1、Risk AssessmentGuide for RoboticArc WeldingAWS D16.3M/D16.3:2009An American National Standard550 N.W. LeJeune Road, Miami, FL 33126AWS D16.3M/D16.3:2009An American National StandardApproved by theAmerican National Standards InstituteNovember 13, 2008Risk Assessment Guidefor Robotic Arc Welding2nd Ed
2、itionSupersedes AWS D16.3M/D16.3:2001Prepared by theAmerican Welding Society (AWS) D16 Committee on Robotic and Automatic WeldingUnder the Direction of theAWS Technical Activities CommitteeApproved by theAWS Board of DirectorsAbstractAWS D16.3M/D16.3:2009, Risk Assessment Guide for Robotic Arc Weldi
3、ng, provides recommendations and guidelinesfor the safe implementation of robotic arc welding. Emphasis is placed on conformance of this process with prevailingindustry standards for hazard analysis and proper safeguarding.iiAWS D16.3M/D16.3:2009International Standard Book Number: 978-0-87171-669-9A
4、merican Welding Society550 N.W. LeJeune Road, Miami, FL 33126 2009 by American Welding SocietyAll rights reservedPrinted in the United States of AmericaPhotocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in anyform, including mechanical, phot
5、ocopying, recording, or otherwise, without the prior written permission of the copyrightowner.Authorization 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
6、Society provided that the appropriatefee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, tel: (978) 750-8400; Internet:.iiiAWS D16.3M/D16.3:2009Statement on the Use of American Welding Society StandardsAll standards (codes, specifications, recommended practices, met
7、hods, classifications, and guides) of the AmericanWelding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of theAmerican National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, ormade part of, documen
8、ts that are included in federal or state laws and regulations, or the regulations of other govern-mental bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWSstandards must be approved by the governmental body having statutory jurisdiction be
9、fore they can become a part ofthose laws and regulations. In all cases, these standards carry the full legal authority of the contract or other documentthat invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirementsof an AWS standard must be by
10、agreement between the contracting parties.AWS American National Standards are developed through a consensus standards development process that bringstogether volunteers representing varied viewpoints and interests to achieve consensus. While the AWS administers theprocess and establishes rules to pr
11、omote fairness in the development of consensus, it does not independently test, evalu-ate, or verify 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 whatsoeve
12、r, whetherspecial, indirect, consequential, or compensatory, directly or indirectly resulting from the publication, use of, or relianceon this standard. AWS also makes no guarantee or warranty as to the accuracy or completeness of any informationpublished herein.In issuing and making this standard a
13、vailable, AWS is neither undertaking to render professional or other services for oron behalf 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 approp
14、riate, seek theadvice of a competent professional in determining the exercise of reasonable care in any given circumstances. It isassumed that the use of this standard and its provisions are entrusted to appropriately qualified and competent personnel.This standard may be superseded by the issuance
15、of new editions. Users should ensure that they have the latest edition.Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard acceptany and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the in
16、fringement ofany patent or product trade name resulting from the use of this standard.Finally, the 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, constituting errata. Such erra
17、ta, 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, inwriting, to the appropriate technical committee. Such requests should be addressed to the American Welding Soci
18、ety,Attention: Managing Director, Technical Services Division, 550 N.W. LeJeune Road, Miami, FL 33126 (see Annex A).With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered.These opinions are offered solely as a convenience to users of this sta
19、ndard, and they do not constitute professionaladvice. Such opinions represent only the personal opinions of the particular individuals giving them. These individuals donot speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations ofAWS. In addit
20、ion, 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 Committee on Robotic and Automatic Welding. It mustbe reviewed every five years, and if not revised, it must be either reaffirmed or w
21、ithdrawn. Comments (recommenda-tions, additions, or deletions) and any pertinent data that may be of use in improving this standard are requiredand should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS D16Committee on Robotic and Automatic Welding and t
22、he author of the comments will be informed of the Committeesresponse to the comments. Guests are invited to attend all meetings of the AWS D16 Committee on Robotic and Auto-matic Welding to express their comments verbally. Procedures for appeal of an adverse decision concerning all suchcomments are
23、provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can beobtained from the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.This page is intentionally blank.ivAWS D16.3M/D16.3:2009vAWS D16.3M/D16.3:2009PersonnelAWS D16 Committee on Robotic
24、 and Automatic WeldingV. L. Mangold, Jr., Chair KaysafetyJ. S. Noruk, 1st Vice Chair Servo Robot CorporationL. K. Gross, 2nd Vice Chair Milwaukee Area Technical CollegeM. Rubin, Secretary American Welding SocietyC. T. Anderson Motoman, IncorporatedJ. M. Blahnik Caterpillar, IncorporatedD. J. Erbe Pa
25、nasonic Factory AutomationM. A. Garman Kawasaki RoboticsK. W. Gerhart General Electric CompanyT. B. Hansen ABB Flexible Automation, IncorporatedG. M. Lipnevicius The Lincoln Electric CompanyR. F. Noch Johnson Controls, IncorporatedM. W. Perry Preston-Eastin, IncorporatedJ. L. Petersen Crenlo, LLCW.
