Industrial Robotic Arm & Automation Cell Safety Inspection Checklist

Verify light curtain functionality by interrupting the beam; robot motion should cease immediately. Record response time.

Confirm light curtains are positioned at a safe distance from the robot's maximum reach, based on stopping time calculations. Document calculations.

Test all emergency stop buttons (E-stops) within the cell; robot motion should cease immediately and reliably. Verify correct wiring and functionality.

Inspect safety gate interlocks; opening the gate should immediately stop robot motion. Check for physical damage and proper alignment.

Examine physical barriers (fences, walls) for damage, gaps, or modifications that could compromise safety. Measure barrier height (min. 1.4 meters).

Check the Safety PLC status indicators for any errors or faults. Review the PLC program for unauthorized modifications.

If equipped, verify two-hand control devices require simultaneous activation to initiate robot motion. Test anti-tie-down and anti-repeat functions.

Inspect any presence-sensing devices (e.g., laser scanners) for proper function and coverage area. Verify correct configuration and response time.

Ensure adequate warning signage is present and clearly visible, indicating robot operation and potential hazards. Verify compliance with ANSI Z535 standards.

Verify the robot cell perimeter is clearly marked with floor tape or paint, indicating the restricted area. Check for wear and tear.

Inspect the teach pendant for physical damage (cracked screen, damaged cable, broken buttons). Replace if necessary.

Verify the teach pendant enable switch functions correctly; robot motion should only be possible when the switch is depressed.

Confirm the robot operates in reduced speed mode (250 mm/s or less) when using the teach pendant inside the cell. Measure actual speed.

Verify access to robot programming is restricted to authorized personnel only. Check password protection and user access levels.

Confirm that robot programs are regularly backed up and stored securely. Verify backup procedures are documented and followed.

Review robot collision detection settings; ensure they are properly configured to prevent damage to the robot and surrounding equipment.

Verify the robot has a defined safe home position that is free from obstructions. Check the home position accuracy.

Observe manual mode operation; ensure operators are trained and follow safe procedures. Check for jerky or erratic movements.

Confirm all personnel using the teach pendant have received adequate training and are competent in its operation. Review training records.

Verify a change log is maintained for all robot program modifications, documenting the changes, date, and author.

Verify that written Lockout/Tagout (LOTO) procedures are readily available at the robot cell. Check for clarity and completeness.

Identify all energy isolation points (electrical, pneumatic, hydraulic) for the robot and associated equipment. Ensure they are clearly labeled.

Ensure sufficient LOTO devices (locks, tags) are available and in good working condition. Check for proper identification and traceability.

Observe LOTO procedures being followed during maintenance; verify proper application of locks and tags at all energy isolation points.

Verify that stored energy (e.g., pneumatic pressure, capacitor charge) is properly released or blocked before starting maintenance. Document verification.

If group LOTO is used, verify that procedures are in place to ensure each worker has individual control over the lockout. Check for accountability.

Confirm all personnel performing maintenance on the robot have received adequate LOTO training. Review training records.

Verify LOTO procedures are reviewed and updated at least annually, or whenever there are changes in equipment or processes. Document review date.

If contractors are performing maintenance, verify that LOTO procedures are coordinated between the contractor and the facility. Document coordination.

Verify that LOTO devices are removed only by the person who applied them, following established procedures. Document removal process.

If the cobot uses force/torque sensors for safety, verify that they are properly calibrated and functioning correctly. Document calibration date.

Verify that the cobot's power and force limiting functions are enabled and properly configured to prevent injury in case of contact. Test force limits.

If using speed and separation monitoring, verify that the safety-rated monitoring system is functioning correctly and maintains a safe distance between the cobot and human workers. Measure minimum safe distance.

Test the cobot's safety-rated stop function; robot motion should cease immediately and reliably upon activation. Verify correct wiring and functionality.

If using hand guiding, verify that the cobot responds smoothly and predictably to human guidance. Check for excessive force or jerky movements.

Verify that a thorough risk assessment has been conducted for the specific collaborative application, addressing potential hazards and mitigation measures. Review risk assessment documentation.

Assess the workcell layout to ensure that it minimizes the risk of collisions between the cobot and human workers. Check for adequate workspace and clear pathways.

Confirm that all operators working with the cobot have received specific training on collaborative robot safety and operation. Review training records.

Determine if any additional protective equipment (e.g., padding, sensors) is required to mitigate specific hazards identified in the risk assessment. Verify equipment is in place and functioning.

Verify that a regular maintenance schedule is in place for the cobot, including checks of safety-related components. Review maintenance records.

Verify grounding continuity of all robot components and electrical enclosures. Measure resistance to ground (should be less than 1 ohm).

Inspect electrical panels for damage, corrosion, or loose connections. Ensure panels are properly labeled and secured.

Examine wiring for signs of damage, abrasion, or deterioration. Replace any damaged wiring immediately.

Verify that overcurrent protection devices (fuses, circuit breakers) are properly sized and functioning correctly. Check for correct amperage ratings.

Test the Emergency Power Off (EPO) circuit; verify that it de-energizes all robot-related equipment immediately. Check for proper wiring and functionality.

Verify that an arc flash hazard assessment has been conducted for the robot cell. Review assessment results and ensure appropriate PPE is available.

Confirm that all personnel working on or near the robot's electrical systems have received adequate electrical safety training. Review training records.

Inspect conduit and cable management systems for proper support and protection. Check for loose or damaged components.

Ensure that high-voltage areas are clearly marked with appropriate warning signs. Verify compliance with ANSI Z535 standards.

Verify that surge protection devices are installed to protect sensitive electronic equipment from voltage spikes. Check for proper grounding.