SICK Safe Robotics Area Protection sBot Speed Operating instructions
- Type
- Operating instructions
O P E R A T I N G I N S T R U C T I O N S
Safe Robotics Area Protection
Safety system
Described product
S
afe Robotics Area Protection
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
T
his work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is only
permissible within the limits of the legal determination of Copyright Law. Any modifica‐
tion, abridgment or translation of this document is prohibited without the express writ‐
ten permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
T
his document is an original document of SICK AG.
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Contents
1 About this document........................................................................ 6
1.1 Purpose of this document........................................................................ 6
1.2 Scope......................................................................................................... 6
1.3 Target groups and structure of these operating instructions................ 6
1.4 Symbols and document conventions...................................................... 6
1.5 Further information................................................................................... 7
2 Safety information............................................................................ 8
2.1 Intended use............................................................................................. 8
2.2 Improper use............................................................................................. 8
2.3 Requirements for the qualification of personnel.................................... 8
2.4 Safe state.................................................................................................. 9
3 Product description........................................................................... 10
3.1 Product identification............................................................................... 10
3.2 Application description............................................................................. 10
3.3 Additional components required............................................................. 10
3.3.1 Emergency stop pushbutton requirements............................ 10
3.3.2 Reset pushbutton requirements............................................. 11
3.3.3 Robot controller requirements................................................ 11
3.3.4 Physical guard.......................................................................... 11
3.4 Set-up and function of the safety system............................................... 11
3.5 Limits of the safety system...................................................................... 12
3.6 Product characteristics............................................................................ 13
3.6.1 Field types................................................................................ 13
3.6.2 Field set.................................................................................... 13
4 Project planning................................................................................ 15
4.1 Manufacturer of the machine.................................................................. 15
4.1.1 Calculating minimum distance............................................... 15
4.1.2 Calculating stopping time........................................................ 16
4.1.3 Calculating the performance level.......................................... 19
4.2 Operating entity of the machine.............................................................. 19
4.3 Safety Functions....................................................................................... 20
4.3.1 Identifying hazards.................................................................. 20
4.3.2 Switching field sets.................................................................. 20
4.3.3 Automatic restart..................................................................... 22
4.3.4 Initiating a stop........................................................................ 22
4.3.5 Emergency stop....................................................................... 23
4.3.6 Preventing an unexpected start-up following an emergency
s
top........................................................................................... 23
4.4 Design........................................................................................................ 24
4.4.1 Safety laser scanner................................................................ 24
4.4.2 Emergency stop pushbutton................................................... 24
CONTENTS
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4.4.3 Reset pushbutton.................................................................... 24
4.5 Integrating the equipment into the electrical control............................. 24
4.5.1 Circuit diagram......................................................................... 25
4.6 Testing plan............................................................................................... 26
5 Mounting............................................................................................. 27
5.1 Mounting the safety laser scanner.......................................................... 27
6 Electrical installation........................................................................ 28
6.1 General requirements.............................................................................. 28
6.2 Safety controller pin assignment............................................................. 29
6.3 Further connections of the individual components................................ 32
6.4 Interfaces and signals.............................................................................. 32
7 Configuration..................................................................................... 33
7.1 Requirements on software and firmware................................................ 33
7.2 Overview of the software structure.......................................................... 34
7.3 Pre-configured project files...................................................................... 35
7.3.1 Project file logic........................................................................ 35
7.3.2 Opening project file.................................................................. 36
7.4 Additional configuration required............................................................ 36
7.4.1 Configuring logics for Flexi Soft CPU...................................... 36
7.4.2 Content of the logic editor....................................................... 39
7.4.3 Configuring the safety laser scanner...................................... 45
8 Commissioning.................................................................................. 53
8.1 Safety......................................................................................................... 53
8.2 Thorough check........................................................................................ 53
9 Operation............................................................................................ 54
9.1 Start sequence......................................................................................... 54
10 Maintenance...................................................................................... 55
10.1 Regular thorough check........................................................................... 55
11 Troubleshooting................................................................................. 57
12 Technical data.................................................................................... 58
12.1 Data sheet................................................................................................. 58
12.2 Response times........................................................................................ 58
13 Ordering information........................................................................ 60
13.1 Scope of delivery....................................................................................... 60
13.2 Ordering information................................................................................. 60
14 Spare parts......................................................................................... 61
14.1 Safety laser scanner................................................................................. 61
14.2 Order Details Safety controller................................................................. 61
CONTENTS
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15 Accessories........................................................................................ 62
15.1 Connectivity............................................................................................... 62
15.2 Mounting bracket...................................................................................... 62
15.3 Emergency stop and reset pushbuttons................................................. 63
16 Annex.................................................................................................. 64
16.1 Checklist for initial commissioning and commissioning........................ 64
16.2 Requirements for automatic restart........................................................ 66
16.3 Overview of sensors and actuators......................................................... 67
CONTENTS
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1 About this document
1.1 Purpose of this document
These operating instructions contain the information required during the life cycle of the
s
afety system. This document describes:
•
The individual components
•
The project planning
•
The mounting and electrical installation, insofar as special measures are neces‐
sary for the safety system
•
The configuration
•
The necessary thorough checks
•
The commissioning
•
The maintenance
•
The troubleshooting
1.2 Scope
These operating instructions contain information regarding the Safe Robotics Area Pro‐
t
ection safety system.
