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Chapter 2: Operational Safety

However, the maximum permissible exposure cannot be exceeded when viewing the laser
with the naked eye. OMRON recommends that you avoid long-term viewing of the laser.

31500-100 RevA

Mobile Robot HD Safety Manual

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Summary of Contents for 37480-00100

Page 1: ...HD Safety Manual I647 E 01 Mobile Robot ...

Page 2: ...riodically reviewed and revised OMRON assumes no responsibility for any errors or omissions in the documentation Copyright 2020 by OMRON All rights reserved Any trademarks from other companies used in this publication are the property of those respective com panies MPEG Layer 3 audio coding technology licensed from Fraunhofer IIS and Thomson Acapela voice technology licensed from ACAPELA GROUP htt...

Page 3: ... provided that in no event shall Omron be responsible for warranty repair indemnity or any other claims or expenses regarding the Products unless Omron s analysis confirms that the Products were properly handled stored installed and maintained and not subject to contamination abuse misuse or inap propriate modification Return of any Products by Buyer must be approved in writing by Omron before shi...

Page 4: ...ny websites catalogs and other materials is provided as a guide for the user in determining suitability and does not constitute a warranty It may rep resent the result of Omron s test conditions and the user must correlate it to actual application requirements Actual performance is subject to the Omron s Warranty and Limitations of Liab ility Change in Specifications Product specifications and acc...

Page 5: ...1 Magnetic Field Hazards 21 Burn Hazard 22 Qualification of Personnel 22 Payload Movement and Transfer 23 Configurable Warning Buzzer 23 Speakers 24 Mechanical Brakes 24 Fleet Management 25 Other Hazards 26 2 6 Risk Assessment 26 Exposure 26 Severity of Injury 26 Obstacle Avoidance 26 Safety System Behavior 27 2 7 Environment 27 General Environmental Conditions 27 Public Access 28 Operating Cleara...

Page 6: ...ty Lasers 41 2 13 Safety System Overspeed Faults 42 2 14 Laser Safety 42 2 15 Interlock Switches 44 2 16 Battery Safety 45 Battery Safety Precautions 46 Battery Maintenance 48 2 17 Charging Station 48 Safety Precautions 49 2 18 Payload Structure 53 Safety 54 Considerations 55 2 19 Additional Safety Information 63 Mobile Robot HD Safety Manual Cat No I647 64 2 20 Additional Safety Information 64 Mo...

Page 7: ...e CAUTION Identifies a potentially hazardous situation which if not avoided might result in minor injury moderate injury or property damage 1 2 Alert Icons The icon that starts each alert can be used to indicate the type of hazard These will be used with the appropriate signal word Danger Warning or Caution to indicate the severity of the hazard The text following the signal word will specify what...

Page 8: ...ier must extend around the hazard completely l Visibility Mark all physical barriers to make sure that the AMR s safety lasers can detect them easily Barriers must extend above and below the laser s sensing plane par ticularly if the floor is not flat Logical Barriers In addition to physical barriers use MobilePlanner to create forbidden areas or lines on the workspace map to prevent AMRs from clo...

Page 9: ...tion IMPORTANT Information to ensure safe use of the product NOTE Information for more effective use of the product Additional Information Offers helpful tips recommendations and best prac tices Version Information Information on differences in specifications for different versions of hardware or software 31500 100 RevA Mobile Robot HD Safety Manual 9 ...

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Page 11: ...sers in order to measure evaluate and constantly improve their AMR fleet performance in the factory Fleet Two or more AMRs operating in the same workspace HD 1500 This is the model name of the AMRplatform This document uses the model name HD 1500 when describing the setup configuration and connections Mobile Robot An alternative industry term for AMR Payload Structure Any passive or dynamic device...

Page 12: ...and AMR are configured correctly with the Call Door Box option l Do not throw an object in front of the AMR or suddenly step into the path of the AMR The AMR braking system cannot be expected to function as designed and specified in such instances WARNING PERSONAL INJURY OR PROPERTY DAMAGE RISK Abrupt appearance of objects or persons in the path of the AMR could result in personal injury or proper...

