Hazards

Robot accidents typically do not occur under normal operating conditions, but instead during programming, program touch-up, maintenance, repair, testing, setup, or adjustment. During these tasks, personnel may be within the robot's working envelope where unintended operations could result in injuries from impact/collision, crushing and trapping, moving/mechanical part failure, or other accidents such as electrial energy, pressurized fluids, metal spatter, dust, electromagnetic or radio-frequency interference, and tripping hazards from equipment and cables on the floor.

Proper selection of an effective robitocs safety system must be based on hazard analysis of the operation involving a particlar robot. Safeguarding means and methods must be implemented in order to control and reduce the likelihood of incidents. Sources of potential robot hazards that should be considered include:

• Human errors, such as the incorrect activation of the "teach pendant" or control panel, or over familiarity with the robots redundant motions and putting ones self in a hazardous position;
• Control errors, such as intrinsic faults withing the control system, software errors, electromagnetic or radio-frequency interference, or faults in the hydraulic, pneumatic, or electrical subcontrols.
• Unauthorized access by individuals who are not familiar with the safeguards in place or the activation status;
• Mechanical hazards or failures, or faulty or unexpected operation;
• Environmental hazards such as electromagnetic or radio frequency interference; 
• Power sources (i.e. electric, hydraulic, and pneumatic) - exposure to, or results of malfunctioning or disrupted signals;
• Fire risks associated with electrical overloads or by flammable hydraulic oil; and
• Improper installation of the robot or robot system.