Residual Risks

General Statement

Despite the implementation of safety measures, certain residual risks remain when using the SD/SDV-Series screwdriver tool as part of a robot system.

Note

Residual risks cannot be completely eliminated and must be addressed through proper system design, risk assessment, and user awareness.

Most Significant Residual Risks

Based on risk assessment, the following risks are considered most significant:

  • Quasi-static contact (crushing or trapping between tool and object)

  • Impact during robot approach to screw position

  • Limited exposure to rotating screw or bit if the safety shield is removed, bypassed, or not functioning correctly

  • Transport of screws near head or eye level

  • Removal or bypass of safety functions (e.g., safety shield)

  • Cable entanglement with robot or personnel

  • Unauthorized modification of electrical connections

Contact and Collision Risks

Residual risk of injury may occur due to:

  • Contact between robot, tool, and human

  • Unexpected robot motion or incorrect positioning

  • Inadequate stopping performance

Note

The severity of these risks depends on robot speed, payload, and system configuration. See Understanding Contact Forces for further explanation of transient and quasi-static risks.

Crushing and Trapping Risks

Residual risk of crushing or trapping may occur:

  • Between the tool and workpiece

  • Between the robot and surrounding equipment

Warning

Quasi-static (sustained) contact situations may result in injury even at relatively low force levels. Design the system so that no one can be trapped between the tool and the workpiece, or between the robot and surrounding equipment.

Screwdriving Process Risks

Residual risks related to the screwdriving process include:

  • Misalignment during screw insertion

  • Sudden tool reaction forces

  • Incorrect torque or process parameters

  • Incorrect step transitions in the screw program

  • Dropped or ejected screws due to misalignment or loss of engagement with the bit

See Understanding Programs for guidance on correct configuration of steps, transitions, and process parameters.

Tool and Bit Risks

Residual risks include:

  • Limited contact with rotating bit or screw in case of misuse, malfunction, or incorrect installation

  • Sharp edges on screws or bit

  • Improperly mounted or loose bits

Note

The SD/SDV-Series includes a safety shield that significantly reduces the risk of contact with rotating parts during normal operation. Residual risk may occur in case of misuse, malfunction, or incorrect installation.

Transport and Handling Risks

Residual risks may occur during transport of screws:

  • Screw transported through robot workspace

  • Potential contact with operator, particularly near head or eye level

Warning

Screws carried through the robot workspace can come into contact with an operator, particularly near head or eye level. Plan robot paths so that screws are not carried near a person’s head, face or eyes.

Cable and Installation Risks

Residual risks may occur due to:

  • Cables getting caught on equipment or personnel

  • Insufficient cable slack during robot motion

  • Incorrect mounting of the tool or Spin Mount

Safety System Limitations

Even when safety functions are implemented, residual risks remain:

  • Safety sensor reduces impact forces but does not eliminate them

  • Incorrect safety wiring or configuration may prevent proper stopping

  • Safety performance depends on robot controller and system integration

Note

The integrated safety sensor primarily reduces transient (impact) forces. Quasi-static risks must be addressed through system design and avoidance of trapping situations.

Note

Removal or bypass of safety features is considered foreseeable misuse and must be addressed in the risk assessment.

Electrical and Communication Risks

Residual risks may occur due to:

  • Incorrect wiring or installation

  • Loss of communication between system components

  • Failure or misconfiguration of I/O signals

Risk Reduction Measures

Residual risks must be minimized by:

  • Performing a complete risk assessment

  • Validating robot motion and stopping behavior

  • Ensuring correct screw program configuration

  • Using proper mounting and cable management

  • Implementing appropriate safety functions

  • Training operators and integrators

Note

Risk reduction shall consider worst-case conditions, including maximum speed, payload, and reach.

Personal Protective Measures

Depending on the application, the following may be required:

  • Safety glasses

  • Protective gloves

  • Restricted access to the robot workspace