ISO 10218: Robotics Functional Safety Consulting, Engineering and Certification Services

• Engineering-Led Robot Safety Expertise 

Robotics safety sits at the intersection of: 

Mechanical Safety + Electrical Safety + Functional Safety + Controls + Software + Human-Machine Interaction 

VerveTronics combines Functional Safety engineering with system-level safety analysis to help customers address these interactions. 

• Functional Safety Engineering 

We support safety functions, safety requirements, safety architectures, safety mechanisms and safety validation. 

• Risk Analysis 

We identify hazardous situations and evaluate the risks associated with robot movement, tools, payloads, workspaces and human interaction. 

• Safety-Related Control Systems 

We support the engineering and analysis of safety-related control systems using appropriate architectures, safety PLCs, sensors, actuators and monitoring mechanisms. 

• Hardware & Software Safety 

We analyze safety-related hardware and software, including diagnostic mechanisms, fault reactions, communication and safety control logic. 

• Assessment & Certification Support 

We help customers prepare technical documentation, evidence and safety cases for independent assessment or certification.

• ISO 10218 Robotics Safety Lifecycle

   A robust robotics safety program should connect risk assessment to the final validated safety functions. 

Our approach can include: 

• 1. Robot / Application Definition 

Understand: 

• Robot type 
• Robot configuration 
• Payload 
• End effector 
• Operating modes 
• Workspace 
• Human interaction 
• Production process 
• Material handling 
• Maintenance activities 

↓ 

• 2. Hazard Identification 

Identify hazards associated with: 

• Robot motion 
• Mechanical energy 
• Electrical energy 
• Pneumatic/hydraulic systems 
• End effectors 
• Workpieces 
• Unexpected movement 
• Maintenance 
• Manual intervention 

↓ 

• 3. Risk Assessment 

Evaluate: 

• Severity 
• Frequency/exposure 
• Possibility of avoidance 
• Operating conditions 
• Maintenance scenarios 
• Abnormal conditions 

↓ 

• 4. Safety Requirements 

Define: 

• Safety functions 
• Safe states 
• Stop functions 
• Speed limitations 
• Protective measures 
• Restart requirements 
• Monitoring requirements 

↓ 

• 5. Safety Architecture 

Develop: 

• Safety sensors 
• Safety PLC/controller 
• Safety I/O 
• Actuator control 
• Communication 
• Diagnostic mechanisms 
• Fault reaction 

↓ 

• 6. Implementation 

Implement and integrate: 

• Safety PLC 
• Emergency stop 
• Guarding 
• Interlocks 
• Light curtains 
• Safety scanners 
• Safety mats 
• Enabling devices 
• Safe motion functions 

↓ 

• 7. Verification & Validation 

Demonstrate that: 

• Safety requirements are implemented 
• Safety functions operate correctly 
• Faults are detected 
• Protective measures work 
• Safe states are achieved 
• Unexpected restart is prevented 

↓ 

• 8. Safety Documentation & Assessment 

Prepare: 

• Risk assessment 
• Safety requirements 
• Safety architecture 
• Safety analysis 
• Verification evidence 
• Validation evidence 
• Technical documentation 
• Assessment/certification evidence 

 

• ISO 10218 Risk Assessment for Industrial Robots 

Risk assessment is the foundation of robot safety. 

VerveTronics supports structured risk assessment considering the complete robot application rather than the robot arm alone. 

• Areas we evaluate can include: 
• Robot movement 
• Reachable workspace 
• Robot speed 
• Robot force 
• Payload 
• End effector 
• Tooling 
• Workpiece 
• Conveyors 
• Fixtures 
• Guarding 
• Access points 
• Operator interaction 
• Maintenance 
• Programming 
• Teaching 
• Setup 
• Recovery from faults 
• Manual intervention 
• Unexpected restart 
• The result is used to identify the necessary protective measures and safety functions. 

 

• Robotics Safety Functions 

A robot application may require multiple safety functions rather than a single emergency stop. 

Examples include: 

• Emergency Stop 

Bring the system to a defined safe condition following an emergency situation. 

• Protective Stop 

Stop robot motion when a protective device or safety condition is triggered. 

• Guard Interlocking 

Prevent hazardous robot motion when access doors or guards are open. 

