AWS D16.1M/D16.1:2004 (R2016)

An American National Standard

Specification for Robotic Arc Welding Safety

AWS D16.1M/D16.1:2004 (R2016)

An American National Standard

Approved by the American National Standards Institute

February 3, 2004

Reaffirmed: May 27, 2016

Specification for Robotic Arc Welding Safety

Prepared by the American Welding Society (AWS) D16 Committee on Robotic and Automatic Welding

Under the Direction of the AWS Technical Activities Committee

Approved by the AWS Board of Directors

Abstract

This standard establishes safety requirements with respect to the design, manufacture, maintenance, and operation of arc weld- ing robot systems and ancillary equipment. It also helps to identify and minimize hazards involved in maintaining, operating, integrating, and setting up of arc welding robot systems.

ISBN-13: 978-0-87171-890-7

© 2015 by American Welding Society

All rights reserved Printed in the United States of America

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Statement on the Use of American Welding Society Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society (AWS) are voluntary consensus standards that have been 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 provisions carry the full legal authority of the statute. In such cases, any changes in those AWS stan- dards 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 authority 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 standard must be by agreement between the contracting parties.

AWS American National Standards are developed through a consensus standards development process that brings together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the pro- cess and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, 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 whatsoever, whether special, indirect, consequential, or compensatory, directly or indirectly resulting from the publication, 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 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 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 publication 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 infringement 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 enforce 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 Society, Attention: Managing Director, Technical Services Division, 8669 NW 36 St, # 130, Miami, FL 33166 (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 standard, 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 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 Committee on Robotic and Automatic Welding. It must be reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may be of use in improving this standard are requested and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS D16 Committee on Robotic and Automatic Welding and the author of the comments will be informed of the Committee’s 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 comments 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.

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Personnel (Reaffirmation)

AWS D16 Committee on Robotic and Automatic Welding

J. S. Noruk, Chair Servo Robot Corporation

V. L. Mangold, Vice-Chair Kaysafety

D. L. Pape, 2nd Vice-Chair Wolf Robotics

P. Portela, Secretary American Welding Society

C. T. Anderson Motoman, Incorporated

J. M. Blahnik Caterpillar, Incorporated

E. Boan John Deere Seeding

1. E. Campbell Banker Steel Company

   E. DiMalanta ABB

   C. Gandee The Lincoln Electric Company

   1. Gilgenbach Airgas, Incorporated

   2. K. Gross Milwaukee Area Technical College

   B. Hackbarth Joy Global Surface Mining

   T. B. Hansen TrinityRail Car

2. M. Henderson Henderson Hanes & Associates

   1. R. Keister Shockride, LLC

      1. D. Lane D & S Manufacturing

         1. Maroney AIDT-RTP

         2. B. Massey Edison Welding Institute

         W. R. Polanin Illinois Central College

         D. L. Pratt Electro-Mechanical Industries

         S. P. Redig Iowa Mold Tooling Company, Incorporated

         P. D. Regrut Preston-Eastin, Incorporated

         N. P. Rice Worthington Industries

         M. F. Sinfield Naval Surface Warfare Center Carderock Division

         P. S. Staunton EDG, Incorporated

         K. Summers Miller Welding Automation

         D. C. Swann OTC DAIHEN, Incorporated

         M. J. Teubert Navus Automation

      2. W. Trumbull Genesis Systems Group

H. Volkhart Midwest Engineering Systems

1. W. Williamson Fronius USA, LLC

   
   

   Advisors to the AWS D16 Committee on Robotic and Automatic Welding

   J. Berge Berge Robotics

   1. J. Bischoff Hobart Brothers

P. Davison Robotic Industries Association

D. J. Erbe Praxair

K. W. Gerhart Edison Welding Institute

K. V. Iyer Larsen and Toubro Limited

H. A. Jacobson Consultant

H. L. Jones, Jr. Dominion/Virginia Power

R. W. Linn Productive Engineering, Incorporated

T. E. Maxey Banker Steel Company

Advisors to the AWS D16 Committee on Robotic and Automatic Welding (Continued)

T. K. Merrifield GM Welding Systems & Services

S. D. Nelson Burns & McDonald

D. P. Rhoda Wolf Robotics

1. W. Savage Caterpillar, Incorporated

   1. Swary Miller Electric

D. A. Wright Wright Welding Technologies

M. J. Yakawich Lead Project Engineer

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Personnel (Original)

