Robot-Printer-SSOP_slp.docx

Operation of Robot Arm Standard Safe Operating Procedure Activity ID: 731.07.0260 Created: November 1, 2019 Revised: June 26, 2023 Location: Bldg. 206/107 and 108 Responsible: Shawn Platt

Contents

1 Overview of Robot Arm The Robot Mortar Printer (RMP) is a six-axis articulated robot mounted to a seventh axis track. A nozzle is mounted to the end of the robot, and a wet mix group pump supplies material to the nozzle. The RMP is located in the Additive Construction Laboratory (ACL) in building 206, room 108. The ACL is divided into four working areas: the control area, the pumping area, the print area, and the observation area. The ACL and the RMP are shown schematically in Figure 1.

Figure 1: Overview of the Robot Mortar Printer located in the Additive Construction Laboratory.

The control area contains the computer where the robot is programmed, and data are collected. The pumping area contains the grout pump, material silo, and spill containers. The print area is bounded by the laboratory north and south walls and the light curtains on the east and west ends. The print area defines the robot cell. The observation area is located on the east end of the ACL, between the exterior wall and the light curtain. A schematic diagram of the robot, with the axes numbered, is given in Figure 2.

Figure 2: Schematic diagram of robot.

1.1 Operations covered by FHLR

This FLHR covers the ABB IRB6700 six-axis articulated robot arm and seventh axis track operation, which is used to dispense a cementitious material to create 3-D printed structures. The operations covered by this FLHR include operating the robot in automatic and manual modes, pumping a cementitious material with a grout pump, the setup and cleanup of the grout pump and robot, as well as moving printed specimens out of the lab.

This FLHR does not cover operations that require access to the hardware inside the robot controller and assembly or disassembly of the robot. Authorized ABB service technicians shall do work requiring access to the robot controller. Assembly and disassembly of the robot are covered by FLHR 731.07.0219 Installation and Commissioning of Robot Arm.

1.2 Documentation

Review the following documentation prior to operating the RMP.

1. 3HAC031045-001: Operating manual General Safety Information

2. 3HAC050941-001: Operating manual IRC5 with FlexPendant

1.3 Materials

1. Hand tools - wrenches, screw drivers, hammer, drills, etc.

2. Overhead crane, slings.

3. Hoses: lab water supply, grout.

4. Portland cement-based cementitious materials.

1.4 Personal Protective Equipment

Required:

1. Safety Glasses

2. Cloth face covering (COVID-19 precaution) Task Specific:

1. Steel-toed Shoes

2. Hard Hat

3. Gloves

4. Dust Mask

1.5 Required Training

NIST P 7100.00 - General Safety Training CLC S 7101.62 - Back Safety and Injury Prevention CLC S 7101.62 - Ergonomics in the Workplace CLC - Hand and Power Tool Safety CLC - Ladder Safety Training CLC - Overhead Crane and Slings (required if operating crane) Required Activity Training: All participants must receive in-person training about the operation of the robot and the safety features. Training in the operation of the grout pump is required to operate the RMP.

May be satisfied by completing US519 - IRC5 OPERATIONS WEB BASED TRAINING from the robot manufacturer, ABB. The goal of this self-paced Web Based Training (https://mylearning-americas.abb.com/) Is to teach students how to operate the robot and modify positions using the FlexPendant. This course has 8 modules and a final assessment. Upon receipt of payment, you have 30 days to complete the course. Student profile This course is intended for personnel responsible for starting and operating the robot. Operators and non-skilled laborers. Prerequisites No formal requirements. Duration Course duration is 5-6 hours.

This web-based course uses both reading and video to deliver the content and assessments are through a virtual environment where the student must operate the system or answer questions by using the virtual FlexPendant and navigating through a series of correct steps to achieve the requested operation.

Course Objectives Upon completion of this course, you’ll be able to:

· Practice safety as it pertains to the robot system

· Identify robot system components and move/ jog the robot using the joystick

· Interpret and respond to event messages

· Perform basic operations

· Modify movement instructions in a basic program

· Demonstrate how to use the input and output instructions in a basic program

· Demonstrate how to save robot information

1.6 Robot Operator Roles

Two individuals are required to operate the RMP and must be identified before starting any robot operation. It is recommended that a third operator be present to assist with the print. The third operator is not required to operate the RMP safely. At any time, during any stage of the robot operation, if any individual present observes unsafe conditions, they are authorized to stop all operations by activating an emergency stop. The roles and responsibilities are:

Required Operators:

Robot Operator: The individual responsible for the safe operation of the robot.

