Automation World Feature: Siemens Robot Safety Blueprint

Ensuring the safety of robots and industrial machinery in manufacturing is a delicate balancing act that demands both innovation and foresight. Automation World recently explored this topic in an interview with Siemens experts Alex Greenberg, Director of Advanced Robotics Simulation, and Eddy Finaro, Product Manager. Their insights shed light on the unique challenges manufacturers face and the advanced solutions available to address them.

Manufacturers must navigate a landscape of emerging technologies to yield higher efficiency and scalability, but with their adoption of new technologies comes a crucial responsibility: ensuring safety. Successful implementation requires more than compliance — it demands strategic planning, digital simulation tools, and ongoing monitoring. With advancements in advanced 3D manufacturing simulation software and digital twin technology, companies now have powerful solutions at their disposal to mitigate risks while optimizing efficiency.

In this exploration of robot and machine safety, we’ll look at how manufacturers can create environments where automation enhances workplace safety. Experts from Siemens share their insights on risk assessment, regulatory compliance, and how cutting-edge software solutions like Process Simulate software are transforming the approach to safety in modern manufacturing.

Understanding risk: robots vs. machines

One of the fundamental differences in risk assessments for robots and industrial machines lies in their design and application, and compliance with safety standards is a critical aspect. Organizations like OSHA, ANSI, and ISO provide guidelines that manufacturers must follow to create safe working environments. Regular risk assessments and updated protocols are essential, but they’re only part of the solution. Training personnel in safety procedures and emergency response is equally important to ensure everyone on the shop floor is prepared to handle potential issues.

While machines are designed for a predefined set of tasks, this makes it possible to perform the risk assessment and do the design for safety as part of the machine design. Versus robots are versatile, flexible and suitable for a variety of tasks and applications. A robot task is programmed at the user’s site, either on the shop floor or using a simulation and offline programming software such as Process Simulate.

The role of collaborative robots

When it comes to collaborative robots, or cobots, the safety conversation takes on a new dimension. Unlike traditional robots, which operate in isolated, enclosed environments, cobots are designed to work alongside humans. This necessitates advanced safety features, such as force and torque limiting, as well as sensors that detect human presence. Cobots adhere to standards like ISO/TS 15066, which outlines permissible force and pressure levels during human-robot interaction. These measures ensure cobots can share workspaces with minimal physical separation, fostering a seamless collaboration between humans and machines.

Building robot safety into the design process

Integrating safety into robotic systems from the outset is a best practice that cannot be overstated. Digital twin and 3D simulation technologies like Process Simulate make this possible by allowing manufacturers to incorporate safety considerations into the planning process. Siemens Process Simulate software, enhanced with the Safety Robots Manager tool, provides an end-to-end solution for validating safety concepts. It helps users visualize safe workspaces, simulate robot paths, and analyze designs against safety standards. This proactive approach not only prevents costly rework during commissioning but also ensures a safer and more efficient production environment. For instance, the Safety Robots Manager can highlight breaches along a robot’s programmed path, offering immediate insights into potential issues and enabling users to address them early in the design phase.

Advanced technologies, such as vision systems and cobots with human-detection capabilities, further enhance safety by enabling robots to navigate dynamic environments more effectively. Digital twin technology plays a crucial role here as well, facilitating continuous analysis and anomaly detection to keep operations running smoothly.”

Alex Greenberg, Director of Advanced Robotics Simulation, Siemens Digital Industries Software

One of the most common challenges manufacturers face is defining safety settings and rules for robotic systems. This task can be particularly complex when accounting for the dynamic positions and sizes of objects in a robotic cell. By leveraging tools like Process Simulate, manufacturers can streamline this process, integrating safety measures seamlessly into their workflows and ensuring compliance with safety standards.

Balancing productivity with safety is a perennial challenge, but Siemens’ solutions make it achievable. By integrating safety into the planning process from the early stages, manufacturers can optimize their operations without compromising on safety. Digital twin and 3D simulation tools enable this balance, ensuring that both efficiency and safety are built into the system from the ground up.

Training and education are also crucial components of a robust safety strategy. Industry standards organizations offer various programs to help safety managers and operators stay informed about the latest regulations and best practices. Siemens supports this effort through its Xcelerator Academy, which provides training on software products for machine and robot simulation, programming, and safety assessment.

As manufacturing continues to evolve, so too must the strategies for ensuring safety. Siemens is at the forefront of this effort, offering innovative tools and technologies that empower manufacturers to create safer, more efficient operations. With solutions like Process Simulate and a commitment to continuous improvement, Siemens is helping the industry strike the perfect balance between safety and productivity.