26、R. Polanin Illinois Central CollegeWRP AssociatesD. L. Pratt Acute Technological Services, LLCD. P. Rhoda Wolf RoboticsK. Summers Miller Electric Manufacturing CompanyK. W. Trumbull Genesis Systems GroupH. Volkhart Cloos Robotic Welding, IncorporatedJ. W. Williamson ABB Flexible Automation, Incorpor
27、atedAdvisors to the AWS D16 Committee on Robotic and Automatic WeldingJ. Berge Berge Engineering and AutomationJ. Fryman Robotic Industries AssociationJ. F. Hinrichs Friction Stir Link, IncorporatedH. L. Jones, Jr. Dominion/Virginia Power CompanyS. D. Nelson Trek Bicycle CorporationG. G. Winchester
28、NEMAC. L. Woodman Automation ConsultantD. A. Wright, Sr. Zephyr Products, IncorporatedThis page is intentionally blank.viAWS D16.3M/D16.3:2009viiAWS D16.3M/D16.3:2009ForewordThis foreword is not part of AWS D16.3M/D16.3:2009, Risk Assessment Guidefor Robotic Arc Welding, but is included for informat
29、ional purposes only.The AWS D16 Committee on Robotic and Automatic Welding was organized in 1985 to provide a centralized source forthe exchange of technical information between manufacturers, installers, and operators of robotic and automated arcwelding equipment.AWS D16.3 was initially published i
30、n 2001. This second edition has been updated with the latest terms and guidelinesand has been reformatted to meet the latest AWS specifications for standards.Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary,AWS D16 Committee on Robotic a
31、nd Automatic Welding, American Welding Society, 550 N.W. LeJeune Road, Miami,FL 33126.This page is intentionally blank.viiiAWS D16.3M/D16.3:2009ixAWS D16.3M/D16.3:2009Table of ContentsPage No.Personnel vForeword.viiList of Tables.xList of Figures.x1. Scope.12. Normative References .13. Definitions 1
32、4. General Considerations 34.1 Risk Assessment Description34.2 Performance 45. Elements of the Risk Assessment .45.1 Application Description45.2 Robot Operating Characteristics.45.3 Robot Classification45.4 Categories of Hazards.45.5 Risk Analysis 46. Documentation.76.1 Classification Summary76.2 Wo
33、rk Cell (Workspace) Description .76.3 Summary of Potential Hazards .86.4 Method of Safeguarding .87. Training 87.1 Risk Assessment Training Program87.2 Other Safety Training Program.8Annex A (Informative)Guidelines for the Preparation of Technical Inquiries.9Annex B (Informative)Informative Referenc
34、es11Annex C (Informative)Sample Risk Assessment Form13List of AWS Documents on Robotics and Automatic Welding .17xAWS D16.3M/D16.3:2009List of TablesTable Page No.1 Robot Operating Subclassification .52 Application Classifications .53 Classification Summary64 Minimum Safeguarding Protocols 6List of
35、FiguresFigure Page No.1 Example of a Robot Arc Welding Work Cell .7AWS D16.3M/D16.3:200911. ScopeThe purpose of D16.3M/D16.3:2009, Risk AssessmentGuide for Robotic Arc Welding, is to identify and evaluatepotential safety hazards associated with robotic arc weld-ing. It is not intended to be a guidel
36、ine for other roboticapplications. This guide is intended for persons perform-ing risk assessment and applies to arc welding robots androbot arc welding systems performing the gas metal arcwelding (GMAW) or flux cored arc welding (FCAW)process.It is not intended to be a guideline for other robotic a
37、ppli-cations, such as:(1) Automatic guided vehicle systems,(2) Undersea and space robots,(3) Automatic conveyor and shuttle systems,(4) Teleoperators,(5) Mobile robots, and(6) Multiple robots.This standard makes use of both the International Systemof Units (SI) and U.S. Customary Units. The latter a
38、reshown within brackets ( ) or in appropriate columnsin tables and figures. The measurements may not beexact equivalents; therefore, each system must be usedindependently.The inclusion of all safety, health issues, and concernsare beyond the scope of any one document and thereforeare not fully addre
