Safety Systems

The RoboSwap System integrates robust safety mechanisms to ensure secure operation.

•
	**System Safety Controller:**Reer MOSAIC M1S controller with multiple expansion
	modules to detect I/O from the system and communicate status with the system
	controller.
	o<br>Safety software is all local to the REER safety system and interacts with the
	rest of the system only to inform the Hive application of the safety system
	status.
	o<br>Safety outputs feed directly into the Kawasaki Robot Controller Cubic-S
	system.
•	**Robot Safety Controller:**KRI Cubic-S Safety Position Controller
	o<br>Used to prevent the robot from entering zones of operation that are not
	allowed based on external safety inputs.
	o<br>Follows instructions from Reer System Safety Controller.
•	**Light Curtains:**Detect unauthorized entry into the robot’s operational zone.
	o<br>The light curtains are rated SIL3, PL e, Category 4, with a detection capability
	of 25 mm.
	o<br>Keyence GL-R type curtains to block out the hallway or robot areas as
	needed.
•	**Floor Scanners:**Continuously monitor obstructions in designated safety zones. The
	scanners are rated SIL2, PL d, Category 3, and cause a Category 0 stop when
	obstacles are detected in the robot zone.
	o<br>Used to prevent any robot motion while a person is in the robot zone.
	o<br>A “warning” trigger is used for hallway occupancy that assists with system
	state. Not used for people-detection in the hallway.
•	**Rack Door Locks:**Keyence GS-M51P latches (IEC61508(SIL3), ISO13849-1:2015(PL e,
	Category 4), ISO14119(Type4), IEC60947-5-3, UL 60947-5-2) can detect door position
	(open/closed) and magnetically latch/control the door.
	o<br>Feedback for the door latches is read by the Safety Controller into an OSSD
	style set of inputs.
•	**Emergency Stops:**Allow manual intervention to immediately halt the system, rated
	SIL3, PL e, Category 4.
**3.4.1 **	Zone Management:
•	**Robot Area (Zone 1):**Protected by a light curtain and monitored by the Cubic-S
	safety controller. A keep-out zone of 514 mm from the light curtain is enforced
	based on calculated stopping distances.
•	**Hallway (Zone 2):**Protected by two light curtains at each end. These are only armed
	during swap sequences and trigger a Category 1 stop if breached.
•	**Rack Zones:**Safety-rated switches prevent robot access if rack doors are open.

Safety Logic:

• Intrusions trigger a Category 0 or 1 stop based on severity.

  • Hallway or Rack zone incursions are Category 1

  • Robot zone incursion is Category 0

• Recovery processes ensure safe resumption of operations.

• Switchable zones for dynamic safety management during operations. o The internals of the racks and hallway zones are activated or deactivated as needed.

  • Example: During a swap sequence, the hallway light curtains are armed, disabling the robot's light curtain and its associated keep-out zone. Once the sequence is complete, the hallway protections are automatically disarmed, and the robot zone becomes active again, ensuring safety and efficient workflow.