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Omron HD Safety Manual

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Mobile Robot
HD
Safety Manual
I647-E-01

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  • Page 1 Mobile Robot Safety Manual I647-E-01...
  • Page 2 Copyright Notice The information contained herein is the property of OMRON, and shall not be reproduced in whole or in part without prior written approval of OMRON. The information herein is subject to change without notice and should not be construed as a commitment by OMRON. The documentation is periodically reviewed and revised.
  • Page 3 LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED IN CONTRACT, WARRANTY, NEGLIGENCE OR STRICT LIABILITY. Further, in no event shall liability of Omron Companies exceed the individual price of the Product on which liability is asserted.
  • Page 4 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.

  • Page 5: Table Of Contents

    2.6 Risk Assessment Exposure Severity of Injury Obstacle Avoidance Safety System Behavior 2.7 Environment General Environmental Conditions Public Access Operating Clearances Obstacles 2.8 Intended and Non-intended Use Intended Use Non-Intended Use HD-1500 Platform Modifications 31500-100 RevA Mobile Robot HD Safety Manual...
  • Page 6 2.17 Charging Station Safety Precautions 2.18 Payload Structure Safety Considerations 2.19 Additional Safety Information Mobile Robot HD Safety Manual (Cat. No. I647) 2.20 Additional Safety Information Mobile Robot HD Safety Manual (Cat. No. I647) 2.21 Disposal Chapter 3: Safety Function Description PL and PFH Mobile Robot HD Safety Manual...

  • Page 7: Chapter 1: Alerts And Special Information

    Hot surface. lowing the signal word. This identifies a haz- This identifies a haz- ardous electrical situ- ardous ESD situation. ation. This warning icon warns This identifies a fire risk. against riding on the AMR. 31500-100 RevA Mobile Robot HD Safety Manual...

  • Page 8: Falling Hazards

    You can also use the configuration parameters FrontPaddingAtSlowSpeed and FrontPad- dingAtFastSpeed to increase the AMR's safety clearances. This causes the AMR to decelerate as it approaches a hazard. See: Fleet Operations Workspace Core User's Manual (Cat. No. I635). Mobile Robot HD Safety Manual 31500-100 RevA...

  • Page 9: Special Information

    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...

  • Page 11: Chapter 2: Operational Safety

    Payload Structure: Any passive or dynamic device attached to and possibly powered by the HD-1500. This could be as simple as a crate for carrying objects such as factory parts or as sophisticated as a robotic arm that picks up and manipulates factory parts.
  • Page 12 Do not use unauthorized parts to repair the AMR. Do not power on the AMR without its wireless antennas in place. Although the lasers used are Class 1 (eye-safe), OMRON recommends that you not look into the laser light. Reflective surfaces can interfere with the AMR's laser operation.

  • Page 13: Unprotected Areas

    The safety interlock switches shall not be defeated or bypassed as this could potentially result in short circuit. The HD-1500 shall only be powered by an HD-1500 battery. Do not use any other bat- teries. The HD-1500 battery shall only be charged by an HD-1500 charger. Do not use any other chargers.
  • Page 14 CAUTION: PERSONAL INJURY OR PROPERTY DAMAGE RISK It is the end user's responsibility to ensure that the area within the radius of 2 m from the center of the HD-1500 is kept clear, when the AMR is traveling at less than 115 mm/s. Mobile Robot HD Safety Manual...
  • Page 15 Chapter 2: Operational Safety Figure 2-2. HD-1500 Protective Zones with Openings for the Charging Paddle - Movement at Less Than 115 mm/s (Dimensions are in mm) Description Description AMR Y-axis Front laser zone AMR X-axis HD-1500 Rear laser zone Safety scanning laser The following figure provides dimensions of the HD-1500 unprotected area.

  • Page 16: What To Do In An Emergency

    CO 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 on a yel- low background).

  • Page 17: Releasing The Brakes

    In case of an emergency or abnormal situation, the AMR can be manually moved. However, only qualified personnel who have read and understood this manual and the HD-1500 Plat- form User's Manual (Cat. No. I645) should manually move the platform. The brakes on the drive wheels can be released with the brake release button.
  • Page 18 Using the brake release button while the HD-1500 is positioned on a slope of greater than 3% will cause the HD-1500 to roll down. You must not use the brake release button to move the HD-1500 manually, when positioned on a slope of greater than 3%, unless necessary precautions have been taken to pre- vent uncontrolled rolling of the HD-1500.