NOTICE
T
he operating instructions of the components also apply.
The relevant information must be made available to the employees for all work per‐
formed on the safety system.
The following documents contain additional information regarding the Safe Robotics
Ar
ea Protection safety system:
Table 1: Available documents
Document type Title Part number
Operating instructions microScan3 Core I/O 8016344
Operating instructions S300 Mini Remote 8014166
Operating instructions Flexi Soft modular safety con‐
t
roller hardware
8012999
Operating instructions Flexi Soft in the Flexi Soft
Designer software
8012998
This document is included with the following SICK part numbers (this document in all
available language versions):
8022410
1.3 Target groups and structure of these operating instructions
These operating instructions are intended for the following target groups: project devel‐
oper
s (planners, developers, designers), installers, electricians, operators, and mainte‐
nance personnel.
These operating instructions are organized by the life phases of the safety system:
project planning, mounting, electrical installation, commissioning, operation and main‐
tenance.
1.4 Symbols and document conventions
The following symbols and conventions are used in this document:
1 A
BOUT THIS DOCUMENT
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Safety notes and other notes
DANGER
Indic
ates a situation presenting imminent danger, which will lead to death or serious
injuries if not prevented.
WARNING
Indic
ates a situation presenting possible danger, which may lead to death or serious
injuries if not prevented.
CAUTION
Indicates a situation presenting possible danger, which may lead to moderate or minor
injuries if not prevented.
NOTICE
Indic
ates a situation presenting possible danger, which may lead to property damage if
not prevented.
NOTE
Indic
ates useful tips and recommendations.
Instructions to action
b
T
he arrow denotes instructions to action.
1. The sequence of instructions for action is numbered.
2. Follow the order in which the numbered instructions are given.
✓
The check mark denotes the result of an instruction.
1.5 Further information
www.sick.com
T
he following information is available via the Internet:
■
This document in other languages
■
Operating instructions and installation instructions of SICK components suitable
for the safety system
■
The Flexi Soft Designer configuration software
■
Pre-configured project file for Flexi Soft Designer for this safety system
■
Pre-configured project file for Safety Designer
■
Prepared subsystems for SISTEMA for this safety system
■
Circuit diagram for the safety system (ePLAN)
■
Guide for Safe Machinery (“Six steps to a safe machine”)
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2 Safety information
2.1 Intended use
This safety system was developed for cooperative work environments with robots (coop‐
er
ative = humans and robots working in the same space at different times).
This safety system protects these cooperative work environments by monitoring access
to hazardous areas using safety laser scanners and, if necessary, slowing or stopping
the robots.
Prerequisites
In or
der to use this safety system, the following requirements must be met:
•
The supplied Flexi Soft file and the SISTEMA file have been adjusted to the individ‐
ual application in accordance with the manufacturer’s requirements.
•
Additional protective devices must be provided by the manufacturer to protect
against hazards that arise independently of the robot movement.
2.2 Improper use
The safety system is no
t suitable for applications to which at least one of the following
features applies:
•
The robot can be accessed from all sides.
