Risk assessment support device, risk assessment support program and risk assessment support procedure

Abstract

A risk assessment support device (1A) comprises a computation unit which receives layout information, which is information relating to the layout of a robot and a nearby object in the vicinity of the robot, and which contains the robot control information, which is information relating to the control of the robot, and which computes a set of solutions with respect to a position of the robot, a position of a device other than the robot, and a movement of the robot, based on an evaluation function which includes a term representing a size of an area for installing a robot system comprising the robot and the device; and an output processing unit (15) which outputs the layout information and the robot control information representing the set of solutions when a risk in the robot system falls within an acceptable range.

Description

Technical area

[0001] The present disclosure relates to a risk assessment support device, a risk assessment support program, and a risk assessment support method, each supporting risk assessment performed during a design phase of a robot system. Technological background

[0002] In recent years, the need for introducing robots into manufacturing facilities, such as factories, has increased. Furthermore, from the perspective of work efficiency, robots often work in cooperation with workers. Such facilities implement various measures to ensure worker safety.

[0003] Patent Literature 1 discloses a risk assessment support device that supports risk assessment in a design phase of a device, such as one in a production line. The risk assessment support device according to Patent Literature 1 identifies a hazard source and determines a hazard zone based on equipment information about the device, and calculates a risk in the hazard zone. The risk assessment support device according to Patent Literature 1 also selects a measure for the risk or changes the equipment information by revising the design if it is determined that the calculated risk is not within an acceptable range. Citation listPatent literature

[0004] Patent Literature 1: Japanese Patent No. 6698042 Short descriptionTechnical problem

[0005] When a robot system comprising a robot and a peripheral device separate from the robot is to be installed in a manufacturing facility, it is required to eliminate inefficient use of space to the greatest extent possible, that is, to save space for the entire robot system. In the risk assessment provided by the conventional technology disclosed in Patent Literature 1, no consideration is given to the space saving of the robot system. Therefore, the conventional technology has a problem in that it is difficult to design a robot system that can provide both safety assurance and space saving.

[0006] The present disclosure has been made in view of the foregoing, and it is an object of the present disclosure to provide a risk assessment support device that enables risk assessment to provide both safety assurance and space saving in a robot system. Solution to the problem

[0007] In order to solve the problems described above and achieve the object, a risk assessment support device according to the present disclosure comprises: a calculation unit for obtaining layout information and robot control information, and for calculating a set of solutions based on an evaluation function, wherein the layout information is information related to a layout of a robot and a nearby object in the vicinity of the robot, wherein the robot control information is information related to the control of the robot, wherein the set of solutions is solutions regarding a position of the robot, regarding a position of a device other than the robot, and regarding a movement of the robot, wherein the evaluation function includes a term representing a size of an area for installing a robot system,wherein the robot system comprises the robot and the device; and an output processing unit for outputting the layout information and the robot control information representing the set of solutions when a risk in the robot system falls within an acceptable range. Advantageous effects of the invention

[0008] A risk assessment support device according to the present disclosure has the advantage of enabling risk assessment to provide both safety assurance and space saving in a robot system. Short description of drawings Fig. 1 is a diagram illustrating an exemplary configuration of a risk assessment support device according to a first embodiment. Fig. 2 is a flowchart illustrating an operation procedure of the risk assessment support device according to the first embodiment. Fig. 3 is a flowchart illustrating a procedure of risk assessment processing performed by a risk assessment processing unit of the risk assessment support apparatus according to the first embodiment. Fig. 4 is a diagram for describing an example of risk estimation performed by the risk estimation processing unit of the risk estimation support device according to the first embodiment. Fig. 5 is a flowchart illustrating a procedure of risk reduction processing performed by a risk reduction processing unit of the risk assessment support apparatus of the first embodiment. Fig. 6 is a diagram illustrating an exemplary configuration of a risk assessment support device according to a second embodiment. Fig. 7 is a diagram illustrating an exemplary configuration of a risk assessment support device according to a third embodiment. Fig. 8 is a diagram illustrating an exemplary configuration of a risk assessment support device according to a fourth embodiment. Fig. 9 is a diagram illustrating an exemplary configuration of a control circuit according to the first to fourth embodiments. Description of embodiments

[0009] A risk assessment support device, a risk assessment support program, and a risk assessment support method according to embodiments will be described in detail below with reference to the drawings. First embodiment.

[0010] Fig. 1 is a diagram illustrating an exemplary configuration of a risk assessment support device 1A according to a first embodiment. The risk assessment support device 1A supports a risk assessment performed during a design phase of a robot system. The robot system is installed in a manufacturing facility such as a factory. The robot system includes a robot and a peripheral device. The peripheral device is a device different from the robot.

[0011] Fig. 1 illustrates a risk assessment support device 1A, an input device 2, and an output device 3. The input device 2 receives an input operation performed by a user of the risk assessment support device 1A. The user is, for example, a developer who designs the robot system. The input device 2 is a device such as a keyboard, a touch panel, a button, or a computer mouse. The input device 2 sends the input information to the risk assessment support device 1A.

[0012] The output device 3 receives information from the risk assessment support device 1A and outputs the received information. The output device 3 is, for example, a display device for displaying information. The display device is, for example, a liquid crystal display (LCD) or an organic electroluminescence display (EL). The output device 3 can be a printer for outputting information by printing, or the like.

