지능형로봇 지능형로봇 안전 안전 표준 표준 Workshop Workshop 지능형로봇 지능형로봇 안전 안전 표준 표준 Workshop Workshop ISO 12100:2010 ISO 12100:2010 ISO 12100:2010 ISO 12100:2010 Safety of machinery Safety of machinery – – General principles General principles for design for design Risk assessment and risk Risk assessment and risk for design for design ––Risk assessment and risk Risk assessment and risk reduction reduction 2011. 2. 18 임성수 경희대학교 기계공학과 지능형로봇 표준포럼 성능/안전성 위원회 의장 IEC SC 59F/WG 5 의장 hi @kh k ssrhim@khu.ac.kr
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ISO 12100:2010ISO 12100:2010ISO 12100:2010ISO 12100:2010Safety of machinery Safety of machinery –– General principles General principles for designfor design Risk assessment and riskRisk assessment and riskfor design for design ––Risk assessment and risk Risk assessment and risk reductionreduction
– Combination of the probability of occurrence of harm and the it f th t h
Safe
severity of that harm
Wh t i HARM? Wh t i SEVERITY? Wh t iWhat is HARM? What is SEVERITY? What is PROBABILITY? What does TOLERABLE mean? ? ? ? ?
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Guideline for Safety Aspects in StandardsGuideline for Safety Aspects in Standards
Safety– Level of freedom from unacceptable risk
Approaches aimed at reducing the risk arising from – use of products– processes – services
Need to consider complete life cycle of a product, p y p ,process or service – Intended use– Reasonably foreseeable misuse
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Terminology (1)Terminology (1)
Harm (상해) – Physical injury or damage to healthPhysical injury or damage to health
Hazard (위험원) Hazard (위험원)– Potential source of harm
Risk (위험도)– Combination of the probability of occurrence of harm and the– Combination of the probability of occurrence of harm and the
severity of that harm
Hazardous situation– Circumstance in which a person is exposed to at least one hazard.Circumstance in which a person is exposed to at least one hazard.
The exposure can immediately or over a period of time result in harm
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Terminology (1) Terminology (1) -- ExampleExample
빙판길- hazard 빙판길 위를 걸어감 h d it ti빙판길 위를 걸어감-hazardous situation 빙판길 위를 걸어가다 넘어지는 성인(?) 중에 10%는 중증 골절
상을 입는다- risk
Risk– Combination of the probability of occurrence of harm and the p y
severity of that harm
빙판길 위에 앉아 있으면?
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Hazard IdentificationHazard Identification
Systematic identification of bl f bl h d ( t h d d th– reasonably foreseeable hazards (permanent hazards and those
which can appear unexpectedly), – hazardous situations and/or– hazardous situations and/or – hazardous events
during all phases of the machine life cycleduring all phases of the machine life cycle.
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HazardsHazards
From 12100:201012100:2010
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HazardsHazards
From 12100:201012100:2010
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RiskRisk
RISK is a function of SEVERITY OF HARM and PROBABILITY OF OCCURRENCE of that harmPROBABILITY OF OCCURRENCE of that harm.
PROBABILITY OF OCCURRENCE
SEVERITY OF
OCCU COFTHAT HARM
RISK
related to
SEVERITY OF HARM
that can result
Exposure of person(s)to the hazard
is a function
ofand
the considered hazard
that can result from the considered hazard
The occurrence of a hazardous event
of
The possibility of avoiding or limiting the
harm
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harm
RiskRisk
The risk associated with a particular hazardous it ti d d th f ll i l tsituation depends on the following elements:– the severity of harm;y– the probability of occurrence of that harm, which is a
function of• the exposure of person(s) to the hazard,• the occurrence of a hazardous event, and• the technical and human possibilities to avoid or limit the harm.