•
It is possible for parts to be propelled in the robot workspace.
•
It is possible for radiation to escape in the robot workspace.
•
Hazards remain even when the robot is stopped, due to causes such as radiation,
heat or electricity.
•
The protective field and warning field of the safety laser scanner cannot com‐
pletely cover all open access points to the robot (see "Field set", page 13).
•
Field sets are not configured correctly, e.g. the protective field is too small.
•
It is possible to enter the hazardous area by climbing over it, standing behind it or
reaching through it.
•
Chairs, ladders or similar objects are used in the safety laser scanner field.
•
Transparent objects are used in the safety laser scanner field.
Limitations
T
his safety system is only suitable for protecting against mechanical hazards caused by
the movement of the robot.
Hazards caused by the ejection of solid or liquid materials, emissions, radiation and
electricity cannot be reduced by this safety system.
NOTICE
In or
der to determine whether Safe Robotics Area Protection can be used for the partic‐
ular application (with or without automatic restart), a risk assessment is required in
accordance with EN ISO 12100.
2.3 Requirements for the qualification of personnel
The protective device must be configured, installed, connected, commissioned, and ser‐
v
iced by qualified safety personnel only.
2 S
AFETY INFORMATION
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Project planning
F
or project planning, a person is considered competent when he/she has expertise and
experience in the selection and use of protective devices on machines and is familiar
with the relevant technical rules and national work safety regulations.
Mechanical mounting
For mechanical mounting, a person is considered competent when he/she has the
expertise and experience in the relevant field and is sufficiently familiar with the appli‐
cation of the protective device on the machine that he/she can assess its operational
safety status.
Electrical installation
For electrical installation, a person is considered competent when he/she has the
expertise and experience in the relevant field and is sufficiently familiar with the appli‐
cation of the protective device on the machine that he/she can assess its operational
safety status.
Commissioning
For commissioning, a person is considered competent when he/she has the expertise
and experience in the relevant field and is sufficiently familiar with the application of
the protective device on the machine that he/she can assess its operational safety sta‐
tus.
Operation and maintenance
For operation and maintenance, a person is considered competent when he/she has
the expertise and experience in the relevant field and is sufficiently familiar with the
application of the protective device on the machine and has been instructed by the
machine operator in its operation.
2.4 Safe state
In the safe state, the accordingly configured safe output signal switching devices are in
t
he OFF state. The robot is and remains switched off.
If the output for the safety-rated monitored speed is set to low, the robot controller must
safely monitor the speed of movement.
The safe state is initiated in the following cases:
•
Protective field infringed
•
Emergency stop pushbutton actuated
•
Connection between the safety laser scanner and safety controller interrupted
•
Voltage supply of the safety laser scanner or the safety controller interrupted
•
Internal error on the safety laser scanner detected
•
Internal fault detected at the safety controller or one of its components
NOTE
W
hen the safety system initiates the safe state, the machine manufacturer and user
must ensure that the safe output signal switching devices are evaluated appropriately
and that the hazard is rectified.
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3 Product description
3.1 Product identification
The part number of the safety system is located on the packaging.
3.2 Application description
The Safe Robotics Area Protection safety system is used in cooperative work environ‐
ments with robots in order to reduce the risk of injuries caused by the movement of the
robot, while also increasing productivity.
The safety system is suitable for work environments such as those in which the haz‐
ardous area surrounding the robot must be entered for repeated operations, e.g. for
loading or product inspection.
Safe Robotics Area Protection ensures that the speed of the robot is reduced when a
person is approaching, and stops the robot when the safe distance between the person
and the hazardous area is below a certain level.
As soon as a person leaves the hazardous area, the robot restarts automatically. The
speed of the robot remains reduced until the person has exited the warning field (for
more details on protective and warning fields see "Field types", page 13). Only at that
point will the robot continue its activity at a normal speed.
If the requirements for executing the automatic restart are not met, then the safety sys‐
tem generally prevents a restart as soon as a person has entered the hazardous area
surrounding the robot. A reset pushbutton must be actuated after exiting the hazardous
area.
