協同作業機器人危害風險評估及改善對策之探討－以電子零組件製程為例

人口老化、缺工嚴重，工業用機器人導入產業，部分製程無法用機械手臂取代，為使機器人能協助工作者，「協同作業機器人」（Cobot）因此產生。「協同作業機器人」具有價格便宜、高速移動快速換線與手動引導模式操作特色，可提升生產彈性，適合小量多樣化產品線，並能安全地與工作者一同工作，已快速導入各產業。國內無「協同作業機器人」運用於產業界、安全風險探討及改善對策之研究，國外參考文獻僅用問卷調查及作業觀察評估「協同作業機器人」作業風險且無改善對策。本研究運用多種手法探討電子零組件製程－「協同作業機器人」運作安全風險，並訂定其改善對策，如訂定浮鎖與滑牙改善對策，提升系統安全可靠度，以降低職業災害。本研究選擇電子零組件自動鎖螺絲作業－「協同作業機器人」站別，利用風險矩陣手法進行風險評估，並運用失誤樹（Fault Tree Analysis, FTA）進行系統失效模式探討及系統安全可靠度之定量分析，此為半量化及量化風險評估，有效鑑定作業之風險等級，可推廣於（半）自動化工廠對於職災之防護。藉由本研究之量化風險／可靠度評估方法，以鎖螺絲站別「協同作業機器人」之作業安全為例，針對人員進入「協同作業空間」作業，該作業是否安裝安全光柵主動式防護裝置，可量化得知人員遭機械手臂撞／刺／夾傷之降低機率。結果顯示，以風險矩陣手法計算，安裝安全光柵後風險等級可由中度風險降至低度風險；而運用FTA計算，安裝安全等級PL=e光柵，人員遭機械手臂撞／刺／夾傷之機率，由6.4*10^(-5)降低至2.4*10^(-7)，顯示安裝安全光柵可有效提升系統安全可靠度；改善滑牙及浮鎖狀況，並加裝PL=e光柵，失效率由6.4*10(-5)降至2.4*10^(-7)，故建議該作業安裝安全光柵防護裝置，以降低（半）自動化工廠職災發生之機率。除工程改善外，運用行政管理手法，如運用本研究設計之檢核表，於採購及驗收階段進行安全檢核，亦有效提升採購、驗收效率，確保作業安全，並運用本研究自訂之「光柵驗證指引」，進行安全光柵驗證，除有助於精進設備檢驗能力外，更可保障工作者安全與健康。

關鍵字

協同作業機器人；風險矩陣；自動化；失誤樹分析；本質較安全設計

並列摘要

As the population is aging and the problem of labor shortage, the industrial robots are introduced into the industry. However, some manufacturing process cannot be replaced by robotic arms. In order to enable robots to assist the workers, the ＂Collaborative robots＂ (Cobot) is introduced. Cobot is famous for its competitive price, fast moving & transferring on production line and can be manually operated to increase flexibility in manufacture, which is fitted for small volume but diversified production lines and can work safely along with workers so that it has been implemented in different industries. In this study, we review the risk of applying Cobot in automatic screw locking machine station in electronics component industry. The risk matrix is used to analyze the risk & the Fault Tree Analysis (FTA) is used to check the system failure modes and quantify the reliability. This can be promoted on prevention of occupational accidence in semi automation factories. There are no domestic researches focused on the applications of Cobots in industries, nor related risk assessment and no CAR (correction action report) as well. So that we used several methodologies to evaluate the operational risk of the electronic component process -(Cobots) and set up the CAR in this study. Some results such as setting up the correction action to thread stripped & un-gear, and increasing the system safety reliability (Failure Rate: 6.4*10^(-5) down to2.4*10^(-7)) have been attained. In order to strengthen the safety of Cobot when workers enter into the ＂cooperative work space＂, we focus on carry out the ＂active safety protection＂ to mitigate the medium level risk under normal production including the installation of gratings to improve system safety and reliability. We performed the risk matrix analysis and found that after installing gratings, the risk level is reduced from moderate to low. We also performed FTA calculation and concluded that after installing safety level PL=e light curtain, the system failure rate can be reduced from 6.4*10^(-5) to 2.4*10^(-7). By using the safety review charts in the procurement and acceptance check periods, we can assure that the procurement of Cobot is regulated by law and satisfies the safety requirements. Thus, the occupational injury can be reduced and workers' safety and health are ensured. There are no applicable national standards on installation of light curtain so we set up the guideline for light curtain for industries. After assembling the light curtain, it is proved to provide better safety and can be verified and reference for industries. The standards of CNS 14490-1, ISO 10218-1 are complicated and do not 100% fit to Cobots, so we set up our own procurement & acceptance standard. The checklist is not only convenient and easy to use, but also 92 items less than CNS 14490-1, which can effectively increase the operating efficiency of the procurement & acceptance procedure.