This individual is the only individual authorized to operate the robot in manual or automatic mode. The robot operator shall complete the “Printing in Automatic Mode Check List” before initiating printing operations. All directions given during the printing operations shall come from the robot operator. The robot operator is responsible for the E-stop located on the FlexPendant. The Robot operator is responsible for the E-stop at the control area if the Control Operator is not present during printing operations.

Required training for individuals conducting a print operation – At least one individual (Robot Operator) must have completed the ABB US519-IRC5 training. All others must have completed the required CLC training as outlined (Section 1.5).

Pump Operator: The pump operator is responsible for the operation of the grout pump. They are to monitor the pressure reading and are responsible for the E-stop located on the west wall.

Recommended Operator:

The control operator is required if printing operations are conducted without the material silo. This is because the pump operator will need to load material and cannot monitor the pressure and E-stop.

Control Operator: This individual is stationed in the control area. The individual is responsible for the E-stop located at the control area and shall monitor the print area and robot functions output to the control computer. The control operator will provide assistance as necessary.

1.7 The FlexPendant

The robot can be operated through a hand-held device. The FlexPendant is a hand-held user interface to the robot. It is used for many tasks associated with operating the robot, for example, running programs, jogging the manipulator, and modifying programs. The FlexPendant is designed for continuous operation in a harsh industrial environment. Its touch screen is easy to clean and resistant to water, oil, and accidental welding splashes. The FlexPendant consists of both hardware and software and is a complete computer in itself. It is connected to the robot controller by an integrated cable and connector. The primary components of the FlexPendant are detailed in Figures 3 and 4. The Robot Operator is the only authorized individual to handle the FlexPendant.

Figure 3: The main features of the FlexPendant

Figure 4: The buttons on the FlexPendant and the function.

2 Safety Features The robot cell is designed to meet the following standards where applicable:

1. ANSI/RIA R15.06-2012

2. ISO 12100:2010

3. ISO 13849-1:2015

4. ISO 13849-2:2012

5. ISO 13855:2010

6. RIA TR R15.306-2016

2.1 Robot Cell Status: Light Stack

The light stack is mounted on the north wall. It provides a visual indication of the status of the RMP. The indicator lights are defined in Table 1. Individuals working around the robot must monitor the status of the robot to determine if it is safe to enter the print area or approach the robot. The illuminated yellow light indicates that power is supplied to the motors, and the robot is ready to move. It is not safe to approach the robot when the yellow light is illuminated.

The green light indicates which mode the robot is operating in. A continuously illuminated green light indicates the robot is in manual mode. This is the default state of the robot when it is powered on. It is safe to enter the print area and approach the robot when the green light is illuminated.

A flashing green light indicates the robot is in automatic mode. The robot is ready to execute a program in this state. An illuminated yellow light and a flashing green light indicate power is supplied to the motors, and the robot is in automatic mode. It is not safe to enter the print area or approach the robot if the green light is flashing or if the green light is flashing and the yellow light is illuminated.

Table 1: Light stack indicator. The illuminated color indicates the status of the robot cell

Flashing: No

2.2 Emergency Stop

The emergency stop buttons are pictured in Figure 5. Two emergency stop buttons, operating in series, are located near the computer in the control area and mounted on the west wall. A third emergency stop is located on the FlexPendant. Pressing an emergency stop will halt all robot and grout pump operations. The emergency stop buttons must be released to recover from an emergency stop. The RMP will be in a state where it cannot operate until the reset button (located at the control area emergency stop) is pressed. Operators are to press the reset button only after all hazards have been mitigated. An emergency stop that needs to be reset is indicated by a flashing red light on the light stack.

Figure 5: Emergency stops are located near the grout pump, the control area, and on the FlexPendant.

2.3 Reduced Speed in Manual Mode

The maximum speed of the robot, under all conditions, is limited to 250 mms−1 (4 s per meter) while in manual mode. See Section 5.8.2 About the manual mode on page 208 of the IRC5 with FlexPendant manual.

Note: Speed is hard set in the software and aligns with current OSHA guidelines

2.4 Axis 1 Limited Movement

The controller has been set to limit the range of movement of axis 1 to ± 90◦ to prevent the robot from crossing the plane of the 7th axis. This is to avoid a collision with the south wall. This software limit is in place in both manual and automatic modes.

