Robots in production: safety, safety zones and programming
From shielded robot cells to collaborative robots that work side by side with humans
The education's competency goal no. 6 requires that the apprentice, based on knowledge of robot safety, can operate a robot for use in industrial production, and later in the course (no. 20 and 22) comes building complex systems with robot technology, offline and online programming, and integration of robots in larger systems. Robots are therefore not a side subject—it is a central part of the modern automation installation.
§Two types of tasks — two sets of standards
Safety around industrial robots is described in a family of international standards. ISO 10218-1 sets requirements for the robot as a product — its design and built-in safety functions. ISO 10218-2 sets requirements for the integrated robotic system, i.e. the robot combined with tools, guarding and peripheral equipment in the specific installation. With the 2025 revision the requirements for collaborative robots — previously described in a separate technical specification ISO/TS 15066:2016 — are integrated directly into ISO 10218-2:2025 so the rules for collaborative operation are now consolidated in one place.
- 01ISO 10218-1 – requirements for the robot itself (design and built-in safety features)
- 02ISO 10218-2 – requirements for the integrated system (cell, tool, guarding, peripheral equipment)
- 03Collaborative operation (formerly ISO/TS 15066) — limits for force, pressure and speed in physical contact between human and robot
§Traditional cell or collaborative robot
A traditional industrial robot typically works behind guarding, light curtains or safety mats because it moves with a force and speed that can seriously hurt a person. A collaborative robot (often called cobot) on the other hand is developed and risk-assessed to be able to share work area with people without full guarding — but only within the force and pressure limits set for the specific task and robot. It is a key point that 'collaborative robot' does not mean 'automatically safe under all conditions' — each installation must be risk-assessed based on the task, tool on the robot and surroundings.
§Programming — online and off-line
Robots are programmed in two main ways. Online programming takes place at the robot itself, often with a handheld programming device, where the robot is moved to the desired positions and saved as points in a program. Off-line programming takes place in software on a computer, where the robot's movements are simulated and planned before the program is transferred to the physical robot — a method that saves production time because the equipment does not have to stand still during the programming itself. The automation technician typically works with both: simple adjustments and setup directly at the robot, and more complex changes prepared offline.
| Situation | Typical safety measure |
|---|---|
| Traditional robot cell | Physical shielding, light curtains, door contacts that stop the robot |
| Collaborative robot | Force/pressure limitation, speed reduction near people, risk assessment per task |
| Service within the cell | Safe condition, de-energized or controlled low-speed condition after procedure |
§Integration in the complete system
A robot rarely works alone. It often has to work together with conveyor belts pick-and-place machines cameras and other automatic units — what competency goal no. 22 describes as integration of robots and other automatic machines in industrial facilities. This requires the technician to understand the entire signal chain between robot control PLC and peripheral equipment so troubleshooting does not stop at the robot cell's boundary but covers the entire system.
“A robot does exactly what it is programmed to do — every time with the same force. That is the strength. That is also why it never on its own discovers that a human is in the way.”