MIR MiR100 User manual

MiR100, MiR200 & MiRHook
Risk Analysis
Technical Documentation
Risk analysis
Release date: 12.07.2019

MiR100, MiR200 & MiRHook Risk Analysis
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1Content
2 Introduction......................................................................................................................................................3
3 Terminology......................................................................................................................................................3
4 Assumptions .....................................................................................................................................................4
5 Safety components overview ...........................................................................................................................5
5.1 Safety laser sensors ..................................................................................................................................5
5.2 Emergency stops.......................................................................................................................................5
5.3 Awareness Indicators ...............................................................................................................................6
6 Use Cases and Risk Identifications ...................................................................................................................7
7 Safety Design and Residual Risks......................................................................................................................8
7.1 Docking to charging station......................................................................................................................8
7.2 Entering and exiting enclosure .............................................................................................................. 12
7.3 Picking up cart ....................................................................................................................................... 17
7.4 Towing cart ............................................................................................................................................ 23
7.5 Parking cart in reverse........................................................................................................................... 26
7.6 Driving with MiRHook without a cart.................................................................................................... 31
8 Appendix A: Resources .................................................................................................................................. 33
9 Appendix B: Illustrations Documentation ..................................................................................................... 33
10 Changelog .................................................................................................................................................. 35

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2Introduction
This document describes scenarios with MiR100, MiR200 and MiRHook that require special attention. First, an
introduction to the terminology, assumptions, safety- and awareness indicators. This is followed by a section
describing normal use case scenarios.
Each scenario is divided into phases. The phases are described in chronological order.
For each residual risk, the compensating safety features are highlighted, and based on this a conclusion is made
on the significance of the residual risk.
Please note that all scenarios are illustrated with MiR200 and MiRHook, but they apply equally for MiR100 and
MiRHook.
This document does not provide an exhaustive list of scenarios in which MiR100, MiR200, MiRHook can be
used with a reduced safety level of the safety system. However, it describes the most common scenarios for
the intended use. The scenarios provided in this document can also be used as a template for making risk
analysis of similar scenarios during the commissioning phase.
3Terminology
•Awareness indicator: Light and/or acoustic signals, see section 4.
•Charging station: Unit connected to a factory power outlet which enables a robot to autonomously
charge its batteries.
•Docking: Precision maneuvering to a relative marker.
•Entry position: Coordinate on the robot’s map that must be reached before initiating a docking
sequence.
•Goal position: Coordinate on the robot’s map that must be reached to finish a docking sequence.
•Relative marker: Object with specific physical dimensions and shape used for precision positioning of
the robot. Examples are pallet rack, charging station, V-, VL- and L-marker.
•Operating hazard zone: Marked area according to standard EN 1525:1997 clause A.3.2. No obstacles
other than those specified by each scenario can be placed inside this zone.
•MiRHook (MiRHook100 and MiRHook200): Top module that enables MiR100 and MiR200 to tow a cart.
•Cart: A cart commissioned to be moved by MiRHook.
•PLd: Performance level d as defined by ISO 13849-1.
•Not a safety function: A function that is not safety rated.
•Protective field: Area in which protective stop is automatically triggered if a person or object enters
the area.
•Tolerance zone: The safety laser scanner measures the distance to a diffuse reflection and causes a
tolerance to the measurement. In most situations, including during tests, the safety laser scanner will
detect a person within the tolerance zone.
•Relative move: When driving using a relative move the robot relies only on wheel encoders for
navigation, and the robot will only move in the specified direction, for example straight forward.