[0013] The risk assessment support device 1A includes a facility information input processing unit 10, a layout information setting unit 11, a robot control information setting unit 12, an optimization calculation unit 13, a residual risk information acquisition unit 14, and an output processing unit 15. The risk assessment support device 1A further includes a storage unit for storing various types of information. The storage unit stores several types of information, including robot arm data, end effector data, nearby object data, behavior data, work environment information, a hazard source database, and safety-related device data. Fig. Figure 1 schematically illustrates each type of information stored in the storage unit.

[0014] Robot arm data is data related to robot arms for each of a plurality of robots that may be included in the robot system. Robot arm data is data related to the structure and / or movement of the robot arms. Each of the robots includes a plurality of arms and drive units provided at respective joints. The joints are each a joint point between arms. The drive units each control the joint angle. Robot arm data includes computer-aided design (CAD) data for each of the robots, the degree of freedom of movement of the robot, arm lengths, ranges of motion, the maximum speed of the arms, the spatial repeatability of the robot, information about the robot drive method, a load capacity of the robot, a body mass of the robot, an allowable (force) moment of the robot, allowable inertia of the robot, and / or the like.

[0015] End-effector data is data related to the structure and / or movement of an end-effector attached to the robot. The term "end-effector" refers to a tool, such as a hand for grasping an object, a screw driver, or a welding torch. End-effector data includes CAD data for each of the end-effectors, body masses for each of the end-effectors, information about the movable point of each of the end-effectors, information about the range of motion of each of the end-effectors, and / or the like.

[0016] The nearby object data is data regarding nearby objects, each of which is an object present near the robot. The nearby objects include a device included in the robot system. A nearby object that is a device included in the robot system is a device such as a transport means, a part feeder, or a fixing jig. The nearby objects also include an object other than a device included in the robot system. Examples of nearby objects other than devices included in the robot system include a table, which is an object placed in a room where the robot system is installed, a wall, a pillar, and a door, which are structures present in a room where the robot system is installed.The following description refers to a device that is a nearby object as a peripheral device. Nearby object data related to a peripheral device includes CAD data of the peripheral device, body mass of the peripheral device, information about the movable point of the peripheral device, information about the moving range of the peripheral device, and / or the like. Nearby object data related to a nearby object that is not a peripheral device includes information about the position of the nearby object, information about the area occupied by the nearby object, and / or the like.

[0017] Behavioral data is data related to the worker's movement. Behavioral data includes information about the worker's range of motion, the worker's movement speed, and information about the assembly work performed by the worker.

[0018] The work environment information is information regarding the worker working near the robot and / or information regarding work to be performed by the worker. The information regarding the worker includes a level representing the skill level of the work and / or the like. The information regarding the work includes information about the worker's movement range, information about work details, information about the frequency of an operation, information about the work process, and / or the like. The information about the frequency of operation is information about the frequency of work, such as eight hours a day or several times a year. The information about the work process is information representing processes of work, such as a starting point of a robot, an operation of a robot, maintenance of a robot, and / or the like.

[0019] The hazard database includes data related to hazards contained in the robot and data related to hazards contained in the equipment. Data related to hazards is hereinafter referred to as hazard data. Hazards include mechanical hazards, electrical hazards, thermal hazards, noise hazards, vibration hazards, radiation hazards, hazards related to a material or substance, ergonomic hazards, and / or the like.

[0020] Examples of mechanical hazards include moving parts such as a robot arm and an end effector. A mechanical hazard can have an impact on humans, such as crushing, impact, entrapment, or cutting. Examples of electrical hazards include parts that can cause an electric shock upon contact, such as a charger or a connector section. Examples of thermal hazards include parts that will have a high temperature and that can cause a burn upon contact, such as an end effector, equipment related to an end effector, and a workpiece. Examples of noise hazards include a noise source. A noise hazard can have an impact on humans, such as hearing loss. Vibration hazards are parts that generate vibrations.A vibration hazard can have an effect on humans, such as neurological damage, caused by contact with it. Radiation hazards are parts that generate different types of electromagnetic waves. A radiation hazard can have an effect on humans, such as damage to an eye or skin caused by exposure to radiation. Examples of hazards related to a material or substance include a liquid and a gas that are dangerous to humans, such as a corrosive gas and corrosive dust. A hazard related to a material or substance can have an effect on humans, such as damage to the skin caused by contact with it, and damage caused by inhalation.Examples of ergonomic hazards include hazards resulting from a failure to adhere to ergonomic principles, such as forcing an unnatural posture and subjecting the user to excessive strain. An ergonomic hazard can have an impact on humans, such as fatigue from an overused part of the human body.

[0021] Safety-related device data is data related to safety-related devices, each of which is a device used to reduce risk. Examples of safety-related devices include a safety gate, a light curtain, and an interlock switch. Safety-related device data includes CAD data of the safety-related devices, body masses of the safety-related devices, data regarding safety functions of the safety-related devices, and / or the like.

[0022] The robot arm data is stored in groups according to, for example, the robot manufacturer, the robot arm specification, or the like. The end effector data is stored in groups according to, for example, the end effector manufacturer, the end effector type, the end effector specification, or the like. The nearby object data related to the peripheral devices is stored in groups according to, for example, the peripheral device manufacturer, the peripheral device type, the peripheral device specification, or the like. The safety-related device data is stored in groups according to, for example, the safety-related device manufacturer, the safety-related device type, the safety-related device specification, or the like.