• Safety Scanner Monitoring 

Detect personnel entering hazardous areas and initiate the appropriate protective action. 

• Light Curtain Monitoring 

Detect access into a hazardous zone. 

• Safe Speed 

Limit robot movement to a defined safe speed under specified operating conditions. 

• Safe Torque / Motion Functions 

Prevent or limit hazardous motor torque or movement where required by the application. 

• Enabling Device 

Allow controlled operation during teaching, setup or maintenance. 

• Restart Prevention 

Prevent unexpected restart after a safety function has been activated. 

 

• ISO 13849 Performance Level for Robotics 

Many robot safety applications use ISO 13849 for the design and evaluation of safety-related control systems. 

VerveTronics supports engineering activities associated with: 

• Performance Level determination 
• Safety functions 
• Required Performance Level 
• Category 
• MTTFd 
• DCavg 
• Common Cause Failure 
• Architecture 
• Diagnostic mechanisms 
• SISTEMA-based analysis 
• Safety validation 

Where the application requires a specific Performance Level such as PL d or PL e, we help translate the safety requirement into an appropriate safety-related control architecture. 

 

• IEC 62061 SIL Engineering for Robotics

   

Depending on the machinery and application, IEC 62061 may also be relevant to the Functional Safety of machinery control systems. 

VerveTronics can support: 

• Safety Integrity Level determination 
• Safety functions 
• Safety-related control architecture 
• Hardware safety analysis 
• Diagnostic coverage 
• Probability of dangerous failure 
• Verification 
• Validation 

This allows the safety architecture to be evaluated using the appropriate machinery Functional Safety framework. 

 

• ISO 10218 + ISO 13849 + IEC 62061 

A common challenge in robotics projects is understanding how the different standards interact. 

• ISO 10218 

Provides requirements and guidance for the safety of industrial robots and robot applications. 

• ISO 13849 

Provides a methodology for designing and evaluating safety-related parts of control systems using Performance Levels. 

• IEC 62061 

Provides a Functional Safety methodology for safety-related control systems of machinery using SIL concepts. 

The applicable standard depends on the robot, machine, application and regulatory environment. 

VerveTronics helps customers establish an appropriate safety engineering strategy rather than treating the standards as isolated compliance activities. 

 

• Relevant Robotics Safety Standards 

Depending on the robot and application, the applicable safety framework may include: 

• ISO 10218 — Industrial robots and robot applications 
• ISO 13849 — Safety-related parts of control systems 
• IEC 62061 — Functional Safety of machinery 
• IEC 61508 — Functional Safety of electrical/electronic/programmable electronic safety-related systems 
• ISO 12100 — Machinery risk assessment and risk reduction 
• ISO 13850 — Emergency stop function 
• ISO 13855 — Positioning of safeguards 
• ISO 13857 — Safety distances 
• Applicable electrical, EMC and machinery requirements 

For AMRs, AGVs and other autonomous systems, additional application-specific standards and regulatory requirements may apply.

• Hardware Safety Engineering for Robotics

   Safety-related hardware may include: 

• Safety PLCs 
• Safety controllers 
• Safety I/O 
• Sensors 
• Encoders 
• Safety scanners 
• Light curtains 
• Relays 
• Contactors 
• Motor drives 
• Safety communication interfaces 
• Power supplies 

VerveTronics can support: 

• Hardware safety requirements 
• Hardware architecture 
• FMEA 
• FTA 
• FMEDA where applicable 
• Diagnostic analysis 
• Fault detection 
• Fault reaction 
• Common-cause analysis 
• Fault injection 
• Safety verification 

 

• Software Safety Engineering for Robots 

Modern robot controllers increasingly rely on sophisticated embedded software. 

VerveTronics supports: 

• Safety software requirements 
• Safety-related control logic 
• Software architecture 
• Safety monitoring 
• Fault handling 
• Diagnostic functions 
• Communication monitoring 
• Software verification 
• Unit testing 
• Integration testing 
• System testing 
• Fault injection 
• Requirements traceability 

For complex autonomous robots, we can also support the analysis of safety-related dependencies between perception, planning, control and actuation. 

 

• Robotics FMEA, FTA & Fault Analysis

   

Safety analysis helps identify how failures can compromise robot safety functions. 