Figure 6: Robot positioned at the controller-limited ± 90◦ of axis 1, preventing the arm from crossing the track (7th axis).

2.5 Hold-to-run operation in manual mode

With the hold-to-run enabled, the operator must depress the switch to the enable position and hold the button associated with the desired action. Once the button is released, the action is immediately stopped. The three-position enabling device must be pressed to activate motors. The robot may move only when the three-position enabling device is pressed. If the operator releases the three-position enabling device, all movements and actions are halted.

2.6 Light Curtain and SafeMove 2

The combination of the light curtains and the SafeMove 2 feature defines the print area. Light curtains define the west and east boundary of the print area. The light curtains provide body protection and are placed according to ISO 13855:2010 - Safety of machinery - Positioning of safeguards with respect to the approach speeds of parts of the human body. Robot functions are halted if the light curtain is broken while the robot is in automatic mode. SafeMove 2 is a feature of the robot controller that allows the operator to define the boundaries of a zone within which the robot can move. Here, SafeMove 2 is used to limit the movement of the robot to inside the boundaries of the print area while in automatic mode.

SafeMove2 allows the operator to define an area within which the robot is able to move while operating in automatic mode. The movement of the RMP is restricted to the print area. The movement of axis 1 is limited to 90◦ when the robot is positioned at the end of the track. ISO 13855:2010 requires guarding be positioned according to Equation 1.

S = (K × T) + C (1) where S is the distance from the robot to the guard, K is the speed of the robot, T is the stopping time and C. = 850 mm is the offset value. The speed of the robot is limited to K = 1000 mms−1, the stopping time at this maximum speed is T = 0.25 s. Applying Equation 1, the light curtain is placed at a distance S = 1.1 m from axis 1.

Note: Speed noted is a maximum that could only occur if the safety limits noted in Section 2.3 were overridden in the factory set programming.

2.7 Interlock

A keyed interlock is located in the control area. Removing the key from the interlock while the robot is in automatic mode disables power to the robot motors.

2.8 Mirror

A mirror is located in the northeast corner of the ACL so that the area behind the robot can be viewed from the control area.

Figure 7: A mirror is located on the east wall so that the print area can be viewed from the control area if objects in the print area obstruct the view.

3 Hazards Table 2: List of hazards and controls

Entering Print Area

Operation in Automatic Mode

Operation in Manual Mode

Releasing Robot Brakes

Pumping Grout

Refer to FLHR 731.07.0220 - Operation of m-tec Duo Mix 2000 Grout Pump

Removing Specimens

Cementitious Materials

4 Safety Considerations: Robot Operation

4.1 Verify Engineering Controls

Several engineering controls are in place to disable the robot in the event of an emergency or unintended entrance to the print area. Verify the operation of all engineering controls after the robot has been powered on and prior to any manual or automatic operation. Engineering controls are to be verified monthly or after any major modifications to the robot cell. Major modifications include updating software, the addition of new hardware components, or changing the robot tool.

1. Inspect print area for obstructions. Verify the parabolic mirror is clean and the robot cell can be observed from where the robot operator is positioned.

2. Verify function of light stack:

· Verify green light is illuminated indicating manual mode operation.

· Press and E-stop and verify light red light is illuminated.

· Release E-stop and verify red light is flashing.

· Press reset button and verify red light turns off.

· Turn on motors and verify yellow light is illuminated.

· Turn on power to the grout pump and verify blue light is illuminated.

· Turn on the pumping motor and verify blue light flashes.

The following inspections need to be performed with the robot in automatic mode. Before placing the robot in automatic mode, follow the procedures in Section 7 to ensure all individuals are clear of the print area.

1. Place the robot in automatic mode.

2. Verify the green light is flashing.

3. Power on the grout pump.

4. Verify function of the three E-stops:

· Run a RAPID code and verify automatic movement of the robot.

· Press control area E-stop and verify robot and grout pump has stopped.

· Repeat for the FlexPendant E-stop and the E-stop near the grout pump.

5. Verify function of light curtain:

· Verify curtains are aligned by inspecting the indicator lights.

· Run a RAPID code and verify automatic movement of pump.

· Using a wand, break the light curtain beam and verify the robot and pump have stopped.

· Check both light curtains at each end of the print area.

