ROBOT- Manufacture, Assembly, Test & Operation

7/30/2019 ROBOT- Manufacture, Assembly, Test & Operation

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During FIRST Robotics

Manufacture, Assembly, Test & Operation

Greg Kirksey, OSHA General Industry Outreach Trainer

Scot Marshall, Lockheed Martin Space Systems, Team 1913

SafetyFIRST


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Overview

SignagePrevention

Training

Personal Protective Equipment (PPE)

Anatomy of Accidents

Hazard Analysis

Safeguards

Team SafetyTransportation

Abuse


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Examples of Safety Signs
http://images.google.com/imgres?imgurl=http://www.seattlesigns.com/images/cautionweareyepro.gif&imgrefurl=http://www.seattlesigns.com/oshacaution.html&h=226&w=298&sz=4&tbnid=0OUK9YC1lJMJ:&tbnh=84&tbnw=111&hl=en&start=17&prev=/images%3Fq%3Dcaution%2Bsigns%26svnum%3D10%26hl%3Den%26lr%3D%26rls%3DGGLD,GGLD:2004-42,GGLD:en%26sa%3DN


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Comply with final inspection requirements assoon as possible to prevent accidents

Arena Safety/OperationEssential personnel only

Stay behind barriersEnter when authorized

Energize when approved

Pit Safety Not just at competitionEye and foot protection at a minimum

Assume you are at risk

Scan for hazards

Chemical SafetyMaterial Safety Data Sheets (MSDS)

General Safety


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System components must be designed, installed, and secured so

that the hazards associated with stored energy are minimized.

Adequate room must be provided for a robot's movement as well as

for workers. There must be a means for controlling the release ofstored energy in all the robotic systems and for shutting off power

from outside the restricted envelope.

A detailed risk assessment should be performed to ensure the safetyof workers who operate, service and maintain the robotics system.

Prevention Overview


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Control & Prevention

Eliminate EXPOSURE to the hazard if at all possible

If there is NO EXPOSURE there is NO RISK of injury

Minimize the hazard if it cant be eliminated

Restrict Access to necessary personnel

Train/Educate those at riskPersonnel who program, operate, maintain, or repair robots orrobot systems should receive adequate safety training and be

able to demonstrate competency in performing their jobs safely.

Protect against the damage or injury

Personnel Protective Equipment (PPE)

Barriers and Safeguards


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When the tool is OFF is it Safe?

Not necessarily

Stored Energy

Potential Energy

Sharp points and edges

How do you know if it is Safe?

Only if you know all the tools systems and hazards

Learn what components can store energy

Learn how energy can be released

Learn the hazards associated with each tool

LEARN HOW TO OPERATE EACH TOOL

BEFORE YOU USE IT

Hazards when Powered OFF


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Safety training is necessary for new operators,

new or altered safeguards, or new machines oroperation

Provide instruction or hands-on training in thefollowing:

Describe and identify the hazards associated with eachmachine

The safeguards themselves, how they provide protection,and the hazards for which they are intended

How to use the safeguards and why

How and under what circumstances safeguards can beremoved, and by whom (Remove an repair by qualifiedtechnician when safeguards are damaged, return to svc.)

What to do and what action to take if a safety incident occurs

Training


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HandGloves

FaceFace Shield

EyeGlasses, Goggles

EarEar Plugs, Ear Muffs

LungMask, RespiratorHead

Hard Hat

Typical Personal Protective Equipment (PPE)


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No Loose Clothing

Unnecessary risk around moving or rotating

machinery

Tripping HazardCan catch on nearby equipment

Lift properly to avoid injury

Head Up, Straight Back, Bend at Hips

Load close to body and directly in front

Lift with Legs, shift feet to turn, elbows in

Not Just PPE


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Conduct a walk-through to identify sourcesof hazards to workers and co-workers fromthe basic hazard categories:

ImpactPenetration

Compression (roll-over)

Chemical

HeatHarmful dust

Light (optical) radiation

Before PPE SelectionSurvey the Site


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MotionMachinery or processes where movement of tools, machineelements or particles could exist, or collision with stationary objects

High Temperatures / Chemical Exposures

Harmful Dust

Light RadiationWelding, brazing, cutting, furnaces, heat treating, high intensitylights, etc.

