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Welding robots have been adopted in manufacturing settings to take on hazardous tasks so that humans don't have to. However, these automatic systems require their own safety features and devices to ensure a safe working environment.
By installing any of the key welding safety devices discussed below, the factory floor will be protected from workplace incidents.
These are essentially fencing panels that cordon off an area where welding industrial robots are working. This sectioned-off area is also called the "robotic work cell."
The work cell consists of walls made up of interlocking gates, which are synched with the robot's power source. When the robot is powered off, the gates open. As soon as the robotic welding commences, the gates close. And, if the gates were to suddenly open while welding, the robotic welder would stop automatically.
This automatic stopping is thanks to the interlock switches that form a part of the gates. In some instances, the interlock switches contain an extra locking device, preventing them from opening until the work cell is completely safe.
Installing interlocking perimeter guards around a welding robot is an OSHA requirement.
A safety light curtain uses infrared beams within the work cell to detect if a person or object enters. It is essential safety equipment for situations where the robot's operator requires frequent access to the welding space.
Transmitters emit infrared light beams to receivers (either vertically or horizontally) and when the beams are broken, the robot receives a stop signal.
Safety light curtains work well in situations where materials must be fed to the robotic welding system. They can be programmed to respond to certain object sizes, allowing some materials to be fed to the welder without causing the system to stop.
Safety laser scanners use lasers to protect the robotic welding cell. The lasers scan the surrounding environment continuously and check for people approaching. If a person (or object) comes into contact with the laser, a stop signal is sent to the robot, bringing hazardous machine motion to a halt.
In some instances, a laser scanner will emit a warning signal if a person comes too close without stopping the robot first.
These mats are safety equipment that are sensitive to pressure. They're usually not the main safety device for robotic welding equipment. Instead, they act as secondary safety measures.
The safety mats are placed behind the interlocking gates. Should the gate open and a person step on the mat, a signal is sent to the robot controller and the robot stops automatically.
Knowing what type of safety device is used to stop welding robots is only one part of welding robot safety.
Operators and workers on the factory floor must also take certain precautions around these automated systems to ensure their own safety.
First and foremost, workers and operators must understand the risks associated with welding operations.
Different welding robots have different response times when the safety equipment is triggered. It is important that everyone on the floor knows the parameters before the welding process commences.
In general, welding accidents don't occur while the welder is operating. It is during testing, programming, and maintenance that accidents are more likely to happen. As soon as someone interacts directly with the system, risks increase.
The most common welding injuries are related to the eyes. For that reason, operators must always wear PPE when maintaining or programming the welder.
Different welding robots have different safety equipment. Some also have customizable features, depending on the project.
Typical standard features are the ones we discussed above:
These safety features are not optional. Although different operations may require certain safety features, operating without them is an OSHA violation.
Understanding the workings and purpose of each feature will ensure the safety of workers.
Regular maintenance is key to ensuring robot systems operate safely. The robots work at extremely high temperatures and often exert a lot of force. If maintenance is neglected, a faulty robot welder can be fatal.
The work cell must also be kept clean to prevent accidental fires or damage to robotic components.
As mentioned, different welding applications have differing safety risks. For that reason, the safety features are customizable, depending on the current hazards.
It is crucial that managers and operators select the correct safety devices for their operations. Not only is it an OSHA requirement, but proper workplace safety can improve productivity and motivation on the floor.
The devices mentioned above are the primary safety devices for robotic welding systems. Not all systems have pressure-sensitive mats; however, due to the hazards of a welding industrial robot, it is better to have these installed as a backup.
Welding robots are implemented to prevent workers from being exposed to the risks associated with welding. But because of the forces and temperatures these robots work at, as well as the haphazard movements of the robot arms, they can also be dangerous to workers.
The main aim of the safety equipment discussed above is to prevent workplace accidents but also to comply with OSHA regulations.
The advantages of a welding robot system include:
After the welding operation, the operator must ensure the robot is stopped (this may involve pressing the stop button, if applicable). Next, the operation mode should be switched to manual or teaching mode. Only then is it safe to enter the work cell.
Don't touch the welding workpiece, as it will be incredibly hot.
With fewer skilled welders and more focus on workplace safety, automated robot welders will continue to be used in the manufacturing industry. And with these developments in automation, safety precautions will have to remain at the forefront of operations.
Along with functioning safety devices, robotic welders must also be well-maintained and correctly programmed to ensure the safety of everyone in the workforce.