[0023] The facility information input processing unit 10 receives facility information of the robot system through a user operation on the input device 2. The user operates the input device 2 to select, as appropriate, a data set to be incorporated into the facility information from each of the robot arm data, the end-effector data, the nearby object data, and the behavior data. Note that if the robot arm data, the end-effector data, the nearby object data, and the behavior data do not contain the desired data, the facility information input processing unit 10 can download new data to be incorporated into the facility information via a network or from a database external to the risk assessment support device 1A. Alternatively, new data to be incorporated into the facility information can be manually input by the user.

[0024] The facility information input processing unit 10 outputs the input facility information to the layout information setting unit 11 and the robot control information setting unit 12. The layout information setting unit 11 sets layout information that reflects the input facility information. The layout information is information regarding the layout of the robot system. The layout information includes information regarding the robot arms, information regarding the end effectors, information regarding the nearby objects, information regarding the worker's position, information regarding the worker's movement range, and / or the like. The layout information setting unit 11 outputs the set layout information to the optimization calculation unit 13.

[0025] The robot control information setting unit 12 sets robot setting information reflecting the inputted facility information. The robot control information is information related to the control of the robot, and is information related to an operation program for use in controlling the robot, and / or the like. The robot control information setting unit 12 can set the robot control information by reflecting the robot arm information included in the facility information in the operation program. The robot control information setting unit 12 outputs the set robot control information to the optimization calculation unit 13. In addition, the facility information input processing unit 10 reflects the behavior data included in the inputted facility information in the work environment information.

[0026] The risk assessment support device 1A optimizes the position of each robot of the robot system, the position of each peripheral device of the robot system, and the movement of each robot of the robot system through calculations performed in the optimization calculation unit 13. In this context, the phrase "the movement of a robot" refers to a command position or a movement path. The risk assessment support device 1A performs such optimization to provide space savings for the robot system and to reduce the cycle time of the robot system (specifically, achieving high speed), in addition to ensuring safety.

[0027] The optimization calculation unit 13 includes an optimization processing unit 16, which is a calculation unit, a risk assessment processing unit 17, and a risk reduction processing unit 18. The optimization processing unit 16 receives the layout information from the layout information setting unit 11 and the robot control information from the robot control information setting unit 12. The optimization processing unit 16 receives the layout information and the robot control information and, based on an evaluation function, calculates an optimal solution, which is a set of solutions with respect to the position of the robot, the position of each of the peripheral devices, and the movement of the robot.That is, the optimization processing unit 16 performs optimization processing with respect to the position of the robot, the position of the peripheral device, and the movement of the robot. The optimization calculation unit 13 outputs the optimal solution obtained by the calculation to the risk assessment processing unit 17.

[0028] The risk assessment processing unit 17 extracts a risk in the robot system when the optimal solution obtained by calculation is applied to the robot system. The risk assessment processing unit 17 receives the work environment information. The risk assessment processing unit 17 further obtains the hazard source data from the hazard source database. The risk extraction processing performed by the risk assessment processing unit 17 is described in detail below. The risk assessment processing unit 17 outputs information about the extracted risk to the risk reduction processing unit 18.

[0029] The risk reduction processing unit 18 performs risk reduction processing to determine whether risk reduction is possible, where risk reduction is an operation for reducing the risk extracted by the risk assessment processing unit 17 to an acceptable range for the risk. The risk reduction processing unit 18 receives the safety-related device data. The risk reduction processing performed by the risk reduction processing unit 18 is described in detail below. If the risk falls within the acceptable range, the risk reduction processing unit 18 outputs an optimal solution to each of the layout information setting unit 11 and the robot control information setting unit 12. The risk reduction processing unit 18 outputs residual risk information to the residual risk information acquisition unit 14.The residual risk information is information about a risk that remains in the robot system when the optimal solution is applied to the robot system when the risk falls within the acceptable range.

[0030] The layout information setting unit 11 outputs the layout information of the robot system representing the optimal solution obtained by the risk reduction processing unit 18 to the output processing unit 15. The robot control information setting unit 12 outputs the robot control information representing the optimal solution obtained by the risk reduction processing unit 18 to the output processing unit 15. The residual risk information acquisition unit 14 receives the residual risk information from the risk reduction processing unit 18 and outputs the residual risk information to the output processing unit 15.

[0031] The output processing unit 15 outputs the layout information obtained from the layout information setting unit 11 and the robot control information obtained from the robot control information setting unit 12 to the output device 3. That is, the output processing unit 15 outputs layout information and robot control information representing the optimal solution when the risk in the robot system falls within the acceptable risk range. The output processing unit 15 further outputs the residual risk information obtained from the residual risk information acquisition unit 14 to the output device 3. The output device 3 outputs the layout information, the robot control information, and the residual risk information.

[0032] An operation of the risk assessment support device 1A will be described next. Fig. 2 is a flowchart illustrating an operation procedure of the risk assessment support device 1A according to the first embodiment.

[0033] In step S1, the risk assessment support device 1A determines whether facility information of the robot system has been input to the facility information input processing unit 10. If no facility information of the robot system has been input (NO in step S1), the risk assessment support device 1A repeats step S1. If facility information of the robot system has been input (YES in step S1), the risk assessment support device 1A proceeds to the process of step S2.