Falling objects or potential for dropping objects

Sharp objects

Rolling or pinching objects which could crush the feet

Layout of workplace and location of co-workersElectrical hazards

Review injury/accident data to help identify problemareas

PPE SelectionHazard Sources


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Anatomy of Robotic Accidents

Lower Incidence During:

Demonstrated Autonomous ModeOperator Control with an Experienced Operator

Higher Incidence During:

Operator Orientation, Training, and ExperimentationProgramming & Program Touchup

New Operations

Maintenance

Adjustment

TestingRepair

Setup

Thats What Youll Be Doing Most!


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Human Errors

New/One-time operations (e.g. crating/uncrating)Prior to programming

Interfacing activated peripheral equipment

Connecting live devices or sensors to themicroprocessor or a peripheral

The greatest problem, however, is overfamiliarity withthe robot or toolso that an individual places himself ina hazardous position.

Control ErrorsFaults within the control system of the robot

Errors in softwareinterference - Electromagnetic or Radio frequency

Unauthorized AccessEntry into a robot's safeguarded area is hazardousbecause the person involved may not be familiar withthe safeguards in place or their activation status.

Sources of Hazards


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Transportation

Rough/uneven floorWheels that are too small for surface

Visibility over and around the robot

Robot that doesnt fit dolly

In a hurry to cue

Grade

Cueing/StagingUnaware of blocking the way for another team

Field behind schedule

Roboteers at restOut-of-Pit Repairs

Improper tool or support

Inadequate time for attempted repair

Sources of Hazards


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Mechanical FailuresOperating programs may not account for cumulativemechanical part failure, and faulty or unexpectedoperation may occur.

Environmental Sources

Electromagnetic or radio-frequency interference(transient signals)

Power SystemsPneumatic or electrical power sources

Electrical shock and release of stored energy from

accumulating devicesImproper Installation

The design and layout of equipment, and facilities, ifinadequately done, can lead to inherent hazards.

Sources of Hazards

Transportation


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Contact

Movement, component malfunction, or program

changes

Crushing, Trapping, Piercing

FailureComponents

Drive System

End Effectors

Peripheral Equipment

Trips, Slips, Falls

Restricted Space

Types of Accidents


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Risk of Injury or Damage

The WORKING ENVELOPE of the machine:

More than just the robot Any machine or toolMaximum, Restricted, Working

Exists when there is energy to be released

Changes DIMENSION when the robot MOVES

The risk exists to the edge the ENVELOPE


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Mechanical Energy StorageCompressed SpringGear

Stalled Motor

Chain Tension

Momentum

Electrical Energy StorageBattery, Capacitor

Pneumatic Energy StorageCharged Air Cylinders

Compressed Air in Lines

Potential EnergyStorageExtended Appendages

Bound Joints

Lifted Weights

Energy Storage and Release


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Release stored energy before power-down

Return it to its home position

Power the equipment OFF

Eliminate the Hazard


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Prevent Contact

The safeguard must prevent hands, arms, and any other partof a worker's body from making contact with moving parts.

SecureWorkers should not be able to easily remove or tamper withthe safeguard

Protect from falling objectsThe safeguard should ensure that no objects can fall intomoving parts.

Create no new hazardsA safeguard defeats its own purpose if it creates a hazard ofits own.

Create no interferenceAny safeguard which impedes a worker from performing thejob quickly and comfortably might soon be overridden ordisregarded.

Allow safe maintenance if possible.

Safeguard Requirements


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RISK ASSESSMENT.At each stage of development of the robot

and robot system a risk assessment should be performed.

SAFEGUARDING DEVICES. Personnel should be safeguardedfrom hazards associated with the restricted envelope (space)through the use of one or more safeguarding devices:

Mechanical limiting devicesNonmechanical limiting devices

Presence-sensing safeguarding devices

Fixed barriers (which prevent contact with moving parts)

Interlocked barrier guards

AWARENESS DEVICESChain or rope barriers

Supporting stanchions or flashing lights

Signs, whistles, and horns

Safeguards


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Point of operation:That point where work is performed on the material, such ascutting, shaping, boring, or forming of stock.

Power transmission apparatus:

All components of the mechanical system which transmitenergy to the part of the machine performing the work. Thesecomponents include flywheels, pulleys, belts, connectingrods, couplings, cams, spindles, chains, cranks, and gears.

Other moving parts:

All parts of the machine which move while the machine isworking. These can include reciprocating, rotating, andtransverse moving parts, as well as feed mechanisms andauxiliary parts of the machine.