• FMEA 

We analyze: 

• Component failure modes 
• System effects 
• Detection mechanisms 
• Safety consequences 
• Fault reactions 
• FTA 

We evaluate combinations of failures that could result in hazardous robot behavior. 

Examples include: 

• Failure of redundant stopping mechanisms 
• Safety controller failure 
• Sensor failure 
• Communication failure 
• Drive failure 
• Brake failure 
• Dependent Failure Analysis 

For architectures using redundancy, we investigate whether a common cause or dependent failure can defeat multiple safety mechanisms simultaneously. 

 

• Safety Verification & Validation for Robotics 

A safety function should not simply be specified—it must be verified and validated. 

VerveTronics supports: 

• Safety Requirement Verification 

Confirm that safety requirements are complete, consistent and testable. 

• Safety Architecture Verification 

Review: 

• Safety architecture 
• Sensor paths 
• Controller logic 
• Actuator paths 
• Fault reactions 
• Fault Injection 

Test behavior under: 

• Sensor failure 
• Communication failure 
• Controller failure 
• Actuator failure 
• Power loss 
• Diagnostic failure 
• Safety Validation 

Validate the robot’s behavior under representative operating and fault conditions. 

Examples include: 

• Emergency stop testing 
• Protective stop testing 
• Guard opening 
• Safety scanner activation 
• Restart prevention 
• Safe speed verification 
• Fault reaction 
• Recovery testing 

 

• Robotics Functional Safety Assessment & Certification Support

   

Organizations may require independent assessment or certification depending on the product, market and applicable standards. 

VerveTronics can support assessment readiness through: 

• Standards gap assessment 
• Risk assessment review 
• Safety requirements review 
• Safety architecture review 
• Safety function analysis 
• PL/SIL analysis 
• FMEA / FTA 
• Safety validation 
• Technical documentation 
• Compliance matrix 
• Safety case 
• Evidence review 
• Assessment preparation 
• Corrective action support 

Formal independent certification or assessment is performed by the applicable accredited or authorized certification/assessment organization. 

 

• ISO 10218 Consulting for Robot Manufacturers 

Robot manufacturers may need to demonstrate that their robot platform meets applicable safety requirements before integration into customer applications. 

VerveTronics can support: 

• Robot safety architecture 
• Safety functions 
• Safety requirements 
• Robot controller safety 
• Safety-rated stop functions 
• Safe motion functions 
• Hardware safety analysis 
• Software safety analysis 
• Risk assessment 
• Verification 
• Validation 
• Technical documentation 
• Certification preparation 

 

• ISO 10218 Consulting for System Integrators 

System integrators must consider the safety of the complete integrated application, not just individual components. 

We support integrators with: 

• Robot cell risk assessment 
• Safety function identification 
• Safety architecture 
• Safety PLC design 
• Safety sensor selection 
• Safety-related control systems 
• PL/SIL analysis 
• Safety validation 
• Technical documentation 
• Customer safety evidence 

 

• ISO 10218 Consulting for End Users 

Manufacturing organizations deploying robots may require independent review of their existing robot cells. 

VerveTronics can help identify: 

• Unprotected hazardous zones 
• Inadequate guarding 
• Inadequate interlocks 
• Safety PLC architecture weaknesses 
• Inadequate safety functions 
• Unexpected restart risks 
• Maintenance hazards 
• Manual intervention hazards 
• Inadequate validation evidence 

We can then develop a prioritized safety improvement plan

• Industrial Robot Safety Architecture

   A typical robot safety architecture may include: 

Safety Sensors 

↓ 

Safety PLC / Safety Controller 

↓ 

Safety Communication / I/O 

↓ 

Robot Controller 

↓ 

Drive / Motor Control 

↓ 

Safe Motion / Safe State 

Additional safety mechanisms may include: 

• Emergency stop 

• Guard interlocks 

• Light curtains 

• Safety laser scanners 

• Safety mats 

• Enabling switches 

• Two-hand controls 

• Safety relays 

• Safe motion monitoring 

• Speed monitoring 

• Position monitoring 

VerveTronics evaluates the complete safety chain to ensure that the required safety function can be achieved. 

 

• Robot Cell Safety 

A robot arm is only one component of an industrial robotic application. 