4.2 Operation in Manual Mode

See Section 6 for the safe operating procedure for operating the robot in manual mode. The hazards and controls while operating in manual mode are discussed in this section.

The following safety considerations must be observed when entering the print area or working within reach of the robot. The three-position enabling device is located on the FlexPendant, refer to Figure 3.

· The robot must be in the manual mode position to render the three-position enabling device operational and to block operation from a computer link or remote-control panel.

· The maximum speed of the robot is limited to 250 mms−1 when operating in manual mode. This should be the normal position when entering the working space.

· Pay attention to the rotating axes of the robot. Keep away from axes to not get entangled with hair or clothing. Also, be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell.

· Keep clear of moving parts so that limbs, hands, or fingers do not get trapped or crushed by the robot.

· To prevent anyone else from taking control of the robot, bring the three-position enabling device with you when entering the working space. Only the robot operator shall have control of the three-position enabling device.

· NEVER, under any circumstances, stay beneath any of the robot’s axes! There is always a risk that the robot will move unexpectedly when robot axes are moved using the three-position enabling device or during other work inside the working range of the robot.

Struck by: The primary hazard associated with manual mode operation is the robot striking an individual inside the print area. This hazard is mitigated by administrative and engineering controls.

1. Robot Speed Limited: The speed of robot movements in manual mode is 250 mms−1.

2. Robot Operator: The individual designated as the robot operator is the only individual authorized to move the robot.

3. Announcing Robot Movements: The robot operator shall announce the robot will move and the direction it is moving prior to executing the movement.

4. Hold-to-run operation Pinch Points: The robot contains several components which create pinch points. Prior to ANY robot movement. The operator shall announce to all individuals the intent to move the robot and the direction it will be moving.

4.2.1 Entering and Exiting Print Area

Entering the print area may be required during the operation of the robot arm. Before entering the print area, all operators are to assess the current status of the robot cell by observing the light stack. If the light stack indicates the robot is in manual mode, the following procedures are to be followed by all personnel entering the print area.

Robot Operator: Controls the robot from the FlexPendant. They are the first to enter the print area and the last to depart. Must account for all individuals entering and leaving the print area.

4.2.2 Energized motors

All operators are to maintain two arm’s lengths distance from the robot while the motors are energized and while the robot is moving. The robot operator is responsible for knowing the location of individuals in the print area and informing them that the motors are energized, and that the robot is moving.

Struck by: The primary hazard associated with entering the print area in manual mode operation is the robot striking an individual inside the print area. This hazard is mitigated by the Safe Operating Procedure outlined in Section 6 and the administrative controls detailed above.

4.3 Operation in Automatic Mode - Printing an Object

Complete the “Printing in Automatic Mode Check List” prior to operating the robot in automatic mode. The check list identifies the roles of the individuals present for the print and reviews safety procedures and protocols. The check list is to be completed by the robot operator and stored in the ACL Safety Binder.

Struck Against: The primary hazard associated with automatic mode operation is the robot striking an individual inside the print area. This hazard is mitigated by administrative and engineering controls.

1. Light curtains: Installed at the east and west ends of the print area. The light curtains will stop all robot movements and pump operations if the light barrier is broken.

2. Parabolic Mirror: The mirror is installed in the northeast corner of the lab. The robot operator inspects the print area to ensure no individuals are present at the start of automatic operation.

3. Safety Check List: Completing the safety check list ensures proper procedures are followed and the printing procedure is executed in the safest manner possible.

4. Physical Barriers: Erect barriers around print area. Place signs on all entrances to building 206/108 and on the barriers indicating the robot is operating in automatic mode and entry is not permitted.

4.4 Freeing Stuck Robot - Releasing Robot Brakes

The robot is equipped with six brakes on each of these six axes of movement. These brakes are engaged whenever the robot is static and must be manually released. If the robot is in a position where it cannot move, the operator must release the brakes and move the robot manually. Figure 8 shows the location of the robot brake release and the robot stuck in the downward position. The brake release buttons are shown in Figure 8a. There are six buttons, one for each axis, labeled 1 through 6. To release the brake for an axis, push and hold the button. Releasing the button will apply the brake.

Figure 8: (a) the brake release buttons and (b) the robot stuck in a downward position.

