Embedding ISO 10218 Safety Compliance in Robots via Control Barrier Functions for Human-Robot Collaboration
Authors: Federico Parma, Cesare Tonola, Nicola Pedrocchi, Manuel Beschi
Abstract
Human-Robot Collaboration (HRC) requires strict adherence to safety standards, such as ISO 10218, to prevent harmful interactions. Standard Speed and Separation Monitoring (SSM) filters calculate safe robotic speeds based on conservative assumptions, such as constant human velocity, which prevents accurate predictions of minimum separation distances and causes unnecessary operational halts. This paper proposes a Control Barrier Function (CBF) that explicitly incorporates human acceleration data to analytically forward-predict the minimum human-robot separation distance during a worst-case robotic stopping trajectory. To guarantee safety at the control level, this predictive CBF is integrated as an inequality constraint within a Sequential Quadratic Programming (SQP) framework. Specifically, two methods are proposed: Method I, a CBF-constrained PD safety filter; and Method II, a task-scaling SQP controller that enforces a spatial tube constraint. Simulated and real-world experiments on a UR10e robot evaluate the two proposed methods against a standard industrial SSM module baseline. Results demonstrate that Method II dynamically modulates execution speed and confines spatial deviations. Compared to Method I, Method II achieves a 63% reduction in mean trajectory error and avoids excessive evasive manoeuvres, ensuring high task throughput while complying with ISO 10218 SSM guidelines.
Physical human-robot interaction offers the potential to leverage human intelligence and robot physical capabilities to enable a range of exciting applications, e.g., collaborative robots for rehabilitation. Safety is critical for the successful deployment of this kind of robotic system. In recent years, Control Barrier Function (CBF) has emerged as an effective approach to enforce safety guarantees, which has been widely applied in various applications, from adaptive cruise control to navigation of legged robots. CBFs can be solved in a Quadratic Programming (QP) problem, which can include many CBF-formulated tasks. To manage a large number of safety tasks, a hierarchical CBF has been used to allow hierarchical relaxation of safety tasks to ensure the feasibility of a solution in the presence of conflicting tasks. In this work, we propose to use a CBF-based Hierarchical Quadratic Programming (HQP) framework in physical human-robot interaction to allow us to design both performance tasks (e.g., preserve the desired behavior at the human-robot interaction point) and safety tasks at any level of a hierarchy to balance the safety and the performance in a more flexible way. Extensive experiments were carried out on a real redundant robot to validate the effectiveness, flexibility, and generality of this approach.
Rui Luo, Jonas Mariager Jakobsen, Wesley Roozing +2
Safety-critical control is essential for humanoid robots operating in complex human-centered environments, where physical safety constraints such as joint limits, self-collision avoidance, obstacle avoidance, and workspace boundaries must be satisfied during real-robot operation. However, existing approaches remain limited because kinematic safety guarantees can be degraded in the presence of unknown disturbances, such as model uncertainties, trajectory-tracking errors, and external perturbations. This paper presents a hierarchical safety-critical whole-body control framework for humanoid robots based on input-to-state safe control barrier functions (ISSf-CBFs). The proposed architecture integrates a kinematic-level whole-body controller (KinWBC), an ISSf-CBF safety filter, and a dynamic-level whole-body controller (DynWBC). KinWBC generates nominal joint-motion references from prioritized tasks; the ISSf-CBF filter minimally modifies these references to satisfy kinematic safety constraints under bounded disturbances; and DynWBC tracks the filtered references while enforcing full-body dynamic feasibility and contact stability. Safety constraints are imposed on a whole-body kinematic model, and the ISSf-CBF parameters are conservatively tuned so that the resulting kinematic safety guarantees can be transferred to full-order humanoid dynamics under unknown disturbances. Simulation and real-robot experiments demonstrate that the proposed framework improves safety margins under model mismatch and reliably enforces multiple safety constraints in real time during locomotion, teleoperation, and single-leg balancing with hand control. Project website: https://kwlee365.github.io/SafeWBC-Website/
What is considered safe for a robot operator during physical human-robot collaboration (HRC) is specified in corresponding HRC standards (e.g., ISO 10218-2:2025). The regime that allows collisions between the moving robot and the operator, called Power and Force Limiting (PFL), restricts the permissible contact forces. Using the same fixed contact thresholds on the entire robot surface results unnecessary productivity losses, as the robot needs to stop even when impact forces are within limits. Here we present a framework that decides whether the robot should interrupt motion based on estimated collision force computed individually for different parts of the robot body and dynamically on the fly, based on the Effective Mass (EM) of each robot link. We performed experiments on a simulated and real collaborative robot arm (UR10e) with sensitive skin (AIRSKIN) for collision detection and isolation. To demonstrate the generality of our method, we added experiments on simulated KUKA LBR iiwa robot, where collision sensing draws on joint torque sensing. On a mock pick-and-place scenario with both transient and quasi-static collisions, we show an increase in productivity over 45% from using the standard approach. The method is applicable to any robot for which the EF can be calculated.