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•Software collision avoidance: Software using safety scanner data to detect persons or obstacles to
avoid these or stop the robot before protective stop is triggered. This works regardless of whether
protective fields are active or not but filters out expected obstacles such as a charging stations or pallet
racks. The software collision avoidance is not safety rated.
•Normal driving position: The speed in normal driving position is 1.5 m/s for MiR100 and 1.1 m/s for
MiR200. In the description of the phases, the normal driving speed for MiR100 is shown first, and the
speed of MiR200 is shown in parenthesis (1.5 (1.1)).
•Driving in reverse: The speed when driving in reverse is shown as negative.
4Assumptions
•Throughout this document it is assumed that the products are used within the specifications of the
robot and top module.
•That the guidelines of correct commissioning have been followed according to the product manuals
and the commissioning documentation, see Appendix A. Commissioning will include the following but
is not limited to:
oProtective field adjusts to the size of the towing cart.
oProtective field adjusts to the increased breaking distance due to the towing cart.
•That carts are commissioned correctly to be towed by MiRHook.
•When towing a cart MiR100 and MiR200 will never drive in reverse, the only exception is when loading
and unloading a cart.
•When the robot drives into an enclosure it is assumed that the passage into the enclosure is not part of
an escape route.

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5Safety components overview
5.1 Safety laser sensors
•Two safety lasers sensors (Pld) are placed at diagonal corners. The safety laser sensors are placed 20
cm from the ground.
•They create a 360° protective field.
•The size of the protective fields depends on robot speed and driving direction. See the specifications of
the robot.
The protective fields of MiR100 and MiR200 will never be turned off. However, the protective fields will
adjust to the speed of the robot.
5.2 Emergency stops
•There is an emergency stop button placed on top of the robot or MiRHook. The emergency button is
within reach from all sides of the robot.
Figure 1 Protective fields of MiR100 and MiR200 when
driving forward.
Figure 2 Protective fields of MiR100 and MiR200 when
driving in reverse.

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5.3 Awareness Indicators
•Light signals:
The robot has LED lights on each side of the robot.
During commissioning the robot must be commissioned to give appropriate light signals when
operating in hazard zones.
•Acoustic signals:
One speaker placed inside the robot.
Acoustical warnings must be addressed during commissioning.

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6Use Cases and Risk Identifications
Use cases
Risks
No.
Dock to charging station
Docking to MiRCharge
Risk of crushing
1
Docking to MiRCharge
Risk of crushing
2
Docking to MiRCharge
Risk of crushing
3
Localization failure
Risk of crushing
4
Entering and exciting
enclosures
Entering/exciting enclosure
Risk of crushing
5
Entering/exciting enclosure
Risk of crushing
6
Attaching to a cart
Alignment to cart
Risk of crushing
7
Attaching to cart
Risk of crushing
8
Attaching to cart
Risk of crushing
9
Attaching to cart
Risk of crushing
10
Towing cart
Towing cart
Risk of crushing
11
Towing cart
Risk of crushing
12
Parking cart in reverse
Unloading cart
Risk of crushing
13
Localization failure
Risk of crushing
14
Driving with MiRHook
Driving with a MiRHook
Risk of crushing
15
Driving with a MiRHook
Risk of crushing
16

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7Safety Design and Residual Risks
7.1 Docking to charging station
Phase 1: Approaching entry position
Phase 2: Marker detection
Maximum speed [m/s]
1.5 (1.1)
Awareness indicator
No
Operating hazard zone
No
Maximum speed [m/s]
0
Awareness indicator
No
Operating hazard zone
No

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Phase 3: Approaching docking station
Phase 4: Docking
Maximum speed [m/s]
0.1
Awareness indicator
Yes
Operating hazard zone
Yes
Maximum speed [m/s]
0.1
Awareness indicator
Yes
Operating hazard zone
Yes
Phase 5: Charging. Final position reached
Maximum speed [m/s]
0
Awareness indicator
No
Operating hazard zone
Yes

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Residual risks
1. A person is standing between the charging station and the
robot while the robot is docking to the charging station 
Risk of being crushed.
But:
•Speed reduced to 0.1 m/s (not a safety function)
•Software collision avoidance (not a safety function) will
detect the person and stop the robot
•Markings on the floor indicate an operating hazard zone
•The severity is considered low, due to low impact of the
robot
Conclusion: Low residual risk
2. A person is staying close to the charging station and robot
while the robot is docking (phase 4). Risk of being crushed.
But:
•Speed reduced to 0.1 m/s (not a safety function)
•Software collision avoidance (not a safety function) will
detect the person and stop the robot
•Markings on the floor indicate an operating hazard zone
•The severity is considered low, due to low impact of the
robot
Conclusion: Residual risk extremely low.

