As robot systems become more advanced and connected, ensuring functional safety and compliance is becoming increasingly complex. With the release of ISO 10218:2025, organisations must understand what’s changed and how to apply it in practice.

The webinar will cover: key updates introduced in ISO 10218:2025; how to select and apply effective safeguarding measures; designing and validating functional safety systems; and reducing risk and achieving compliance in real-world applications.

The webinar will be presented by Hefin Llewellyn-Evans, Technical Trainer (Functional Safety), TUV SUD. With hands-on experience delivering safety-critical projects in manufacturing environments, Hefin brings practical insight into applying functional safety in modern robotics.

If you can’t join live, register anyway, and you’ll be sent the webinar recording so you won’t miss any of the valuable insights.

Every year, Cranswick produces millions of “pigs-in-blankets” (sausages wrapped in bacon) for the Christmas market. The final stage of the process – picking the sausages off the conveyor belt and placing them in their packaging – was still performed manually, which introduced delays and other constraints. Cranswick commissioned CWM Automation to design and deliver a fully automated pick-and-place system, allowing those employees to take on more skilled tasks.

“Automating this stage of the process presented some complex challenges,” said Asa Arvidsson, regional vice president EMEA north region, Rockwell Automation. “The new system had to operate with remarkable precision and speed. With our strategic collaboration with autonox Robotics, we were able to support CWM Automation in making this possible.”

Powered by Rockwell Automation Allen-Bradley Kinetix VP low inertia servo motors controlled by an Allen-Bradley GuardLogix 5380 safety controller, the new end-of-line pick-and-place system accurately detects the presence and orientation of each sausage. It then uses an autonox Delta robot to pick up the sausage, properly align it and place it in the appropriate package – 240 times a minute.

“We’re very happy with the new pick-and-place system,” said Mark Lundgren, chief engineering manager at Cranswick Gourmet Sausage. “Thanks to Rockwell Automation and CWM Automation, we’re able to meet our production goals and deadlines in a way that is far more efficient and cost effective. Our labour productivity on the line is greatly increased and that means our staff not only have more skilled and comfortable jobs, they’re also often free to work on other production lines.”

“Cranswick had to have the new system up and running to meet their annual production target,” explained Mick Williams, managing director, CWM Automation, a Rockwell Automation Gold-Level OEM. “To achieve this, we worked closely with the Cranswick engineering team and the systems consultants at Rockwell Automation. It was a great cooperation, and together we met what was a very challenging deadline.”

Visit the Rockwell Automation website for more information

See all stories for Rockwell Automation

The safety controller combines motion, force, and zone monitoring into a single platform, enabling targeted support for future safety requirements. The architecture, which is independent of manufacturers, can be seamlessly integrated into robotics applications that utilise EtherCAT.

The updated ISO 10218:2025 standard expands the scope of robotics safety to include the secure integration into applications and robotic cell environments. In addition to position and speed, force monitoring, dynamic safety zones, and safety functions for collaborative and partially collaborative applications are receiving greater focus. The Kendrion Safety Architecture for Robotics combines a SIL3/PLe certified Safety PLC with a robotics library for kinematic safety functions.

The Safety PLC performs kinematic safety monitoring of the entire robot’s movement and processes safety-relevant data from all connected axes and drives in real time. The system tracks the position and speed of industrial robots and cobots, along with forces, torques, and customisable safety zones. Kinematic safety functions are processed with a minimum cycle time of 2 ms. With suitable FSoE drives (Fail Safe over EtherCAT), safety functions such as STO and SS1, as well as application-specific speed and zone monitoring, can be implemented.

Scalable for different robotics applications

Kendrion provides its safety architecture in the versions: Motion, Force, and Zone. The Motion version covers position and speed monitoring for traditional industrial robot applications. The Force version broadens its capabilities by including model-based and optional sensor-based monitoring of force and torque, making it particularly suitable for human-robot collaboration (HRC). The Zone version supports monitoring of up to 20 safety zones, allowing flexible protection of work areas and efficient implementation of modern HRC applications. The architecture accommodates serial robotic structures with two to nine axes, which can be either linear or rotary.