When the brake is released, the robot is free to move about that axis. Releasing the brakes could cause the robot to move in an unintended way. For example, if the arm is raised (as in Figure 2 and the brake for axis two is released, the arm will swing in a downward motion around axis two. This movement is uncontrolled and could cause injury to operators or damage equipment.

The following procedure is to be followed If the robot is in a position it cannot move from, and an operator must physically touch the robot to free it from the stuck position. Two operators are required to perform this operation.

1. Stop all activities and release all pressure from the grout pump.

2. Assess the situation with the robot. Determine how the robot is stuck and which axes need to be moved. Axes four, five, and six can be moved by a single operator.

The overhead crane is required to move axes two and three. See 4.4.1

3. If it is determined that freeing the robot will take considerable time and effort, begin the clean up procedure for the grout pump prior to freeing the robot.

4. Clear the print area of any obstructions near the robot. This may require moving printed objects or other pieces of equipment.

5. Before releasing the brakes on any axis, secure axes two and three using jack stands to prevent movement in the event of an accidental brake release.

6. The robot operator shall clear the print area of all personnel except the pump or control operator who will move the axis.

7. The pump operator shall stand clear of the robot while the robot operator pushes the brake release for the required axis. Allow the robot to settle at an equilibrium.

8. The pump operator will move the robot axis as quickly as possible. Once moved, the pump operator will indicate to the robot operator that the axis is clear.

In Figure 8b, the robot is stuck in a downward position. The robot can be freed from this position by rotating axis five upward. The brake for axis five must be released so that the pump operator can move the axis. The movement of axis two and three is secured by creating a crib under the arm, as shown in Figure 8b. The cribbing secures the downward movement axis two and three while allowing axis five to rotate. The robot operator clears the print area and presses and holds the brake release for axis five. Once it is determined that axes two and three are secured, the pump operator can move axis five to free the robot. The axis is moved with a quick upward movement, and the brake is re-applied. The robot is jogged to a secure position.

4.4.1 Moving Axis 2 and Axis 3

The overhead crane shall NOT be used to prevent free fall of the robot when axis brakes are released.

The overhead crane and slings shall be used to move axes two and three. The mass of these two axes are below the critical lift capacity of the robot but cannot be moved by a single operator. Before moving the axes:

1. Use jack stands or cribbing to secure the axis when the brakes are released.

2. Attach the slings and crane to the axis.

3. Release the brakes for the axis that will be moved and allow the jack stands or cribbing to support the weight of the axes.

4. Use the crane to lift the axis (or axes) of the jack stands or cribbing to a secure location and re-apply the brakes.

Do not attempt to move axis two or three with the crane without first securing the axes with jack stands or cribbing. Moving unsecured axes with the crane could cause the the slings to slip and the axes to fall in an uncontrolled manner. Always support the axes before moving them with the crane to reduce the distance the axes can fall if the slings slip.

4.5 Removing Specimens

The following safety procedures apply to specimens with a mass less than 1500 kg (3500 lbf). The overhead crane, pallet jack, or forklift can be used to move these specimens. Crane safety training and forklift operation and safety training are required to move the specimens using the overhead crane and forklift. If the specimen mass is greater than 1500 kg, a separate safety procedure must be created.

Please refer to the following FLHRs for the overhead crane and forklift before removing a specimen.

· FLHR 731.01.0026 - Operation of Overhead Crane - up to 20 ton

· FLHR 731.01.0036 - Operation of Industrial Powered Lift Truck - up to 15,000 lbf

Struck by: The primary hazard associated with removing specimens is the specimen striking an individual. This hazard is mitigated by administrative and engineering controls.

1. Estimate mass of printed specimens by estimating the volume of printed material (estimated from the CAD model) and the material bulk density.

2. Specimens shall be removed either by the overhead crane or forklift. Only qualified operators shall operate the over-head crane or forklift.

4.6 Cementitious Materials

Respiratory Irritant, Dust: The primary hazard associated with cementitious materials is the dust generated while loading the material. The use of a dust collector and voluntary use of dust mask mitigate this hazard. Hazards associated with the preparation and handling of cementitious materials are discussed in FLHR 731.07.0230 - Mortar Mixing and FLHR 731.07.0182 - Mixing Concrete.

4.7 Over Pressurization

An alarm will sound should the pressure in the grout pump exceed 300 psi. Stop all pumping operations and robot movements to address the over pressurization. Follow procedures in FLHR 731.07.0220 to clear and remove blockage.

