What are the safety standards for collaborative robots?

Collaborative robots, or cobots, have transformed how manufacturing and logistics businesses automate tasks.¹ These robots are designed to work alongside humans safely, guided by strict safety standards.² But how do these standards translate to real-world applications? Many assume that simply following these certifications is enough, but ensuring safety often demands more. Let’s explore what these standards cover, where they fall short, and how customized measures can create safer workplaces.

Collaborative robot safety standards establish a baseline for safe human-robot interaction, focusing on aspects like force limits, emergency stop features, and collision detection. However, to fully realize safety in dynamic environments, businesses must consider additional customizations, such as laser sensors and adaptive programming tailored to their specific needs.

When I’ve worked with manufacturing clients, many have misunderstood the scope of safety standards, assuming these alone suffice for all environments. But as dynamic workspaces demand flexibility, customization often becomes a critical requirement. Here’s how you can rethink safety standards for your application.

What are the key safety standards for collaborative robots?

Collaborative robot safety standards aim to minimize the risk of injury during human-robot interaction.

Key standards relevant to cobot safety include:

• ISO 10218-1 and ISO 10218-2³: These cover the design, setup, and operation requirements for industrial robots and systems.
• ISO/TS 15066⁴: This technical specification complements ISO 10218 by addressing human-robot collaboration specifically, including force and pressure limits for safe usage.

While these standards ensure that robots meet safety thresholds, they aren't one-size-fits-all solutions. In high-traffic or complex environments, they often serve as a starting point, requiring additional safety configurations tailored to your site.

Diving deeper into safety standards

ISO 10218 focuses on broad scenarios of robot installation and usage, providing principles like proper guarding and emergency stop procedures. ISO/TS 15066 goes further by examining human pain thresholds and providing guidelines on building cobots that limit force in the event of a collision.

However, what these standards don't account for is the variability in real-world applications. For example, in fast-paced logistics centers, operators may need cobots that temporarily stop or slow down when humans enter their zone⁵. Basic compliance won't always account for these dynamic behaviors.

In one project, I assisted a client in a constrained factory layout where workers frequently moved around cobots. Simply relying on certified safety features wasn’t enough. We had to integrate a pause-on-detection laser sensor system⁶, which would temporarily immobilize the cobot in small, tight areas. This customization went beyond the standards to ensure complete safety.

Why aren't safety standards enough for dynamic environments?

Even when cobots meet international safety certifications, complexities of specific workflows often expose gaps in readiness.

Many buyers mistakenly believe a certified cobot is inherently safe, regardless of its surroundings. However, cobots in static environments — like clean assembly lines — face fewer risks than those placed in dynamic settings like warehouses with forklifts, conveyor belts, or pedestrian workers.

Dynamic environments often require additional safety measures to account for constantly shifting risks. Beyond compliance, businesses must assess conditions like crowd density, lighting, and speed of operations to customize safety features.

Balancing functionality with safety

Consider a logistics scenario where cobots handle parcel stacking. The cobots may meet initial safety certifications, but risks arise when forklifts share the space⁷ or when goods are piled unexpectedly high. Preemptive measures like sensors that detect obstructions, auditory alarms, and configurable safe zones ensure that these unpredictable events don’t result in injury or downtime.

Such adaptations do come with added costs. However, these investments lead to safer, more reliable operations. I’ve seen companies improve their accident rates and productivity⁸ simply by upgrading safety mechanisms when their cobots were installed in high-traffic, unpredictable spaces.

What custom safety features should you consider?

Custom safety features enable cobots to function seamlessly in unique or challenging environments.

Some commonly implemented enhancements include:

• Laser sensors and photoelectric barriers: Alert the system when humans enter a robot’s working zone, pausing motion or diverting operations.
• Speed and force adjustments: Allow the cobot to operate at reduced intensity near people while maintaining speed when no humans are present.
• Safety mats and light curtains: Create virtual safety perimeters that trigger a response if breached.
• Emergency brake systems: Offer secondary stop mechanisms for super-sensitive tasks.
• Vision systems: Integrate cameras to detect gestures, ensuring cobots respond to hand signals or disengage more effectively.

These adaptive features align cobot performance with the environment while addressing risks not covered under general safety standards. They also encourage greater comfort for workers, boosting productivity through reassurance⁹.

In a recent implementation for a food-packaging facility, we combined vision systems and light curtains¹⁰ to mitigate risks from varying pallet sizes and fast-moving employees. By customizing the cobot’s safety envelope for such variables, workers could safely perform their tasks quicker and with greater confidence.

How can manufacturers and logistics companies ensure compliance and safety?

To ensure compliance and operational safety, manufacturing and logistics professionals must take a proactive, application-focused approach.

Following the prescribed standards is only half the journey. Site-specific safety assessments are key when adopting collaborative robots, especially in environments with frequent human activity and spatial constraints.

Steps to ensure safety:

1. Evaluate the environment: Start with an on-site assessment to identify potential safety risks, such as constrained spaces or dynamic workflows.
2. Match standards to your needs: Evaluate cobot certifications like ISO/TS 15066, but analyze gaps related to your specific operations.
3. Collaborate with experts: Work with your cobot supplier or integrator to design customized safety configurations.
4. Modify workflows: Train operators and adjust workflows to enhance safety while balancing efficiency.
5. Test before deployment: Conduct comprehensive pre-deployment testing using real scenarios to ensure setup safety.
6. Regular safety audits: Periodically review cobot operation and safety functionality as your workspace evolves.

By systematically layering customized safety features on top of compliance, you can build a safely automated environment without compromising operational efficiency or worker confidence.

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Frequently Asked Questions

Are all collaborative robots safe by default?

No. While collaborative robots are designed with safety in mind, real-world environments often introduce variables not fully accounted for by standard certifications. Tailored safety measures are often crucial to ensuring safe operation.

Can I install a cobot without understanding safety standards?

No, you must refer to safety standards like ISO 10218 and ISO/TS 15066 for legal compliance and to implement basic safety measures. Consulting an integrator is advised for site-specific safety assessments and customizations.

Do dynamic workspaces always need extra safety measures?

In most cases, yes. Dynamic workspaces, especially those with high employee activity or shared equipment, typically require investments in additional safety measures like sensors, barriers, or adaptive programming.

Conclusion

Collaborative robots have set a new benchmark for safe automation¹¹, but safety standards like ISO 10218 and ISO/TS 15066 are just part of the equation. Real-world applications, particularly in dynamic environments, demand tailored solutions like laser sensors, adaptive speed programming, or light curtains to ensure safe and effective integration.

When deploying cobots, the balance between safety and functionality isn’t optional — it’s essential. Collaborating with experts to design modifications ensures your operations stay productive and your workforce remains protected. Looking to integrate cobots seamlessly into your workflow? Reach out to explore customized safety solutions today.

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