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.
Important
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
Important
These risks must be specifically addressed during system design, programming, and operation.
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 section on “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.
These situations must be avoided by proper system design.
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
Note
Incorrect screw program configuration may lead to unstable behavior or unexpected tool movement.
Note
See section on “Screw Program” 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
Transport of screws shall be carefully considered in the robot path planning.
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 SpinMount
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
Important
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.
User Awareness
Important
Operators and integrators must be aware of residual risks and ensure that appropriate precautions are taken during all phases of operation.
Personal Protective Measures
Depending on the application, the following may be required:
Safety glasses
Protective gloves
Restricted access to the robot workspace
Final Responsibility
Warning
The integrator is responsible for ensuring that residual risks are reduced to an acceptable level and properly communicated to all users of the system.
This includes implementation of appropriate safety measures, validation of system performance, and user training.