  • Page 19: Releasing An E-Stop

    Chapter 2: Operational Safety OMRON recommends that you train personnel on the safe use of the brake release button, and procedures for safely pushing an HD-1500. CAUTION: PERSONAL INJURY RISK The pushing locations of the AMR are low. You must use safe pushing/ pulling practices when manually moving the AMR.

  • Page 20: User's Responsibilities

    Safe use of the AMR requires that you: Read the installation and operation instructions, in addition to the HD-1500 Platform User's Manual (Cat. No. I645), before using the AMR. Review, and understand the safety protections (E-Stops, safety laser stopping distances, overhanging load, etc.) associated with your specific application and environment.

  • Page 21: Electrical Hazards

    Never access the interior of the platform with the charger attached. Avoid shorting the battery terminals or connectors. Do not use any charger or battery not supplied by OMRON. The charger shall only be used to charge an HD-1500 battery.

  • Page 22: Burn Hazard

    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: Skilled persons have technical knowledge or sufficient experience to enable them to avoid either electrical or mechanical dangers.

  • Page 23: Payload Movement And Transfer

    AMR will be operating. The warning buzzer is configured with MobilePlanner. The buzzer must be audible above the ambient noise of the environment that the HD-1500 operates in. In environments with higher levels of noise, you may need to supply and install an additional warning buzzer to an appropriate location on the payload structure.

  • Page 24: Speakers

    Speakers The HD-1500 is equipped with two speakers, located at 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.

  • Page 25: Fleet Management

    When two similar AMRs approach each other their scanning lasers will detect the inner surface of that channel and not the outer perimeter of the other AMR. Operating an HD-1500 with any of its skins detached will worsen this effect. Typically this will not present a problem, however, in close proximity each AMR will plan its motion more accurately with information from the Fleet Manager about the position of the other AMR.

  • Page 26: Other Hazards

    The severity of injury depends on the type of payload and how the payload is integrated with the HD-1500. The severity of injury increases with the mass of the payload. Follow all indus- trial safety practices, such as use of steel-toe shoes around the AMR, and adding additional protection like side lasers, etc.

  • Page 27: Safety System Behavior

    Provide physical barriers that the HD-1500 can detect accurately with its scanning laser so that it does not attempt to drive near the hazard. Be aware that in addition to being easily detectable, a barrier must be strong enough to resist a fully-loaded HD-1500 trav- eling at its maximum speed.

  • Page 28: Public Access

    The HD-1500 travels in forward and backward directions. To change its direction, the HD- 1500 rotates on its center of rotation (turns in place). The HD-1500 has a full safety coverage of 360°, and therefore, obstacles will trigger a safety system event when the AMR rotates.
  • Page 29 Figure 2-8. Goal Position - 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...

  • Page 30: Obstacles

    2.7  Environment Figure 2-10. HD-1500 Docked with the Docking Target, (A) 500 mm, and (B) Floor Marking Obstacles Before an AMR enters a high-traffic area, you must take appropriate precautions to alert people working in those areas: The HD-1500 provides programmable warning features such as a warning buzzer, speech synthesis, and warning indicator lights.

  • Page 31: Intended And Non-Intended Use

    AMR. See: Center of Gravity (CG) on page 60. OMRON does not provide the method of loading the payload onto or off the HD-1500. It is the end user's responsibility to perform a complete task-based risk assessment in accordance with EN ISO 12100, and ensure safe transfer of the payload.
  • Page 32 Towing applications. Personnel riding vehicle. IMPORTANT: The HD-1500 is not intended to be used with a battery that is not supplied by OMRON. Additionally, it is not intended to be charged by any charger other than the OMRON charging station.

  • Page 33: Hd-1500 Platform Modifications

    HD-1500 footprint, you must contact your OMRON representative for assist- ance with modifying the safety zones. The final design of the HD-1500 meets all relevant local and national safety standards, and requirements for the new intended use. There is no reduction in functionality.

  • Page 34: Electrical Hazards

    There is high voltage inside, and the covers are not interlocked. 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. Electrical Hazard Precautions There are no user-serviceable parts inside of the battery.

