Robots are steadily becoming part of the American workforce as they assist human workers and help boost productivity. However, this shift also brings new safety concerns for employees sharing workspaces with robots. Ohio is stepping up to meet these challenges. The Ohio Bureau of Workers’ Compensation recently awarded $9.4 million in grants for safety projects, including two innovative solutions from the University of Cincinnati (UC) that seek to enhance worker safety around robotics and improve hard hat design.
What are the safety risks in robot-enabled workplaces?
The International Federation of Robotics reported that for every 10,000 workers in the United States, 285 robots now share their space. However, this surge comes with an increased risk of collisions and injuries, particularly in areas where visibility may be limited.
According to UC Professor Sam Anand, robots can cause major injury due to their weight. "It’s a problem. Humans don’t have eyes on the back of their heads. And people can be careless. But you can’t blame the human," said Anand.
Direct impact with robots in the workplace can lead to serious injuries and workers' compensation claims. These include:
- Painful bruising and contusions
- Crushing injuries
- Cuts and lacerations
- Bone fractures
- Concussions and serious traumatic brain injury
- Loss of limbs or digits
How is UC enhancing robot safety?
To address these safety concerns, UC researchers are developing tools to teach robots how to anticipate human movement in workspaces. Researchers can simulate different scenarios to prepare robots for real-life situations using “digital twins” (which are virtual replicas of real-world environments). This simulation technology allows engineers to program robots with predictive motion-planning capabilities, which helps them recognize potential collisions with workers.
The project uses generative AI to analyze thousands of human movement patterns. It also creates a database of likely scenarios that robots can draw from when maneuvering around people. Professor Anand likened it to a “flight simulator for AI, enabling it to practice collision avoidance.”
UC’s robotics safety project collaborates with industry leaders to validate these new methods in real workplace settings. Kelly Cohen, a UC professor with expertise in autonomous navigation, also contributes to this cutting-edge research. Their goal is to reduce risks posed by autonomous systems and keep workers safe.
How is hard hat technology advancing?
Safety in physical work environments involves more than avoiding robot collisions. Protecting workers from head injuries remains a key priority, especially in high-risk jobs. While hard hats have been used since the construction of the Hoover Dam, little has changed in their design. UC's goal is to improve upon this with new research and technologies.
The university’s second safety project explores better materials and embedded sensors for hard hats. Led by UC Professor Jing Shi, the research team is developing liners that can absorb more impact energy to reduce the severity of head injuries. Sensors inside the hard hats can measure impact force and notify workers immediately if they need medical attention after a head injury.
UC’s advanced hard hat project includes collaboration with Ohio-based companies like Cintas and Malta Dynamics. Together, they’re working on a helmet that both protects and informs. These hard hats are equipped with impact sensors and can send alerts. This allows workers to quickly assess injury severity and seek help if necessary. Eric Nauman, a UC biomedical engineering professor involved in the project, believes this technology could “save lives where we couldn’t before.”
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