745 Welding, Cutting, and Brazing Safety

Robot Welding Safety

Many industries use robot welders in place of human workers on the assembly line. Robotic welding uses programmable machines (robots) to perform various types of welding processes including arc welding, spot welding, laser welding, and plasma arc welding. Using robots to weld improves speed, accuracy, and safety, especially for repetitive or hazardous work.

Hazards

Even though robotic welding removes people from the welding process, it still comes with risks. Here are the most common process and equipment hazards:

• Mechanical Hazards: Robots move quickly and with force. They can cause crushing, pinching, or impact injuries if workers enter their workspace.
• Electrical Hazards: Welding robots run on high-voltage power. Faulty wiring or damaged cables can cause shocks or burns.
• Fire and Explosion: Welding sparks and heat can ignite flammable materials nearby. Accumulated gases may explode if ventilation is poor.
• Fumes and Gases: Welding produces toxic fumes (like ozone, nitrogen oxides, and metal fumes). Breathing these can harm the lungs and other organs.
• Eye and Skin Damage: The welding arc emits intense UV radiation. This can cause "arc eye" (a painful eye injury) and skin burns.
• Noise: Welding operations can generate loud noise, which may cause hearing loss.

Precautions

To control these hazards, follow these precautions:

• Guarding and Fencing: Use physical barriers, such as cages or light curtains, to prevent accidental entry into the robot’s workspace. Only trained personnel should bypass safety guards.
• Training: All workers must be trained to recognize hazards and follow safe procedures. They should understand the robot’s movement patterns and emergency stops.
• Lockout/Tagout (LOTO): Always de-energize the robot before performing maintenance. Use lockout/tagout procedures to prevent accidental start-up.
• Ventilation: Use exhaust systems to remove fumes and gases. If needed, wear respirators approved for welding fumes.
• Personal Protective Equipment (PPE): Wear a welding helmet with proper shade filter. Use flame-resistant gloves, aprons, and sleeves. Use hearing protection if noise levels are high.
• Housekeeping: Keep flammable materials away from welding areas. Clean up oil, grease, and metal dust that could fuel a fire.
• Emergency Stops: Make sure emergency stop buttons are clearly marked and easy to reach.

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