39、ssed herein. Safety and health infor-mation is available from other sources, including, butnot limited to, ANSI Z49.1, Safety in Welding, Cutting,and Allied Processes, and applicable federal and stateregulations.2. Normative ReferencesThe following standards contain provisions, whichthrough referenc
40、e in this text, constitute provisions ofthis AWS standard. For undated references, the latest edi-tion of the referenced standard shall apply. For dated ref-erences, subsequent amendments to, or revisions of, anyof these publications do not apply.AWS Documents1ANSI Z49.1, Safety in Welding, Cutting,
41、 and AlliedProcessesAWS A3.0, Standard Welding Terms and DefinitionsOther DocumentsRIA R15.06, American National Standard for Indus-trial Robot and Robot SystemsSafety Requirements.23. DefinitionsTerms used in this document are in accordance withAWS 3.0, Standard Welding Terms and Definitions. Inadd
42、ition, for the purposes of this document, the follow-ing terms and definitions apply:application program. The set of instructions that definethe specific intended tasks of robots and robot sys-tems. This program may be originated and modifiedby the robot user.audible alarm. An electrical or mechanic
43、al signal,clearly discernible above environmental noise, indi-cating a condition requiring the operators attention.automatic mode. The robot state in which automaticoperation can occur.automatic operation. The state in which the robot isexecuting its programmed task as intended.barrier. A physical m
44、eans of isolating a hazard or defin-ing a space.1AWS standards are published by the American WeldingSociety, 550 N.W. LeJeune Road, Miami, FL 33126.2RIA standards are published by the Robotic Industries Associ-ation, 900 Victors Way, P.O. Box 3724, Ann Arbor, MI 48106.Risk Assessment Guide for Robot
45、ic Arc WeldingAWS D16.3M/D16.3:20092control device. Any piece of control hardware providinga means for human intervention in the control of arobot or robot system, such as an emergency-stop but-ton, a start button, or a selector switch.control program. The inherent set of control instruc-tions that
46、define the capabilities, actions, andresponses of the robot system. This program is usu-ally not intended for modification by the user.device. Any piece of control hardware, such as anemergency-stop button, a selector switch, a controlpendant, a relay, a solenoid valve, or a sensor.discrete input. A
47、n on-off signal from peripheral equip-ment to the robot controller.discrete output. An on-off signal to peripheral equip-ment from the robot controller.emergency stop. The operation of a circuit using hard-ware-based components that overrides all other con-trols, reduces all mechanisms to a zero ene
48、rgy state,causes the cessation of all mechanical movement, andterminates the electrical welding output of the weld-ing power source.enabling device. A manually operated device that, whencontinuously activated, permits motion. Deactivatingthe device stops robot motion and motion of associ-ated equipm
49、ent that may present a hazard.end-effector. An accessory device or tool specificallydesigned for attachment to the robot wrist or toolmounting plate to enable the robot to perform itsintended task. (Examples may include gripper, spotweld gun, arc weld gun, spray paint gun, or any otherapplication tools.)envelope (space), maximum. The volume of spaceencompassing the maximum designed movements ofall robot parts including the end-effector, workpiece,and attachments.envelope (space), restricted. That portion of the maxi-mum envelope to which a robot is restricted by limit-ing devices. Th
