ISO 10218, the international safety standard for industrial robotics, is foundational for manufacturers, integrators, and health & safety (H&S) bodies worldwide. The standard is split into:
- ISO 10218-1: Safety requirements for industrial robots
- ISO 10218-2: Safety requirements for robot systems and integration
Understanding and applying ISO 10218-2 is critical for building safe, standards-compliant robot applications. Here’s a breakdown of key elements and how they apply.
1. Understand Your Context: Scope and Classification
ISO 10218 is a Type C standard, meaning it overrides Type A or B standards when addressing specific application safety.
However, ISO 10218 excludes:
- Military, space, medical, and service robots
- Mobile platforms (covered by ISO 3691-4)
That said, ISO 10218-1 and -2 apply when industrial robots are integrated with:
- Automated Mobile Robots (AMRs)
- Automated Storage and Retrieval Systems (ASRS)
- Automated Guided Vehicles (AGVs)
2. Key Design and Safety Requirements
Mechanical Strength and Hazardous Energy
Robots must operate safely under stress:
“The robot shall be designed and constructed to withstand an overload in static tests without permanent deformation...” – Section 5.1.2.3
- Static test coefficient ≥ 1.25
- Dynamic test coefficient ≥ 1.1
- Test at max speed, including simultaneous motion scenarios
Note: For a robot to qualify as Class I, it must:
- Weigh < 10kg
- Exert < 50N
- Move < 250 mm/s
This is rare in industrial settings.
Hazardous energy management is especially important in systems like AMRs, where sudden power loss poses safety risks.
Configurable Capabilities and Control Modes
ISO 10218 outlines:
- Requirements for configuring Tool Center Point (TCP) and payloads
- Differences between manual and automatic modes
- Rules for external/direct control
Emergency and Stop Functions
The standard distinguishes between:
- Emergency Stop: Immediate safety action (e.g., e-stop on teach pendants)
- Protective Stop: Risk-reducing measure
- Normal Stop: Routine halt for non-hazard scenarios
Communications and Wireless Safety
- Cableless control systems must comply with IEC 62745
- Safety-related data communications must follow IEC 61508
3. Risk Assessment and Functional Safety
Risk Assessment (ISO 12100)
- Part 1: Safety derived from anticipated robot use
- Part 2: Application-specific risk assessment required
Functional Safety (ISO 13849 / IEC 62061)
- Requires a Performance Level (PLr) or SIL based on risk
- Includes metrics like Mean Time to Dangerous Failure and Diagnostic Coverage
4. Special Categories: Lasers, Mobility, and Instruction Handbooks
Lasers and Laser Equipment
Laser-equipped systems must follow extra guidelines for optical safety, reflecting their increasing use in industrial robotics.
Instruction Requirements
ISO 10218 mandates comprehensive manuals covering:
- Installation
- Intended use
- Emergency scenarios
- Cybersecurity
- Teach pendants
- Abnormal events
ISO 10218-2 adds even stricter requirements for integrators and applications.
5. Standards Interoperability
For hazards not covered in ISO 10218, use:
- ISO 3691-4 for mobile robots and AGVs
- EN 528 for rail-dependent ASRS systems
These standards fill in critical gaps in mobility safety and storage system compliance.
Achieving Safe and Compliant Robot Systems
ISO 10218 offers a structured, application-specific framework for safe industrial robot design and deployment. While it doesn’t address every edge case (especially in mobile systems), it provides the foundation for:
- Consistent risk reduction
- Functional and mechanical safety
- Regulatory confidence for OEMs and integrators
For teams integrating Saphira or similar tools, ISO 10218 provides the blueprint for building trustworthy robotic systems.