Moving Part Safeguarding


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Safety Captain

Independent monitor of operations during concept, manufacturingprocess, shipping / receiving, field trip, and competition

Uninvolved in the proceedings while observing

Answers only to Coach & Mentors

Identifies safety hazards and prevents safety incidents

SpottersUsed during every movement of a tool or equipmentEliminate hazards for the transportation team

Ensures clearances, accessibility, coordination

Disciplinarian Consequences of Safety InfractionsVerbal

DocumentationCumulative documentation

Disciplinary action up to and including: Being relieved of you job on the team

Exclusion from travel to the regional

Dismissal from the team

Team Safety


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Personnel in working area without Safety Briefing

Visitors

Nonessential Personnel

Authorized and qualified personnel on break

Equipment Location

Equipment Configuration

Improper fixturing of parts

Misplaced Tools

Damaged Tools

Hazardous Situations

Eye, Ear, Face, Hand, Body, Foot, Trip,

Team SafetyOperations Checklist


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Abuse and harassment may be emotional, physical, or sexual.

FIRST now has eligibility procedures for volunteer selection,training and supervision for FIRST Robotics Competition(FRC) regional events and all components of the FIRSTChampionship similar to those being used by many otheryouth-serving organizations.

Staff and volunteers at FIRST events are easilydistinguishable.

Participants are expected to be in pairs or larger groups at alltimes going to, coming from, and during FIRST events.

Volunteers and participants should avoid isolated situationswhere incidents or allegations are more likely to occur.

Report any suspicions of harassment or abuse immediately.FIRST will follow up on all reports, and will take appropriateaction.

Abuse


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Transportation-related risks for drivers, vehicles,and passengers:Drivers of vehicles should be properly licensed,insured, be adequately trained to drive the kind ofvehicle used.

Drive prudently and not be under the influence ofalcohol or drugs.

Vehicles should be in good condition, and haverequired safety equipment, insurance, andinspections, and not be overloaded.

Passengers should act safely, refrain fromdistracting the driver, and take proper safetyprecautions (i.e., use seat belts in vehicles soequipped).

Safety During Transportation


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FIRST asks everyone involved in FIRSTs programs toplace the highest priority on safety, looking out not onlyfor ones own safety but also the safety of others. Donot hesitate to speak up or act in the interest of safety.FIRST particularly wants to highlight safety measures

in the areas of transportation, equipment and worksafety, and guarding against abuse.

http://www.osha.gov/SLTC/robotics/solutions.html


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Safety Captains Job

My job is to make sure every teammate

goes home from the FIRST Robotics work

in the same condition as when they came

to it!


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Back-up Charts


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All students wishing to be a part of FIRST ROBOTICS competition must

avoid receiving 10 or more checks on the following check listStudents that collect 10 checks or more will not be able to go to theRegional and will lose all possible recognition for participation.

Checks 1 thru 9 can result in lost of participation at the Regional and orChampionship. In some cases, careless action while on school grounds andfield trip activities may invoke school administrative discipline.

First offense - Verbal warning with check box on check list circled Two (2) or more circled check points will be considered a check for each.

Second offense - Check made in check boxThird offense Additional checks, invoke appeal process, consequences

Students are either returned to team assignment, reassigned, placed onsuspension, or dismissed from the team.

Academic Probation, failing a class, school suspension or expulsion areconsidered severe and may result in immediate expulsion from FIRSTROBOTICS

Court of Appeals: Teacher / Mentors. Students will have a right to explaintheir complaints or differences.

Team SafetyDiscipline Consequences


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Horseplay during construction, manufacturing, shipping, fieldtrip, competition

Disregard for posted signs and set safety rules in place

Lack of Gracious Professionalism or respect among fellowstudents and mentors

Operating tools or equipment unsafely

Careless handling or a hazard to self or others Abuse or playing with equipment or tools

Irresponsible to team duties or no participation in work activity

Disrespect of rules set forth by Team Captain, Safety Captain,Mentors, or Coaches

Theft of school, robot, or team members property Absent, late, or unexcused early departure from Robotics

program activity

Failing a class, academic probation, suspension or expulsion

Team SafetyDiscipline Checklist


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1. Have Students create their own version of Robotic Safety

2. Use the following slide to get students involved with making

safety signage

3. Discuss what causes accidents between man and machines

4. With Coaches, Mentors and Team members.

Training Project

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ROBOT- Manufacture, Assembly, Test & Operation

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