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Cory Grant Spring 2011 Illinois State University Slide 2 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) Slide 3 Slide 4 Slide 5 Slide 6 Screw/Torque Screws into Base Slide 7 Load Shaft and Cover from Table Mounted Inventory Stand Slide 8 Slide 9 Table Mounted Inventory Stand Assemblies Arrive on Conveyor Slide 10 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. Slide 11 Slide 12 Slide 13 Slide 14 Slide 15 Slide 16 Created risk assessment chart based on RIA standard and ISUs ABB risk assessment Station currently does not include any safety equipment Used standard set of safety equipment to predict risk reduction Slide 17 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 Slide 18 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 Slide 19 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 Slide 20 1.5in Square Openings 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 Envelope11in Per Figure B.1 Slide 21 5 Foot Fencing 1.5 Square Openings AB Light Curtain Awareness Signal to Be Added Station Controls Moved to Fencing Slide 22 12=Required Figure-B.2c 19>Required Figure-A.2 48=Required Figure-B.2c And Figure B.1 Slide 23 12=Required Figure-A.3 11>Required Figure-B.2 Slide 24 Slide 25 12=Required Figure-A.3 53>Required Figure-B.2 Real Distance25 Slide 26 Slide 27 Slide 28 Slide 29 Slide 30 Slide 31 Slide 32 Slide 33 Slide 34 Fencing Interferes With Robot Envelope Possible Solutions: -Axis Limits -Additional Hard Stops Slide 35 Student Checking PLC Panel Without Safety Mat Robot Could Be Reset and Motion Started Possible Solutions: -Add Safety Mat Under Student Slide 36 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 Slide 37 Accessing Center of System No Presence Sensing Devices Inside System Possible Solutions: -Add Safety Chains Over Gaps -Add Safety Mat Inside Slide 38 Two proximity sensors added to the base to detect J1 movement towards fencing Slide 39 Gap chains added to prevent entry into center of the system without setting off light curtain Slide 40 Standard procedures for safe operation booklets added to outside fencing for operator reference Slide 41 Slide 42 Student technician outside of fencing while troubleshooting Slide 43 Slide 44 Slide 45 Slide 46 Unable to reach reset button from inside fencing Slide 47 Back Slide 48 Slide 49 Slide 50 Slide 51