1. Getting Started

• Set up a workcell using the robot’s safety-related functions and interfaces according to the risk assessment performed by the system integrator in regard to the robot’s application. For the information necessary for this process, please sufficiently acquaint yourself with Doosan Robotics Installation and User manual and consult it.
• When the robot’s safety system has found a system fault (when a wire breakage has occurred in the emergency stop circuit), when the position sensor has been damaged, or when a hardware abnormality such as a failure with control-purpose communication has been detected: stop category 0 starts immediately. When the robot’s safety system detects a violation during the execution of safety monitoring (when the emergency stop switch has been pressed), when a protective stop signal has been inputted, when an external shock has been detected, or when a physical parameter such as the robot’s position, speed, or momentum has exceeded its set limit: the robot is stopped according to the stop mode specified in the Safety settings menu. (Select one from among stop categories 0, 1 and 2)

2. Safety-Rated Stop Function

• STO(Safe Torque Off): All Stop Modes corresponding to Stop Category 0 immediately cut off the power supply to all joint module motors, and brake engagement forces the operation to stop. The brake for each joint of the robot is not intended for deceleration, but for keeping the robot in stop status when its operating power has been lost due to reasons such as a power cut-off. Frequent use of STO can wear the brake and shorten the life span of the decelerator. Therefore, we recommend you use SS1 instead, unless the use of STO is absolutely necessary.
• SS1(Safe Stop 1): All joints are stopped with maximum deceleration by a Stop Mode corresponding to Stop Category 1, the power supply to the motor is cut off, and the brake is engaged to stop. As the operation of STO mode, the robot is decelerated and stopped. Also the motor is in the state of power down. Operation of the robot is practicable under the condition Servo On after releasing stop function.
• SS2(Safe Stop 2): All joints are stopped with maximum deceleration by a Stop Mode corresponding to Stop Category 2, and SOS (Safe Operating Stop) is engaged.

• SOS(Safe Operating Stop): In this mode, the robot’s current position is maintained in the Servo On status, in which the motor power is supplied, and the brake has not been engaged. Once an abnormal position change is detected in this mode, the robot switches to STO.

• For emergency stop, SS1(Safe Stop 1) Mode is set as a default. 
• If an additional emergency stop button is required, you can attach one to the control box after performing a risk assessment.
• Emergency stop must not be used as a means of reducing risk and must be used as a secondary protective measure.
• If an additional emergency stop button needs to be connected to the control box, you must determine whether to do so through a robot application risk assessment. Additional emergency stop buttons must comply with I EC 60947 5 5.

3. Safety-Rated Monitoring Function

• Joint Position Monitoring (SLP): Limits the maximum rotation angle of a joint
• Joint Speed Monitoring (SLS): Limits the maximum rotation speed of a joint
• TCP Position/Direction Monitoring: Limits and monitors TCP position/direction at an orthogonal space (Operating area, independent work area, collaboration work area, restricted area, tool direction retainment monitoring area, collision detection specification area)
• TCP Speed Monitoring: Limits the maximum TCP movement speed 
• TCP External Force Monitoring: Limits the external force applied to TCP
• Collision Detection: Limits the torque of external force applied to the robot arm and each joint
• Momentum Monitoring: Limits the maximum momentum applied to the robot arm
• Mechanical Power Monitoring: Limits the maximum power the robot arm can output

4. Safety-Rated IO

 

• If a discrepancy between input signals is detected based on a redundant interface, or a discrepancy is detected in the feedback on the output signal, the robot is stopped and an error message is displayed. A function defined in combination such as ports 1-2 and 3-4 means a redundant interface is being used.

• Safe Torque Off: When low, immediately cuts off the motor power and force stops the robot by engaging the brake.
• Emergency Stop: When low, stops the robot according to the stop mode for emergency stop set in safety stop mode.
• Protective Stop: When low, stops the robot according to the stop mode for protective stop set in safety stop mode.
• Reduced Speed: When low, if the collaborative workspace has not been set, the robot operates at 20% of the speed set in Task. If there is an operation speed ratio specified upon the setting up of the collaborative workspace, the robot operates at a decreased speed corresponding to that ratio.
• 3 Pos Enable Switch: An operation permission device for operator protection used when connecting the 3-position switch. When low, disables the jog feature in manual mode, Servo On unavailable. 
• Handguiding Switch: An operation permission device for operator protection used when connecting the handguiding switch. When low, Handguiding unavailable. 
• Playback Resume: After using manual guide including handguiding during Auto mode, used to resume the execution of the program. When high, resumes the execution of the Auto mode program.
• Protective Stop & Auto Resume: Used with safety device (ex. safety mat etc.) and when high, in case of ‘protective stop’ by input signal, Program restart is operated automatically, without the manual execution of ‘program restart’ using the Teach Pendant.
• Dynamic Zone Enable: Used when collision temporary space is activated dynamically and when high, under the registration of safety input for collision temporary space, collision temporary space is activated.

• Emergency Stop: Used to notify the external system of the necessity of emergency stop upon the detection of the pressing of the TP emergency stop switch or an external emergency stop switch, or the detection of an error by self-diagnosis. When low, emergency stop is required.
• Safe Torque Off: When low, the robot is in STO status. 
• Safe Operating Stop: When low, the robot is in SOS status. 
• Safe Stop Event: When low, a safety stop situation occurs. 
• Normal Speed: When low, the robot operates at the normal speed set in Task. 
• Reduced Speed: When low, the robot is located in the collaborative workspace or operates at a decreased speed due to the input of an external deceleration mode signal. 
• Auto Mode: When low, the current status of the robot is in Auto mode. 
• Manual Mode: When low, the current status of the robot is in Manual mode.
• Standalone Workspace: When low, the robot’s TCP is located in the standalone workspace. 
• Collaborative Workspace: When low, the robot’s TCP is located in the collaborative workspace. 
• Collision Detection Overriding Zone: When low, the robot’s TCP is located in the separately designated collision detection area. 
• Tool Orientation Monitoring Zone: When low, the robot’s TCP is located in the tool direction retainment monitoring area. 

5. Summary

• International Organization for Standardization, ISO 10218-1 & 2
• International Organization for Standardization Technical Specification, ISO/TS 15066
• Doosan Robotics Installation & User manual, https://robotlab.doosanrobotics.com