Safety Issues Concerning Robotic Welding of Large Elements


Article Preview

Robotic welding of large elements poses significant difficulties regarding the technological process, robot functions and the safety of the operator and other people. The health risks involved arise out of the weight of elements, high heat capacity, harmful gases and fumes. Under the Eureka project, the PIAP team is developing a model of a robotized cell designed mainly for welding large elements. Occupational safety is of paramount importance and hence is a constructive discussion on occupational health risk factors. The replacement of human workers with robots on assembly nests, especially in SMEs, eliminates the exposure of workers to hazard, but is focused on a reduction in employment rather than in significant improvements to the workplace. The paper analyzes and discusses European safety regulations contained in the European directives and applicable EN standards. Appropriate safety programs of diverse welding processes and materials to be implemented by designers and suppliers of robotic welding stations and lines, as well as by the users thereof, will be indicated.



Solid State Phenomena (Volumes 220-221)

Edited by:

Algirdas V. Valiulis, Olegas Černašėjus and Vadim Mokšin




W. J. Klimasara et al., "Safety Issues Concerning Robotic Welding of Large Elements", Solid State Phenomena, Vols. 220-221, pp. 818-823, 2015

Online since:

January 2015




* - Corresponding Author

[1] World Robotics 2011 Industrial Robots, International Federation for Robotics (IFR), VDMA, Frankfurt Germany, (2010).

[2] Z. Pilat, Different solution of robotic cells for metal sheets beveling, Applied Mechanics and Materials, Trans Tech Publications, Switzerland, 282 (2013) 66-73.


[3] RobWeld Super-MIG® project web site www. robweld. eu.

[4] C. Goldsberry, Evolution has made MIG welding a universal process, Welding Design & Fabrication, 2008-01-01, http: /weldingdesign. com/archive/evolution-has-made-mig-welding-universal-process.


[5] Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery (Machinery Directive).

[6] EN 169: 2002 Personal eye-protection. Filters for welding and related techniques. Transmittance requirements and recommended use.


[7] EN 470-1: 1995 Protective clothing for use in welding and allied processes. General requirements.

[8] Directive 90/269/EEC – manual handling of loads of 29 May 1990 on the minimum health and safety requirements for the manual handling of loads where there is a risk particularly of back injury to workers (fourth individual Directive within the meaning of Article 16 (1) of Directive 89/391/EEC).

[9] EN ISO 10218-1: 2011 Robots and robotic devices – Safety requirements for industrial robots – Part 1: Robots.


[10] Directive 89/391/EEC of 12 June 1989 on the introduction of measures to encourage improvements in the safety and health of workers at work (OSH Framework Directive, ).

[11] W. J. Klimasara, New Machinery Directive 2006/42/WE – the overview of changes (in Polish) Pomiary Automatyka Robotyka 11/(2009).

[12] ISO 13849-1: 2006 Safety of machinery – Safety-related parts of control systems – Part 1: General principles for design.

[13] ISO 12100: 2010 Safety of machinery – General principles for design – Risk assessment and risk reduction.

[14] EN 61508-1: 2010 Functional safety of electrical/electronic/programmable electronic safety-related systems – Part 1: General requirements.