[0034] In step S2, the risk assessment support device 1A sets the layout information and the robot control information. The risk assessment support device 1A causes the layout information setting unit 11 to set layout information reflecting the facility information inputted in step S1. The risk assessment support device 1A causes the robot control information setting unit 12 to set robot control information reflecting the facility information inputted in step S1. The facility information input processing unit 10 reflects the behavior data included in the input facility information into the work environment information.

[0035] The optimization processing unit 16 receives the layout information and the robot control information set in step S2. In step S3, the optimization processing unit 16 calculates an optimal solution for the robot position, the peripheral device position, and the robot motion.

[0036] Using the following equation (1), the optimization processing unit 16 calculates x^, which is the optimal solution for the position of the robot, the position of the peripheral device, and the motion of the robot. Equation 1: x^=argminx∈A f(x)

[0037] In this respect, set A includes all placeable positions for all robots included in the robot system, all placeable positions for all peripherals included in the robot system, and all controllable movements for all robots included in the robot system. The function f(x) is an evaluation function.

[0038] The evaluation function f(x) can be expressed, for example, by the following equation (2). f(x)=f1(x)+f2(x)

[0039] The first term f1(x) contained in the evaluation function f(x) is a term representing the cycle time of the robot system. The second term f2(x) contained in the evaluation function f(x) is a term representing the installation footprint, which is the area of ​​the entire robot system, including the robot and peripheral devices. Thus, the evaluation function f(x) contains f1(x), which is a term representing the utilization rate of the robot system, and f2(x), which is a term representing the area for installing the robot system.

[0040] Note that f2(x) may be a term representing the volume of the space in which the robot system is installed, rather than the installation footprint. This means that f2(x) may be a term that includes, as an element, the length in each three-dimensional direction relative to the area for installing the robot system. Even in this case, f2(x) is still a term representing the size of the area for installing the robot system. Note that the method for using optimization processing may be a method such as an exhaustive method, a gradient method, or a genetic algorithm.

[0041] In step S4, the risk estimation processing unit 17 performs risk estimation processing. The risk estimation processing unit 17 calculates the risk when the calculated values ​​of x^ are applied to the position of the robot, the position of the peripheral device, and the movement of the robot.

[0042] Next, the risk assessment processing performed by the risk assessment processing unit 17 will be described in detail. Fig. 3 is a flowchart illustrating a procedure of the risk estimation processing performed by the risk estimation processing unit 17 of the risk estimation support device 1A according to the first embodiment.

[0043] The risk assessment processing unit 17 receives the work environment information and the hazard source data. In step S11, the risk assessment processing unit 17 identifies a hazard source and determines a hazard zone. The risk assessment processing unit 17 identifies a hazard source based on the work environment information and the hazard source data.

[0044] For example, the risk assessment processing unit 17 identifies as hazard sources components that include a drive source, such as a robot arm, an end effector, and a transport device that is a peripheral device. Additionally, the risk assessment processing unit 17 determines whether the hazard source movement area overlaps with the worker's movement area. The risk assessment processing unit 17 determines that an overlap area between the hazard source movement area and the worker's movement area is a danger zone. Based on the hazard source movement area, the risk assessment processing unit 17 determines whether a human body may be trapped between hazard sources.The risk assessment processing unit 17 determines, based on the hazard source movement area, whether a human body may be trapped between a hazard source and a nearby object, such as a table, wall, pillar, or door. The risk assessment processing unit 17 designates an area in which a human body may be trapped between these elements as a hazard zone. Note that the method for identifying a hazard source and the method for determining a hazard zone have been explained here by way of example. The risk assessment processing unit 17 may use any method to identify a hazard source and determine a hazard zone based on the work environment information and the hazard source data.

[0045] Next, the risk assessment processing unit 17 performs a risk assessment in step S12. Through the risk assessment, the risk assessment processing unit 17 determines a potentially dangerous event / hazardous event associated with the hazard source identified in step S11 and the hazard zone determined in step S11. The risk assessment processing unit 17 also determines any damage to the human body that may be caused in connection with the potentially dangerous event.

[0046] For example, if the worker's movement range overlaps with the robot arm's movement range, an event that will be determined as a hazardous event is "being struck by a robot arm." If an area that is the worker's movement range and an area that is the robot arm's movement range are separated by a distance less than a predetermined distance, the worker may also be struck by the robot arm. In this case, the event of "being struck by a robot arm" is also determined as a hazardous event. If the robot arm's movement range and a nearby object are separated by a distance less than a predetermined distance, an event that will be determined as a hazardous event is "being sandwiched between a robot arm and a nearby object."An example of damage when the hazard event is "struck by a robot arm" is "crushing or fracture." An example of damage when the hazard event is "caught between a robot arm and a nearby object" is "serious injury as severe as or more severe than a fracture." The risk assessment processing unit 17 determines these hazard events and these damages based on the hazard source data. The risk assessment processing unit 17 performs the risk assessment using factors such as the severity of damage, frequency of occurrence, and the possibility of avoiding damage.

[0047] The risk assessment processing unit 17 can use any method for the risk assessment process. Examples of risk assessment methods include a risk graph using a tree diagram, a risk matrix using a table, numerical scoring using the addition and multiplication of values, and a hybrid tool, which is a combination thereof.

[0048] Next, a description is given of an example of risk estimation using a risk graph method, which is an example of the risk estimation method. Fig. 4 is a diagram for describing an example of risk estimation performed by the risk estimation processing unit 17 of the risk estimation support device 1A according to the first embodiment. Fig. Figure 4 shows an example of a tree diagram used in the risk graph method.