  • Page 35: Esd Hazards

    ESD Hazards CAUTION: PROPERTY DAMAGE RISK The electrical charge accumulated on the HD-1500's skins does not have a path to ground, and therefore can not discharge. This can be hazardous to elec- trostatic sensitive devices. Users must keep the electrostatic sensitive devices at least 30 cm away from the AMR skins.
  • Page 36 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 of the Module to be Probed Mobile Robot HD Safety Manual 31500-100 RevA...
  • Page 37 1. Turn the power off. You can do this by switching the main disconnect switch, located on the electrician access box, to OFF position. Figure 2-14. Main Disconnect Switch on the Electrician Access Box, (A) ON Position, and (B) OFF Position 31500-100 RevA Mobile Robot HD Safety Manual...
  • Page 38 3. Verify that the power is off. You can do this by checking the LED indicators, located on the power supply box. When there is no power going through the power supply box, the Mobile Robot HD Safety Manual 31500-100 RevA...

  • Page 39: Safety Inspection

    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) for more information. Front and Back Lights Check the front and back lights of the AMR for proper function.

  • Page 40: Warning Labels

    The only warning labels that are shipped with the HD-1500, unattached to the platform, are the No Riding labels. All other labels are installed in the factory. For information on where to attach the No Riding labels, refer to the HD-1500 Platform User's Manual (Cat. No. I645).

  • Page 41: Protective Stops Initiated By Amr Safety Lasers

    This may cause the AMR to turn around, and move in a different direction. If no such path is available, the AMR fails the current job, and waits for the Fleet Manager to assign a new job. 31500-100 RevA Mobile Robot HD Safety Manual...

  • Page 42: Safety System Overspeed Faults

    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.
  • Page 43 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...

  • Page 44: Interlock Switches

    2.15  Interlock Switches 2.15 Interlock Switches The HD-1500 is equipped with the interlock switches located on the battery door, and the AMR side skins. The interlock switches continuously monitor and ensure that the battery door, and the side skins are properly attached to the platform. This is to ensure that the battery com- partment as well as the electronics bay enclosure are isolated, and protected from unau- thorized/unsafe access.

  • Page 45: Battery Safety

    IMPORTANT: If you remove the side skins or open the battery door while the HD-1500 is docked, and is charging its battery, the charging will stop. Once the removed skin is re-installed or the battery door properly closed, the charging will not re-engage automatically.

  • Page 46: Battery Safety Precautions

    2.16 Battery Safety battery below a usable state, which would require battery replacement. For information on the battery indicator, refer to the HD-1500 Platform User's Manual (Cat. No. I645). Battery Safety Precautions This section provides safety information and precautions when storing, transporting, and removing/installing the battery.
  • Page 47 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.

  • Page 48: Battery Maintenance

    LEDs when the state of charge is ≥ 80%). 2.17 Charging Station The HD-1500charging station consists of two main parts; the power supply box, and the dock- ing target which the AMR drives itself into. The charging station provides both manual and automated methods of recharging the AMR's battery.

  • Page 49: Safety Precautions

    1500's battery. The docking target ensures that the voltage presented is between 40 to 57 volts. It also uses a detection sensor to verify the presence of the HD-1500. The power supply box uses a 4 meter long power cord (25.4 mm diameter) to transfer power to the docking target.
  • Page 50 2. Make sure that the facility power is in off state. 3. Wire the facility power to the electrician access box as instructed in the HD-1500 Plat- form User's Manual (Cat. No. I645). You must make sure to adjust the jumpers as required for the voltage range.
  • Page 51 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...
  • Page 52 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-1500 Platform User's Manual (Cat. No. I645). Mobile Robot HD Safety Manual...

  • Page 53: Payload Structure

    2.18 Payload Structure A payload structure is any mechanical equipment that you attach to the HD-1500 for the pur- pose of performing a task. It might be as simple as shelves to receive bins of parts or as com- plex as a robot arm.

  • Page 54: Safety

    The only warning labels that are shipped with the HD-1500, unattached to the platform, are the No Riding labels. All other labels are installed in the factory. For information on where to attach the No Riding labels, refer to the HD-1500 Platform User's Manual (Cat. No. I645).

