Safety Features of Modern Manipulators

In today’s industrial manufacturing, alongside speed and efficiency, increasing emphasis is placed on workplace safety and ergonomics. Wherever there is a need to handle heavy, bulky, or difficult-to-grip loads, manipulators step in – devices designed to ease human labor while eliminating risks naturally associated with manual handling.

Unlike fully autonomous robotic arms that operate independently of humans, manual and pneumatic manipulators fall into the category of “human-controlled” equipment. This includes single or multi-joint systems, crane or overhead manipulators equipped with, for example, vacuum suction cups. They use electric or pneumatic control systems. Their main task is to shift the load from the human to the machine – but the responsibility for safety remains on both sides.

Why is safety absolutely crucial for manipulators?

Manipulators operate in direct contact with humans. The operator is in close proximity to moving parts, interacts with controls, and works under load. If the structure fails, ergonomics are poor, or the operator makes a mistake, the consequences can be serious – from equipment damage to worker injuries.

Safety features of modern manipulators are therefore a fundamental part of good design, without which effective or sustainable operation is not possible. They also significantly impact user comfort and long-term personnel performance.

This article presents key safety features now considered standard in industrial manipulators – and places them within the context of Czech legislation and standards.

Key Safety Features: What a Modern Manipulator Should Deliver

Emergency Stop (ČSN EN ISO 13850)

One of the most essential machine rules. Every manipulator should be equipped with an emergency button (so-called "central stop") that immediately halts movement and brings the device to a safe state in case of danger. This function must be easily accessible and clearly visible to the operator.

Modern systems also implement “safe stop” modes to prevent the load from collapsing after activation – crucial for pneumatic arms using vacuum gripping.

Protective Covers and Mechanical Barriers (ČSN EN ISO 14120, ČSN EN ISO 13857)

All moving and potentially hazardous parts (e.g. joints, gears, guide systems) must be structurally protected against direct contact. This applies not only to the arm itself but also to crane or overhead track connections.

Some manipulators should also include optical or physical barriers around the workspace.

Safety Switches and Interlocks (ČSN EN ISO 14119)

Another key feature is interlocking systems – safety switches that prevent operation unless certain conditions are met (e.g. closed covers, neutral arm position, released controller).

High-quality manipulators often combine these with visual indicators (LEDs, warning symbols) or automatic warning sequences.

Ergonomic Design and Controls

Safety is not only about technical safeguards. Control ergonomics – how the machine responds to user inputs – is equally important. A well-designed manipulator avoids unnatural body movements, minimizes required force, and follows the natural path of arm movement.

Modern ergonomics also include controller feedback, adjustable movement resistance, and optimized handle height and reach.

Visual and Acoustic Signaling

Operators must always know the status of the device. Modern manipulators include LED operation signals, warning beeps for faults, or automatic alerts for pressure drops, vacuum loss, or unusual system behavior.

Sensors and Vacuum/Grip Safety Mechanisms

When handling heavy or fragile loads, it’s critical that the system can detect potential grip loss. Vacuum sensors monitor suction, triggering safety protocols upon pressure drops – e.g. holding mode, mechanical lock, or movement interruption.

Some systems go further – combining vacuum with weight sensors or optical monitoring of the load in real-time.

Legislation and Standards in the Czech Republic

Labour Code (Act No. 262/2006 Coll.)

The Labour Code requires employers to provide a safe work environment and equip workplaces with technologies that minimize injury risk. For manipulators, this means choosing and operating equipment that meets its intended purpose and OHS standards.

Government Regulation No. 378/2001 Coll.

This regulation defines safety requirements for technical equipment, their inspection, maintenance, and operator training responsibilities.

ČSN EN ISO 12100:2011

The basic standard for machine safety. It outlines how to assess risks, design safety measures, and integrate them into technical design.

ČSN EN ISO 13849-1

This standard addresses functional safety – i.e. the reliability of safety control systems. It also applies to manipulators with electric or electronic control.

ČSN EN 14238+A1

A specific standard for manually guided handling devices, including TRIOM pneumatic manipulators. It defines construction safety, ergonomics, and human-machine interaction requirements.

Practical Examples from Our Work

Safety by design – not as an afterthought

A hallmark of a quality manipulator is that safety is embedded in the design from the start. At TRIOM, this approach aligns with our philosophy of tailored technical solutions – safety features are integrated directly into design, control, and operational processes.

Pneumatic Manipulator for Glass Handling – Where Precision Matters

Glass sheets or covers for electronics require a different approach than metal parts – with sensitivity, even pressure, and full reliability being top priorities.

TRIOM’s solution included:

• Vacuum suction cups with sensors that prevent lifting until stable vacuum is achieved.
• An automatic locking mechanism that halts movement and mechanically holds the load if pressure drops.
• Soft stops and controlled movement deceleration to prevent shocks and protect both product and operator.
• Acoustic alarms triggered by vacuum issues.

Telescopic Manipulator with Gripper on Rail – Ergonomics and Simplicity

Tank handling during production included several ergonomic and safety features:

• Two-hand control to prevent the operator from placing body parts between gripper jaws.
• Covered rotating parts to prevent operator contact with hazardous areas.

Risk Assessment and Safety Implementation

Safety starts with analysis – not at installation

Safety isn’t accidental. It’s a managed process that begins long before manufacturing. TRIOM follows this mindset – every device undergoes systematic risk assessment under ČSN EN ISO 12100 and related standards.

1. Hazard Identification

The first step is mapping all potential risks to operators, maintenance, or the surrounding environment, including:

• Mechanical hazards (crushing, impact, falling loads),
• Energy loss risks (vacuum or pressure failure),
• Ergonomic risks (repetitive motion, height, tilt),
• Human error risks (improper operation, missed warnings).

2. Risk Estimation and Evaluation

Each risk is rated by likelihood and consequence severity. These factors form a risk profile, which determines the required safety measures.

For example:

• Risk of “dropping a heavy load” = high severity, medium probability → high risk → requires multi-level safety.

3. Design of Technical and Organizational Measures

Identified risks are addressed through a combination of:

• Technical measures – design, locks, covers, sensors,
• Electronic measures – emergency buttons, alerts,
• Organizational measures – training, labeling, operational rules.

At TRIOM, we aim for synergy between these measures so they reinforce each other.

4. Validation – Functionality Verification

After production and installation, all safety features are tested. For example:

• How quickly the emergency stop reacts,
• Whether interlocks work under abnormal conditions,
• System reaction to simulated faults (e.g. suction cup disconnection).

Commissioning includes load and electrical inspections.

5. Operator Training as a Key Factor

Even the best design fails if operators are not properly trained. TRIOM emphasizes comprehensive training for both operators and maintenance staff, including:

• Practical control instruction,
• Fault simulation,
• Instruction for visual status inspection.

6. Ergonomic Innovations

Modern devices are designed for intuitive operation – using handle shapes, controller feedback, self-balancing systems, or auto-brakes. The goal is to reduce physical strain and the risk of fatigue errors.

Conclusion

Safety is not static. It’s a dynamic and deliberate process that starts with design and extends through long-term operation. At TRIOM, safety is embedded in every project – from single-joint arms to specialized manipulators and custom-built machines.

A safe manipulator is a true operational partner – protecting people, enhancing performance, and providing certainty in every shift.