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Severity of Harm Severity of Harm
Severity of injuries or damage to health, for lexample,
– slightg– serious– deathdeath
E t t f h f l tExtent of harm, for example, to– one person– several persons
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Probability of Occurrence of HarmProbability of Occurrence of Harm
Exposure of persons to the hazardN d f t th h d– Need for access to the hazard zone
– Time spent in the hazard zone
Occurrence of a hazardous eventR li bilit d th t ti ti l d t– Reliability and other statistical data
– Accident history
Possibility of avoiding or limiting harmdiff t h b d t th h d( ) f l– different persons who can be exposed to the hazard(s), for example,
– how quickly the hazardous situation could lead to harm, for exampleexample,
– any awareness of risk
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Terminology (2)Terminology (2)
To increase the safety we have to reduce the riskRi k R d ti– Risk Reduction
T l bl i k Tolerable risk– Risk which is accepted in a given context based on the current
values of societyvalues of society
Risk analysis (위험도 분석)S t ti f il bl i f ti t id tif h d d t– Systematic use of available information to identify hazards and to estimate the risk
Risk evaluation (위험도 판정) Risk evaluation (위험도 판정)– Procedure based on the risk analysis to determine whether the
tolerable risk has been achievedtolerable risk has been achieved
Risk assessment (위험도 평가)Overall process comprising a risk analysis and a risk evaluation
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– Overall process comprising a risk analysis and a risk evaluation
Risk EstimationRisk Estimation
RISK is a function of SEVERITY OF HARM and PROBABILITY OF OCCURRENCE of that harmPROBABILITY OF OCCURRENCE of that harm.
RISK is a function of SEVERITY OF HARM and PROBABILITY OF OCCURRENCE of that harm.
Risk Matrix 및 Risk Graph과유사한형태이나, 해당위험요소들에 Score를설정하여해당위험요소의중요도및위험성소들에 Score를설정하여해당위험요소의중요도및위험성을쉽게인지.
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Terminology (3)Terminology (3)
Protective measures (보호 대책)M d t d i k– Means used to reduce risk
I h tl f d i (본질적 안전 설계 대책) Inherently safe design measure (본질적 안전 설계 대책)– Protective measure which either eliminates hazards or reduces the
risks associated with hazards by changing he design or operatingrisks associated with hazards by changing he design or operating characteristics of the machine without the use of guards or protective devices
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Why do we need 12100? Why do we need 12100?
Safety of Machine? Ri k R d ti ! EASY ?– Risk Reduction! EASY ?
– NO! NO! NO!
Confusion – Hazard, Risk, Harm ….
Lack of Information – What kinds of Hazards? – How to reduce the risk?
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Risk Reduction Process Risk Reduction Process Risk Assessment(designer)
Risk Analysis Definition of intended use Foreseeable misuseH d id tifi ti(designer) Hazard identificationRisk estimation
Ri k E l ti D t i h th th t l bl i k hRisk Evaluation Determine whether the tolerable risk has been achieved
Protective • Organization (safe working procedures, measures taken by the user
supervision, permit-to-work system)• Provision and use of additional safeguards• Use of personal protective equipment p p q p• Training
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Residual Risk Residual Risk Risk assessment
Protective measures implemented by designerdesigner
– Inherently safe design measures
– Safeguarding and complementary protective measures
– Information for use
Protective measures Protective measures implemented by user
– Education/Training– Supervision– Provision and use of
additional safeguards
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g
Risk Reduction ProcessRisk Reduction Process
Start
Determination of the Limits of the machinery (Clause 5)
Hazard Identification (Clause 6)Risk
Analysis
Risk Estimation (Clause 7)
Risk
Risk Evaluation (Clause 8)Assessment
Too High
Risk Reduction
Documentation
Has the Risk been adequately reduced? END
Adequate
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Adequate
Risk Reduction ProcessRisk Reduction Process
3 steps in design process
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Other TerminologyOther Terminology
ReliabilityM i t i bilitMaintainability Relevant hazard Significant hazard Guard Guard Interlocking guard Interlocking guard with guard locking Interlocking guard with guard locking Hold-to-run control device Sensitive protective equipment Impeding device Safety function Failure to danger Failure to danger
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Drafting (Type C) Safety StandardDrafting (Type C) Safety Standard
Safety aspects to be considered in the standard
Before drafting
Hazard identification Hazard identification Inherently safe design measures Safeguarding complementary measures Safeguarding, complementary measures Information for use
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Safety Aspects to be Considered (1)Safety Aspects to be Considered (1)
Intended use and reasonably foreseeable misuse; Ability to perform under expected conditions of use; Ability to perform under expected conditions of use; Environmental compatibility; Ergonomic factors; Regulatory requirements;g y q Existing standards; Reliability; Reliability; Serviceability (including “service maintenance”, such as
ease of access to serviceable items method ofease of access to serviceable items, method of refuelling/lubrication);
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Safety Aspects to be Considered (2)Safety Aspects to be Considered (2)
Durability; Di bilit (i l di l t i t ti ) Disposability (including any relevant instructions); Special needs of users [e.g. children (see ISO/IEC Guide
50), elderly people, the disabled] of the product, Process or service; Failure characteristics;Markings and informationMarkings and information.