4.8 Equipment Inspections

Prior to each use, inspect the robot and grout pump for damage and excessive wearing or deterioration. Inspect hoses and cables for kinks and bends. Inspect plug and hose connections to ensure they are secure and can operate as intended.

5 Safety Considerations: Grout Pump Refer to FLHR 731.07.0220 - Operation of m-tec Duo Mix 2000 Grout Pump for complete safety consideration while operating the grout pump including operating it while connected to the robot arm.

6 Safe Operating Procedure for Manual Movement The following procedure must be followed before moving the robot in manual mode.

1. Designate one individual as the operator. Only the operator shall be authorized to move the robot.

2. Obtain a head count of all individuals working in the laboratory space.

3. Visually inspect the print area for obstructions. Observe the status of the robot as indicated by the light stack. Check the parabolic mirror to verify the southeast corner of the print area is free of obstructions.

4. Announce to all individuals present to clear the print area.

5. Visually inspect the print area for obstructions.

6. Announce to all individuals that the robot is moving.

7. Visually inspect the print area after everyone has cleared the area to ensure it is clear of personnel and obstructions.

8. Plan the movement of the robot ensuring the path is free of obstructions.

9. Begin moving the robot toward its intended destination by lightly moving the joystick in one direction.

10. Continually observe the intended path of the to ensure it is free of obstructions

11. Once the robot is in the intended position and the motors are deactivated, announce that the print area is clear for entrance.

6.1 First Run of RAPID Program

When a new RAPID program is created, it must be tested on the robot prior to running in automatic mode. The program is tested by stepping through the code line-by-line in manual mode. To do this, the robot operator must have the three-position enabling device in hand. Individual lines of the program are executed by pressing the step forward button while the three-position enabling switch is pressed. Step through the first 10 to 15 move commands to verify the robot movements. The program can be executed automatically by pressing the start button while holding the three-position enabling device.

Prior to stepping through the robot program, the robot operator shall clear the print area of all personnel and obstructions. Barriers are to be erected around the print area with signs indicating automatic movement of the robot.

7 Safe Operating Procedure for Printing a Specimen The following procedure must be followed before printing a specimen. The robot operator is responsible for executing the following:

1. Complete the “Printing in Automatic Mode Checklist”

2. Setup grout pump.

3. Verify individuals are clear of print area. Each individual present will raise their hand and indicate they are clear of the print area. Take a head count and compare to check list.

4. Verify all individuals know and understand their assigned roles.

5. Visually inspect print area for individuals or obstructions

6. Announce: “Robot entering automatic mode”

7. Announce: “Activating robot motors”

8. Announce: “Robot motors are active”

9. Announce: “Starting the print”

10. Announce: “Print is starting”

7.1 Entering Print Area while in Automatic Mode

All robot movements must be paused prior to entering. The drives must be turned off. An interlock key is located at the control area. The interlock key is removed to prevent the robot motors from activating. The individual with the interlock key is responsible for the operation of the robot. They are the first to enter the print area and the last to exit. Their primary responsibility is to maintain a head count of individuals inside the print area and ensure everyone is clear of the print area before resuming automatic operations. The following procedures must be followed by the individual entering the print area:

1. Communicate to the robot operator intent to enter the print area.

2. Wait for confirmation from the robot operator that the robot has stopped moving and the motors are deactivated.

3. Verify the motors are deactivated by checking the light stack.

4. Indicate to the robot operator that the interlock key has been removed.

5. Take a head count on individuals entering the print area.

6. Enter print area and survey for hazards. Once clear, ask all individuals to enter print area.

7. Enter print area and perform task.

8. Ask all individuals in the print area to exit.

9. Take a head count of all individuals in the lab space by asking them to raise their hand and indicate they are clear of print area.

10. Return the key to the interlock. Indicate to the robot operator the key has been returned.

The robot operator shall follow the following procedure to re-start printing operations.

1. Take a head count and compare to check list.

2. Verify all individuals are in their assigned roles.

3. Visually inspect print area for individuals or obstructions

4. Announce: “Robot entering automatic mode”

5. Announce: “Activating robot motors”

6. Announce: “Robot motors are active”

7. Announce: “Starting the print”

8. Announce: “Print is starting”

Visitor: Observing the printing operation. Restricted to observation or control area.

· Required PPE: Safety glasses Operation Assistant: A researcher who is assisting with the printing operations. Their role is limited to pump and control operator.

