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Page 1: Robotic Arc Welding Safety - American Welding Society · Arc Welding Robot System Manufacturing Requirements.. ... Weld Fixture Requirements ... Specification for Robotic Arc Welding

Specification forRobotic ArcWelding Safety

AWS D16.1M/D16.1:2004An American National Standard

Page 2: Robotic Arc Welding Safety - American Welding Society · Arc Welding Robot System Manufacturing Requirements.. ... Weld Fixture Requirements ... Specification for Robotic Arc Welding

550 N.W. LeJeune Road, Miami, Florida 33126

AWS D16.1M/D16.1:2004An American National Standard

Approved byAmerican National Standards Institute

February 3, 2004

Specification for

Robotic Arc Welding Safety

Prepared byAWS D16 Committee on Robotic and Automatic Welding

Under the Direction ofAWS Technical Activities Committee

Approved byAWS Board of Directors

AbstractThis standard establishes safety requirements with respect to the design, manufacture, maintenance, and operation of arcwelding robot systems and ancillary equipment. It also helps to identify and minimize hazards involved in maintaining,operating, integrating, and setting up of arc welding robot systems.

Key Words—Robot, robotic arc welding, robot welding systems, robotic welding operator, qualified robot technician, safety, risk assessment

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Table of Contents

Page No.

Personnel .................................................................................................................................................................... iiiForeword ......................................................................................................................................................................vList of Figures..............................................................................................................................................................ix

1. Scope .....................................................................................................................................................................11.1 Scope and Objectives...................................................................................................................................11.2 Applications.................................................................................................................................................11.3 Exclusions....................................................................................................................................................11.4 Responsibilities............................................................................................................................................1

2. Normative References ...........................................................................................................................................2

3. Definitions.............................................................................................................................................................3

4. Arc Welding Robot System Manufacturing Requirements...................................................................................54.1 Hazards to Personnel ...................................................................................................................................54.2 Actuating Controls.......................................................................................................................................64.3 Pendant and Other Teaching Controls.........................................................................................................64.4 Attended Weld Program Verification..........................................................................................................64.5 Slow Speed Control .....................................................................................................................................64.6 Singularity Protection ..................................................................................................................................64.7 Axis Limiting Devices.................................................................................................................................74.8 Provisions for Lifting...................................................................................................................................74.9 Electrical Connectors...................................................................................................................................74.10 Pinch Points .................................................................................................................................................74.11 Electrical Controls .......................................................................................................................................74.12 Hydraulic Fluids and Compressed Gases ....................................................................................................84.13 Manual Mode...............................................................................................................................................84.14 Safety Signs .................................................................................................................................................8

5. Weld Fixture Requirements ..................................................................................................................................85.1 Design, Construction and Use .....................................................................................................................85.2 Fixture Setting .............................................................................................................................................85.3 Fixture Changing System ............................................................................................................................8

6. System Requirements............................................................................................................................................96.1 Ancillary Equipment....................................................................................................................................96.2 Emergency Stop Circuitry .........................................................................................................................106.3 Control Interlocks ......................................................................................................................................10

7. User Requirements ..............................................................................................................................................107.1 Training......................................................................................................................................................107.2 Lockout/Tagout..........................................................................................................................................107.3 Risk Assessment ........................................................................................................................................107.4 Work Area .................................................................................................................................................107.5 Personal Protective Equipment..................................................................................................................107.6 Ventilation .................................................................................................................................................10

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8. Maintenance Requirements .................................................................................................................................108.1 Training......................................................................................................................................................108.2 Lockout/Tagout..........................................................................................................................................108.3 Risk Assessment ........................................................................................................................................108.4 Maintenance Operations While Under Power ...........................................................................................10

9. General Information ............................................................................................................................................109.1 Equipment Identification ...........................................................................................................................109.2 Machine Manual ........................................................................................................................................11

Nonmandatory Annex .................................................................................................................................................13Annex A—Guidelines for Preparation of Technical Inquiries for AWS Technical Committees ................................13List of AWS Documents on Robotic and Automatic Welding .....................................................................................15

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List of Figures

Figure Page No.

1 Example of a Typical Robotic Arc Welding Cell ..........................................................................................2

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AWS D16.1M/D16.1:2004

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1. Scope1.1 Scope and Objectives. The requirements of thisstandard apply to industrial robots that are used to per-form the gas metal arc welding (GMAW) and flux coredarc welding (FCAW) processes. The purpose of thisstandard is to establish minimum safety requirementswith respect to the design, manufacture, maintenance,and operation of arc welding robot systems and ancillaryequipment. It is also designed to help identify andminimize hazards involved in maintaining, operating,and setting up of arc welding robot systems.

A robotic arc welding system consists of a manipula-tor, power source, arc welding torch and accessories;electrode feed system, dereeling system, welding circuit,shielding and communication control, and groundingsystem. There may be other accessories that are outsidethe scope of this document. A typical system is illus-trated in Figure 1.

This specification makes use of both U.S. CustomaryUnits and the International System of Units (SI). Thesemeasurements may not be exact equivalents; thereforeeach system must be used independently of the otherwithout combining in any way. The specificationD16.1M uses SI units. The specification with the desig-nation D16.1 uses U.S. Customary Units. The latter areshown in appropriate columns in tables or within paren-theses ( ) when used in the text.

1.2 Applications

1.2.1 New or Remanufactured Installations. Therequirements of this standard pertaining to design andmanufacture shall apply to all new or remanufactured arcwelding robot systems, fixtures, and ancillary equipmentmanufactured for installation or installed after the com-pliance date subsequent to the ANSI approval date of thisstandard. Compliance to the standard shall be 12 monthsafter the ANSI approval date.

1.2.2 Existing or Rebuilt Installations. Existinginstallations or the repair or rebuilding thereof shall becompliant with the standards in effect at the time of theiroriginal installation. Modifications to fixtures, end-of-

arm devices, or ancillary equipment shall be reviewedfor the creation of new hazards. Such new hazards shallbe safeguarded in accordance with the applicable sec-tions of this standard.

1.2.3 All Installations. The requirements of Sections7 and 8 of this standard pertaining to the use and mainte-nance of arc welding robot systems shall apply to allusers subsequent to the approval of this standard.

1.3 Exclusions. This standard applies to arc weldingrobot systems and is not intended to apply to the follow-ing machines:

(1) Robots with a payload capacity greater than 20 kg(45 lbs)

(2) Automated guided vehicle systems(3) Undersea and space robotics(4) Automatic conveyor and shuttle systems(5) Teleoperators(6) Mobile robots(7) Resistance welding robotsThis list is not intended to be all-inclusive.

1.4 Responsibilities. The responsibility for the applica-tion of this standard is defined by this standard.

1.4.1 Manufacturer or Remanufacturer. It shallbe the responsibility of the arc welding robot machinemanufacturer or remanufacturer to design and constructthe arc welding robot system in accordance with Section4 of this standard.

1.4.2 Rebuilder or Modifier. It shall be the responsi-bility of any person rebuilding or modifying arc weldingrobot systems to do so in accordance with portions ofSection 4 of this standard applicable to componentsbeing rebuilt or modified.

1.4.3 System Integrator. The system integrator shallensure that the system complies with Section 6 of thisstandard. The System Integrator has the responsibility toensure that any modifications made to the arc weldingrobot systems shall conform to Section 4. The employershall be the system integrator unless another party con-tractually accepts responsibility as the system integrator.

Specification for Robotic Arc Welding Safety


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