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3. A person enters during docking Risk of being crushed.
But:
•Speed reduced to 0.1 m/s (not a safety
function)
•Software collision avoidance (not a safety
function) will detect the person and stop the robot
•Markings on the floor indicate an operating hazard zone
•The severity is considered low, due to low impact of the
robot
•Very improbable behavior Staff and visitors need to
be trained
Conclusion: Residual risk low.
4. Localization fault: The robot is not well localized and the robot docks to a
marker/object different than the desired charging station, and a person is
staying between the marker/object and robot Risk of being crushed.
But:
•Localization fault is improbable
•The robot must detect a shape similar to the characteristic shape of
a charging station before initiating docking sequence
•Software collision avoidance (not safety function) will detect the
person and stop the robot
Conclusion: Residual risk extremely low.

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7.2 Entering and exiting enclosure
Phase 1: Approaching entry position
Phase 2: Entering operating hazard zone
Maximum speed [m/s]
1.5 (1.1)
Awareness indicator
No
Operating hazard zone
No
Maximum speed [m/s]
0.3
Awareness indicator
No
Operating hazard zone
Yes

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Phase 3: Enter enclosure
Phase 4: Reach goal position
Maximum speed [m/s]
0.3
Awareness indicator
Yes
Operating hazard zone
Yes
Maximum speed [m/s]
0.3
Awareness indicator
Yes
Operating hazard zone
Yes

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Phase 5: Initiate exit move
Phase 6: Approaching exit goal position
Maximum speed [m/s]
0.3
Awareness indicator
Yes
Operating hazard zone
Yes
Maximum speed [m/s]
0.3
Awareness indicator
Yes
Operating hazard zone
Yes

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Phase 7: Normal driving position
Maximum speed [m/s]
1.5 (1.1)
Awareness indicator
No
Operating hazard zone
No

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Residual risks
5. Person standing in entry of the passage when the robot drives through
(phase 3 and phase 6). Lack of escape zone. Risk of being crushed or
sheared between the door and the robot.
But:
•Protective field will trigger protective stop if the person is
staying in the area
•Software collision avoidance (not a safety function) will detect
the person and stop the robot
•Markings on the floor indicate an operating hazard zone
Conclusion: Residual risk low.
6. Person enter entry passage when the robot drives through (phase
3 and phase 6). Risk of being crushed.
But:
•Protective field will trigger protective stop if the person
is in the area
•Markings on the floor indicate an operating hazard zone
•Very improbable behavior. Staff and visitors need to
be trained
Conclusion: Residual risk extremely low.

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7.3 Picking up cart
Phase 1: Approaching cart. Locating long range
Phase 2: Setting search height
Maximum speed [m/s]
1.5 (1.1)
Awareness indicator
No
Operating hazard zone
No
Maximum speed [m/s]
0
Awareness indicator
Yes
Operating hazard zone
No

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Phase 3: Long range docking
Phase 4: Setting entry height. Locating short range
Maximum speed [m/s]
-0.3
Awareness indicator
Yes
Operating hazard zone
No
Maximum speed [m/s]
0
Awareness indicator
Yes
Operating hazard zone
No

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Phase 5: Short range docking
Phase 6: Setting lock height
Maximum speed [m/s]
-0.3
Awareness indicator
Yes
Operating hazard zone
No
Maximum speed [m/s]
0
Awareness indicator
Yes
Operating hazard zone
No

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Phase 7: Locking to cart
Phase 8: Normal driving position
Maximum speed [m/s]
-0.3
Awareness indicator
Yes
Operating hazard zone
No
Maximum speed [m/s]
1.5 (1.1)
Awareness indicator
Yes
Operating hazard zone
No