3.3 Additional components required
The following additional components are essential for using the Safe Robotics Area Pro‐
t
ection safety system in an application:
•
Emergency stop pushbutton
•
Reset pushbutton
•
Robot controller
•
Additional protective devices (e.g., fencing)
NOTE
All nece
ssary components influence the parameters of the entire application that relate
to safety technology. The components must therefore have an MTTF
d
value suitable for
the entire application and satisfy the necessary performance level.
The necessary performance level results from the risk assessment. For evaluating the
performance level achieved, subsystems for SISTEMA are available under:
www.sick.com
For the components included with delivery see "S
cope of delivery", page 60.
3.3.1 Emergency stop pushbutton requirements
At least two emergency stop pushbuttons must be installed:
•
Inside t
he protective field - as close as possible to the robot
•
Outside the hazardous area - as an added safety function
Depending on the manufacturer’s risk assessment, it may be necessary to install addi‐
tional emergency stop pushbuttons.
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RODUCT DESCRIPTION
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The emergency stop pushbuttons must be designed in accordance with the following
s
tandards:
•
ISO 13850
•
IEC 60204
3.3.2 Reset pushbutton requirements
The reset pushbutton must be installed outside of the hazardous area. From the posi‐
t
ion of the pushbutton, there must be a complete view of the hazardous area.
The pushbutton must be designed according to the following standard:
•
EN 60204
3.3.3 Robot controller requirements
The robot controller must be equipped with the following safety functions (in Category
3, P
L d according to EN ISO 13849):
•
Emergency stop
•
Protective stop
•
Safety-rated monitored speed
The robot controller must have the following, non-safe automation functions:
•
Adjustment of the speed depending on the digital input, which is responsible for
initiating the speed reduction/increase.
Reset and restart requirements
T
he safety controller is responsible for resetting the emergency stop. The possibility of
resetting the emergency stop is analyzed in the Flexi Soft program.
Restarting the robot is only possible if the user has executed a reset. Restarting the
robot is the responsibility of the manufacturer.
The robot controller must prevent a restart after a change in the operating mode. A
restart is only possible after a valid reset.
3.3.4 Physical guard
Pursuant to the manufacturer’s risk assessment, it may be necessary to install
mec
hanical protective devices such as fencing around the robot’s hazardous area.
In addition to the applicable C standards for the application, the following standards
provide additional information on designing physical guards:
•
EN ISO 14120
•
EN ISO 13857
NOTICE
The possibility of entering the hazardous area by climbing over it, standing behind it or
reaching through it must be prevented.
3.4 Set-up and function of the safety system
The safety laser scanner monitors a defined area around the robot.
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DANGER
Ris
k of death
The safety laser scanner only monitors a limited area around the robot.
b
Prevent access to the areas not being monitored (e.g., by providing fencing).
During normal robot operation, the safety laser scanner monitors two field sets. Each of
t
hese consist of a warning field and a protective field.
If a warning field is infringed, the robot reduces the speed of its movements. If a protec‐
tive field is infringed, movement of the robot is stopped.
Once the protective field is no longer infringed, the robot automatically continues its
movement at a slow speed. When the warning field is no longer infringed, the robot
moves again at normal speed.
NOTE
In or
der to determine whether an automatic restart of the robot can be executed in the
application, it must be thoroughly checked with a risk assessment in accordance with
DIN EN ISO 12100.
Otherwise, after an infringement of the protective field, the robot must be set in motion
again using a pushbutton, see "Reset pushbutton requirements", page 11.
3.5 Limits of the safety system
The safety system ends at all inputs and outputs that are not used to wire the compo‐
nent
s of the safety system.
For detailed information about the interfaces see "Electrical installation", page 28.
The limits of the safety system are presented in abstract and general terms in the figure
below:
1
3
2
7
4 5
6
Figure 1: Limits of the safety system
1
Sensors
2
Logic (safety controller and safety relay)
3
Sub-safety function
4
Wiring between sensors and logic
5
Wiring between safety system components and components outside the safety system
6
Limit of the safety system
7
Components outside the safety system, e.g., actuators, robot controller, or higher-level
cont
roller
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RODUCT DESCRIPTION
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3.6 Product characteristics
3.6.1 Field types
During operation, the safety laser scanner uses its laser beams to continuously check
whether people are present in one or more areas. The areas to be checked are called
fields. A distinction is made between the following field types:
•
Warning field
•
Protective field
Warning field
T
he warning field monitors a larger area than the protective field. If the warning field is
infringed, the speed of movement of the robot is reduced by a control.
