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AI agent for robotics engineers

Robot Safety Zone Validation Agent

A cell whose every safety zone and stop meets its stop-time and distance limits after each change

Quality controlRisk managementComplianceIT and development
See how it worksGet access
Robot Safety Zone Validation Agent: what goes in, what the agent does and what you get

What it does

A robot cell is safe only if its zones, light curtains and emergency stops still work after every program or layout change, yet checks happen rarely. This agent reads the current zone configuration and compares it with the last approved version. It builds test scenarios from the differences, such as a person entering a zone at different speeds, and runs them first in simulation and then on the cell when the safety officer allows it. For each scenario it measures stop time and stopping distance against the limits from the risk assessment. Failures are flagged with the exact setting. After a fix, it reruns every failed scenario and a sample of passing ones. The safety officer approves before the cell returns to production. Edge case: a new tool makes the arm longer, so a zone that was safe now falls short.

How it works

Follow the arrows from top to bottom. The orange dashed arrow is the loop: when a check fails, the agent goes back and tries again.

Start and resultWhat it doesA check on its own workWaits for your OKGoes back and retries
Yes, continueApprovedYes, continueApprovedNoNo 1 STARTS WHEN Configuration or tool change is logged on the cell 2 USES A TOOL Read the current zone configuration and the lastapproved one 3 DOES List differences and build test scenarios for each 4 USES A TOOL Run the scenarios in simulation and record stoptimes 5 CHECKS THE RESULT Do all simulated stop times and distances meet thelimits? If not: flag the failing zone and setting and draft acorrection. Back to step 3. 6 YOU APPROVE Safety officer allows the physical test on the cell 7 USES A TOOL Run the physical scenarios and record measured stops 8 CHECKS THE RESULT Do measured stops match simulation and meet thelimits? If not: adjust the model or settings, then rerun thefailed scenarios. Back to step 3. 9 DOES Rerun a sample of earlier passing scenarios for sideeffects 10 YOU APPROVE Safety officer approves return to production 11 RESULT Validation record with stop times per zone
Read the steps as a list
  1. Configuration or tool change is logged on the cell
  2. Read the current zone configuration and the last approved one
  3. List differences and build test scenarios for each
  4. Run the scenarios in simulation and record stop times
  5. Do all simulated stop times and distances meet the limits?If not: flag the failing zone and setting and draft a correction. Back to step 3.
  6. Safety officer allows the physical test on the cellThe agent waits here for your OK.
  7. Run the physical scenarios and record measured stops
  8. Do measured stops match simulation and meet the limits?If not: adjust the model or settings, then rerun the failed scenarios. Back to step 3.
  9. Rerun a sample of earlier passing scenarios for side effects
  10. Safety officer approves return to productionThe agent waits here for your OK.
  11. Validation record with stop times per zone

How it decides

A scenario passes only if stop time and distance are within limits with margin. Any change in tools or layout forces a full rerun.

  • Require a margin of 10 percent below the stop-time limit
  • Rerun all scenarios if a tool or payload changed
  • Never allow a physical test until simulation passes
  • Keep the cell locked out until approval

Make it yours

Every agent is a starting point. You choose these settings for your own situation.

  • Stop-time margin (default 10 percent)
  • Which cells it covers
  • Schedule for routine checks
  • Who signs off

What keeps you in control

It always asks you first

  • Physical test on the cell
  • Return to production
  • Any change to safety settings

Hard limits

  • Never changes safety settings on the live controller
  • Never runs a physical test without the safety officer's go-ahead

It stops when

  • Done: all scenarios pass and the officer signs off
  • Stop: any physical stop exceeds the limit

Set it up

We guide you through the set-up, step by step

Members get the full set-up guide for this agent. No technical skills needed: you copy, paste and upload.

10 minto set it up in your AI
5 AIsChatGPT, Claude, Copilot, Gemini, Grok
  • One set of instructions to paste into your AI, with the clicks for ChatGPT, Claude, Microsoft 365 Copilot, Gemini and Grok
  • The agent then walks you through connecting your own data, one source at a time
  • A downloadable copy with the flow chart, the rules and the full guide
Get access to this agent

An example run

What happensAfter a gripper change on Cell 4, the agent built 14 scenarios. In simulation, zone B stopped the arm in 0.52 seconds against a 0.50 limit. It flagged the setting and suggested a slower approach speed. After the fix, simulation passed, the officer allowed the cell test, and measured stops averaged 0.41. All 14 scenarios and 5 earlier ones passed, and the officer signed.

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