Humanoids and Legged Robotics: Addressing New Safety Challenges
The Rise of Humanoid and Legged Robots
Humanoid and legged robots have been a hot topic in industrial automation, with experts predicting their widespread adoption in the near future. However, the unique characteristics of these robots, particularly their dynamic motion and stability issues, pose new safety challenges. Unlike traditional, statically stable robots, humanoid and four-legged robots are susceptible to falls when power is cut, presenting residual risks.
To address these concerns, international standards such as ISO 26058-1 and ISO 25785-1 have been introduced, focusing on mobile robotics that are dynamically stable. These standards aim to mitigate the risks of falls and unanticipated movements, ensuring that safety measures are in place for these advanced systems.
Preparing for Mass Adoption
The lack of established safety regulations for humanoid robots remains a significant barrier to large-scale deployment. Without comprehensive safety standards, companies face the risk of personal injury and equipment damage due to robot falls. However, with new guidelines being developed, manufacturers are now better positioned to create robots that can be safely integrated into industrial environments, accelerating the adoption of humanoid robots across various sectors.
ISO 10218 Updates: Enhancing Collaboration and Safety Requirements
ISO 10218: Key Changes in Industrial Robot Safety Standards
A significant portion of the IRSC focused on updates to the ISO 10218 standards for industrial robots, particularly ISO 10218-1 (safety requirements for industrial robots) and ISO 10218-2 (robot applications and cells). The revised standards emphasize a risk-based approach to collaboration, no longer treating collaborative robots (cobots) as a separate category. Instead, the focus is now on assessing the entire robot application, including the surrounding environment, to determine the risks involved.
This shift in the standards means that manufacturers will need to take a more holistic view of robot safety during the design and integration phases. The new guidelines also introduce stricter functional safety requirements, structured lifecycle coverage, and enhanced documentation obligations. As a result, industrial robot vendors will need to update their product development and integration processes to comply with these revised standards.
Collaborative Applications: A Growing Trend
The revised ISO 10218 standard will likely drive the further expansion of collaborative robots (cobots) into traditional industrial applications such as palletizing, welding, and inspection. By eliminating the distinction between cobots and traditional robots, the updated standard encourages greater integration of collaborative technologies into environments where human workers and robots coexist. This shift is expected to increase cobot penetration in the market, with projections indicating that cobots will account for 16% of global industrial robot shipments by 2030.
Functional Safety: A System-Level Approach
Embedding Safety in Industrial Automation Systems
At the IRSC, functional safety emerged as a critical theme, with growing emphasis on integrating safety measures within the entire robot system, including motors, drives, and controllers. Standards such as ISO 13849 and ISO 62061 continue to form the foundation for functional safety in industrial robotics. As safety becomes increasingly embedded within the systems themselves, companies must adopt a system-level approach to ensure comprehensive protection.
Design and Documentation: Key to Compliance
For manufacturers, functional safety now extends beyond individual components to encompass the entire robot cell. Safety must be considered at every stage of the design process, from input and logic to output. Proper documentation of safety-related parts of control systems (SRP/CS) will become essential for meeting the new regulatory requirements. This emphasis on safety documentation will also facilitate compliance with future regulatory frameworks, such as the Cyber Resilience Act and AI Act, which are expected to impact the robotics sector significantly.
European Regulations: Cybersecurity, AI, and Machinery Regulations
Navigating European Regulatory Changes
The IRSC also focused on the upcoming regulatory changes in Europe, particularly the Cyber Resilience Act (CRA), AI Act, and Machinery Regulation. These regulations are poised to reshape the industrial automation landscape by introducing more stringent requirements for cybersecurity, risk management, and AI safety.
As robots and automation systems become more interconnected, the potential for cyber vulnerabilities increases. To comply with these regulations, manufacturers will need to ensure that their products are designed with cybersecurity in mind, incorporating lifecycle-long resilience and structured risk assessments for AI functions. Additionally, the Machinery Regulation will require compliance with updated safety and cybersecurity standards, affecting how AI-enabled systems are developed, deployed, and supported.
Industry Response: Increased Focus on Cybersecurity and AI Compliance
The new regulations will have far-reaching implications for industrial automation suppliers. Companies must not only enhance their cybersecurity measures but also integrate AI compliance into their development processes. As a result, the role of AI governance and data privacy will be central to the development of safe and secure robotic systems, particularly in high-risk industrial environments.
Market Impact: Preparing for Regulatory Shifts
The Changing Landscape of Industrial Robotics
The updated ISO 10218 standard and emerging European regulations will undoubtedly have a profound impact on the robotics market. Manufacturers are already adjusting their research and development strategies to comply with these new standards, anticipating changes in production costs and timelines. While some Asian robot suppliers are already preparing solutions for the European market, others are taking a wait-and-see approach.
The transition to collaborative applications and the growing demand for humanoid robots will lead to shifts in the competitive landscape. As cobots become more common in traditional industrial environments, companies will need to adapt quickly to meet the rising demand for safe, scalable automation solutions.
What Should Manufacturers Do Now?
Proactive Steps to Meet Future Safety Standards
To stay ahead of the curve, manufacturers and integrators must begin preparing for the upcoming revisions to safety standards and regulations. Early preparation will help avoid costly redesigns and last-minute compliance efforts. Companies that adopt a proactive approach to safety design, functional safety integration, and regulatory compliance will be better positioned to deliver products that meet the evolving demands of the market.
Safety by Design: A Competitive Advantage
As safety functionality becomes a mandatory requirement in industrial automation, companies that prioritize safety in the design phase will have a competitive advantage. Ensuring that robots are compliant with the latest safety standards from the outset will streamline the approval process and increase market acceptance.
Strengthening Cybersecurity and AI Compliance
Given the growing importance of cybersecurity and AI in industrial automation, manufacturers must strengthen their compliance processes to meet new regulatory requirements. Establishing dedicated teams for cybersecurity and AI compliance will be crucial to reducing risks and ensuring that products are secure and compliant with the upcoming regulations.
Conclusion: Preparing for the Future of Safe Automation
The 2025 International Robotic Safety Conference highlighted the significant shifts occurring in industrial robotics safety and standards. As new technologies like humanoids and AI-driven robots gain ground, safety regulations and functional safety measures must evolve to ensure their safe and scalable deployment. Manufacturers that take early action to align their processes with the new standards and regulations will be better positioned to lead the industry in the years ahead.