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Safety System Design in Human-Robot Collaboration Implementation for a Demonstrator Case in Compliance with ISO/TS 15066

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Safety System Design in Human-Robot Collaboration Implementation for a Demonstrator Case in Compliance with ISO/TS 15066 DEGREE PROJECT IN MECHANICAL ENGINEERING, SECOND CYCLE, 30 CREDITS STOCKHOLM, SWEDEN 2019 Safety system design in human-robot collaboration Implementation for a demonstrator case in compliance with ISO/TS 15066 CAROLIN SCHAFFERT KTH ROYAL INSTITUTE OF TECHNOLOGY SCHOOL OF INDUSTRIAL ENGINEERING AND MANAGEMENT Safety system design in human-robot collaboration Implementation for a demonstrator case in compliance with ISO/TS 15066 Carolin Schaffert Master of Science Thesis TPRMM 2019 KTH Industrial Engineering and Management Production Engineering SE-100 44 Stockholm 1 Abstract A close collaboration between humans and robots is one approach to achieve flexible production flows and a high degree of automation at the same time. In human-robot collaboration, both entities work alongside each other in a fenceless, shared environment. These workstations combine human flexibility, tactile sense and intelligence with robotic speed, endurance, and accuracy. This leads to improved ergonomic working conditions for the operator, better quality and higher efficiency. However, the widespread adoption of human-robot collaboration is limited by the current safety legislation. Robots are powerful machines and without spatial separation to the operator the risks drastically increase. The technical specification ISO/TS 15066 serves as a guideline for collaborative operations and supplements the international standard ISO 10218 for industrial robots. Because ISO/TS 15066 represents the first draft for a coming standard, companies have to gain knowledge in applying ISO/TS 15066. Currently, the guideline prohibits a collision with the head in transient contact. In this thesis work, a safety system is designed which is in compliance with ISO/TS 15066 and where certified safety technologies are used. Four theoretical safety system designs with a laser scanner as a presence sensing device and a collaborative robot, the KUKA lbr iiwa, are proposed. The system either stops the robot motion, reduces the robot’s speed and then triggers a stop or only activates a stop after a collision between the robot and the human occurred. In system 3 the size of the stop zone is decreased by combining the speed and separation monitoring principle with the power- and force-limiting safeguarding mode. The safety zones are static and are calculated according to the protective separation distance in ISO/TS 15066. A risk assessment is performed to reduce all risks to an acceptable level and lead to the final safety system design after three iterations. As a proof of concept the final safety system design is implemented for a demonstrator in a laboratory environment at Scania. With a feasibility study, the implementation differences between theory and praxis for the four proposed designs are identified and a feasible safety system behavior is developed. The robot reaction is realized through the safety configuration of the robot. There three ESM states are defined to use the internal safety functions of the robot and to integrate the laser scanner signal. The laser scanner is connected as a digital input to the discrete safety interface of the robot controller. To sum up, this thesis work describes the safety system design with all implementation details. I Sammanfattning Ett nära samarbete mellan människor och robotar är ett sätt att uppnå flexibla produktionsflöden och en hög grad av automatisering samtidigt. I människa-robotsamarbeten arbetar båda enheterna tillsammans med varandra i en gemensam miljö utan skyddsstaket. Dessa arbetsstationer kombinerar mänsklig flexibilitet, taktil känsla och intelligens med robothastighet, uthållighet och noggrannhet. Detta leder till förbättrade ergonomiska arbetsförhållanden för operatören, bättre kvalitet och högre effektivitet. Det breda antagandet av människa- robotsamarbeten är emellertid begränsat av den nuvarande säkerhetslagstiftningen. Robotar är kraftfulla maskiner och utan rymdseparation till operatören riskerna drastiskt ökar. Den tekniska specifikationen ISO / TS 15066 fungerar som riktlinje för samverkan och kompletterar den internationella standarden ISO 10218 för industrirobotar. Eftersom ISO / TS 15066 representerar det första utkastet för en kommande standard, måste företagen få kunskap om att tillämpa ISO / TS 15066. För närvarande förbjuder riktlinjen en kollision med huvudet i övergående kontakt. I detta avhandlingar är ett säkerhetssystem utformat som överensstämmer med ISO / TS 15066 och där certifierad säkerhetsteknik används. Fyra teoretiska säkerhetssystemdesigner med en laserskanner som närvarosensor och en samarbetsrobot, KUKA lbr iiwa, föreslås. Systemet