[0049] An example will now be described in which the risk assessment is performed based on the severity of the damage, the frequency of occurrence, and the possibility of avoidance. It should be noted that the factors used in the risk assessment are not limited to those described in the first embodiment, but can be any factor. For the severity of the damage, one of two classes of "mild" and "serious" is selected. For the frequency of occurrence, one of three classes of "low," "medium," and "high" is selected. For the possibility of avoidance, one of two classes of "possible" and "impossible" is selected. The selection of each of the severity of the damage, the frequency of occurrence, and the possibility of avoidance results in a determination as to which risk level from risk level "1" to risk level "6" the risk level in question falls into, as shown in Fig. 4. The risk level represents the severity of damage. Risk level "1" indicates the least damage among the six risk levels. Risk level "6" indicates the most serious damage among the six risk levels. The risk assessment processing unit 17 determines which risk level, from risk level "1" to risk level "6," the risk level in question falls into, thus performing the risk assessment. Although this example uses six risk levels, from risk level "1" to risk level "6," to indicate the severity of damage, any number of risk levels may be used.

[0050] Next, the risk assessment processing unit 17 performs a risk evaluation in step S13. In this operation, the risk assessment processing unit 17 evaluates whether the risk determined by the risk assessment in step S12 is an acceptable risk. The risk assessment processing unit 17 evaluates the risk by comparing the result of determining the risk level, which is the result of the risk assessment, with a threshold value. For example, if the value indicated by the risk level is less than or equal to a threshold value, the risk assessment processing unit 17 determines that the risk is an acceptable risk. On the other hand, if the value indicated by the risk level is greater than the threshold value, the risk assessment processing unit 17 determines that the risk is not an acceptable risk.After completion of step S13, the risk estimation processing unit 17 terminates the risk estimation processing according to the procedure shown in . Fig. 3 procedure shown.

[0051] In the Fig. In step S5 shown in FIG. 2, the risk assessment processing unit 17 determines whether the risk extracted by the risk assessment in step S12 is an acceptable risk. The risk assessment processing unit 17 determines whether the risk is an acceptable risk based on the result of the risk evaluation in step S13. If the risk is an acceptable risk (YES in step S5), the risk assessment support device 1A proceeds to the process of step S9. On the other hand, if the risk is not an acceptable risk (NO in step S5), the risk assessment support device 1A proceeds to the process of step S6. If the risk is not an acceptable risk, the risk assessment processing unit 17 instructs the risk reduction processing unit 18 to perform risk reduction processing with respect to the risk determined to be an unacceptable risk.

[0052] In step S6, the risk reduction processing unit 18 determines whether risk reduction is possible for the risk determined to be unacceptable in step S5. The risk reduction processing unit 18 receives the safety-related device data. Based on the safety-related device data, the risk reduction processing unit 18 determines whether risk reduction is possible by using a safety-related device.

[0053] Next, the risk reduction processing performed by the risk reduction processing unit 18 will be described in detail. Fig. 5 is a flowchart illustrating a procedure of the risk reduction processing performed by the risk reduction processing unit 18 of the risk assessment support device 1A according to the first embodiment.

[0054] In step S21, the risk reduction processing unit 18 determines, based on the safety-related device data, whether risk reduction is possible by using a safety protection measure and an additional protection measure. The risk reduction processing unit 18 determines whether risk reduction is possible by spatially separating the worker and the hazard source, for example, using a safety gate, as a safety protection measure. The risk reduction processing unit 18 determines whether risk reduction is possible by stopping or slowing down the hazard source when, for example, a light curtain, which is a protective device, detects the worker's entry into a danger zone. The risk reduction processing unit 18 determines whether risk reduction is possible by stopping the hazard source, for example, using a lock, as an additional protection measure.If the risk reduction processing unit 18 determines that risk reduction is possible (YES in step S21), the risk reduction processing unit 18 proceeds to the process of step S23. Otherwise, if the risk reduction processing unit 18 determines that risk reduction is not possible (NO in step S21), the risk reduction processing unit 18 proceeds to the process of step S22.

[0055] In step S22, the risk reduction processing unit 18 determines, based on the usage information, whether risk reduction is possible if the worker takes appropriate action. If the risk reduction processing unit 18 determines that risk reduction is possible (YES in step S22), the risk reduction processing unit 18 proceeds to the process of step S23. Otherwise, if the risk reduction processing unit 18 determines that risk reduction is not possible (NO in step S22), the risk reduction processing unit 18 proceeds to the process of step S24.

[0056] In step S23, the risk reduction processing unit 18 determines that risk reduction is possible. In step S24, the risk reduction processing unit 18 determines that risk reduction is not possible. After completion of step S23 or step S24, the risk reduction processing unit 18 ends the risk reduction processing according to the Fig. 5 procedure shown.

[0057] The operation of step S6 is a procedure of determining whether risk reduction is possible through the risk reduction processing from step S21 to step S24. If the risk reduction processing unit 18 determines that risk reduction is possible (YES in step S6), the risk reduction processing unit 18 instructs the risk estimation processing unit 17 to perform risk estimation processing for the case where risk reduction has been performed. The risk estimation support device 1A proceeds to the process of step S7. Otherwise, if the risk reduction processing unit 18 determines that risk reduction is not possible (NO in step S6), the risk estimation support device 1A returns to the process of step S3. The risk estimation support device 1A again performs the optimization processing performed by the optimization processing unit 16.The optimization processing unit 16 calculates a new optimal solution from a set A' which excludes the optimal solution x^ that has already been calculated.