Compatible with existing robotics platforms

The EtherCAT master communicates directly with safe FSoE servo drives through the Kendrion Safety PLC, enabling continuous safety communication for robot systems with up to nine axes. The Kendrion safety architecture can be incorporated into existing EtherCAT-based robotics systems and works with standard FSoE drives. There is no requirement to rely on proprietary robot controllers.

Manufacturers have the flexibility to incorporate their own functions, kinematics, and additional I/O systems. This facilitates the easy integration of laser scanners, encoders, and other safety-relevant sensors into the safety architecture. The open system architecture creates a high degree of flexibility for future robotics platforms and supports the implementation of new safety requirements.

Along with the Manufacturing Technology Centre (MTC), the organisations are working together with government and industry to support the safe and responsible adoption of robotics in the workplace, providing businesses with clarity on regulatory requirements and support to increase their use.

At present, the UK ranks 24th globally for industrial robot density – half the EU average – despite ranking first for academic robotics research. A key barrier to adoption is uncertainty around compliance, particularly that surrounding collaborative robots (cobots), with industry estimating that between 15-20% of customer enquiries on automation stall due to safety uncertainly alone.

The guidance assimilated by this project aims to address that uncertainty thereby removing the barrier.

The project launched at London Tech Week this week and will produce the first ever HSE-supported guidance on advanced robotics applications. As the UK’s leasing industry association, Automate UK estimates that the adoption of collaborative robots will increase by 25% by the end of 2027.

The first stage of the project, launching this summer, will deliver regulatory clarity for collaborative applications and aims to give the industry confidence in how it can ensure robots can work safely alongside humans.

A second stage will focus on cutting-edge use cases, where artificial intelligence embedded in robotic systems is raising new safety questions. To kickstart work on stage 2, this summer RIO is convening stakeholders to explore how tools like synthetic testing can help regulators and industry to support safe adoption of robots.

Andrew Curran CBE, Director of Science and Chief Scientific Adviser at the Health and Safety Executive, said: “We recognise how guidance and advice can give employers the confidence to innovate safely and provide a platform for new technology to improve productivity and enable growth.

“We understand that despite there being no barrier to adoption in health and safety law there is a fear of non-compliance, which is limiting adoption. Therefore, we are committed to working with the Regulatory Innovation Office and industry partners to deliver the first joint HSE and industry guidance on the use of cobots to address this barrier and improve business confidence.”

Oliver Selby, Chair of BARA (British Automation and Robotics Association), part of Automate UK, said: “Automate UK and BARA welcome the focus by the Regulatory Innovation Office on reducing barriers to robotics adoption. Based on feedback from our membership, the current regulatory framework is sufficient and adequate for enabling the safe deployment of robots used in a collaborative application.

“However, there remains a significant gap in understanding and confidence among end-user stakeholders. Greater education and practical guidance are needed to help businesses fully embrace robots working safely alongside people.

“While relevant information is already contained within existing standards, as well as the current Machinery Directive and forthcoming Machinery Regulation, awareness of these resources is limited.”

In this session, you will learn: what is changing under the Machinery Regulation; the role of Common Specifications, Market Surveillance, and Conformity Assessments; and how organisations can start preparing for the new requirements

Hosted on Zoom, this 30-minute session is led by safety experts and includes a live Q&A, with a recording available afterwards.

Click here to sign up for the webinar.

Presented by Jamie Thomas, a TÜV-Certified Machinery Safety and CE Marking Expert, this webinar will guide attendees through the key changes and new requirements introduced in the revised ISO 10218. Jamie will break down what the updates mean for manufacturers, system integrators and end users, and explore practical approaches and technologies that can support compliance with the updated standard.

If you are interested but the time of the webinar isn’t suitable for your schedule, please register anyway and you will send you a recording of the webinar after the event.

Jamie has an electro-mechanical background and nearly 20 years of experience in industrial automation and safety.

Pilz’s free Webinar series aims to give you the essential facts and updates on a range of key Machinery Safety topics without you having to leave the office. Presenters will cover the key facts in around an hour and will offer participants the added opportunity to get instant support for specific questions.