AWS D16 Committee on Robotic and Automatic Welding

J. S. Noruk, Chair Servo Robot Corporation

V. L. Mangold, Jr., 1st Vice Chair ISS

1. Howe, Secretary American Welding Society

   1. T. Anderson Motoman Incorporated

      J. Berge Wolf Robotics, Incorporated

      J. Blahnik Caterpillar Incorporated

      *A. Q. Bracarense Universidades Federal de Minas Gerais, Brazil

      *A. L. Cox Caterpillar, Incorporated

      D. J. Erbe Panasonic Factory Automation

      *J. Fryman Robotic Industries Association

      L. K. Gross Milwaukee Area Technical College

      W. Guest Daihen, Incorporated

      1. B. Hansen ABB Flexible Automation, Incorporated

         *J. F. Hinrichs Friction Stir Link, Incorporated

         *H. L. Jones, Jr. Dominion/Virginia Power Company

         1. Kamra Tower Automotive, Incorporated

            J. Mattern NAVSEA Carderock Division

         2. D. Nelson Trek Bicycle Corporation

J. C. Nicklas The Lincoln Electric Company

R. F. Noch Johnson Controls, Incorporated

A. Nywening Ingersoll-Rand, Incorporated

M. W. Perry Preston-Eastin, Incorporated

*J. S. Phillips Detroit Center Tool

W. R. Polanin Illinois Central College—WRP Associates

*H. F. Prah Prah Engineering Company

*J. W. Schlosser Air Liquide America Corporation

H. W. Smith, III Capital Machine Robotics, Incorporated

K. Summers Miller Electric Manufacturing Company

K. W. Trumbull Genesis Systems Group

*N. Urai Daihen, Incorporated

*T. H. Via Via Technologies

H. Volkhart Cloos Robotic Welding, Incorporated

*M. M. Weir Panasonic Factory Automation

*G. G. Winchester NEMA

*C. L. Woodman Consultant

*D. A. Wright, Sr. Zephyr Products, Incorporated

*Advisor

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Foreword

This foreword is not part of this standard but is included for informational purposes only.

The AWS D16 Committee on Robotic and Automatic Welding was organized in 1985 to provide a centralized source for the exchange of technical information between manufacturers, installers, integrators, and operators of robotic and automated equipment. It has developed a number of standards related to robotic arc welding systems and their applications (see List of AWS Documents on Robotic and Automatic Welding).

This first edition of AWS D16.1M/D16.1:2004, Specification for Robotic Arc Welding Safety, provides guidelines for the safe use of arc welding robots. Although safe practices for arc welding are covered in many standards, this standard focuses on safety aspects unique to robotic arc welding applications.

This document was reaffirmed in 2016 and the following minor, editorial changes were made:

1. All occurrences of “Section” were changed to “Clause.”

2. Annex A, previously labeled as “Nonmandatory” was changed to “Informative.”

3. The address for AWS was updated.

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, 8669 NW 36 St, # 130, Miami FL 33166.

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Table of Contents

Page No.

Personnel (Reaffirmation) v

Personnel (Original) vii

Foreword ix

List of Figures xiii

1. Scope 1

   1. Scope and Objectives 1

   2. Applications 2

   3. Exclusions 2

   4. Responsibilities 2

2. Normative References 2

3. Definitions 3

4. Arc Welding Robot System Manufacturing Requirements 7

   1. Hazards to Personnel 7

   2. Actuating Controls 7

   3. Pendant and Other Teaching Controls 7

   4. Attended Weld Program Verification 8

   5. Slow Speed Control 8

   6. Singularity Protection 8

   7. Axis Limiting Devices 8

   8. Provisions for Lifting 8

   9. Electrical Connectors 8

   10. Pinch Points 8

   11. Electrical Controls 8

   12. Hydraulic Fluids and Compressed Gases 9

   13. Manual Mode 10

   14. Safety Signs 10

5. Weld Fixture Requirements 10

   1. Design, Construction and Use 10

   2. Fixture Setting 10

   3. Fixture Changing System 10

6. System Requirements 11

   1. Ancillary Equipment 11

   2. Emergency Stop Circuitry 12

   3. Control Interlocks 12

7. User Requirements 12

   1. Training 12

   2. Lockout/Tagout 12

   3. Risk Assessment 12

   4. Work Area 12

   5. Personal Protective Equipment 12

   6. Ventilation 12

      Page No.

8. Maintenance Requirements 13

   1. Training 13

   2. Lockout/Tagout 13

   3. Risk Assessment 13

   4. Maintenance Operations While Under Power 13

9. General Information 13

   1. Equipment Identification 13

   2. Machine Manual 13

Annex A (Informative)—Guidelines for Preparation of Technical Inquiries 15

List of AWS Documents on Robotic and Automatic Welding 17

xii

List of Figures

Figure Page No.

1 Example of a Typical Robotic Arc Welding Cell 1

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Specification for Robotic Arc Welding Safety

1. Scope

1.1 Scope and Objectives. The requirements of this standard apply to industrial robots that are used to perform the gas metal arc welding (GMAW) and flux cored arc welding (FCAW) processes. The purpose of this standard is to establish minimum safety requirements with respect to the design, manufacture, maintenance, and operation of arc welding robot systems and ancillary equipment. It is also designed to help identify and minimize hazards involved in maintaining, operating, and setting up of arc welding robot systems.

A robotic arc welding system consists of a manipulator, power source, arc welding torch and accessories; electrode feed system, dereeling system, welding circuit, shielding and communication control, and grounding system. There may be other accessories that are outside the scope of this document. A typical system is illustrated in Figure 1.

This specification makes use of both U.S. Customary Units and the International System of Units (SI). These measure- ments may not be exact equivalents; therefore each system must be used independently of the other without combining in any way. The specification D16.1M uses SI Units. The specification with the designation D16.1 uses U.S. Customary Units. The latter are shown in appropriate columns in tables or within parentheses ( ) when used in the text.

Figure 1—Example of a Typical Robotic Arc Welding Cell