📋 Case Study

Automated Assembly Line Robot Cell Risk Assessment

New collaborative robot (cobot) integration without physical guarding

🏗️ Project Overview

Tier-1 automotive supplier, Ohio plant upgrade

🎯 Challenge

New collaborative robot (cobot) integration without physical guarding

🔧 Design Approach

ISO/TS 15066-compliant speed-and-separation monitoring with validated safety distance calculations

📐 Design Diagram

AI-generated project design illustration

📐 Key Calculations

Minimum Safety Distance (S)

S = (K × T) + C

Result: 725 mm

Ensures operator stops before contact

Performance Level (PL) Verification

PL = PLr per ISO 13849-1

Result: PLd

Validates reliability of safety circuit

📊 Results

Zero incidents over 18 months; achieved PLd compliance; reduced cycle time by 12%

💡 Lessons Learned

• •Safety validation must precede production commissioning
• •Human-robot interaction zones require dynamic re-evaluation

✅ Key Takeaways

• 1Safety validation must precede production commissioning
• 2Human-robot interaction zones require dynamic re-evaluation