The complete cell can contain: 

• Industrial robot 

• Conveyor 

• Gripper 

• Welding equipment 

• Cutting tools 

• Presses 

• Fixtures 

• Vision systems 

• Sensors 

• Pneumatic systems 

• Hydraulic systems 

• Safety PLC 

• Safety scanners 

• Safety gates 

• Human-machine interfaces 

The safety assessment therefore needs to consider the entire robot cell and its operating modes. 

VerveTronics supports safety analysis across the complete integrated system. 

• AMR & AGV Functional Safety Consulting 

Autonomous Mobile Robots and Automated Guided Vehicles introduce additional safety challenges because the machine itself moves through a dynamic environment. 

VerveTronics supports Functional Safety engineering for: 

• AMRs 

• AGVs 

• Autonomous warehouse robots 

• Material-handling robots 

• Mobile industrial robots 

• Fleet-controlled robots 

Potential safety functions include: 

• Obstacle detection 

• Protective stopping 

• Speed limitation 

• Safe navigation 

• Personnel detection 

• Collision avoidance 

• Emergency stop 

• Safety-rated monitoring 

• Safe docking 

• Charging safety 

• Safe recovery 

For mobile robots, Functional Safety needs to be considered alongside the applicable robotics, machinery, electrical and application-specific requirements. 

 

• Collaborative Robotics Safety 

Collaborative robot applications require careful consideration of human interaction with the robot. 

Depending on the application, safety engineering can address: 

• Power and force limitation 

• Speed limitation 

• Separation monitoring 

• Protective stopping 

• Workspace monitoring 

• Human detection 

• Safety-rated sensing 

• Collaborative operating modes 

• Restart behavior 

• Tool and payload hazards 

The safety assessment must consider the complete robot application, including the end effector, workpiece and surrounding equipment.

• ISO 10218 Engineering Approach 

• Risk-Based : We begin with the machine hazards and required risk reduction. 

• Function-Based: We define safety functions rather than simply selecting safety components. 

• Architecture-Driven: We select and evaluate the appropriate architecture against the required Performance Level. 

• Quantitative: We use relevant parameters including: MTTFd + DCavg + CCF + Category → Achieved PL 

• Validation-Focused : We verify that the actual machine performs the required safety functions under normal and fault conditions. 

• Evidence-Based: We establish traceability between: 

Risk → Safety Function → PLr → Architecture → Analysis → Implementation → Verification → Validation 

• ISO 10218 Consulting Engagement Models 

• Fixed-Scope Safety Assessment 

Suitable for: Machinery risk assessment review, PLr review, SISTEMA review, Safety architecture review, Safety validation review, ISO 13849 gap assessment,  

• Engineering Work Package 

VerveTronics takes ownership of defined safety engineering activities such as: Risk assessment, Safety functions, PLr, Safety architecture, FMEA, FTA, MTTFd, DCavg, CCF, SISTEMA, Safety validation 

• Dedicated Robotics Safety Team 

A dedicated team can support a robotics program through multiple development phases. 

Potential roles include: Functional Safety Manager, Robot Safety Engineer, System Safety Engineer, Hardware Safety Engineer, Software Safety Engineer, Verification Engineer, Expert Advisory 

• Expert Advisory 

Senior Functional Safety specialists support: Safety architecture, Risk assessment, PL/SIL decisions, Design reviews, SISTEMA analysis, Assessment preparation 

• Managed Machinery Safety Program 

VerveTronics can manage multiple safety workstreams including planning, analysis, engineering, verification, validation and assessment readiness. 

• What is ISO 10218? – ISO 10218 is a key international standard addressing safety requirements for industrial robots and robot applications. 

• What is ISO 10218 consulting? – ISO 10218 consulting helps robot manufacturers, integrators and end users understand and implement applicable robot safety requirements through risk assessment, safety functions, protective measures, Functional Safety engineering, verification and validation. 

• Does ISO 10218 cover the complete robot cell? – Robot safety needs to be considered in the context of the complete application. The robot, end effector, tooling, workpiece, surrounding machinery and human interaction can all contribute to risk. 

• Is ISO 10218 the same as ISO 13849? – No. ISO 10218 addresses industrial robot safety, while ISO 13849 provides a methodology for designing and evaluating safety-related parts of control systems. They can be used together depending on the application. 

