---
title: Residual Risks
description: This section describes residual risks associated with the use of SmoothTool X that could not be eliminated by design, as well as risks that may arise when SmoothTool X is integrated into a complete robotic welding system. The information provided…
url: "https://hub.smooth-robotics.com/docs/compliance-residual-risks/"
updated: "2026-09-23"
category: Compliance
---

# Residual Risks

This section describes residual risks associated with the use of SmoothTool X that could not be eliminated by design, as well as risks that may arise when SmoothTool X is integrated into a complete robotic welding system.

The information provided in this section is intended to support the system integrator's risk assessment of the complete installation. Safe operation depends on the safety functions, protective measures, and operating limits provided by the robot, welding power source, and overall system integration.

Residual risks may remain even when equipment is installed, configured, and operated as intended.

## Risks Introduced by System Integration

### Mechanical Hazards

Collaborative robots are designed with safety functions intended to reduce the risk of injury during operation. However, residual risks remain depending on the application, tooling, workpiece, and operating environment.

Personnel may be exposed to impact, trapping, pinching, or contact hazards when interacting with the robot, welding torch, fixtures, workpieces, or other equipment within the work cell. These risks may be present during automatic operation, teaching, testing, recovery procedures, or manual intervention within the robot workspace.

The suitability of collaborative operation depends on the complete system design and application-specific risk assessment performed by the system integrator.

### System Integration Hazards

SmoothTool X forms part of a complete robotic welding system. Failures in communication, power supply, robot configuration, welding equipment, or external devices may result in unexpected operating conditions or interruptions to the welding process.

The system integrator is responsible for verifying the correct interaction between all components of the installation and implementing appropriate safeguards where required.

## Risks That Cannot Be Eliminated by Design

### Welding Hazards

Welding operations generate heat, arc radiation, sparks, molten material, and weld spatter. Exposure to these hazards may result in burns, eye injuries, fire, or damage to equipment and surrounding materials.

### Fumes and Gases

Welding processes may generate fumes and gases that can be hazardous if inhaled. Appropriate ventilation and fume extraction measures must be provided as part of the complete installation.

### Electrical Hazards

Welding equipment and associated electrical systems may contain hazardous voltages. Risks of electric shock may exist during installation, maintenance, troubleshooting, or operation of connected equipment.

### Process and Programming Hazards

Incorrect weld parameters, improperly defined weld paths, unsuitable process settings, or programming errors may result in defective welds, equipment damage, workpiece damage, or unintended robot behavior.

The quality and safety of generated weld paths depend on the accuracy of user-defined inputs, workpiece definitions, weld locations, and process parameters.