Page 13: ...ould potentially result in short circuit l The HD 1500 shall only be powered by an HD 1500 battery Do not use any other bat teries l The HD 1500 battery shall only be charged by an HD 1500 charger Do not use any other chargers 2 3 Unprotected Areas The HD 1500 charges its battery autonomously by driving itself to the docking target where it mates with the docking target s charging paddle as displa...

Page 14: ... front and rear ends of the AMR The operator must take necessary precautions to ensure that the operator s hands or other body parts do not get stuck in between the charging pad and the platform when docking l At speeds above 115 mm s the hardware based laser protective zones are fully active and there are no unprotected areas The following table lists the hardware based safety laser protection zo...

Page 15: ...n A AMR Y axis D Front laser zone B AMR X axis E HD 1500 C Rear laser zone F Safety scanning laser The following figure provides dimensions of the HD 1500 unprotected area The same dimen sions are true for the rear laser unprotected area A B Figure 2 3 HD 1500 s Unprotected Zone Dimensions Movement at Less Than 115 mm s A AMR Y Axis and B AMR X Axis 31500 100 RevA Mobile Robot HD Safety Manual 15 ...

Page 16: ...urn off the power supply box in case a docked AMR is E Stopped CAUTION Combustible Lithium Battery For AMR fire suppression use either foam dry chemical extinguisher ABC AB powdered graphite copper powder or a CO2 extinguisher The HD 1500 has four E Stop buttons two on either side of the platform a red push lock but ton The Operator Panel provides an additional E Stop button a red push lock button...

Page 17: ...vation of the E Stop button and manual reset of the AMR through the ON button for the AMR to restart its operation The AMR will not automatically recover from an emergency stop initiated by pressing one of the E Stop buttons on the AMR To use an E Stop button 1 Push firmly on the red button so that it latches 2 Follow your site specific emergency and safety procedures If you need to move the AMR m...

Page 18: ...es significant effort and might cause personal injury or property damage Take appropriate care and follow all safety instruc tions WARNING PINCH RISK Take necessary precautions when moving an AMR without its skins attached The motor and motor assemblies will be exposed when the side skins are removed exposing the potential pinch points Refer to the following figure The rear and top of the AMR also...

Page 19: ...AMR has room to maneuver 2 Rotate the E Stop button in the direction of the arrows on the button and allow it to pop up 3 After you release the E Stop button you must enable the motors manually by pressing the green ON button on the operator panel After you enable the motors there is a delay of several seconds before the AMR can resume operation NOTE If you manually move the AMR while it is powere...

Page 20: ...ards and legal requirements WARNING PERSONAL INJURY OR PROPERTY DAMAGE RISK It is the end user s responsibility to make sure that the AMR is operated within its specifications intended use and intended environments Safe use of the AMR requires that you l Read the installation and operation instructions in addition to the HD 1500 Platform User s Manual Cat No I645 before using the AMR l Review and ...

Page 21: ...ll possible liquid and allow the AMR to air dry thoroughly before restoring power Contact your OMRON representative if you suspect that liquid has penetrated the skins or contaminated the AMR s interior l Avoid liquid near the charging station and the AMR l Do not open the power supply box electrician access box or even the docking target until you have read the appropriate sections of this user s...

Page 22: ...priate training and have a working knowledge of the system The user must provide the necessary additional training for all personnel who will be working with the system As described in this guide and the HD 1500 Platform User s Manual Cat No I645 you should allow only skilled persons or instructed persons to do certain procedures l Skilled persons have technical knowledge or sufficient experience ...

Page 23: ...e end user s responsibility to design an appropriate inter lock to prevent this During movement and transfer you must actively monitor and confirm the transfer operation to make sure that it completes successfully If any operation fails a fail safe interlock must trig ger an AMR E Stop condition An E Stop condition prevents the AMR from moving until you resolve the problem and confirm that it is s...

Page 24: ...the front of the AMR When speakers are used as a means of notifying personnel of an approaching AMR you must routinely verify that they are still functioning normally Verify that the speakers are audible and the sound level is at the same level as needed during the operation Mechanical Brakes Perform annual inspection of the mechanical brakes for proper function Follow these steps to verify that t...

