ANSI AWS D16.3M D16.3-2017 Risk Assessment Guide for Robotic Arc Welding (3rd Edition).pdf

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1、Risk Assessment Guide for Robotic Arc WeldingAWS D16.3M/D16.3:2017An American National StandardAWS D16.3M/D16.3:2017An American National StandardApproved byAmerican National Standards InstituteJanuary 24, 2017Risk Assessment Guide forRobotic Arc Welding3rd EditionSupersedes AWS D16.3M/D16.3:2009Prep

2、ared 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/D16.3:2017, Risk Assessment Guide for Robotic Arc Welding, provides recommendations and guidelin

3、es for the safe implementation of robotic arc welding. Emphasis is placed on conformance of this process with prevailing industry standards for hazard analysis and proper safeguarding.AWS D16.3M/D16.3:2017iiISBN-13: 978-0-87171-907-2 2017 by American Welding SocietyAll rights reservedPrinted in the

4、United States of AmericaPhotocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in any form, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyright owner.Authorization to photocopy items

5、 for internal, personal, or educational classroom use only or the internal, personal, or educational classroom use only of specific clients is granted by the American Welding Society provided that the appropri-ate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923,

6、tel: (978) 750-8400; Internet: .AWS D16.3M/D16.3:2017iiiStatement on the Use of American Welding Society StandardsAll standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society (AWS) are voluntary consensus standards that have been

7、developed in accordance with the rules of the American National Standards Institute (ANSI). When AWS American National 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 governmen-tal bodies, their

8、provisions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the governmental body having statutory jurisdiction before they can become a part of those laws and regulations. In all cases, these standards carry the full legal authorit

9、y of the contract or other document that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS stand-ard must be by agreement between the contracting parties.AWS American National Standards are developed through a consensus standa

10、rds development process that brings together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the proc-ess and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or verify the accuracy of

11、 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 special, indirect, consequential, or compensatory, directly or indirectly resulting from the publication,

12、 use of, or reliance on this standard. AWS also makes no guarantee or warranty as to the accuracy or completeness of any information pub-lished herein.In issuing and making this standard available, AWS is neither undertaking to render professional or other services for or on behalf of any person or

13、entity, nor is AWS undertaking to perform any duty owed by any person or entity to someone else. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the advice of a competent professional in determining the exercise of reasonable care in any given

14、 circumstances. It is assumed that the use of this standard and its provisions is entrusted to appropriately qualified and competent personnel.This standard may be superseded by new editions. This standard may also be corrected through publication of amend-ments or errata, or supplemented by publica

15、tion of addenda. Information on the latest editions of AWS standards includ-ing amendments, errata, and addenda is posted on the AWS web page (www.aws.org). Users should ensure that they have the latest edition, amendments, errata, and addenda.Publication of this standard does not authorize infringe

16、ment of any patent or trade name. Users of this standard accept any and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement of any patent or product trade name resulting from the use of this standard.AWS does not monitor, police, or enforc

17、e compliance with this standard, nor does it have the power to do so.Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request, in writing, to the appropriate technical committee. Such requests should be addressed to the American Welding

18、 Society, Attention: Managing Director, Standards Development, 8669 NW 36 St, # 130, Miami, FL 33166 (see Annex C). 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 st

19、andard, and they do not constitute professional advice. Such opinions represent only the personal opinions of the particular individuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In a

20、ddi-tion, 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 must be reviewed every five years, and if not revised, it must be either reaffirme

21、d or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS D16 Committee on Robotic and Automatic Weldin

22、g and the author of the comments will be informed of the Committees response to the comments. Guests are invited to attend all meetings of the AWS D16 Committee on Robotic and Automatic Welding to express their comments verbally. Procedures for appeal of an adverse decision concerning all such comme

23、nts are pro-vided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 8669 NW 36 St, # 130, Miami, FL 33166.AWS D16.3M/D16.3:2017ivThis page is intentionally blank.AWS D16.3M/D16.3:2017vPersonnelAWS D16 Committee o

24、n Robotic and Automatic WeldingD. L. Pape, Chair Wolf RoboticsK. Gilgenbach, Vice Chair Airgas, IncorporatedJ. S. Noruk, 2nd Vice Chair Servo Robot CorporationP. Portela, Secretary American Welding SocietyC. T. Anderson Motoman, IncorporatedJ. M. Blahnik Caterpillar, IncorporatedE. Boan John Deere S

25、eedingR. E. Campbell Banker Steel CompanyE. DiMalanta ABBC. Gandee Lincoln ElectricL. K. Gross Milwaukee Area Technical CollegeB. Hackbarth Joy Global Surface MiningT. B. Hansen Trinity Rail CarS. M. Henderson Ocean-EJ. R. Keister Shockride LLCJ. D. Lane D therefore, each system must be used indepen

26、dently.1.3 Safety. Safety and health issues and concerns are beyond the scope of this standard; some safety and health information is provided, but such issues are not fully addressed herein. Safety and health information is available from the following sources:American Welding Society:(1) ANSI Z49.