The warning field must not be used for safety-related tasks.
When the speed has been safely reduced, the field set is switched, see "Switching field
sets", page 20.
Protective field
T
he protective field protects the hazardous area immediate surrounding the robot. If the
protective field is infringed, the robot is stopped.
3.6.2 Field set
The safety system provides two field sets.
Each field set in turn consists of 2 fields: a warning field and a protective field. The
f
ields of a field set are monitored simultaneously, and the field size are adjusted to the
respective safety conditions.
•
Field set 1 = warning field + protective field 1 (large)
•
Field set 2 = warning field + protective field 2 (small)
Field set 1
1
2
3
4
65
Figure 2: Field set 1
1
Physical guard
2
Robot
3
Safety laser scanner
4
Protective field
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5
Warning field
6
Machine
Field set 2
1
2
3
4
65
Figure 3: Field set 2
1
Physical guard
2
Robot
3
Safety laser scanner
4
Protective field
5
Warning field
6
Machine
Field set 1 is active by default. If a warning field is infringed, the robot reduces its
s
peed. When the reduced speed is safely reached, a smaller protective field is required
than is necessary when operating at full speed. The safety system switches to field set
2. As long as the warning field is infringed, the reduced speed level remains activated.
The robot stops when the protective field from field set 2 is infringed. The robot will only
become active again at a reduced speed when the infringement of the protective field
has ended.
When first the protective field and then the warning field are again clear, field set 2 will
be switched back to field set 1. The robot will resume work at maximum speed only
once the warning field and the protective field are clear.
For more information see "Set-up and function of the safety system", page 11.
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4 Project planning
4.1 Manufacturer of the machine
DANGER
H
azard due to lack of effectiveness of the protective device
In the case of non-compliance, it is possible that the dangerous state of the machine
may not be stopped or not stopped in a timely manner.
b
Use of the safety system requires a risk assessment. Check whether additional
protective measures are required.
b
Comply with the applicable national laws, regulations and standards derived from
the application (e.g., work safety regulations, safety rules, or other relevant safety
guidelines).
The safety system was developed under consideration of typical application cases. A
par
tial safety function can be implemented with the safety system in these application
cases. The manufacturer must check whether the safety system is suitable for its spe‐
cific application case (risk assessment).
If the thorough check shows that the safety system is not suitable for the specific appli‐
cation case, the safety system can be used as a basis for an individualized develop‐
ment suitable for the specific application case. This case will not be considered further
in this document.
In any event, additional work is necessary for the safety system to be used, e.g. subse‐
quent configuration of the safety controller.
The manufacturer has the following duties:
b
Executing a risk assessment.
b
Verifying and validating the safety functions.
b
Integrating the individual components in accordance with the appropriate stan‐
dards.
b
Compliance with the applicable laws, regulations and standards is required.
4.1.1 Calculating minimum distance
The minimum distance to a hazardous area depends on the following factors:
•
Appr
oach speed of the body or parts of the body
•
Machine stopping time
•
Response time of the safety laser scanner (see "Response times", page 58)
•
Response time of the safety controller (see "Response times", page 58)
•
Supplement to prevent reaching over
•
Supplement for general and potential reflection-based measurement errors
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S C
tool
C
robot
S
total
1
2
3
4
Figure 4: Calculating minimum distance
1
Warning field
2
Protective field
3
Safety laser scanner
4
Robot
The safe minimum distance is determined using the following formula:
S
t
otal
= S + C
tool
+ C
robot
S = K * T + C
C = 1200 - (0.4 x H)
NOTE
W
orkpieces must also be taken into account during the calculations.
Table 2: Variables in the calculation
Formula symbols Relevance
S Minimum safety distance (safe distance) resulting from the stop‐
pin
g time of the system
C Supplement to prevent reaching over
C
r
obot
Maximum scanning range of the robot
C
t
ool
Distance between the mounting plate of the robot and the end
point of the end effector (tool) including the workpiece
K Approach speed (1,600 mm/s according to EN ISO 13855)
M Mounting height of the laser scanner
NOTE
If t
he robot’s range of motion is reliably restricted, the safety distances may decrease
(e.g. if the robot is equipped with a safety function that safely limits the robot move‐
ment).