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Before Drafting (Type C) StandardBefore Drafting (Type C) Standard
Detailed working knowledge of the product, process or serviceservice
Accident/incident history Feedback based on experience by users of the product,
process or service Knowledge of the available protective measures Knowledge of the future development of the product, g p p ,
process or service Legal framework Legal framework
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Iterative Risk Reduction ProcessIterative Risk Reduction Process
3 step protective Risk Assessment(designer)
Risk Analysis Definition of intended use Foreseeable misuseH d id tifi timeasures taken by the
designer
(designer) Hazard identificationRisk estimation
Ri k E l ti D t i h th th t l bl i k hRisk Evaluation Determine whether the tolerable risk has been achieved
Hazards to be taken into account – Mechanical hazardMechanical hazard – Electrical hazard – Thermal hazard – Hazard generated by noise– Hazard generated by vibrationg y– Hazard generated by radiation– Hazard generated by materials and substances– Hazards generated by neglecting ergonomic principles – Slipping, tripping and falling hazards– Hazard combinations– Hazards associated with the environment in which the
Description Example(s) of related hazardous situations Related danger zone
H d t d b l ti i i i l i th d iHazards generated by neglecting ergonomic principles in the design process
Unhealthy postures or excessive effort (repetitive strain) Poorly designed teach pendant Teach pendant
Inadequate consideration of hand-arm or foot-leg anatomy Inappropriate location of controls
At load/unload work piece and tool mounting
tti itia o oot eg a ato y or setting positions
Inadequate design, location or identification of manual controls Inadvertent operation of controls At or near robot cell entification of manual controls
Inadequate design or location of visual display units Misinterpretation of displayed information At or near robot cell
Geometrical factors and physical aspectsT li d ki ( f t t t )– Traveling and working area (zone of movement, contact area,…)
– The shape, sharp edges and corners, rough surface, no protruding parts openings gaps between componentsparts, openings, gaps between components, …
– Limiting the actuating force (mass, velocity, acceleration…)– Limiting the emission (noise hazardous substances radiationLimiting the emission (noise, hazardous substances, radiation,
General technical knowledge regarding machine design General technical knowledge regarding machine design– Mechanical stresses and fatigue, Dynamic balancing, Materials and
Choice of appropriate technology C id th ki diti d h i t– Consider the working conditions and choose appropriate technologies to eliminate/reduce risks
– Explosive atmospheres High temperature– Explosive atmospheres, High temperature, ….