Page 25: ...kspace you must use a EM2100 appliance configured as a Fleet Manager running the Fleet Operations Workspace FLOW soft ware The Fleet Manager controls AMRs over a wireless network WiFi improving the efficiency of AMR operations by sharing the information between all AMRs in the fleet The shared inform ation includes improving the efficiency of AMR operations l Dynamic position and heading velocity ...

Page 26: ...r staying in the vicinity of the AMR for long periods when ON or while charging will expose you to the magnetic fields gen erated by the AMR l The users must be aware of the HD 1500 unprotected zones operating hazard zones and keep a safe distance from the AMR to prevent personal injury Severity of Injury The severity of injury depends on the type of payload and how the payload is integrated with ...

Page 27: ...nnot be protected by the AMR detection devices Only authorized persons are permitted to enter You can use map features such as forbidden areas to keep HD 1500s within their designated area of operation See the Fleet Operations Workspace Core User s Manual Cat No I635 for information about editing your workspace map l Operating Hazard Zones These operating zones are areas of inadequate clearance le...

Page 28: ...equate side clearance free space on both sides of the AMR so that it cannot trap a person against a wall or other fixed object Consult the applicable Autonomous Vehicle and Robotics operating standards for your locale An AMR must often maneuver close to machinery conveyors or other fixed objects In such cases operating standards usually allow an exception to side clearance requirements For informa...

Page 29: ...ion Measured From the Center of the Docking Target to the Center of the HD 1500 A Docking Target and B HD 1500 1300 Figure 2 9 Goal Position Measured from the Front Face of the HD 1500 to the Charging Paddle 31500 100 RevA Mobile Robot HD Safety Manual 29 ...

Page 30: ... the AMR s operating parameters to reduce the risk of a col lision You can do this by l Editing the workspace map to include features that restrict the AMR s operation in spe cific areas such as preferred lines resisted areas and movement parameter sectors to reduce speed l Editing the AMR s configuration to affect its behavior in all locations such as restricting its maximum speed Additional Info...

Page 31: ...nough doorways to be navigable by an HD 1500 The HD 1500 can operate at its maximum speed through a 2200 mm opening and will traverse at a slower speed through a 2100 mm opening DANGER PERSONAL INJURY RISK Improper operation of the AMR on inclined floors that do not comply with the applicable operating specifications can result in the AMR tipping over and consequently a serious personal injury The...

Page 32: ...nary areas including moving floors or any type of land vehicle watercraft or aircraft HD 1500 navigation is assisted by sensing embedded in the AMR Controller that requires a stationary environment to be effective IMPORTANT You must always observe the instructions for operation install ation and maintenance provided in this guide and in the HD 1500 Platform User s Manual Cat No I645 Other non inte...

Page 33: ...y features if determined to be necessary based on risk assess ment results l You perform proper risk assessment in accordance with EN ISO 12100 and identify any risks associated with the modification made to the HD 1500 platform It is the end user s responsibility to ensure that these risks are properly mitigated eliminated so the AMR does not cause personal injury or property damage 2 9 Safety Co...

Page 34: ...ust take appropriate precautions to avoid potential short circuit Electrical Hazard Precautions l There are no user serviceable parts inside of the battery Do not open the battery l Do not use any charger not supplied by OMRON l If the AMR comes into contact with any liquid 1 Power off the AMR 2 Clean off as much liquid as is possible 3 Allow the AMR to air dry thoroughly before restoring power 4 ...

Page 35: ...ess the ON button on the Operator Panel Lock Out Tag Out Procedure You must complete the appropriate Lock Out Tag Out LOTO procedure prior to any main tenance work on the charging station or the AMR The following sections describe the LOTO procedure for the AMR and the charging station LOTO Procedure for the AMR Follow this LOTO procedure for the AMR 1 Prepare the AMR for shutdown You must make su...