4.1.2 Calculating stopping time
Stopping time of the machine
t
M
= t
FX3
+ t
R
elay
+ t
Robot
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Table 3: Variables in the calculation
Formula symbols Relevance
t
M
Machine stopping time
t
FX3
Safety controller response time
t
Relay
Relay module response time
t
R
obot
Robot stopping time
Different calculation formulas are used depending on the type of laser scanner.
4.1.2.1 S300 Mini Remote stopping time and minimum distance
S
t
otal
= S + C
tool
+ C
robot
S
total
= K * (t
M
+ t
S
) + Z
g
+ C + C
tool
+ C
robot
S
total
= 1,600 mm/s * (t
IN
+ t
PROG
+ t
OUT
+ t
Relay
+ t
Robot
+ t
S
) + Z
g
+ C + C
tool
+ C
robot
S
total
= 1,600 mm/s * (138 ms + 2 * t
LogicCycleTime
+ t
Robot
+ t
MS
) + 100 mm + C + C
tool
+
C
robot
NOTE
T
he following variables are dependent on the application and must be determined by
the manufacturer:
•
t
LogicCycleTime
•
t
Robot
•
t
MS
•
C
•
C
tool
•
C
robot
NOTE
W
orkpieces must also be taken into account during the calculations.
Table 4: Variables in the calculation
Formula symbols Relevance
S Minimum safety distance resulting from the stopping time of the
s
ystem
C Supplement to prevent reaching over
C
r
obot
Maximum scanning range of the robot
C
t
ool
Distance between the mounting plate of the robot and the end
point of the end effector (tool) including the workpiece
K Approach speed (1,600 mm/s according to EN ISO 13855)
M Mounting height of the laser scanner
t
IN
Input processing time
t
P
ROG
Program processing time, 2x logic cycle time
t
OUT
Output processing time
t
L
ogicCycleTime
Logic execution time
t
R
Response time
t
S
S300 Mini Remote response time
t
MS
Supplement due to multiple sampling
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Formula symbols Relevance
Z
g
General safety supplement for S300 Mini Remote
Z
r
Supplement for measurement error due to reflection
Example calculation
Factors
•
Height of the scan plane: 300 mm
•
Multiple sampling: 2×
•
Logic cycle time: 4 ms
•
Robot stopping time: 200 ms
S
total
= 1,600 mm/s * (138 ms + 2 * t
LogicCycleTime
+ t
Robot
+ t
MS
) + 100 mm + C + C
tool
+
C
robot
= 1,600 mm/s * (138 ms + 2 * 4 ms + 200 ms + 0 ms) + 100 mm + 1,080 mm + C
tool
+ C
robot
= 1,600 mm/s * (346 ms) + 1,180 mm + C
tool
+ C
robot
= 553.6 mm + 1,180 mm + C
tool
+ C
robot
= 1,733.6 mm + C
tool
+ C
robot
4.1.2.2 MicroScan3 stopping time and minimum distance
S
t
otal
= S + C
tool
+ C
robot
S
total
= K * (t
M
+ t
R
) + C + C
tool
+ C
robot
S
total
= 1,600 mm/s * (t
IN
+ t
PROG
+ t
OUT
+ t
Relay
+ t
Robot
+ t
R
) + C + C
tool
+ C
robot
S
total
= 1,600 mm/s * (6.5 ms + 2 * t
LogicCycleTime
+ 4.5 ms + 30 ms + t
Robot
+ t
R
) + C +
C
tool
+ C
robot
S
total
= 1,600 mm/s * (41 ms + 2 * t
LogicCycleTime
+ t
Robot
+ t
R
) + C + C
tool
+ C
robot
NOTE
T
he following variables are dependent on the application and must be determined by
the manufacturer:
•
t
LogicCycleTime
•
t
R
•
C
•
C
tool
•
C
robot
NOTE
W
orkpieces must also be taken into account during the calculations.
