Robotics & Automation worked example

Robot Safety Distance with robot approach and reach speed k of 4,000 mm / sec: a worked example

Push robot approach and reach speed k up to 4,000 mm / sec and the picture changes. This example computes every intermediate figure at that operating point. Use it during cell layout to size guarding distance to a light curtain, scanner, or safety mat before commissioning, then confirm with a safety stop test.

The inputs for this scenario

  • Robot approach/reach speed K: 4,000 mm / sec (raised for this scenario; the documented default is 1,600)
  • Total stopping time T (robot + control response): 0.35 sec (unchanged)
  • Reach-past intrusion allowance C: 128 mm (unchanged)
  • Applied safety margin multiplier: 1.2 x (unchanged)

Working through the calculation

  • Applying the documented formula (Base safety distance = (approach speed K x overall system stopping time T) + intrusion distance C) to the inputs above produces each figure below.
  • At this operating point the engine returns 215,040 in for required safety distance, the number this scenario is built around.
  • At this operating point the engine returns 179,200 value for base product.
  • At this operating point the engine returns 1.2 x for multiplier.
  • At this operating point the engine returns 1,400 value for factor a x b.

How this compares with the baseline

  • Against the tool's baseline example, where robot approach and reach speed k sits at 1,600 mm / sec and the headline result is 86,016 in, this scenario comes in 150% above the baseline at 215,040 in.
  • It multiplies approach speed by total stopping time, adds the intrusion allowance, then applies a safety margin to return the minimum safeguarding distance. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Required safety distance: 215,040 in (headline result)
  • Base product: 179,200 value
  • Multiplier: 1.2 x
  • Factor A x B: 1,400 value

Run it with your numbers

  • Every input above is editable in the live Robot Safety Distance calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.