Visit the Pilz website for more information

See all stories for Pilz

Safety Requirements and Integration of AGVs is an advanced level course held on Tuesday 17 March and Tuesday 7 July. This course is designed for those working with AGVs, AGV systems and AMRs in industrial environments. It covers the latest safety standards – including ISO 3691-4 – and provides practical guidance on risk assessment, hazard reduction, and safe system integration.

Robot Safety and Integration is an advanced level course held on Monday 16 March and Monday 6 July. This course is designed for those integrating robots and collaborative applications into industrial environments. It covers key international standards like ISO 10218-1 and 2, and dives into risk assessment, cyber security, safety functions, and validation requirements. Participants learn how to design risk reduction measures and implement integrated control strategies – all while maintaining high productivity.

Both courses are running from the Machinery Safety Training Academy in Corby, Northamptonshire.

Pilz UK Training Courses offer delegates the opportunity to build up their Machinery Safety knowledge to their individual level of qualification. Delegates can expect to walk away from both courses with an understanding of their relevant standards, potential pitfalls and proven risk reduction methods. Increase your productivity… safely!

Visit the Pilz website for more information

See all stories for Pilz

What does EN ISO 13855 regulate and what’s new?

The international standard EN ISO 13855 forms the basis for the safe design of machinery. It defines how safeguards such as light curtains, laser scanners or guards must be positioned so that people are reliably protected. The focus is on the safety distance, i.e. the distance required for machinery to stop in time before a person is endangered.

With the 2024 revision, the standards body is responding to technical developments and practical experience gained in recent years. There are key changes:

• New terms and definitions
• The basis for calculating the safety distance has been adjusted
• Additional notes on practical application

This gives design engineers, planners and inspectors a more precise and practical basis for standard-compliant implementation.

Benefits of the Safety Distance Calculator

• Automatic calculation of the safety distance for all safety light curtains on the market
• Suitable product recommendation from the ranges PSENopt and PSENopt II
• Saves time by shortening the search for the right light curtain
• Intuitive operation with additional information and graphical representation of the calculation
• Flexibility for applications in special purpose machine building and retrofitting

From safety level to the right product

The Safety Distance Calculator helps users calculate applications with vertical protected fields (perpendicular approach) for finger, hand and body protection. The tool suggests a suitable product, based on the calculations and the required safety level. Integrated info points provide in-depth explanations, while the graphical representation makes the calculation transparent and comprehensible.

Determine the appropriate safety distance in accordance with EN ISO 13855:2024 now.

Visit the Pilz website for more information

See all stories for Pilz

High productivity and flexibility are key competitive advantages in times of digitalisation. With SICK as your partner, you benefit not only from one of the world’s largest networks of experts for functional safety, but also from a comprehensive range of safety solutions that ensure personal safety and efficient processes.

The SICK safety portfolio includes safety controllers, safety switches, safety distance sensors, safety laser scanners, safety radar sensors, safe series connection, safety relays and safety multibeam scanners, and the company has the ability to provide complete safety systems.

Visit the SICK website for more information

See all stories for SICK

Within its “Identification and Access Management” portfolio, Pilz offers a comprehensive range of products, solutions and software for the implementation of both safety and security tasks.

These cover applications from simple authentication to complex access permissions, and access management through to safe operating mode selection, maintenance safeguarding and safeguarding of data and networks.

One such solution is the ‘key-in-pocket’ maintenance safeguarding system for protection against unauthorised restart. This solution ensures that a machine cannot resume operation while people are still in the danger zone. The key-in-pocket maintenance safeguarding system is designed for machines with danger zones, which are protected by a safety fence and which employees need to access – robot cells for example.

In comparison with conventional lockout-tagout (LOTO) systems, maintenance safeguarding with the Key-in-pocket solution is implemented via RFID keys with corresponding permissions and a safe list in the Pilz controllers. As a result, it provides purely electronic restart protection and makes mechanical interlocking devices and warning tags redundant.

Visit the Pilz website for more information

See all stories for Pilz