Safety Features & Speed Limiting

Worked on a multi-layer defense-in-depth safety system spanning firmware, middleware, and tablet UI. Touches on principles addressed by industry standards like ISO 10218 (cobot safety) and IEC 62443 (industrial cybersecurity).

Implemented defense-in-depth software guards that require hardware safety devices to be in known states before allowing certain operations — software enforcing the use of physical safety mechanisms. Also added contextual state gating so that operator inputs are only honored during the appropriate phases of an operation cycle.

Worked on per-joint temperature and current limit enforcement at two independent levels: thermal limits written into the motor controller's configuration operate independently of the higher-level software stack, while per-joint current limits are configurable via the motor dashboard UI and enforced in the real-time control loop. Each joint has independent limits reflecting its mechanical capabilities.

Designed a two-tier speed authorization system: a conservative default ceiling for precision work near workpieces, with a high-speed mode for large moves between weld points. Enabling high-speed requires explicit operator opt-in through a safety confirmation modal. Range validation prevents weld speeds outside the practical process window.