Development of safety solutions for robotized manufacturing cells in automotive industry

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Dr. Kiss Bálint
Department of Control Engineering and Information Technology

The demand for modern cars is growing, and in line with this trend, to meet the necessary quality standards are becoming stricter, while the manufacturers are trying to widen the range of products as well, so more and more new models are coming out. In order to be able to keep this hectic pace, accuracy, speed, flexibility and adaptability provided by the robots are in need, so automatic production lines already use hundreds of robots. The entire production is built up around them, but there is still a need for human presence, even if it’s role limited to support the automatic system, and to handle the unexpected events. In order to preserve the benefits of such a system, like productivity, it is necessary to avoid accidents, property damage and shutdowns. These claims are so strong and generalized, that various guidelines and standards have been established to regulate the development of safety systems. The system integrator is responsible for designing manufacturing cells in a manner that is in accordance with the applicable standards, operates safely, and if an accident occurs, and the standards are not applied properly, the responsibility lies with him. My thesis is related to this area, it describes the applicable standards of safety, the safety solutions of robots, and their safety interface. The robot is working in cooperation with several other devices, so the safety control of the complete system requires additional safety components. To selecting these components I performed a risk analysis. Based on its result , I made a complete list of the required safety devices, and I planned the electronic connections between the devices and the safety controller, with Eplan Electric P8. I planned the emergency stop functions of the system considering to the applicable standards, and the result of risk analysis, and I configured the robots. At this point the manufacturing robot cell’s safety system is almost ready, the only task remaining is to program the safety controller.


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