Exploring ISO 10218: Safety Standards for Industrial Robots and Applications

ISO 10218, the international series of standards for industrial robotic safety, are foundational documents for manufacturers, integrators, and safety (H&S) bodies worldwide. This standard is broken down into two parts: ISO 10218-1 for just the industrial robot and ISO 10218-2 for complete industrial robot applications. Understanding and adhering to ISO 10218-2 is crucial for ensuring that robot applications are safe and compliant with standards. Here’s an overview of its key aspects and considerations.

The Scope of the ISO 10218 series

ISO 10218 standards are classified as Type C standards according to ISO, meaning it is product or application specific and takes precedence over more general Type A and B standards when it comes to safety requirements. This specificity is essential, as it tailors requirements directly to the unique risks and characteristics of industrial robots and their applications.

However, ISO 10218 explicitly excludes certain categories of robots, such as those used in military, space, medical, and service. The ISO 10218 series does not specify requirements for mobile platforms as these are covered by other standards, for example ISO 3691-4.  ISO 10218-1 and -2 are applicable when industrial robots are integrated with mobile autonomous platforms, such as Automated Mobile Robots (AMRs), Automated Storage and Retrieval Systems (ASRS), and Driverless Industrial Trucks (also called Automated Guided Vehicles (AGVs)).

Key Safety Requirements

1. Mechanical Strength and Hazardous Energy Management

   • ISO 10218 sets out requirements for mechanical strength and stability. Robots must operate safely even under specified overloads, and their position-holding ability must prevent hazardous movements that could endanger workers.

     • Section 5.1.2.3 states:

“The robot shall be designed and constructed to:

·  withstand an overload in static tests without permanent deformation or patent defect, where strength calculations shall have a minimum static test coefficient of 1.25

·  undergo, without failure, dynamic tests using the maximum unit payload multiplied by the dynamic test coefficient, where the dynamic test coefficient shall be at least 1.1.

Tests shall be performed at the maximum speed. If simultaneous motion can be programmed, the tests shall be done using the least favorable conditions.”

• One major aspect to consider here is that for a robot to be a Class I, it must be less than 10kg, exert less than 50N force, and not be capable of speeds over 250 mm/s.  To meet all three conditions is uncommon for industrial applications.

• Power loss and hazardous energy management are emphasized, where sudden loss of power could pose safety risks. Hazardous energy handling is a critical focus in some AMR systems, as we have learned with some of our clients.

2.                      Configurable Capabilities and Direct Control

• The standard dictates requirements for configurable settings, such as the Tool Center Point (TCP) and Payload, to ensure reliable operation.

• Direct control and external control requirements are presented.

• A particular distinction is made between Manual and Automatic modes, with ISO 10218 and the activation of these modes.

3.                      Emergency, Protective, and Other Stop Functions

• ISO 10218 delineates three types of stops:

  • Emergency Stop: An immediate stop in case of a hazard, often associated with emergency stop (e-stop) buttons on teach pendants. For example, the e-stop on teach pendants give operators a quick and reliable means to stop in emergency situations.

  • Protective Stop: Activated for safety-related purposes to reduce risks.

  • Normal Stop: For normal, non-emergency, stopping purposes.

4.                      Communications and Wireless Safety

• For cableless control systems, the standard defers to IEC 62745, ensuring that safety-related cableless communication (such as radio or infrared links) adheres to robust standards.

• When data communications are used in the implementation of a safety function, ISO 10218 references IEC 61508.

5.                      Risk Assessment

• A comprehensive risk assessment based on ISO 12100 is central to ISO 10218.

  • For Part 1, the requirements stated reflect the results of the risk assessment for the intended uses. 

  • For Part 2, requirements are stated but not all applications can be foreseen.  Therefore, an application risk assessment is required to augment the Part 2 requirements.

6.                      Functional Safety and Related Standards

• ISO 10218 requires ISO 13849 or IEC 62061 conformity for functional safety. This results in there being a Performance Level Required (PLr) or a SIL for a given safety function. The PL or SIL reflects the level of risk reduction needed to keep workers safe.

• ISO 13849-1 describes the elements of Mean Time to Dangerous Failure, Diagnostic Coverage, and Common Cause Failures.

7.                      Special Considerations for Lasers and Laser Equipment

• Due to their increasing prevalence in industrial robotics, lasers receive specific attention in ISO 10218. The standard ensures that laser-equipped robots and robot applications adhere to the appropriate safety standards.

8.                      Information for use (Instruction Handbook) Requirements

• ISO 10218-1 mandates comprehensive instructions for each robot, including sections on Identification, Intended Use, Installation, Operation, Maintenance, and Emergency Situations.  ISO 10218-2 has even more requirements of information to be provided for the robot application.

• Instructions must also cover specific elements like cybersecurity, functional safety, teach pendant use, and abnormal scenarios.

Conclusion

The ISO 10218 series provides a comprehensive framework for ensuring the safety of industrial robots and industrial robot applications. It offers a structured approach. This standard emphasizes the requirements to ensure safe operation in industrial environments.

However, the ISO 10218 series does not address hazards related to mobility that can be present in Driverless Industrial Trucks (AGVs and AMRs) and ASRS.  For these purposes, compliance with ISO 3691-4 (Driverless Industrial Trucks) and/or EN 528 (Rail dependent storage and retrieval equipment) would also be applied.

For products and applications outside manipulator-based robotics, supplementary guidance from other standards is likely to be needed, however ISO 10218 offers valuable insights.

In sum, ISO 10218 is invaluable for OEMs, integrators, and H&S bodies aiming to create safe, efficient, and compliant industrial robotic applications.