Ensuring Machinery Safety in Robotics: Pilz’s Holistic Approach to Risk, Standards, and Innovation
The rise of robotics has transformed industries, from automotive assembly lines to precision manufacturing. Yet, as robots become indispensable collaborators, their integration demands more than just efficiency—it requires an unwavering commitment to safety. At Pilz, we don’t just comply with standards; we redefine them through tailored solutions that address real-world challenges. Let’s explore how our expertise turns risks into reliability. To safeguard both human workers and robots, it’s essential to implement robust safety measures. This includes designing robots with advanced safety features, adhering to rigorous safety standards, and conducting regular maintenance and inspections. As we embrace this technological evolution, prioritizing safety will be key to unlocking the full potential of robotics.
Real-World Hazards: When Robotics Meets Human Interaction: Imagine a car assembly line where robots weld, lift, and assemble components at lightning speed. The flapping areas—zones where robotic arms move unpredictably—pose a constant threat. Without proper safeguarding, human intervention during maintenance or troubleshooting could lead to catastrophic collisions. Similarly, in a robotics pick-and-place function, unexpected robotic movements created “direct access” dangers, leaving operators vulnerable. Or consider a high-pressure deburring station, where synchronized robots clean components: an unguarded hazard zone turns routine maintenance into a perilous task. These scenarios aren’t hypothetical—they’re daily realities Pilz has resolved.
From Risk Assessment to Robust Solutions – Pilz’s Methodology: Every robotic application begins with a thorough risk assessment (RA). Take the car assembly line: Pilz experts identified hazards in the flapping area and intervention zones. By integrating PSENme5 coded safety switches and PSENslock magnetic interlocks, we safeguarded access points while ensuring seamless operations. Our “try and buy” approach allowed the customer to experience firsthand how modular safety gate systems, paired with safety controller PNOZ m b0.1 from PNOZmulti 2 controller family, could mitigate risks without disrupting productivity. For the hobbing machine, the challenge was twofold: outdated controls and insufficient guarding. Pilz upgraded the control system to comply with ISO 13849 (Cat 3 PL d) using the PNOZ mb0.1 safety relay and introduced PSENmlock with escape release—a failsafe for workers trapped in faulty guards. This locking mechanism not only met ISO 14119 standard but also addressed ergonomic risks often overlooked by vendors. In the deburring application of robotic cell, where multiple robots operated in sync, Pilz recommended interlocking switches on existing guards post-risk assessment. By aligning with ISO 13855 for light curtains and ISO 13857 for fencing, we closed critical access gaps, transforming an open hazard zone into a secure workspace.
Standards as a Foundation, Innovation as a Driver: Compliance is non-negotiable. ISO 10218-2 dictates robotic safety requirements and ensures collaborative robots (cobots) operate safely alongside humans; ISO 13849-1 governs control systems. But standards alone aren’t enough. Pilz’s solutions bridge compliance with practicality:
Safe Sensor Technology: Combines mechanical and magnetic locking for tamper-proof access control. Safety light curtains, safety scanners and safety radar systems for safe zone monitoring inside robotic cells.
Safe Control Technology: The versatile safety controllers, smaller in size that adapts to dynamic robotic environments.
Smooth and point-to-point communication: We ensure that the safety controllers and sensors communicate effectively at the field level, and data transmission is done efficiently. For the same our IO-Link safety stands at the forefront and help factories in making workplaces safe.
At Pilz, we know that knowledge is the ultimate safeguard, and our training programs demystify standards like ISO 12100 (risk reduction) and ISO 13849-1 (safety control system). Through workshops and safety campaigns, we turn operators into advocates for a culture of safety. From automotive giants to niche manufacturers, Pilz transforms robotic hazards into opportunities for innovation. Our end-to-end services—risk assessment, design, validation, and training—ensure compliance today while anticipating tomorrow’s challenges. We are ready to undertake the entire conformity assessment procedure in accordance with the Machinery directive, and the EU Machinery Regulation. Because in the world of robotics, safety isn’t a checkbox; it’s the foundation of progress. We have a team where our certified experts and safety consultants are actively involved in MED40 committee of BIS (Bureau of Indian Standards), for implementation of safety standards in India’s machinery landscape.
Let it be any industry for robotic applications, packaging, automotive, or pure robotics; we have got the grip. So, are you ready to future-proof your robotic and automation systems? Partner with Pilz—where safety engineering meets industrial ingenuity.
For more information,
www.pilz.in
