1*à S0† F2à F1 DifficultP2

• Access restriction to reduce F• Speed supervision to reduce S

Cleaning,dismounting

Acceptable Noneassociatedwith robotoperation

n.a. n.a. • Standard measures

* Note: exclude applications that would lead to S2, i.e. sharp edges etc.† Note: Here “S0” designates “no injury”


Required Safety Performance of Safety FunctionsStandard Robots and “Typical” Collaborative Robots

Can potentially cause “S2” events, i.e. “irreversible” injury


Required Safety Performance of Safety Functions“Harmless” Collaborative Robot

Can cause at most “S1” events, i.e. “reversible” injury


Required Safety Performance of Safety FunctionsABB YuMi®

Worst case is minor, fully reversible injury (S1)

Continuous exposure (F2)

Very low probability of hazard occurrence (P1)


Risk Assessment – Safety Measures and ResidualRisk

Use case Safety measures Safetyfunctions

Safety PL Residual risk

Setup,programming,maintenance

• Specially trainedpersonnel

• Supervised speed

Speedsupervision

S1* / F2 / P1à PL b

Occasionalharmless contact

Normal productionoperation

• Trained personnel• Supervised speed

Speedsupervision

S1* / F1 / P2à PL b


Manualintervention

• Trained personnel• Supervised speed

Speedsupervision

S1* / F2 / P1à PL b


Foreseeablemisuse

• Preventunauthorizedaccess

• Supervised speed

Speedsupervision

S1* / F1 / P2à PL b

Rare harmlesscontact

Cleaning,dismounting

• Standard bestpractice

None n.a. None from robotsystem

* Note: exclude applications that would lead to S2, i.e. sharp edges etc.† Note: Here “S0” designates “no injury”


Multi-HRC stations for scalable automation

§ Safety§ Many persons exposed to multiple robots§ Increased role of safety sensors?§ Risk assessment update after reconfiguration of line?

§ Flexibility§ Methods and tools for quick commissioning of new applications§ Optimal sequence of stations§ Optimal assignment of manufacturing steps to robots and workers

§ Productivity§ Best layout and operating parameters for ergonomics

… going to multiple HRC lines – New Questions

Documents

Björn Matthias, ABB Corporate Research, 2015-10-02 Risk ...scalinon/IROS2015WS/BjoernMatthias-slides.pdf · Risk Assessment for Human-Robot Collaborative Applications Workshop IROS