Page 36: ... stores energy You must check and make sure that the voltage left is less than 7 V Probe the appropriate connector pins on the module displayed in Figure 2 12 using a digital multimeter Prob the back of the pin 4 positive and pin 3 negative as shown in Figure 2 13 WARNING ELECTRICAL SHOCK RISK Do not perform maintenance work on the AMR until the measured voltage is below 7 V Figure 2 12 Location o...

Page 37: ...e ON OFF button on the Operator Panel LOTO Procedure for the Charging Station Follow this LOTO procedure for the charging station 1 Turn the power off You can do this by switching the main disconnect switch located on the electrician access box to OFF position A A B Figure 2 14 Main Disconnect Switch on the Electrician Access Box A ON Position and B OFF Position 31500 100 RevA Mobile Robot HD Safe...

Page 38: ...ends on your needs and your facility LOTO requirements You may also add your name to the lock or have multiple names on the lock This lets other users know who has locked the power supply box in case they must get in touch with that person Figure 2 16 Main Disconnect Switch Locked 3 Verify that the power is off You can do this by checking the LED indicators located on the power supply box When the...

Page 39: ... have a readily visible flashing light to serve as a warning whenever the AMR is ready to move or is moving The exact nature of this light will vary depending on the design of the payload structure For more information refer to HD 1500 Platform User s Manual Cat No I645 Light Discs Check the light discs on each side of the AMR for proper function Refer to HD 1500 Platform User s Manual Cat No I645...

Page 40: ... during the operation E Stop Buttons Inspect the E Stop buttons for any sign of physical damage and check for proper function Mechanical Brakes Check the AMR mechanical brakes at least once a year and make sure that the mechanical brakes properly engage and disengage For instructions on how to perform the inspection refer to the HD 1500 Platform User s Manual Cat No I645 Warning Labels The only wa...

Page 41: ...on field differs from pressing an E Stop button After you press an E Stop button you must first resolve the problem and then manually resume AMR operation See What to Do in an Emergency on page 16 Other circumstances might cause a protective stop such as l User supplied sensors connected to the Safety Controller After the AMR comes to a complete protective stop caused by laser protection zone intr...

Page 42: ...r continuously mon itors the deceleration If the AMR is not able to stop quickly enough the Safety Controller dis ables the drive motors and engages the mechanical motor brakes in order to stop the AMR The motor brakes are powerful enough to stop a fully loaded HD 1500 traveling at its top speed However engaging the mechanical motor brakes to stop the AMR is not a typical func tion In the unlikely...

Page 43: ...l Safety However the maximum permissible exposure cannot be exceeded when viewing the laser with the naked eye OMRON recommends that you avoid long term viewing of the laser 31500 100 RevA Mobile Robot HD Safety Manual 43 ...

Page 44: ...e electronics bay enclosure are isolated and protected from unau thorized unsafe access If the battery door or any of the side skins opens or get removed the interlock switches disable the AMR s motion and disable power to the main bus bars CAUTION BURN RISK Do not touch the AMR drive wheel motors when the side skins are removed as the drive wheel motors can get extremely hot during the operation ...

Page 45: ...us charging and re start charging WARNING ELECTRICAL SHOCK RISK FIRE RISK BURN RISK The interlock switches shall not be defeated or bypassed as this would energize the AMR and expose the user to potential electrical hazards 2 16 Battery Safety Effective April 1 2016 IATA regulations UN 3480 PI 965 require that air shipped lithium ion batteries must be transported at a state of charge not exceeding...

Page 46: ... 60 C 5 95 RH non condensing Storage Position The batteries must be stored as displayed in the following figure You must not lay the bat teries on their sides top front or rear end A B D D C C Figure 2 20 Position of the Battery for Storage ID Description ID Description A Front of the battery C Side of the battery B Rear of the battery D Top of the battery Environmental Considerations l Batteries ...

Page 47: ...oam dry chemical ABC AB powdered graphite copper powder or CO Battery Removal Installation Removal or installation of the battery must be performed by persons who have read and under stood this manual as well as the HD 1500 Platform User s Manual Cat No I645 Refer to HD 1500 Platform User s Manual Cat No I645 for instructions on how to replace the HD 1500 bat tery WARNING PERSONAL INJURY OR PROPER...