• Is SIL required for robot safety? – Not necessarily. The applicable safety framework depends on the robot and application. Machinery safety applications may use Performance Levels under ISO 13849 or SIL methodologies under IEC 62061, depending on the applicable requirements. 

• Can VerveTronics support PL d and PL e? – Yes. VerveTronics supports Functional Safety engineering and safety-related control system analysis for applications targeting Performance Levels such as PL d and PL e, subject to project scope. 

• Can VerveTronics support SIL 2 or SIL 3 robotics projects? – Yes. VerveTronics has experience supporting safety-critical robotics and control applications involving SIL-oriented Functional Safety engineering. 

• Does ISO 10218 apply to AMRs and AGVs? – The applicability of ISO 10218 depends on the particular robot/application and the edition and scope of the applicable standard. AMR/AGV projects should also consider the standards specifically applicable to mobile robotic equipment and its operating environment. 

• Can VerveTronics provide ISO 10218 certification? – VerveTronics provides ISO 10218 consulting, engineering, compliance and certification/assessment preparation support. Formal independent certification or assessment, where required, is performed by the applicable certification or assessment organization. 

• When should we involve a robotics Functional Safety consultant? – Ideally, safety engineering should begin during the robot or application concept phase. Early involvement helps prevent costly redesign of guarding, controls, safety architecture and operating modes later in the development cycle.

• What is ISO 10218? –  ISO 10218 is a key international standard addressing safety requirements for industrial robots and robot applications. 

• What is ISO 10218 consulting? – ISO 10218 consulting helps robot manufacturers, integrators and end users understand and implement applicable robot safety requirements through risk assessment, safety functions, protective measures, Functional Safety engineering, verification and validation. 

• Does ISO 10218 cover the complete robot cell? – Robot safety needs to be considered in the context of the complete application. The robot, end effector, tooling, workpiece, surrounding machinery and human interaction can all contribute to risk. 

• Is ISO 10218 the same as ISO 13849? – No. ISO 10218 addresses industrial robot safety, while ISO 13849 provides a methodology for designing and evaluating safety-related parts of control systems. They can be used together depending on the application. 

• Is SIL required for robot safety? – Not necessarily. The applicable safety framework depends on the robot and application. Machinery safety applications may use Performance Levels under ISO 13849 or SIL methodologies under IEC 62061, depending on the applicable requirements. 

• Can VerveTronics support PL d and PL e? – Yes. VerveTronics supports Functional Safety engineering and safety-related control system analysis for applications targeting Performance Levels such as PL d and PL e, subject to project scope. 

• Can VerveTronics support SIL 2 or SIL 3 robotics projects? – Yes. VerveTronics has experience supporting safety-critical robotics and control applications involving SIL-oriented Functional Safety engineering. 

• Does ISO 10218 apply to AMRs and AGVs? – The applicability of ISO 10218 depends on the particular robot/application and the edition and scope of the applicable standard. AMR/AGV projects should also consider the standards specifically applicable to mobile robotic equipment and its operating environment. 

• Can VerveTronics provide ISO 10218 certification? – VerveTronics provides ISO 10218 consulting, engineering, compliance and certification/assessment preparation support. Formal independent certification or assessment, where required, is performed by the applicable certification or assessment organization. 

• When should we involve a robotics Functional Safety consultant? – Ideally, safety engineering should begin during the robot or application concept phase. Early involvement helps prevent costly redesign of guarding, controls, safety architecture and operating modes later in the development cycle.

Developing an industrial robot, robot cell, AMR, AGV or automated manufacturing system? 

VerveTronics can support your team with ISO 10218 consulting, robotics Functional Safety engineering, risk assessment, PL/SIL analysis, safety architecture, safety validation and certification/assessment preparation. 

• Typical engagement areas 
• ISO 10218 Consulting 
• Industrial Robot Safety 
• Robot Risk Assessment 
• Robot Cell Safety 
• Functional Safety 
• Safety Functions 
• Safety Requirements 
• ISO 13849 PL d / PL e 
• IEC 62061 SIL Engineering 
• Safety PLC Architecture 
• Safety Sensors & Actuators 
• FMEA / FTA 
• Hardware Safety 
• Software Safety 
• AMR / AGV Safety 
• Collaborative Robotics 
• Safety Verification & Validation 
• Safety Assessment 
• Certification Support 

Talk to a Robotics Functional Safety Expert