[0058] In step S7, the risk estimation processing unit 17 performs the risk estimation processing again. In step S8, the risk estimation processing unit 17 determines whether the risk extracted during the risk estimation is an acceptable risk. If the risk is an acceptable risk (YES in step S8), the risk estimation support device 1A proceeds to the process of step S9. Otherwise, if the risk is not an acceptable risk (NO in step S8), the risk estimation support device 1A returns to the process of step S3. The risk estimation support device 1A performs the optimization processing again, which is performed by the optimization processing unit 16. The optimization processing unit 16 calculates a new optimal solution from a set A' that excludes the optimal solution x^ that has already been calculated.

[0059] The risk assessment support device 1A repeats the operations from step S3 to step S8 until it is determined that the risk extracted in step S5 or step S8 is an acceptable risk. The layout information setting unit 11 and the robot control information setting unit 12 each receive the optimal solution from the risk reduction processing unit 18 when the risk falls within the acceptable range. The layout information setting unit 11 then outputs layout information representing the optimal solution obtained from the risk reduction processing unit 18 to the output processing unit 15. The robot control information setting unit 12 outputs robot control information representing the optimal solution obtained from the risk reduction processing unit 18 to the output processing unit 15.The risk reduction processing unit 18 outputs residual risk information to the residual risk information acquisition unit 14. The residual risk information acquisition unit 14 receives the residual risk information from the risk reduction processing unit 18 and outputs the residual risk information to the output processing unit 15.

[0060] In step S9, the output processing unit 15 outputs the layout information, the robot control information, and the residual risk information to the output device 3. Thus, the risk assessment support device 1A ends the operation according to the Fig. 2 procedure shown.

[0061] According to the first embodiment, the risk assessment support device 1A calculates a set of solutions for the position of the robot, the position of the peripheral device, and the movement of the robot based on an evaluation function including a term representing the size of an area for installing the robot system. The risk assessment support device 1A then outputs layout information and robot control information, each representing the set of solutions, when the risk in the robot system falls within the acceptable range. This provides an advantage in the ability of the risk assessment support device 1A to perform risk assessment to provide both safety assurance and space savings in a robot system.In addition, the additional inclusion of a term representing the utilization rate of the robot system in the evaluation function enables the risk assessment support device 1A to perform the risk assessment in such a way that it ensures a high utilization rate of the robot system. Second embodiment.

[0062] Fig. Fig. 6 is a diagram illustrating an exemplary configuration of a risk assessment support device 1B according to a second embodiment. The risk assessment support device 1B includes components that support the Fig. 1, and a motion detection processing unit 19. In the second embodiment, the same components as those of the above-described first embodiment are denoted by the same reference numerals, and differences in configuration from the first embodiment will be described.

[0063] Fig. Figure 6 illustrates the risk assessment support device 1B, the input device 2, the output device 3, and a vision sensor 4. The vision sensor 4 captures an image of the robot system and the worker. The vision sensor 4 can be either a two-dimensional sensor or a three-dimensional sensor. The vision sensor 4 outputs the acquired image to the risk assessment support device 1B. The image can be either a still image or a moving image.

[0064] The motion detection processing unit 19 receives the image acquired by the vision sensor 4. The motion detection processing unit 19 performs processing to detect the movement of the worker based on the image showing the robot system and the worker. From this image, the motion detection processing unit 19 detects the movement range of each of the robots of the robot system, the movement range of each of the peripheral devices of the robot system, and the movement range of the worker.

[0065] The motion detection processing unit 19 also detects the worker's body parts from an image showing the worker. The body parts include the head, torso, upper arms, forearms, hands, thighs, lower legs, feet, and the like. The motion detection processing unit 19 detects the worker's work details based on the selected body parts. The work details to be detected include features such as the movement range, movement speed, and assembly work. The motion detection processing unit 19 generates data related to the worker's movement based on the detected work details. The data generated by the motion detection processing unit 19 is stored in the storage unit in the risk assessment support device 1B as work environment information. Fig. Figure 6 schematically illustrates each type of information stored in the storage unit.

[0066] The motion detection processing unit 19 also detects a level representing the skill level of the work, the frequency of the operation, and the work progress based on the detected work details. The frequency of the operation is the frequency of the work, such as eight hours a day or several times a year. The work process is a process of work, such as starting a robot, operating a robot, or maintaining a robot. Information representing the level, information representing the frequency of the operation, or information representing the work process is stored as work environment information in the storage unit of the risk assessment support device 1B.

[0067] The motion detection processing unit 19 further detects potential hazards, such as a worker being trapped, based on the detected work details and the image of each of the robots, each of the peripheral devices, and a nearby object. Information regarding the detected potential hazards is stored in the hazard source database.

[0068] According to the second embodiment, including the motion detection processing unit 19 enables the risk assessment support device 1B to obtain work environment information through processing performed in the motion detection processing unit 19. Therefore, the risk assessment support device 1B can reduce the user's workload for inputting data related to the work environment information. Third embodiment.