Table 5: Variables in the calculation
Formula symbols Relevance
S Minimum safety distance (safe distance) resulting from the stop‐
ping time of the system
C Supplement to prevent reaching over
C
r
obot
Maximum scanning range of the robot
C
t
ool
Distance between the mounting plate of the robot and the end
point of the end effector (tool) including the workpiece
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Subject to change without notice
Formula symbols Relevance
K Approach speed (1,600 mm/s according to EN ISO 13855)
M Mounting height of the laser scanner
t
IN
Input processing time
t
PROG
Program processing time, 2x logic cycle time
t
OUT
Output processing time
t
L
ogicCycleTime
Logic execution time
t
R
Response time
t
R
obot
Robot stopping time
Example calculation
F
actors
•
Height of the scan plane: 300 mm
•
Scanning time: 40 ms
•
Multiple sampling: 2×
•
Time for display: 10 ms
•
Response time of the safety laser scanner: 90 ms
•
Logic cycle time: 4 ms
•
Robot stopping time: 200 ms
S
total
= 1,600 mm/s * (41 ms + 2* t
LogicCycleTime
+ t
Robot
+ t
R
) + C + C
tool
+ C
robot
= 1,600 mm/s * (41 ms + 2 * 4 ms + 200 ms + 90 ms) + 1,080 mm + C
tool
+ C
robot
= 1,600 mm/s * (339 ms) + 1,080 mm + C
tool
+ C
robot
= 542.4 mm + 1,080 mm + C
tool
+ C
robot
= 1,622.4 mm + C
tool
+ C
robot
4.1.3 Calculating the performance level
The calculation of the performance level can be carried out using the SISTEMA file. The
f
ile is available on the Internet for this functional security system. The manufacturer of
the machine must decide which measures should be taken against failures with the
same cause.
These measures must be selected in the SISTEMA project file for each user-defined
sub-system. In addition, the correct values for the value must be chosen for the compo‐
nents that are not part of the scope of delivery, see "General requirements", page 28.
4.2 Operating entity of the machine
DANGER
H
azard due to lack of effectiveness of the protective device
In the case of non-compliance, it is possible that the dangerous state of the machine
may not be stopped or not stopped in a timely manner.
b
Changes to the electrical integration of the safety system in the machine control
and changes to the mechanical mounting of the safety system necessitate a new
risk assessment. The results of this risk assessment may require the entity operat‐
ing the machine to meet the obligations of a manufacturer.
b
Changes to the safety system’s configuration may impair the protective function.
The effectiveness of the safety system must be checked after any change to the
configuration. The person carrying out the change is also responsible for maintain‐
ing the protective function of the safety system.
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19
Subject to change without notice
4.3 Safety Functions
4.3.1 Identifying hazards
This document considers the following risks according to ISO 10218-1:
Mechanical hazards
•
Crushing
•
Cutting
•
Impacts
Dangers posed at the end effector of the robot must also be considered by the manu‐
facturer. If necessary, further measures must be taken to minimize the resulting risks.
Other residual risks, e.g., due to small parts being propelled, are not considered and
must be considered in detail in the risk assessment, see "Manufacturer of the
machine", page 15.
4.3.2 Switching field sets
Two field sets must be configured for the safety laser scanner, each containing a warn‐
in
g and a protective field, (see "Field types", page 13):
•
Field set 1 = warning field + protective field 1 (large)
•
Field set 2 = warning field + protective field 2 (small)
4.3.2.1 Approaching the hazardous area
Figure 5: Switching field sets
If t
he warning field is infringed, a request for reduced speed is sent. After a defined
delay time, the safety-rated monitored speed is activated. When the reduced speed is
reached, there is a switch from field set 1 to field set 2.
This delay time must be adjusted for each application accordingly.
If the delay time is too long, but the safety-rated monitored speed has not yet been acti‐
vated, then no switch of field sets is executed.
If the delay time is too short, the safety-rated monitored speed is activated before the
robot has reached the reduced speed. This means that the actual speed is higher than
the reduced speed and the robot will stop.
Table 6: Switching field sets when the warning field is infringed
Trigger Time delay after requesting a speed reduction
Condition Safety-rated monitored speed is active
Reaction Field set 1 of the safety laser scanner switches to field set 2
Safe state Speed of the robot is reduced and the protective field is clear
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Subject to change without notice
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SICK Safe Robotics Area Protection sBot Speed Operating instructions
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