1、Specification forRobotic ArcWelding SafetyAWS D16.1M/D16.1:2004An American National Standard550 N.W. LeJeune Road, Miami, Florida 33126AWS D16.1M/D16.1:2004An American National StandardApproved byAmerican National Standards InstituteFebruary 3, 2004Specification forRobotic Arc Welding SafetyPrepared
2、 byAWS D16 Committee on Robotic and Automatic WeldingUnder the Direction ofAWS Technical Activities CommitteeApproved byAWS Board of DirectorsAbstractThis standard establishes safety requirements with respect to the design, manufacture, maintenance, and operation of arcwelding robot systems and anci
3、llary equipment. It also helps to identify and minimize hazards involved in maintaining,operating, integrating, and setting up of arc welding robot systems.Key WordsRobot, robotic arc welding, robot welding systems, robotic welding operator, qualified robot technician, safety, risk assessmentStateme
4、nt on Use of AWS American National StandardsAll standards (codes, specifications, recommended practices, methods, classifications, and guides) of the AmericanWelding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of theAmerican National Standard
5、s Institute (ANSI). When AWS standards are either incorporated in, or made part of,documents that are included in federal or state laws and regulations, or the regulations of other governmental bodies,their provisions carry the full legal authority of the statute. In such cases, any changes in those
6、 AWS standards must beapproved by the governmental body having statutory jurisdiction before they can become a part of those laws andregulations. In all cases, these standards carry the full legal authority of the contract or other document that invokes theAWS standards. Where this contractual relat
7、ionship exists, changes in or deviations from requirements of an AWSstandard must be by agreement between the contracting parties.International Standard Book Number: 0-87171-719-0American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126 2004 by American Welding Society. All rights reservedPri
8、nted in the United States of AmericaAWS American National Standards are developed through a consensus standards development process that bringstogether volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the processand establishes rules to promote fair
9、ness in the development of consensus, it does not independently test, evaluate, orverify the accuracy of any information or the soundness of any judgments contained in its standards.AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether s
10、pe-cial, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on thisstandard. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein.In issuing and making this standard available, A
11、WS is not undertaking to render professional or other services for or onbehalf of any person or entity. Nor is AWS undertaking to perform any duty owed by any person or entity to someoneelse. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the
12、 adviceof a competent professional in determining the exercise of reasonable care in any given circumstances.This standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.Publication of this standard does not authorize infringement of any pate
13、nt. AWS disclaims liability for the infringementof any patent resulting from the use or reliance on this standard.Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.On occasion, text, tables, or figures are printed incorrectly, consti
14、tuting errata. Such errata, when discovered, are postedon the AWS web page (www.aws.org).Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request, in writ-ing, to the Managing Director, Technical Services Division, American Welding Soci
15、ety, 550 N.W. LeJeune Road, Miami, FL33126 (see Annex A). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standardsmay be rendered. However, such opinions represent only the personal opinions of the particular individuals giving them. Theseindividuals do not sp
16、eak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpreta-tions of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation.This standard is subject to revision at any time by the AWS D16 Commit
17、tee on Robotic and Automatic Welding. It mustbe reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommenda-tions, additions, or deletions) and any pertinent data that may be of use in improving this standard are required andshould be addressed to A
18、WS Headquarters. Such comments will receive careful consideration by the AWS D16 Commit-tee on Robotic and Automatic Welding and the author of the comments will be informed of the Committees response tothe comments. Guests are invited to attend all meetings of the AWS D16 Committee on Robotic and Au
19、tomatic Weldingto express their comments verbally. Procedures for appeal of an adverse decision concerning all such comments areprovided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained fromthe American Welding Society, 550 N.W. LeJeune Road, Mia
20、mi, FL 33126.Photocopy RightsAuthorization to photocopy items for internal, personal, or educational classroom use only, or the internal, personal, oreducational classroom use only of specific clients, is granted by the American Welding Society (AWS) provided that theappropriate fee is paid to the C
21、opyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, Tel: 978-750-8400;online: http:/.iiiPersonnelAWS D16 Committee on Robotic and Automatic WeldingJ. S. Noruk, Chair Servo Robot CorporationV. L. Mangold, Jr., 1st Vice Chair ISSP. Howe, Secretary American Welding SocietyC. T. Anderson M