stoppar antingen robotrörelsen, reducerar robotens hastighet och triggar sedan ett stopp eller aktiverar bara ett stopp efter en kollision mellan roboten och människan inträffade. I system 3 minskas storleken på stoppzonen genom att kombinera hastighets- och separationsövervakningsprincipen med det kraft- och kraftbegränsande skyddsläget. Säkerhetszoner är statiska och beräknas enligt skyddsavståndet i ISO / TS 15066. En riskbedömning görs för att minska alla risker till en acceptabel nivå och leda till den slutliga säkerhetssystemdesignen efter tre iterationer. Som ett bevis på konceptet är den slutliga säkerhetssystemdesignen implementerad för en demonstrant i en laboratoriemiljö hos Scania. Genom en genomförbarhetsstudie identifieras implementeringsskillnaderna mellan teori och praxis för de fyra föreslagna mönster och ett genomförbart säkerhetssystem beteende utvecklas. Robotreaktionen realiseras genom robotens säkerhetskonfiguration. Där definieras tre ESM-tillstånd för att använda robotens interna säkerhetsfunktioner och för att integrera laserscannersignalen. Laserskannern är ansluten som en digital ingång till robotkontrollens diskreta säkerhetsgränssnitt. Sammanfattningsvis beskriver detta avhandlingar säkerhetssystemdesignen med alla implementeringsdetaljer. II Acknowledgments This degree project is a part of the master’s degree in Production Engineering and Management at KTH Royal Institute of Technology in Stockholm, Sweden. It is equivalent to 30 credits out of a total of 120 credits and extended over 20 weeks from January to June 2019. The thesis was conducted in the Smart Factory at Scania AB in Södertälje, Sweden. I am grateful for all the support and advice I have received during this challenging but definitely educational time. First of all, I would like to thank my company supervisor Juan Luis Jiménez Sánchez. Without his help, the results in this thesis work would not have been achieved. He solved many robot programming issues with me and was always willing to answer all my questions. Additionally, I would like to thank Fredrik Ore for his overall support and in specific for his knowledge in the risk assessment. Further, I would like to express my appreciation to my academic supervisor from the Royal Institute of Technology Xi Vincent Wang for his counsel. His valuable input and criticism helped me to identify the improvements areas of my system and definitely lead to a better result. Also, I would like to thank my colleagues in the Smart Factory at Scania. It was a lot of fun working with you and being part of such a young and innovative team. Finally, I would like to thank Fredrik Lilkaer for his encouragement and enthusiasm for my thesis throughout the last months. Lastly, a big thank you goes to my parents for supporting me throughout my entire bachelor and master program, no matter where I decided to move. III Table of Contents 1 Introduction .................................................................................................................................................... 1 1.1 Background ............................................................................................................................................ 1 1.2 Problem description .............................................................................................................................. 1 1.3 Research questions ................................................................................................................................ 2 1.4 Research approach ................................................................................................................................ 3 1.5 Delimitations ......................................................................................................................................... 4 1.6 Outline ................................................................................................................................................... 4 2 Literature review ............................................................................................................................................ 5 2.1 Human-robot collaboration ................................................................................................................... 5 2.1.1 Levels of interaction .......................................................................................................................... 5 2.1.2 Industrial applications ....................................................................................................................... 8 2.2 Safety in human-robot collaboration .................................................................................................... 8 2.2.1 General safety aspects ...................................................................................................................... 8 2.2.2 Risk reduction process
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