27、1, Safety in Welding, Cutting, and Allied Processes(2) AWS Safety and Health Fact Sheets(3) Other safety and health information on the AWS websiteMaterial or Equipment Manufacturers:(1) Safety Data Sheets supplied by materials manufacturers(2) Operating Manuals supplied by equipment manufacturersApp

28、licable Regulatory AgenciesWork performed in accordance with this standard may involve the use of materials that have been deemed hazardous, and may involve operations or equipment that may cause injury or death. This standard does not purport to address all safety and health risks that may be encou

29、ntered. The user of this standard should establish an appropriate safety program to AWS D16.3M/D16.3:20172address such risks as well as to meet applicable regulatory requirements. ANSI Z49.1 should be considered when devel-oping the safety program.2. Normative ReferencesThe standards listed below co

30、ntain provisions, which through reference in this text, constitute provisions of this AWS standard. For undated references, the latest edition of the referenced standard shall apply. For dated references, subse-quent amendments to, or revisions of, any of these publications do not apply.AWS Document

31、sANSI Z49.1Safety in Welding, Cutting, and Allied ProcessesAWS A3.0M/A3.0Standard Welding Terms and Definitions, Including Terms for Adhesive Bonding, Brazing, Soldering, Thermal Cutting, and Thermal Spraying AWS D16.1Robotic Arc Welding SafetyAWS D16.2Guide for Components of Robotic and Automatic A

32、rc Welding InstallationsAWS D16.4Specification for the Qualification of Robotic Arc Welding PersonnelOther StandardsRIA R15.06-1999 American National Standard for Industrial Robot and Robot SystemsANSI/NFPA 79Electrical Standard for Industrial EquipmentANSI/UL 1740Safety Standard for Robots and Robo

33、tic EquipmentANSI/B11.0Safety of MachineryANSI/B11.19Performance Criteria for SafeguardingANSI/B11.20Safety Requirements for Integrated Manufacturing SystemsUS Federal RegulationsOSHA 1904General requirement for recording and reporting occupational injuries and illnessesOSHA 1910.147Control of hazar

34、dous energy (Lockout/Tagout)OSHA 1910.212General requirements for all machines (Machine guarding)OSHA 1910.219Mechanical power transmission apparatus3. Terms and DefinitionsAWS A3.0M/A3.0, Standard Welding Terms and Definitions, Including Terms for Adhesive Bonding, Brazing, Soldering, Thermal Cutti

35、ng, and Thermal Spraying, provides the basis for terms and definitions used herein. The following terms and definitions are included below to accommodate usage specific to this document.actuating control. Mechanical mechanism within a control device. (e.g., a rod which opens contacts).actuator. A me

36、chanism used to affect motion.(a) A power mechanism which converts electrical, hydraulic, or pneumatic energy to effect motion.(b) A mechanical mechanism within a control device (e.g., a rod which opens contacts).(c) A device (e.g., specialized key) which initiates a (un)locking sequence.ancillary e

37、quipment. A component added to an industrial robotic welding system to provide an extra function to support the welding process or its application. (e.g., laser scanners, video cameras, torch cleaners, wire cutters, anti-spatter spray, wire straighteners).application. The type of welding application

38、 will influence the risk assessment. A description of the components that are to be welded, the weld process to be used, the sequence of operation of the welding robot(s), and any other information that is needed to understand the operation of the system should be compiled by the user.AWS D16.3M/D16

39、.3:20173approved. To accept as satisfactory.audible alarm. An electrical or mechanical signal, clearly discernable above environmental noise, indicating a condition requiring the operators attention.automatic mode. Operating mode in which the robot control system operates in accordance with the task

40、 program ISO 8373:1994, definition 5.3.8.1.auxiliary equipment. A component integrated into an industrial robot system to provide a function additive to that of the primary robot. (e.g., integrated servo positioner under teach pendant control).barrier. A physical means of separating persons from the

41、 hazard.certification. The act of determining, verifying, and attesting in writing to the qualification of personnel in conformance to specified requirements.Certified Operator. Any individual who has earned an AWS Certification in Robotic Arc Welding (CRAW).control device. Any piece of control hard

42、ware providing a means for human intervention in the control of a robot or robot system, such as an emergency-stop button, a start button, or a selector switch.control program. The inherent set of control instructions which defines the capabilities, actions and responses of the robot system. This pr

43、ogram is usually not intended to be modified by the user.control station. Part of the robot system which contains one or more control devices intended to activate or deactivate functions of the system or parts of the system. The control station can be fixed in place (e.g., control panel), or mov-abl

44、e (e.g., control pendant).design risk assessment. A hazard analysis that is conducted during the design phase and occurs prior to system installation.drive power. The energy source or sources for the robot actuators.emergency stop. The operation of a circuit that overrides all other robot controls,

45、removes drive power, causes all mov-ing parts to stop, and removes power from other hazardous functions present in the safeguarded space but does not cause additional hazards.enabling device. A manually operated device which when continuously activated, permits motion.end-effector. An accessory devi

46、ce or tool specifically designed for attachment to the robot wrist or tool mounting plate to enable the robot to perform its intended task. (Examples may include gripper, spot weld torch, arc weld torch, spray paint torch, or any other application tools.)energy source. Any electrical, mechanical, hy

47、draulic, pneumatic, chemical, thermal, potential, kinetic, or other sources of power/movement.envelope. The three-dimensional space encompassing the movements of all robot parts (see space).field risk assessment. A type of hazard analysis that occurs after the system is complete, at time of installa

48、tion, and at inspection periods thereafter as deemed appropriate, includes but is not limited to relocation and process change. The field risk assessment typically references the Design Risk Assessment.guard. A physical barrier which protects personnel from exposure to a hazardous area.hard stop. Ri

49、gid mechanical interface device which will prevent movement of a robotic system past the point of contact.hazard. A potential source of harm.hazardous motion. Any motion that is likely to cause personal physical harm.industrial arc welding robot system (robot system).(1) An industrial robot combined with ancillary and auxiliary equipment necessary to perform a production arc weld-ing process. Typically, the robot is electrically interfaced to the ancillary and auxiliary equipment.(2) Any equipment, devices, or sensors required for the robot to perform its task.AWS D16.3M/D16