PrazamanaLoading
The H-GLASS Robotic Cell 3 had four open pallet access points, no external safety boundary, and no Safety PLC integration — leaving personnel exposed to the robot, pallet, and roller conveyor from any side of the cell. Here's what we found — and the solution we engineered.
The cell pairs a robot handling pick-and-place operations with pallet in/out movement across four access points — 1A, 1B, 2A, and 2B — and a roller conveyor system. A pre-project hazard review walked the cell end to end and found fifteen distinct ways a person could be exposed to hazardous motion, from open access on any of the four sides to a complete absence of Safety PLC integration. Every modification below was implemented specifically against one or more of these findings.
Hazards Identified15
Safety Systems Integrated5
A pre-project hazard review of the cell found 15 distinct ways personnel could be exposed to hazardous motion.
In short, the cell exposed personnel to
Uncontrolled Robot & Roller Movement
Unexpected or continued movement of the robot arm, gripper, and roller conveyor could strike, trap, or crush personnel working in or near the cell.
Open Access From Four Sides
The 1A, 1B, 2A, and 2B pallet access points weren't safety-controlled, letting personnel — or a person riding the pallet itself — enter the hazardous area from any side.
Incomplete Safety Control
With no presence detection, interlocking, or accessible Emergency Stop, a hazardous condition could go undetected and a safe stop couldn't be guaranteed.
All 15 hazards, in detail
The robot arm moves at high speed during pick and place operations. Unexpected or uncontrolled movement can cause serious impact, collision or crushing injuries.
The robotic cell had four access points: 1A, 1B, 2A and 2B. Personnel could potentially enter the hazardous robot operating area during machine operation.
During pallet loading and unloading, personnel could enter between the roller conveyor sections. This could result in trapping, crushing or serious injury.
A person could sit or stand on the pallet and enter the robotic cell along with the pallet. This could expose the person directly to the moving robot.
A person inside the cell could be struck by the robot arm, gripper or other moving mechanisms. This could result in severe impact, crushing or fatal injury.
Moving rollers and conveyor mechanisms could create trapping, crushing and pinch-point hazards. Hands, feet or other body parts could become caught between moving components.
The 1A, 1B, 2A and 2B access points were not adequately safety-controlled. Personnel could approach or enter the hazardous zone from any of these sides.
Emergency Stop devices were not adequately provided at the required access locations. In an emergency, stopping the robot and conveyor could therefore be delayed.
The access points were not fully interlocked with the robot safety circuit. The robot could potentially continue operation while an access point was open.
Adequate personnel presence detection was not available inside the hazardous area. A person could remain inside the cell without being detected before robot operation.
The robot or conveyor could start unexpectedly after reset, power restoration or a control command. This could result in sudden movement and serious injury.
Pinch and crushing points existed around the robot, gripper, pallet, rollers, fixtures and mechanical components. Personnel could suffer hand, leg or body injuries.
The robot could continue its automatic pick and place cycle while a person was inside the hazardous area. This created a significant risk of collision, trapping or crushing.
Manual intervention, troubleshooting or maintenance inside the cell could expose personnel to unexpected machine movement. Safe isolation and controlled access were not adequately integrated.
The cell did not have complete safety integration covering guarding, access control, E-Stops, interlocking and personnel protection. This resulted in a high risk of serious or fatal accidents.
Overall, the H-GLASS Robotic Cell 3 hazards were addressed by integrating external light curtains and mirrors around all four pallet access sides, pallet/roller safety interlocking, a Safety PLC with full signal feedback and machine communication, Emergency Stop and door monitoring, and reset and restart-prevention logic — separating personnel from the robot, pallet, and roller operating area on every side of the cell.
Tell us about your cell or line and we'll walk it the same way — hazard by hazard.