  • Page 55: Considerations

    4. Then, connect the other end of the buzzer cable to the buzzer device itself, if it isn’t con- nected already. 5. Configure the buzzer as appropriate for the environment in which the HD-1500 oper- ates. 6. Mount the buzzer on your desired location, and verify that the buzzer works properly.
  • Page 56 (ms) (user power) Payload Attachment Location The HD-1500 chassis is where you attach and secure your payload structure to the platform. The user panel allows you to make the necessary electrical connections from your payload structure to the AMR Controller.
  • Page 57 The entire payload, and anything it carries, must be kept higher than the top of the platform. If the payload blocks any of the HD-1500's sensors, it cannot func- tion correctly. This is important in the case of the side lasers.
  • Page 58 IMPORTANT: Do not exceed 10 kN per mounting point. For the location of the center of gravity, refer to the HD-1500 Platform User's Manual (Cat. No. I645). The chassis steel bars bear the main structural load of any payload. You can easily adjust and move your payload in relationship to the HD-1500's center of gravity.
  • Page 59 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 right sides of the AMR.
  • Page 60 HD-1500 Platform User's Manual (Cat. No. I645). Center of Gravity (CG) Keep your payload structure's center of gravity (CG) centered over the HD-1500's own center of gravity and as low (close to the HD-1500's top) as possible. This provides optimum stability, Mobile Robot HD Safety Manual 31500-100 RevA...
  • Page 61 See: AMR Coordinate System on page 59. Tilt Detection and Reporting The tilt detection feature monitors the angle of the HD-1500 (with respect to flat ground) dur- ing its operation. If the AMR tilts 60 degrees or more in any direction, an E-Stop occurs and the power is discontinued to any user-supplied equipment.
  • Page 62 2.18  Payload Structure Figure 2-29. 3D View of Recommended Payload CG, (A) HD-1500 Figure 2-30. Top View of Recommended Payload CG, (A) HD-1500 Mobile Robot HD Safety Manual 31500-100 RevA...

  • Page 63: Additional Safety Information

    Chapter 2: Operational Safety Figure 2-31. Front View of Recommended Payload CG, (A) HD-1500 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...

  • Page 64: Mobile Robot Hd Safety Manual (Cat. No. I647)

    For information about disposal of your old equipment, contact your OMRON representative. Do not incinerate or dispose of the HD-1500 battery. Return the end-of-life or defective batteries to a designated facility per the appropriate local regulations. Mobile Robot HD Safety Manual...

  • Page 65: Chapter 3: Safety Function Description

    PL and PFH The Performance Level (PL) calculation for safety functions of the OMRON AMRs are based on the ISO 13849 standard. PL evaluation has been performed for the HD-1500, including the supplied pendant. The PL achieved and the Probability of Dangerous Failure per Hour (PFH) are calculated using SISTEMA as per ISO 13849-1 for the following Safety Functions: Table 3-1.
  • Page 66 PFHd value (logic and output) combined with the user supplied E-Stop (input) PFHd values. If no user E-Stop is connected to the user access panel SCPU connector, then an E-Stop jumper Mobile Robot HD Safety Manual 31500-100 RevA...
  • Page 67 The AMR linear speed is limited to 1800 mm/s (both forward and backward). If the calculated speed exceeds this speed lim- its, the HD-1500 protective stop is triggered. In such cases, the AMR safely stops, and requires manual re-set.
  • Page 68 Safety Function Description controlled nector, then an E-Stop jumper must be attached to the connector. Refer to HD-1500 Platform User's Manual (Cat. No. I645) for spe- cific information. The final SF7 functional safety rating is to be calculated using the given PFHd value (logic and output) combined with the user supplied protective device (input) PFHd values.
  • Page 70 OMRON ROBOTICS AND SAFETY TECHNOLOGIES, INC. No. 438A Alexandra Road # 05-05/08 (Lobby 2), 4225 Hacienda Drive, Pleasanton, CA 94588 U.S.A © OMRON Corporation 2020 All Rights Reserved. Alexandra Technopark, Tel: (1) 925-245-3400/Fax: (1) 925-960-0590 In the interest of product improvement, specifications are Singapore 119967 subject to change without notice.

This manual is also suitable for:

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