Best AI Prompts for Electrical Engineering

				
					Act as a Machine Safety Specialist and Control Systems Engineer.
Your TASK is to outline key design considerations for a safety interlock system for an industrial robotic cell used for `{robotic_cell_application_description}` (e.g.
 'Automated welding of automotive parts'
 'Robotic pick-and-place for packaging'
 'CNC machine tending by robot arm').
The system must protect personnel from hazards listed in `{types_of_hazards_present_csv}` (e.g.
 'Robot_arm_impact_crushing
Weld_arc_flash_UV
Moving_conveyor_entanglement
Part_ejection').
The design should consider principles from `{relevant_safety_standard_e_g_iso10218}` (e.g.
 ISO 10218-2 'Robots and robotic devices - Safety requirements for industrial robots - Part 2: Robot systems and integration'
 IEC 62061
 ISO 13849-1).

**SAFETY INTERLOCK SYSTEM DESIGN CONSIDERATIONS (Markdown format):**

**1. Risk Assessment & Performance Level (PL) / Safety Integrity Level (SIL) Determination:**
    *   `[ ]` **Perform a Thorough Risk Assessment**: Identify all tasks (operation
 maintenance
 setup
 cleaning)
 hazards from `{types_of_hazards_present_csv}`
 and potential human interactions.
    *   `[ ]` **Determine Required PL/SIL**: For each safety function provided by the interlock system (e.g.
 guard door interlock
 light curtain muting)
 determine the required Performance Level (PLr) according to ISO 13849-1 or Safety Integrity Level (SIL CL) according to IEC 62061 based on risk severity
 frequency of exposure
 and possibility of avoidance.

**2. Guarding and Access Control:**
    *   `[ ]` **Perimeter Guarding**: Fixed guards (fencing) to prevent unauthorized access to the robot's restricted space. Ensure height and construction meet standards (e.g.
 ISO 13857 for safety distances).
    *   `[ ]` **Access Doors/Gates**: 
        *   `[ ]` Equip all access doors/gates with interlocking devices.
        *   `[ ]` Interlocks should signal the robot control system to stop hazardous motion (e.g.
 Safety Stop 1 or Safety Stop 0 as per ISO 10218) when the guard is opened.
    *   `[ ]` **Types of Interlocking Devices**: Select based on PLr/SIL CL
 frequency of access
 and environmental conditions:
        *   `[ ]` Mechanical (tongue/key operated switches).
        *   `[ ]` Non-contact (magnetic
 RFID coded). Coded switches prevent simple defeat.
        *   `[ ]` Trapped-key systems for complex access sequences.
    *   `[ ]` **Guard Locking**: If stopping time of hazard is longer than access time
 implement guard locking. The guard remains locked until the hazard has ceased. Consider:
        *   `[ ]` Spring-to-lock
 power-to-unlock (safer for power failure).
        *   `[ ]` Monitoring of lock status.
        *   `[ ]` Emergency release from inside the guarded space (if whole-body access is possible).

**3. Presence Sensing Devices (Active Optoelectronic Protective Devices - AOPDs):**
    *   `[ ]` **Light Curtains**: For frequently accessed openings. Ensure correct resolution
 height
 and safety distance from hazard zone (calculated based on stopping time and approach speed - ISO 13855).
    *   `[ ]` **Laser Scanners (Area Scanners)**: For complex or irregular shaped zones. Define warning and safety zones.
    *   `[ ]` **Pressure-Sensitive Mats**: Detect presence within a defined area.
    *   `[ ]` **Muting/Blanking**: If AOPDs need to be temporarily suspended for material pass-through
 implement muting functions strictly according to standards (e.g.
 IEC 62046). Muting should be time-limited
 sequence-controlled
 and use diverse sensors.

**4. Emergency Stop System:**
    *   `[ ]` **E-Stop Buttons**: Clearly visible
 easily accessible
 and compliant (e.g.
 red mushroom head on yellow background).
    *   `[ ]` E-Stop circuit must be hardwired or achieve equivalent safety via safety network.
    *   `[ ]` E-Stop should initiate a Category 0 or Category 1 stop (as per IEC 60204-1) for all hazardous motions in the cell.
    *   `[ ]` E-Stop must override all other controls
 except for some specific rescue operations.
    *   `[ ]` Resetting an E-Stop must not automatically restart machinery.

**5. Robot Control System Safety Functions (as per `{relevant_safety_standard_e_g_iso10218}`):**
    *   `[ ]` **Safe Robot Stop**: Ensure reliable stop functions (SS1
 SS2
 STO - Safe Torque Off).
    *   `[ ]` **Safe Speed Monitoring**: If collaborative operation or reduced speed during teaching/maintenance is used.
    *   `[ ]` **Safe Zone Limiting**: Restricting robot's working space dynamically or statically.
    *   `[ ]` **Enabling Device (Hold-to-Run / Three-Position Switch)**: For teach mode or manual intervention inside the guarded space.

**6. Safety Logic Solver / Safety Controller:**
    *   `[ ]` Use safety-rated relays
 safety PLCs
 or integrated safety controllers that meet the required PLr/SIL CL.
    *   `[ ]` **Redundancy and Monitoring**: Implement principles like dual-channel inputs
 cross-monitoring
 fault detection
 and defined fault reaction (e.g.
 revert to safe state).
    *   `[ ]` **Logic Design**: Ensure safety logic is clear
 tested
 and validated. Avoid complexity that could introduce errors.
    *   `[ ]` **Prevention of Unexpected Start-up (ISO 14118)**: Ensure measures are in place to prevent machinery from starting unexpectedly after a stop or interlock activation.

**7. Reset Procedures:**
    *   `[ ]` A deliberate manual reset action
 performed from outside the hazard zone
 should be required after an interlock or E-Stop has been cleared before restarting the system.
    *   `[ ]` Ensure the cause of the stop has been rectified before reset is possible.

**8. Wiring and Installation:**
    *   `[ ]` Use safety-rated components and wiring practices.
    *   `[ ]` Protect wiring from mechanical damage
 EMI
 and environmental factors.
    *   `[ ]` Ensure proper grounding and shielding.

**9. Validation and Testing:**
    *   `[ ]` Develop a validation plan for all safety functions.
    *   `[ ]` Functionally test every interlock
 E-Stop
 AOPD
 and safety logic under all foreseeable operating and fault conditions before putting the cell into service.
    *   `[ ]` Document all validation results.

**IMPORTANT**: The design of safety systems is a critical task that must be performed by competent personnel and strictly adhere to all applicable local and international safety standards
 including `{relevant_safety_standard_e_g_iso10218}`. This checklist is a starting point for consideration.