Addressing the Hidden Dangers of Arc Flashes in Automated Operations

Welding is one of the more hazardous processes in manufacturing. Arc flash injuries are particularly concerning, as they arise suddenly and carry severe consequences. Given these risks, many manufacturers have turned to robotic welding solutions, but these systems are not a perfect fix.

While automation does reduce welding-related hazards, it does not eliminate them. Robotic machinery may even carry risks that manual processes do not. Manufacturers must adapt their arc flash safety protocols to these new concerns.

Automated Welding’s Impact on Arc Flash Injury Risks

Automated welding is a net positive for arc flash safety. Human error contributes to almost all workplace accidents, so removing the element makes incidents less likely. At the same time, it is a mistake to assume it makes injuries impossible.

Employees may no longer perform the welds themselves, but they may still pass by. Arc flashes can reach temperatures above 35,000˚ Fahrenheit — enough to melt metal within milliseconds. At those extremes, workers can incur injuries without being next to a flash. Anyone in proximity to a welding bot is still at risk.

Robots may also introduce additional arc hazards, as they are electrical equipment themselves. More circuitry means more opportunities for shocks, flashes and related incidents.

These risks may be easier to overlook than those in manual welding workflows. Teams might become complacent about safety protocols because they assume automation removes them from harm. As a result, they may be more inclined to behave unsafely around automated welding tools than manual alternatives.

Arc Flash Safety Best Practices

In light of these hazards, manufacturers must revamp arc flash safety procedures when dealing with automated equipment. The following five best practices are a good start.

Install Safeguards on Welding Robots

The most fundamental step in preventing arc flash injuries with robotic welders is to install physical protections. Applicable safeguards include infrastructure around the robot and features within the machine itself.

In some facilities, plexiglass barriers between robots and areas where humans work may be sufficient. Manufacturers with higher budgets can implement hazard detection systems on their welding bots to prevent run-ins. Hall effect sensors, for example, can detect movement and distance to stop robot motion when people get too close.

Internal monitoring features are also ideal. Robot welders should use sensors to detect arc flash hazards or similar electrical issues in real time to enable timely power shut-offs. Such solutions may increase automation costs, but the resulting savings from fewer injuries will compensate for the expense.

Minimize Environmental Hazards

Manufacturers must also pay attention to the robot’s environment. Arc flashes will become less prominent a concern if the surrounding area is not conducive to electrical arcing.

Keeping the workroom clean is a straightforward but important part of this step. Airborne contaminants like dust or excess moisture may make arcs more likely, so regularly cleaning and maintaining HVAC equipment will minimize hazards. Similarly, manufacturers should stow flammable or electrically conductive surfaces a safe distance from welding workflows.

Environmental factors affecting employees’ hazard perception are another risk factor. Increasing visibility and reducing distractions will make it easier for them to focus and notice anything out of the ordinary. They can then follow proper procedures and notify managers of unusual conditions if necessary.

Error Proof Inspection Processes

Some of the biggest arc flash safety hazards with automated equipment come from regular inspections. Checkups require staff to get closer to robots, removing the advantage of physical barriers and workflow separation. In infrared thermography, equipment must remain energized during inspection, so de-electrification is not a possibility.

Any checks not requiring energized equipment must include a formal lockout/tagout procedure before someone approaches the robot. Machines needing infrared inspections should use clear panels over circuitry. That way, there is still a barrier between live wires and the technician, but infrared light can still pass through.

In all these considerations, manufacturers must design inspections to feature as little room for error as possible. Any process that requires careful attention to detail introduces the possibility of mistakes jeopardizing someone’s safety. Simplifying workflows to remove the opportunity to err is a far safer option.

Train Employees

As with many safety considerations, employee training is essential. Even though they may not handle the actual welding in an automated workflow, they must know how to manage robots safely. Similarly, any staff near a welding bot must understand arc flash prevention best practices.

Training should cover maintaining safe distances from electrical circuits, lockout/tagout procedures, de-energizing equipment after use and using relevant PPE. Robot technicians or others working directly with welding bots require additional education. While not everyone may need this training, anyone who does not receive it must not have access to areas with robot welders.

Manufacturers should also regularly re-train their workers to avoid complacency and keep best practices at the front of everyone’s mind. The NFPA 70E standard requires refreshers every three years, so this re-training is often crucial to regulatory compliance.

Maintain Equipment Regularly

Maintenance is another easy-to-miss but critical part of arc flash safety. Robot welders will be more likely to short-circuit or experience other electrical issues if they go longer without repairs. Proactive care will prevent such incidents.

Facilities with tight budgets can implement a schedule-based repair scheme based on their robot’s OEM recommendations. However, predictive maintenance is more effective if a manufacturer can afford it. This alternative will also save money in the long term because it reduces downtime from unnecessary repairs.

In either case, any maintenance activities must follow strict safety guidelines. De-energizing equipment and wearing non-conductive PPE are two of the most important steps. All employees other than certified technicians should steer clear of the area during maintenance to minimize chances for errors.

Arc Flash Safety Is Paramount for Automated Solutions

Arc flash injuries are all too common in welding workflows. Automation can reduce these instances, but it does not eliminate them entirely. Manufacturers must avoid becoming complacent and pay attention to robots’ unique safety concerns to protect their workforce and maintain productivity.

These five steps form the basis for an effective arc flash safety program. Tailoring each point to a facility’s specific situation will ensure a safer, more reliable robotic welding process.