[0069] Fig. Fig. 7 is a diagram illustrating an exemplary configuration of a risk assessment support device 1C according to a third embodiment. The risk assessment support device 1C includes components similar to those shown in Fig. 6. The storage unit of the risk assessment support device 1B additionally stores weighting data. In the third embodiment, the same components as the components of the first or second embodiment described above are denoted by the same reference numerals, and differences from the configuration in the first or second embodiment will be described primarily. Fig. Figure 7 schematically illustrates each type of information stored in the storage unit.

[0070] The risk assessment support device 1C sets weight data representing weights for the first term and the second term of the evaluation function, that is, for the term representing the size of the area and for the term representing the utilization rate.

[0071] In the third embodiment, the evaluation function f(x) is expressed by, for example, the following equation (3). f(x)=w1f1(x)+w2f2(x)

[0072] The factor w1 is a weighting factor that represents the weight of the term representing the utilization rate. The factor w2 is a weighting factor that represents the weight of the term representing the area size. The weighting data are the weighting factors w1 and w2. The weighting factors w1 and w2 satisfy the following equation (4). w1+w2=1.0

[0073] The optimization processing unit 16 receives the weight data. In the third embodiment, the terms of the evaluation function f(x) are weighted according to the weight data, as shown by Equation (3).

[0074] According to the third embodiment, the risk assessment support device 1C can adjust the relationship between saving the space of the robot system and increasing the utilization rate of the robot system to any desired ratio using the weighting data. This enables the risk assessment support device 1C to provide risk assessment support according to the respective needs. Note that, in the third embodiment, it is assumed that the risk assessment support device 1C includes the weighting data, and the weighting data is added to the configuration similar to the configuration of the risk assessment support device 1B of the second embodiment, but the weighting data may also be added to the configuration similar to the configuration of the risk assessment support device 1A of the first embodiment. Fourth embodiment.

[0075] Fig. Fig. 8 is a diagram illustrating an exemplary configuration of a risk assessment support device 1D according to a fourth embodiment. The risk assessment support device 1D includes components that support the Fig. 7 are similar to the components of the risk assessment support device 1C. The storage unit of the risk assessment support device 1D additionally stores restriction condition information. In the fourth embodiment, the same components as the components of the first to fourth embodiments are denoted by the same reference numerals, and differences from the configuration in the first to third embodiments will be described primarily. Fig. Figure 8 schematically illustrates each type of information stored in the storage unit.

[0076] The constraint condition is a condition for restricting at least one of the layout information and the robot control information. The constraint condition can be set to any condition by a user. The constraint condition information is information representing the constraint condition. The optimization processing unit 16 receives the constraint condition information. The optimization processing unit 16 calculates an optimal solution reflecting the constraint condition.

[0077] The constraint condition is a condition that restricts the position and orientation of each of the robots of the robot system, a condition that restricts the position and orientation of each device of the robot system, or a condition that restricts the movement of the robot, and / or the like. In addition, the constraint condition may include a condition regarding a relational positional dependency between a robot and a nearby object, a condition regarding a position of a structure present in a space for installing the robot system, such as a wall, a pillar, and a door, a condition for restricting the movement range of the robot, a condition regarding the orientation of an end effector at the time of fixation, and / or the like.

[0078] According to the fourth embodiment, setting a constraint condition restricts at least one of the layout information and the robot control information and enables the risk assessment support device 1D to provide risk assessment support in accordance with the need (ie, the needs). Note that in the fourth embodiment, it is assumed that the risk assessment support device 1D includes the constraint condition information, and the constraint condition information is added to the configuration similar to the configuration of the risk assessment support device 1C of the third embodiment, but the constraint condition information may also be added to the configuration similar to the configuration of either the risk assessment support device 1A or 1B of the first or second embodiment.

[0079] Next, hardware for implementing the risk assessment support devices 1A, 1B, 1C, and 1D according to the first to fourth embodiments will be described. The risk assessment support devices 1A, 1B, 1C, and 1D are implemented by a processing circuit. The processing circuit is a circuit including a processor that executes a software program.

[0080] If the processing circuit is implemented by software, the processing circuit is, for example, a Fig. Control circuit shown in Figure 9. Fig. 9 is a diagram illustrating an exemplary configuration of a control circuit 30 according to the first to fourth embodiments. The control circuit 30 includes an input unit 31, a processor 32, a data memory 33, and an output unit 34. The input unit 31 is an interface circuit for receiving data input from outside the control circuit 30 and providing the data to the processor 32. The output unit 34 is an interface circuit for sending data from the processor 32 or the data memory 33 to outside the control circuit 30.

[0081] If the processing circuitry Fig. 9, the risk assessment support devices 1A, 1B, 1C, and 1D are implemented in software, firmware, or a combination of software and firmware. The software or firmware is written in the form of a program and stored in the data memory 33. In the processing circuit, the processor 32 reads and executes a program stored in the data memory 33 to implement a respective functionality. That is, the processing circuit includes the data memory 33 for storing a risk assessment support program, which is a program that causes processing to be executed according to each of the risk assessment support devices 1A, 1B, 1C, and 1D.In addition, it can be said that the risk assessment support program causes a computer to execute a procedure and method to be executed by the risk assessment support devices 1A, 1B, 1C and 1D.

[0082] The processor 32 is a central processing unit (CPU), a computing unit, a processing unit, a microprocessor, a microcomputer, or a digital signal processor (DSP). The data memory 33 is a volatile or non-volatile semiconductor memory such as a random access memory (RAM), a read-only memory (ROM), a flash memory, an erasable programmable read-only memory (EPROM), or an electrically erasable programmable read-only memory (EEPROM) (registered trademark).