Principle of the positive mechanical action of a component Principle of the positive mechanical action of a component on another component – Moving parts (driver-driven) need to be connected in the positive– Moving parts (driver-driven) need to be connected in the positive
manner (no free movement by the driven)
Stability – Geometry of the base, weight distribution, oscillation of the CG,Geometry of the base, weight distribution, oscillation of the CG,
characteristics of the supporting surface, external force,…– Consider the conditions of use
Preventing hazards from pneumatic and hydraulic equipmentequipment – Maximum rated pressure level, pressure surges, hazardous fluid, …
Minimizing the probability of failure of safety functions U f li bl t i t d f il d ( d i t– Use of reliable components, oriented failure mode (predominant failure mode is known), redundancy (duplication of components or subsystems), …subsystems), …
Mechanization or automation of loading (feeding)/unloading(removal) operations(feeding)/unloading(removal) operations– Automation to reduce the exposure of the operator to hazards
Location of the setting and maintenance points outside of danger zones – Danger zone (hazard zone): any space within and/or around
hi i hi h b d t h dmachinery in which a person can be exposed to hazard
Control system Control system needs to avoid unforeseen and potentially– Control system needs to avoid unforeseen and potentially hazardous machine behavior
– Typical causes of hazardous machine behavioursTypical causes of hazardous machine behaviours• Unsuitable design or modification (accidental or deliberate) of the
control system logic• Temporary or permanent defect or a failure of one or several
components• unintended / unexpected start-up (see ISO 14118);unintended / unexpected start up (see ISO 14118);• a variation or a failure in the power supply of the control system
– Typical examples of hazardous machine behavioury• uncontrolled speed change;• failure to stop moving parts;• dropping or ejection of a mobile part of the machine or of a
workpiece clamped by the machine;• machine action resulting from inhibition (defeating or failure) of
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machine action resulting from inhibition (defeating or failure) of protective devices.
– Design consideration for control system • Starting of an internal power source/switching on an external Starting of an internal power source/switching on an external
power supply• Starting/stopping of a mechanism• Restart after power interruption• Interruption of power supply• Use of automatic monitoring• Use of automatic monitoring• Safety functions implemented by programmable electronic control
systems (H/W aspects, S/W aspects)• Principles relating to manual control • Control mode for setting, teaching, process changeover, fault-
finding cleaning or maintenancefinding, cleaning or maintenance • Selection of control and operating modes • Electromagnetic compatibility (EMC)g p y ( )• Diagnostic system to aid fault-finding
Guards and/or protective devices shall be used to protect persons whenever inherently safe design does notpersons whenever inherently safe design does not reasonably make it possible either to remove hazards or to sufficiently reduce riskssufficiently reduce risks.
Selection and implementation of guards and protective devicesdevices – Where access to the hazard zone is not required during normal
operationoperation– Where access to the hazard zone is required during normal
operation p– Where access to the hazard zone is required for machine setting,
teaching, process changeover, fault finding, cleaning or imaintenance
– Sensitive protective equipment Can be sed for tripping p rposes for presence sensing for re initiate• Can be used for tripping purposes, for presence sensing, for re-initiate machine operation, …
• Light curtains, scanning devices, pressure sensitive mats, trip bars, …g g p p
Other protective measures P ibl h d it ti– Possible hazardous situations
• when the operator has insufficient visibility of the hazard zone;• when the operator lacks knowledge of the actual value of a safety-when the operator lacks knowledge of the actual value of a safety-
related parameter (e.g. a distance, a speed, the mass of a load, the angle of a slope);
• when hazards may result from operations other than those controlled by the operator.
