Mobile Manipulators Are the Future. Compliance Is the Gatekeeper.
Robots that move and manipulate—so-called mobile manipulators—are redefining what's possible in warehouses, fulfillment centers, and light manufacturing.
By combining autonomous mobility with robotic arms, these systems can perform complex tasks like stocking, picking, and transporting. But with that added complexity comes a bigger responsibility: keeping humans and systems safe.
Why These Robots Are a Unique Compliance Challenge
Mobile manipulators live at the intersection of several different domains:
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They move independently through shared spaces
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They use powerful actuators to interact with the environment
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They rely on batteries, sensors, and wireless communication
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They often operate near or around people, even if not directly collaborating with them
Each of these capabilities introduces new risks—and with risk comes the need for formal safety and compliance processes.
What Compliance Actually Involves
For these robots, compliance isn't just about passing a final safety check. It requires:
Defining the Robot Capabilities: defining the robot operational use cases, what is designed for and what is not capable off, align with assumptions and limitations of the robot
Defining and Scoping the Robot Operating Environment: what can potentially exists in that environment that can potentially impaired and limit robot operation
Defining Risk Scope: what are the potential risks to consider when robot operate within the defined environment and exercising the define operational use cases. What risk(s) are out of scope in risk analysis ?
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Risk Assessments: Understanding potential hazards across use cases and lifecycle stages
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Safety Function Design: Including emergency stops, safe-speed modes, and power isolation
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Sensor Integration: Ensuring obstacle detection and human awareness are accurate and fail-safe
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Power System Safety: Verifying that batteries, connectors, and chargers meet required safety levels
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Environmental & EMC Considerations: Ensuring that electronics don't interfere with, or get disrupted by, other systems
Importantly, each subsystem must work together safely—not just in isolation.
The Compliance Roadmap for Mobile Manipulators
At Saphira, we work with robotics teams to bring their mobile manipulators to market faster, safer, and audit-ready. Here's the high-level roadmap we use:
1. Risk Assessment & Lifecycle Analysis
Standards: ISO 12100 / ANSI B11.0
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Assess all robot modes: start-up, autonomous, manual, maintenance, restart
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Identify hazards: crushing, shearing, ejected material, energy loss, misuse
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Define safety functions (e.g., power isolation, speed control, obstacle detection)
2. Functional Safety Architecture
Standards: ISO 13849-1/2, ANSI B11.19, IEC 61508
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Define Safety Functions (SRS):
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SF1: E-stop → Contactors → Power Isolation
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SF2: Mode Selector (Manual vs Auto)
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SF3: LIDAR Detection → Safety Stop
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SF4: Reduced speed in warning zones
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Validate PLd or higher for core safety circuits
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Implement redundancy, diagnostics, fault detection
3. Electrical & EMC Safety
Standards: UL 3100, UL 1740, UL 2580, NFPA 79, IEC 60204-1, FCC Part 15
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Validate wiring (UL 758), transformers (UL 5085), and connectors (UL 1997/2734)
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Perform key tests:
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Dielectric withstand
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Ground continuity
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Battery overcharge, imbalance, drop
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IP rating (UL 50/50E)
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Temperature and vibration (UL 3100)
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4. Human Detection & Safety-Zone Enforcement
Standards: IEC 61496, ISO 13857
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Use certified LIDAR for 360° obstacle detection
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Enforce zone-based speed reduction or stop functions
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Ensure failsafe monitoring of edges, stairs, or hazardous areas
5. Maintenance, Reduced-Speed Mode, and Documentation
Standards: ISO 13849, IEC 61508, IEC 62061
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Define safe maintenance mode with torque/speed limits
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Validate operator access points, labeling, and guarding
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Prepare documentation: FMEA, FTA, schematics, SRS, software validation logs
Strategic Compliance Starts Early
Too often, teams treat compliance like a checkbox. But in systems this complex, it's a strategic advantage to start early.
Building compliance into your roadmap helps:
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Avoid costly redesigns
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Earn stakeholder trust
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Accelerate deployment approval
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Ensure operator safety in the real world
Robots that aren't provably safe simply won't scale.
Looking Ahead
Mobile manipulators are unlocking new efficiencies across industries—but only when safety is a forethought, not an afterthought.
In a world where robots operate in close proximity to people, compliance isn't just paperwork. It's the foundation of product readiness, customer confidence, and long-term success.