[0083] Fig.9 illustrates a hardware example where the components of the risk assessment support devices 1A, 1B, 1C, and 1D are implemented by a general-purpose processor 32 and a general-purpose data memory 33, but these components may also be implemented by dedicated hardware circuits. The risk assessment support devices 1A, 1B, 1C, and 1D may comprise an integrated circuit, such as an application-specific integrated circuit (ASIC) or a field-programmable gate array (FPGA). The risk assessment support devices 1A, 1B, 1C, and 1D may be implemented by two or more devices.The risk assessment support program may be stored on a recording medium such as a compact disc (CD)-ROM or a digital versatile disc (DVD)-ROM, and the recording medium may then be provided to implement any of the embodiments.

[0084] The configurations described in the foregoing embodiments are merely examples and aspects of the present disclosure. The configuration of each embodiment can be combined with other known technologies. Configurations of different embodiments can be appropriately combined among the first to fourth embodiments. Part of the configuration of each embodiment may be omitted and / or modified without departing from the spirit of the present disclosure. List of reference symbols 1A, 1B, 1C, 1D Risk assessment support device; 2 input device; 3 output device; 4 visual sensor; 10 Plant information input processing unit; 11 Layout information setting unit; 12 Robot control information setting unit; 13 Optimization calculation unit; 14 Residual risk information reference unit; 15 Output processing unit; 16 Optimization processing unit; 17 Risk Assessment Processing Unit; 18 Risk Reduction Processing Unit; 19 Motion detection processing unit; 30 control circuit; 31 input unit; 32 processor; 33 data storage; 34 output unit. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] JP 6 698 042

[0004]

Claims

[1] Risk assessment support device, comprising: a calculation unit for obtaining layout information and robot control information and for calculating a set of solutions based on an evaluation function, wherein the layout information is information related to a layout of a robot and a nearby object in the vicinity of the robot, wherein the robot control information is information related to control of the robot, wherein the set of solutions is solutions regarding a position of the robot, regarding a position of a device other than the robot, and regarding a movement of the robot, wherein the evaluation function includes a term representing a size of an area for installing a robot system, the robot system comprising the robot and the device; and an output processing unit for outputting the layout information and the robot control information representing the set of solutions for a case where a risk in the robot system falls within an acceptable range. [2] The risk assessment support device according to claim 1, wherein the evaluation function further includes a term representing a utilization rate of the robot system. [3] Risk assessment support device according to claim 2, wherein Weighting data are stored, where the weighting data represent weights on the term representing the size of an area and on the term representing the degree of utilization, and each of the terms of the evaluation function is weighted based on the weighting data. [4] Risk assessment support device according to one of claims 1 to 3, further comprising: a risk assessment processing unit to extract the risk; and a risk reduction processing unit to determine whether risk reduction is possible, wherein risk reduction is an operation of reducing the risk that has been extracted so that it falls within the acceptable range. [5] The risk assessment support device according to claim 4, wherein the risk assessment processing unit extracts the risk based on work environment information and hazard source data, wherein the work environment information is information regarding a worker working near the robot or information regarding work to be performed by the worker, wherein the hazard source data is data regarding a hazard source included in the robot system. [6] Risk assessment support device according to claim 5, further comprising: a motion detection processing unit for performing processing of detecting a movement of the worker based on an image showing the robot system and the worker, wherein the motion detection processing unit receives a result of detecting the movement of the worker in both the Work environment information as well as hazard source data. [7] Risk assessment support device according to one of claims 1 to 6, further comprising: a system information input processing unit to receive system information of the robot system, where the calculation unit receives the layout information reflecting the system information and receives the robot control information reflecting the system information. [8] The risk assessment support device according to any one of claims 1 to 7, wherein the output processing unit further outputs information regarding a residual risk, the residual risk being a risk remaining in the robot system. [9] Risk assessment support device according to one of claims 1 to 8, wherein a restriction condition is stored, wherein the restriction condition is a condition that restricts the layout information and / or the robot control information, and the calculation unit calculates the set of solutions with respect to the position of the robot, with respect to the position of the device, and with respect to the movement of the robot, wherein the set of solutions reflects the constraint condition. [10] Risk assessment support program that causes a computer to execute: a step of obtaining layout information and robot control information, and calculating a set of solutions based on an evaluation function, wherein the layout information is information related to a layout of a robot and a nearby object in the vicinity of the robot, wherein the robot control information is information related to control of the robot, wherein the set of solutions is solutions regarding a position of the robot, regarding a position of a device other than the robot, and regarding a movement of the robot, wherein the evaluation function includes a term representing a size of an area for installing a robot system, the robot system comprising the robot and the device; and a step of outputting the layout information and the robot control information representing the set of solutions for a case where a risk of the robot system falls within an acceptable range. [11] Risk assessment support procedure, comprising: a step of obtaining layout information and robot control information, and calculating a set of solutions based on an evaluation function, wherein the layout information is information related to a layout of a robot and a nearby object in the vicinity of the robot, wherein the robot control information is information related to control of the robot, wherein the set of solutions is solutions regarding a position of the robot, regarding a position of a device other than the robot, and regarding a movement of the robot, wherein the evaluation function includes a term representing a size of an area for installing a robot system, the robot system comprising the robot and the device; and a step of outputting the layout information and the robot control information representing the set of solutions when a risk of the robot system falls within an acceptable range.

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