Page 48: ... 6 84 kW of power and can charge a fully depleted battery pack in 40 minutes WARNING FIRE RISK ELECTRICAL BURN RISK The HD 1500 battery and the charger outputs have high current You must take appropriate precautions to avoid potential short circuit WARNING ELECTRICAL SHOCK RISK The charging station transfers high electric power and contains hazardous voltage The user must take necessary precaution...

Page 49: ... the power cord WARNING HOT SURFACE HAZARD The docking target charging contacts heat up during the charging process Take necessary precautions to avoid burn dangers Safety Precautions Lock out Tag out LOTO Prior to any maintenance work on the charging station you must perform Lock Out Tag Out LOTO procedure For information on how to perform LOTO see Lock Out Tag Out Pro cedure on page 35 Decommiss...

Page 50: ... form User s Manual Cat No I645 You must make sure to adjust the jumpers as required for the voltage range To connect the facility power cable to electrician access box you must punch a hole through the electrician access box and install a proper strain relief or conduit for the facility power cable used 4 Once the wiring is complete and the facility power cable is connected to the electrician acc...

Page 51: ...trician Access Box ON Position 6 Turn the power supply box main disconnect switch located on the electrician access box to ON position vertical position This will allow the facility AC power to run through the power supply box 31500 100 RevA Mobile Robot HD Safety Manual 51 ...

Page 52: ...n You must follow the instructions provided in this document for safe and correct installation of the charging station Consider the following safety measures for power supply box installation l The power supply box and the docking target must be properly secured to the wall or floor prior to start up For instructions on how to install the power supply box and the docking target refer to the HD 150...

Page 53: ... condensing Environmental Considerations l In case of fire use a class C extinguisher foam dry chemical or CO l IP rating for the power supply box is IP20 l IP rating for the docking target is IP20 NOTE The IP rating for the copper charging pads is IP10 Do not expose them to liquid 2 18 Payload Structure A payload structure is any mechanical equipment that you attach to the HD 1500 for the pur pos...

Page 54: ...1500 Platform User s Manual Cat No I645 for more information l Colored light strips in front and back of the AMR Similar to light discs these light strips provide visual cues about the AMR s movement status Refer to the HD 1500 Plat form User s Manual Cat No I645 for more information l Provision for an auxiliary warning light on the AMR Controller Refer to the HD 1500 Platform User s Manual Cat No...

Page 55: ...ayload l Serviceability and maintenance requirements Weight Constraints The total operating weight of the AMR should comply with its specifications for payload and any objects carried DANGER PERSONAL INJURY OR PROPERTY DAMAGE RISK The end user of the AMR must perform a risk assessment to identify and mit igate any additional personal and property damage hazards caused by the pay load When designin...

Page 56: ...consumption whenever possible The battery is rated at 3696 W hr 3 7 kWh Power Limits OMRON recommends that you use external current limiting devices to prevent transient cur rent overload The limits are l For Battery_Out max inrush peak current is 50A Momentary current spikes over these thresholds will activate current limiting protection caus ing power loss at the connector Simultaneous inrush lo...

Page 57: ... AMR s accurate dimensions are used during path planning and obstacle avoidance Side lasers are useful if the overhang might cause the AMR to encounter obstacles that are not visible to the safety scanning lasers or the low lasers Do Not Block AMR Lasers WARNING PERSONAL INJURY OR PROPERTY DAMAGE RISK The entire payload and anything it carries must be kept higher than the top of the platform If th...

Page 58: ...Stop buttons shall be placed within 600 mm of reach The operator should be able to easily reach an E Stop button from any approach angle without the need to reach across the moving AMR or any moving payload parts The payload structure shall not be positioned in such a way that would put the operator in danger while trying to reach an E Stop button Do Not Block Light Discs Front and Back Light Stri...

Page 59: ... 660 00 650 00 0 187 50 300 00 187 50 300 00 394 00 394 00 Figure 2 27 Chassis Payload Mount Locations 20 M12 X 1 75 Threaded Holes and 4 M16 X 2 0 Threaded Holes units are in mm AMR Coordinate System OMRON AMRs use the X Y Z and Theta θ coordinate system displayed in Figure 2 28 This information is relevant for some of the procedures used in this manual such as identifying which are the left or r...

