Robots in the Workplace: A Forensic Engineering Perspective
When I was a kid, my favorite cartoon, the Jetsons, showed a future where humans interacted with machines and robots as a normal part of life. I dreamed of how great it would be to have a “Rosie the Robot” to help me with my chores. Years later, I met my first industrial robot during an internship in college, but this robot was nothing like Rosie. It was big, powerful, and had the potential to injure or even kill. This robot was enclosed by a fence with interlocked doors that shut off power when opened and was surrounded by pressure sensitive mats to prevent operation when someone was nearby. These safety devices were utilized to keep humans away to reduce or eliminate industrial accidents.
Fast forward to today, and the landscape of robotics has evolved significantly. We now have collaborative robots, that are designed to work right alongside human workers.
Collaborative robots, called cobots, are designed not to replace human workers, but to work in collaboration with humans by utilizing several safety features, including:
- Force and torque sensing: Cobots can be equipped with sensors that can detect changes in force or torque, allowing them to quickly stop or slow down if they encounter an unexpected obstacle or resistance.
- Speed and position monitoring: Cobots can monitor their own speed and position to ensure that they are not moving too quickly or too close to human workers and can slow down or stop if necessary.
- Safety-rated sensors and cameras: Cobots often have sensors and cameras that are specifically designed for safety, such as light curtains, laser scanners, or depth cameras, which can detect when a human worker is nearby and slow or stop the robot.
Since the human worker and cobot can work side by side, work tasks can be shared to optimize safety, quality, and productivity. For example, operators were reporting repetitive motion injuries from an inspection process that required a part be lifted and rotated reveal all the surfaces on the part. A cobot was added to handle the part positioning, improving ergonomics for the worker and resulting in fewer injuries while reducing cycle time for the process.
While cobots are still a small percentage of total industrial robot installations, their use has grown at rates over 70 percent year over year for the past several years. Soon, many industrial workers will be spending their workday alongside a robot colleague.
Despite all the advancements, incidents still happen. When something fails—whether due to a design flaw, a manufacturing defect, or user error—pinpointing the root cause is essential. That’s where forensic engineering plays a crucial role. We dive deep into these incidents, offering a clear understanding of what went wrong and helping to prevent it from happening again.
As cobots become more common in various industries, the need for detailed investigations and thorough analysis will only increase. Whether we’re working with complex machinery or navigating new technologies, our priority is always on ensuring safety and clarity in every scenario.
About the Author:
Kevin L. Brown, M.S., P.E., CFEI, CVFI, is a seasoned Consulting Engineer at EDT Forensic Engineering & Consulting. With over three decades of experience in mechanical engineering and a deep background in manufacturing systems, Kevin specializes in uncovering the root causes of machinery and product failures. His expertise is built on a foundation of rigorous analysis and a commitment to uncovering the truth, making him a trusted partner in complex product liability cases.