Cory Grant
Spring 2011
Illinois State University
 Study
ANSI/RIA R15.06 Safety Standard
 Develop Risk Assessments Per Standard
 Design Physical/Electrical Safety System
 Implement Designed Safety System
 Check Implemented Safety System
Against Standard
 Present Project to Illinois State University
(Employer)
 Present Project to Heartland Community
College (Customer)
Screw/Torque Screws
into Base
Load Shaft and Cover
from Table Mounted
Inventory Stand
Assemblies Arrive on
Conveyor
Table Mounted
Inventory Stand
 Additional
functions for external projects
• Ex: Using robot for SIT Conference to write
student participants names
 May
use table area, conveyor area, area
in front of table, or any combination.
 Created
risk assessment chart based on
RIA standard and ISU’s ABB risk
assessment
 Station currently does not include any
safety equipment
 Used standard set of safety equipment to
predict risk reduction
 Presence
sensing devices (curtain/mat)
 Barriers (fencing)
 Programming requirements (PLC/robot)
 Standard procedure training (classroom)
 Properly designed safety circuits (per NEC)
 Awareness Signal on Fencing
 Station Controls Moved to Fencing
 Allen
Bradley PAC T4H 3400N
 3 Beams
 23mm Beam Width
 400mm Beam Center to Center
 Min Os=Beam C2C-Beam Width
 Min Os=400mm-23mm
 Min Os=377mm (14.85in)
Therefore, Dpf=178mm (7.5in)
Per Figure B.2
 Allen
Bradley PAC T4H 3400N
 3 Beams
 23mm Beam Width
 400mm Beam Center to Center
 Min Os=Beam C2C-Beam Width
 Min Os=400mm-23mm
 Min Os=377mm (14.85in)
Therefore, Dpf=178mm (7.5in)
Per Figure B.2
 1.5in
Square Openings
 Per Figure B.1
Per Figure B.1
• 1.25in Opening =6.5in Distance from Hazard
• 1.875in Opening=17.5in Distance from Hazard
 1.875in-1.25in=0.625in
(∆Opening)
 17.5in-6.5in=11in (∆Distance)
 11in/0.625in=17.6 (Distance Ratio)
 1.5in>1.25in by 0.25in (Opening Increase)
 17.6*0.25in=4.4in (Additional Distance)
 6.5in+4.4in=10.9in (Total Distance)
Therefore Fence to Envelope≈11in
5 Foot Fencing
1.5” Square Openings
Awareness Signal to
Be Added
Station Controls
Moved to Fencing
AB Light Curtain
19”>Required
Figure-A.2
And Figure B.1
48”=Required
Figure-B.2c
12”=Required
Figure-B.2c
11”>Required
Figure-B.2
12”=Required
Figure-A.3
53”>Required
Figure-B.2
12”=Required
Figure-A.3
Real
Distance≈25”
Fencing Interferes
With Robot
Envelope
Possible
Solutions:
-Axis Limits
-Additional Hard
Stops
Student Checking
PLC Panel
Without Safety
Mat Robot Could
Be Reset and
Motion Started
Possible Solutions:
-Add Safety Mat
Under Student
Possibly
Unprotected Area
Inside System
-Gaps at 4
Corners
-Crawl Through
Access to Inside
Possible
Solutions:
-Safety Chains at 4
Corners
-Barriers
-Safety Mat Inside
Accessing Center
of System
No Presence
Sensing Devices
Inside System
Possible Solutions:
-Add Safety
Chains Over Gaps
-Add Safety Mat
Inside
Two proximity
sensors added to the
base to detect J1
movement towards
fencing
Gap chains added to prevent entry into center of the
system without setting off light curtain
Standard procedures for
safe operation booklets
added to outside fencing
for operator reference
Student technician
outside of fencing
while
troubleshooting
Unable to reach reset
button from inside
fencing
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