Page 60: ...of rotation which determines its head ing or direction of travel The origin of the vertical coordinate Z is set at ground level Z 0 The value of Z is required when you calculate the mount position of options such as side lasers You then specify the position of the option in MobilePlanner Y Z X D A B C Figure 2 28 AMR Coordinate System Callout AMR Reference Theta θ Rotation X Y Coordinate A Left si...

Page 61: ... an E Stop occurs and the power is discontinued to any user supplied equipment This will not prevent an improp erly loaded AMR from tipping over Safe Payload Placement The following figures show the calculated safe CG placements for HD 1500 s maximum allowed payload weight 1500 kg The payload structure s CG must be within the area shown Assumptions in these calculations are l The payload is secure...

Page 62: ...62 Mobile Robot HD Safety Manual 31500 100 RevA 2 18 Payload Structure A Figure 2 29 3D View of Recommended Payload CG A HD 1500 A Figure 2 30 Top View of Recommended Payload CG A HD 1500 ...

Page 63: ...w of Recommended Payload CG A HD 1500 A Figure 2 32 Side View of Recommended Payload CG A HD 1500 2 19 Additional Safety Information Contact your OMRON representative for other sources of safety information 31500 100 RevA Mobile Robot HD Safety Manual 63 ...

Page 64: ...HD 1500 and provides detailed information about safe operation of your HD 1500 It also provides resources for information about relevant standards 2 21 Disposal Dispose of in accordance with applicable regulations Customers can contribute to resource conservation and protecting the environment by the proper disposal of WEEE Waste Electronics and Electrical Equipment All electrical and elec tronic ...

Page 65: ...t Emergency Stop Manual Reset d 3 5 67E 07 SF1 Enabling Device on Pendant Protective Stop Automatic Reset d 3 5 67E 07 SF2 E Stop Button on Operator Panel Emergency Stop Manual Reset d 3 5 67E 07 SF3 E Stop Connection on User Panel Emergency Stop Manual Reset TBD by the user 3 5 79E 08 SF4 E Stop Buttons on Side of AMR Emergency Stop Manual Reset d 3 5 67E 07 SF5 Safety Laser Scanner Detection Pro...

Page 66: ... pendant enabling device is held in the center enable position SF1 has functional safety rating of Pld Cat egory 3 2 AMR SF2 E Stop Button on Operator Panel Pressing the E Stop button on the Operator Panel results in an emergency stop controlled stop 1 In this case the power to the AMR motors remains on in order to achieve a con trolled stop Once the controlled stop is achieved the power to the mo...

Page 67: ...rigger a protective stop category 1 stop Since this is also a controlled stop the power to the AMR motors remains on in order to achieve a con trolled stop In such cases the AMR safely stops and then resumes operation after a delay of two seconds and after confirming that its protected zone is clear of obstacles SF5 has functional safety rating of Pld Cat egory 3 2 AMR SF6 Safe Motion Detec tion T...

Page 68: ... functional safety rating of Plb Cat egory B AMR SF9 Warnings SF9 is for the visual warning system and has functional safety rating of Plb Category B AMR SF10 Automatic Battery Charging SF10 is used to ensure that the AMR is prop erly connected to docking target before the charging contacts are activated SF10 has functional safety rating of Plb Cat egory 1 AMR 1 Stop Categories according to IEC 60...

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Page 70: ...SAFETY TECHNOLOGIES INC 4225 Hacienda Drive Pleasanton CA 94588 U S A Tel 1 925 245 3400 Fax 1 925 960 0590 Regional Headquarters OMRON EUROPE B V Wegalaan 67 69 2132 JD Hoofddorp The Netherlands Tel 31 2356 81 300 Fax 31 2356 81 388 Contact www ia omron com Kyoto JAPAN OMRON ASIA PACIFIC PTE LTD No 438A Alexandra Road 05 05 08 Lobby 2 Alexandra Technopark Singapore 119967 Tel 65 6835 3011 Fax 65 ...

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