· Must complete all NIST/EL/MSSD/Activity required training and authorized to work in a lab

· Must compete in-person and classroom training on the operation of the robot mortar printer Active User: A researcher currently conducting a research experiment using the robot mortar printer.

· Operation Assistant training

· Must file a research plan detailing the printing operations in the scope of work Instrument Scientist: A researcher who is authorized to program and execute a print with the robot mortar printer without assistance.

· Active User training

· Training from the robot integrator/ABB supported training/current Instrument Scientist

· Active users can request Instrument scientist status from current Instrument Scientist

– Must complete a successful print as robot operator under supervision of current Instrument Scientist

8.2 Training

All Operation Assistants, Active Users, and Instrument Scientist must complete this training before working in the Additive Construction Laboratory

8.2.1 Classroom Training

Review of the Additive Construction Laboratory safety procedures

· Safety overview PowerPoint

· Identification of catastrophic hazards and the importance of operation procedures as a control measure

· Overview of how to complete printing checklist and printing plan worksheet

8.2.2 Hands-on Training

Recommended laboratory training in front of the robot

· Overview of the safety features of the Additive Construction Laboratory

· Jogging the robot in Manual Mode

· Operation of the Grout Pump

· Loading A RAPID program and running it from FlexPendant

· I do/we do/you do approach

8.3 ABB Robotics Training

ABB robotics training is available In the event that training cannot be provided by the Instrument Scientist or the robot service contractor. Full list of training can be found here: https://new.abb.com/service/training/abb-university/united-states/robotics. In person and online training is available:

· Online: Course Code US519

· In person: Course Code: US419 9 Incident and Emergency Response Plan In the event of an emergency, shut off the power to the robot and grout pump by pressing the emergency stop. Open valves to release pressure in hoses and evacuate or shelter in place as required.

The main electrical shut-off is located on the wall behind the track. To turn off the power, pull the handle downward to the off position.

· Safety Emergency: Power off equipment and attend to the emergency.

· Power Outage: Power off all equipment in preparation for power being restored.

· Building Evacuation: Power off equipment (in preparation for power being restored) and then evacuate the building, heading to the meeting location to the south of the building.

· Shelter-In-Place: Power off equipment (in preparation for power being restored) and then move to the corridor between the Garage and Room 107.

10 COVID-19 and Infectious Disease Control The primary safety controls to prevent the spread of COVID-19 and other infectious diseases are the use of barriers between occupants and mandatory cloth face covering. There are two operating conditions to consider: operating the RMP in automatic mode and general laboratory work in the space. Regardless of the operating conditions, the following safety measures are to be implemented.

1. Cloth face coverings are to be worn at all times inside the laboratory space.

2. Wash and sanitize hands after entering the building and prior to beginning laboratory work.

3. Eye protection with side shields are to be worn at all times. All safety glasses for public use are to be stored in a UV sanitizing cabinet.

4. Doors are to remain open to ensure proper ventilation. Turn on exhaust fans to increase air flow out of the space.

5. Tools, work benches, computers, and all surfaces which are touched shall be disinfected at the beginning and end of the work shift.

10.1 Operating RMP in Automatic Mode

Operating the RMP in automatic mode requires individuals to gather at one end of the building. Three individuals are required to operate the RMP and must be positioned in the control area and pumping area (Figure 1). Maintaining 2 m social distance will be difficult. Each operator is to be positioned at the locations shown in Figure 9. Plexiglass barriers will be erected between each operator. In this configuration, each operator has access to an E-stop and the robot operator can view the entire print and pump area. There is a clear path to the building exits in the event of an emergency.

10.2 General Laboratory Work

General laboratory work includes activities related to configuring and programming the robot, mixing mortar, pumping mortar, and cleaning equipment. 2 m social distancing shall be maintained at all times. The following safety protocols are to be implemented:

1. No more than 4 individuals are to be present in the lab at one time.

2. Pedestal fans are not to be used as they can help spread viruses from one individual to another.

3. Each occupant of the lab is to bring their own water source as drinking fountains are not to be used.

4. Take a 15 min breaks every hour.

5. When handing an item to another person, place it on a surface and step away.

6. Utilize cranes and lifts when lifting heavy objects instead of a two-person lift.

Figure 9: Overview of the Robot Mortar Printer with engineering controls to guard against the spread of infectious diseases.

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