– The necessary devices• devices for limiting parameters of movement (distance angle• devices for limiting parameters of movement (distance, angle,
velocity, acceleration);• overloading and moment limiting devices;• devices to prevent collisions or interference with other machines;• devices for preventing hazards to pedestrian operators of mobile
machinery or other pedestrians;machinery or other pedestrians;• torque limiting devices, breakage points to prevent excessive stress
of components and assemblies;• devices for limiting pressure, temperature;• devices for monitoring emissions;
d i t t ti i th b f th t t th• devices to prevent operation in the absence of the operator at the control position;
• devices to prevent lifting operations unless stabilizers are in place;de ces to p e e t t g ope at o s u ess stab e s a e p ace;• devices to limit inclination of the machine on a slope;• devices to ensure that components are in a safe position before
Complementary protective measures P t ti hi h ith i h tl f d i– Protective measures which are neither inherently safe design measures, nor safeguarding (implementation of guards and/or protective devices), nor information for usep ),
– Components and elements to achieve the emergency stop fun (ISO 13850)
• If a machine needs to be fitted with components and elements to achieve an emergency stop function to enable actual or impending emergency situations to be avertedemergency situations to be averted
– the actuators shall be clearly identifiable, visible and readily accessible;
– the hazardous process shall be stopped as quickly as possible without creating additional hazards. If this is not possible or the risk cannot be reduced, it should be questioned whether , qimplementation of an emergency stop function is the best solution;
– the emergency stop control shall trigger or permit the triggering of certain safeguard movements where necessary
Complementary protective measures M f th d f t d– Measures for the escape and rescue of trapped persons
• escape routes and shelters in installations generating operator-trapping hazards;;
• arrangements for moving some elements by hand, after an emergency stop;
• arrangements for reversing the movement of some elements;• anchorage points for descender devices;• means of communication to enable trapped operators to call for help• means of communication to enable trapped operators to call for help.
Complementary protective measures M f i l ti d di i ti– Measures for isolation and energy dissipation
a) isolating (disconnecting, separating) the machine (or defined parts of the machine) from all power supplies;) p pp ;
b) locking (or otherwise securing) all the isolating units in the isolating position;
c) dissipating or, if this is not possible or practicable, restraining (containing) any stored energy which may give rise to a hazard;
d) verifying, by means of a safe working procedure, that the actions takend) verifying, by means of a safe working procedure, that the actions taken according to a), b) and c) above have produced the desired effect.
– Easy and safe handling of machines and their heavy component parts
Complementary protective measures E d f h dli f hi d th i h t– Easy and safe handling of machines and their heavy component parts
• standardized lifting appliances with slings hooks eyebolts or tappedstandardized lifting appliances with slings, hooks, eyebolts, or tapped holes for appliance fixing;
• appliances for automatic grabbing with a lifting hook when attachment i t ibl f th dis not possible from the ground;
• guiding grooves for machines to be transported by a fork truck;• lifting gear and appliances integrated into the machinelifting gear and appliances integrated into the machine.
Complementary protective measuresM f f t hi– Measures for safe access to machinery
• operation and all routine tasks relating to setting and/or maintenance, to be carried out, as far as possible, by a person remaining at ground , p , y p g glevel. Where this is not possible, machines shall have built-in platforms, stairs or other facilities to provide safe access for those tasks, but care should be taken to ensure that such platforms or stairs do not givecare should be taken to ensure that such platforms or stairs do not give access to danger zones of machinery.
• The walking areas shall be made from materials which remain as slip resistant as practicable under working conditions and, depending on the height from the ground, suitable guard-rails (see ISO 14122-3) shall be provided.p
• In large automated installations, particular attention shall be given to safe means of access such as walkways, conveyor bridges or crossover pointspoints.
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Information for Use Information for Use
General requirements L ti d t f th i f ti f Location and nature of the information for use Signals and warning devices Markings, signs (pictograms), written warnings Accompanying documents (in particular, instruction Accompanying documents (in particular, instruction
handbook)
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References References
ISO/IEC Guide 51:1999 Safety aspects — Guidelines for their inclusion in standardsin standards
ISO 12100-1:2003 Safety of machinery — Basic concepts, general principles for design — Part 1: Basic terminology, methodology
ISO 12100-2:2003 Safety of machinery — Basic concepts, general principles for design — Part 2: Technical principles industrial robots — Coodi t t d ti l trdinate systems and motion nomenclatures
ISO 10218-1:2006 Robots for industrial environments — Safety requirements — Part 1: Robotments — Part 1: Robot
ISO 12100:2010 Safety of machinery — General principles for design — Risk assessment and risk reduction
ISO 14121-1:2007 Safety of Machinery – Risk Assessment — Part 1: Principles