22、otoman IncorporatedJ. Berge Wolf Robotics, IncorporatedJ. Blahnik Caterpillar Incorporated*A. Q. Bracarense Universidades Federal de Minas Gerais, Brazil*A. L. Cox Caterpillar, IncorporatedD. J. Erbe Panasonic Factory Automation*J. Fryman Robotic Industries AssociationL. K. Gross Milwaukee Area Tech
23、nical CollegeW. Guest Daihen, IncorporatedT. B. Hansen ABB Flexible Automation, Incorporated*J. F. Hinrichs Friction Stir Link, Incorporated*H. L. Jones, Jr. Dominion/Virginia Power CompanyR. Kamra Tower Automotive, IncorporatedJ. Mattern NAVSEA Carderock DivisionS. D. Nelson Trek Bicycle Corporatio
24、nJ. C. Nicklas The Lincoln Electric CompanyR. F. Noch Johnson Controls, IncorporatedA. Nywening Ingersoll-Rand, IncorporatedM. W. Perry Preston-Eastin, Incorporated*J. S. Phillips Detroit Center ToolW. R. Polanin Illinois Central CollegeWRP Associates*H. F. Prah Prah Engineering Company*J. W. Schlos
25、ser Air Liquide America CorporationH. W. Smith, III Capital Machine Robotics, IncorporatedK. Summers Miller Electric Manufacturing CompanyK. W. Trumbull Genesis Systems Group*N. Urai Daihen, Incorporated*T. H. Via Via TechnologiesH. Volkhart Cloos Robotic Welding, Incorporated*M. M. Weir Panasonic F
26、actory Automation*G. G. Winchester NEMA*C. L. Woodman Consultant*D. A. Wright, Sr. Zephyr Products, Incorporated*AdvisorThis page is intentionally blank.vForeword(This Foreword is not a part of AWS D16.1, 2004, Specification for Robotic Arc Welding Safety,but is included for informational purposes o
27、nly.)The AWS D16 Committee on Robotic and Automatic Welding was organized in 1985 to provide a centralized sourcefor the exchange of technical information between manufacturers, installers, integrators, and operators of robotic andautomated equipment. It has developed a number of standards related t
28、o robotic arc welding systems and their applica-tions (see Annex B).This first edition of AWS D16.1M/D16.1:2004, Specification for Robotic Arc Welding Safety, provides guidelines forthe safe use of arc welding robots. Although safe practices for arc welding are covered in many standards, this standa
29、rdfocuses on safety aspects unique to robotic arc welding applications.Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary,AWS D16 Committee on Robotic and Automatic Welding, American Welding Society, 550 N.W. LeJeune Road,Miami, FL 33126.O
30、fficial interpretations of any of the technical requirements of this standard may be obtained by sending a request, inwriting, to the Managing Director, Technical Services Division, American Welding Society. A formal reply will beissued after it has been reviewed by the appropriate personnel followi
31、ng established procedures (see Annex A).This page is intentionally blank.viiTable of ContentsPage No.Personnel iiiForeword vList of Figuresix1. Scope .11.1 Scope and Objectives.11.2 Applications.11.3 Exclusions11.4 Responsibilities12. Normative References .23. Definitions.34. Arc Welding Robot Syste
32、m Manufacturing Requirements.54.1 Hazards to Personnel .54.2 Actuating Controls.64.3 Pendant and Other Teaching Controls.64.4 Attended Weld Program Verification64.5 Slow Speed Control .64.6 Singularity Protection 64.7 Axis Limiting Devices.74.8 Provisions for Lifting.74.9 Electrical Connectors.74.10
33、 Pinch Points .74.11 Electrical Controls .74.12 Hydraulic Fluids and Compressed Gases 84.13 Manual Mode.84.14 Safety Signs .85. Weld Fixture Requirements 85.1 Design, Construction and Use .85.2 Fixture Setting .85.3 Fixture Changing System 86. System Requirements96.1 Ancillary Equipment96.2 Emergenc
34、y Stop Circuitry .106.3 Control Interlocks 107. User Requirements 107.1 Training107.2 Lockout/Tagout107.3 Risk Assessment 107.4 Work Area .107.5 Personal Protective Equipment107.6 Ventilation .10viiiPage No.8. Maintenance Requirements .108.1 Training108.2 Lockout/Tagout108.3 Risk Assessment 108.4 Ma
35、intenance Operations While Under Power .109. General Information 109.1 Equipment Identification .109.2 Machine Manual 11Nonmandatory Annex .13Annex AGuidelines for Preparation of Technical Inquiries for AWS Technical Committees 13List of AWS Documents on Robotic and Automatic Welding.15ixList of Fig
36、uresFigure Page No.1 Example of a Typical Robotic Arc Welding Cell 2xThis page is intentionally blank.AWS D16.1M/D16.1:200411. 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 weldi
37、ng (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, operat
38、ing,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 t
39、hat 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 otherwit
40、hout 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 Applications1.2.1 New or Remanufactured Installations.
41、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. Complia
42、nce 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 device
43、s, 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 we
44、lding 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
45、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.
46、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 r
47、ebuilding 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 Integrato
48、r 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 SafetyAWS D16
49、.1M/D16.1:200421.4.4 Employers. Employers should make trainingavailable for operators, programmers, and maintenancetechnicians to help them attain and maintain certifica-tions, such as the Certified Robotic Arc Welding Techni-cian/Operator Program.2. Normative References1The following standards contain provisions, which,through reference in this text, constitute provisions ofthis American National Standard. All standards are sub-ject to revision, and parties are encouraged to use themost recent editions of the standards indicated below.(1) ANSI/NFPA279, Electrical Standa
