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A well-designed safety system has seamlessly integrated measures that accommodates user needs and makes their tasks easier to perform. Current safety solutions are not adequate when technology and generational trends consistently evolve. However, understanding the factors that drove past development leads to the implementation of relevant future designs. Current systems reduce risk by physically separating operators from hazards. New technologies enable collaborative applications by embedding inherently safe designs within the machine. Operator interaction also differs based on their capabilities, tendencies, experiences and motivation. Communication methods may also be shifted. Previous generations of operators received information from printed material. Industry experts provided in-depth understanding of the technology and its use. Now, younger generations of operators receive digital documents, video and audio tutorials, and other information from a variety of online sources.

Recent advances in technology allow machine safeguarding to shift from a system that completely shuts down the hazardous part of a machine, regardless of the action, to one with a controlled response. This intelligent robotics safeguarding can be based on conditions such as the type of task, how it is performed, entry and exit locations, and the operator’s movement within the hazard zone. Such a strategy could increase production rates by allowing robots to operate at higher speeds within dynamic environments. When used as part of a preventative maintenance program, reliability data can predict component failure rates and reduce the probability that operators will access the hazard zone. Programming techniques, such as function blocks to monitor component usage, can be used to evaluate trends. SQL (Structured Query Language) databases can track access and frequency trends, which can lead to design improvements and indicate changes affecting the system.

Applications using industrial robotics have typically led to establishing a safeguarded space encompassing a wide radius around the robot. Operator access to this hazard zone was restricted by a combination of means, such as hard guarding, safeguarding, awareness means, and personal protective equipment. The introduction of collaborative robots is redefining safeguarding requirements. Many collaborative robots have inherently safe designs that enable an operator and a robot to work within a shared, collaborative workspace. New technology in industrial robotics has opened up opportunities for collaborative operation. Collaborative operation could include either industrial or collaborative robots, depending on its application. The current defined modes of collaborative operation are hand guiding; speed and separation monitoring; safety-rated monitored stop; and, power and force limiting.