METHOD FOR OPERATING A SENSOR SYSTEM, SENSOR ELEMENT AND SENSOR SYSTEM

Description

State of the art

[0001] The invention relates to a method for operating a sensor system according to the preamble of claim 1. Furthermore, the invention relates to a sensor system for carrying out the method according to the invention.

[0002] A method for operating a sensor system according to the preamble of claim 1 and a sensor system operating according to such a method are known from US 2007 / 0109274 A1. The known method, which is used particularly in connection with touch-sensitive user interfaces, is characterized in particular by the fact that several electric fields are simultaneously formed between the sensor elements of the sensor system, with one sensor element acting as a transmitting electrode and at least two sensor elements acting as receiving electrodes.

[0003] Another method for operating a sensor system according to the preamble of claim 1, as well as a sensor system operating according to such a method, are known from US 2013 / 0262004 A1. From this document, it is known that two sensor elements are simultaneously connected as transmitting electrodes, which interact with a sensor element acting as a receiving electrode.

[0004] From DE 10 2009 029 021 A1 by the applicant, another sensor system is known which comprises at least one capacitive sensor element, the electric field generated by it changing when a body or object approaches, whereby the change can be detected and evaluated. The known sensor system is used, in particular in handling robots or similar machines or systems, to switch the machine into a safety mode when a person or an object approaches a moving machine part, for example a robot arm. This mode stops or at least slows down the movement of the relevant machine component. This makes it possible, in particular, to avoid or at least minimize injuries in the event of a collision between the handling device and a person, or to avoid damage to objects or the handling device.The known sensor system preferably comprises a plurality of flat sensor elements which, for example, cover the entire surface of a handling device in the manner of a sensor skin and are connected to one another by circuitry.

[0005] Furthermore, it is also known from the cited document to simultaneously analyze two directly adjacent sensor elements or the electrical fields formed between these sensor elements, for example, to bridge gaps or similar in a machine and / or to increase the range of the sensor elements. The electrical field formed between two sensor elements is also monitored or analyzed. It is also essential that the sensor elements known from the cited document always have two electrical potentials, i.e., that an electrical field can be formed by a single sensor element.

[0006] From DE 10 2010 064 328 A1 of the applicant it is also known to control or address two different sensor elements of a sensor system simultaneously by different central units.

[0007] The prior art also includes the documents US 5 914 610 A, US 2015 / 227229 A1 and WO 2015 / 046058 A1. Disclosure of the invention

[0008] Based on the prior art described, the object of the invention is to further develop a method for operating a sensor system according to the preamble of claim 1 in such a way that increased safety and / or a denser monitoring field is achieved compared to the prior art and approaches between the sensor elements and a body or an object can be detected particularly reliably and at an early stage.

[0009] This object is achieved according to the invention in a method for operating a sensor system having the features of claim 1.

[0010] The invention is based on the idea of ​​monitoring and evaluating, in contrast to the prior art, not only the electric fields between two adjacent sensor elements, but in an extreme case, all electric fields formed between a first sensor element acting as a transmitting electrode and all other second sensor elements acting as receiving electrodes. Specifically, the invention proposes that the method according to the invention be designed such that at least two electric fields are formed simultaneously between a first sensor element acting as a transmitting electrode and two second sensor elements acting as receiving electrodes, or that the at least two simultaneously formed electric fields are formed between two first sensor elements acting as a transmitting electrode and a second sensor element acting as a receiving electrode.In summary, in the method according to the invention, at least three sensor elements are active or involved in generating electric fields at any one time. Such a design of the method therefore makes it possible to increase the range by using or evaluating a large number of electric fields, or to detect any malfunctions in the sensor system by checking and comparing the individual electric fields. Within the scope of the invention, a transmitting electrode is understood to mean the application of an alternating electric field to an electrode or electrode element. A receiving electrode is understood to mean the measurement of alternating electric fields at the electrode or electrode element.

[0011] Advantageous developments of the method according to the invention for operating a sensor system are listed in the subclaims.

[0012] In a first concrete development of the basic inventive concept described so far, it is provided that all sensor elements not acting as transmitting electrodes are simultaneously switched as receiving electrodes. This type of method ensures maximum range and the earliest possible detection of a potential collision hazard and accelerates the monitoring process by simultaneously performing multiple measurements. Furthermore, knowledge of the arrangement or position of the individual sensor elements acting as receiving electrodes makes it possible, for example, to particularly easily analyze a possible approach with regard to a potential hazard by detecting changes in the individual electric fields.

[0013] In order to achieve redundancy, i.e. to ensure or verify the analysis of individual electric fields, it is further provided in a further embodiment of the method according to the invention that at least two sensor elements, preferably arranged directly next to one another, are switched sequentially as transmitting electrodes, and that the sensor element previously acting as transmitting electrode is switched as receiving electrode.

[0014] In a further embodiment of the invention, which makes it possible to better determine the distance of a person or an object from the sensor elements, it is proposed that measurement signals from electrical fields arranged spatially close to one another are compared with measurement signals from electrical fields arranged spatially far from one another by means of an algorithm.

[0015] A further advantageous embodiment of the method according to the invention, which in particular enables greater ranges of the sensor system in areas with structural interruptions (e.g. gaps), provides that several sensor elements acting as receiving electrodes and / or several sensor elements acting as transmitting electrodes are electrically interconnected.

[0016] In principle, a previously analyzed electric field can be verified or redundantly determined, regardless of the distance between two sensor elements, i.e. even with further sensor elements arranged between the two sensor elements, if in a first step an electric field formed between two sensor elements is generated by operating a first sensor element as a transmitting electrode and a second sensor element as a receiving electrode, and that in a second step the electric field is generated by operating the second sensor element as a transmitting electrode of the first sensor element as a receiving electrode.

[0017] According to the invention, the method provides for some electric fields to be generated simultaneously and other electric fields to be generated sequentially. This allows regions on a machine or robot to be divided into different relevant regions, such that, for example, regions moving at a relatively high speed (e.g., a gripper arm) are assessed differently with regard to the relevance for a potential collision than regions of a robot (e.g., a stationary column region) where there is assumed to be a lower risk of collision. According to the invention, the particularly relevant region is then monitored by electric fields generated simultaneously.

[0018] While in the prior art, as explained in the above section, a sensor element always has two electrical potentials or electrodes, it is possible within the scope of the invention, by simultaneously using several sensor elements to form electrical fields, to design a sensor element for carrying out the method according to the invention in such a way that the sensor element has a single electrode for forming part of an electrical field, wherein the single electrode can be connected to a different electrical potential, in such a way that the single electrode acts optionally as a receiving electrode or as a transmitting electrode. Such a structure of a sensor element is therefore particularly simple and cost-effective to implement, so that in particular with a large number of sensor elements, as is the case with large machines or systems to be monitored.Machine components in which the individual sensor elements are interconnected in the form of a sensor skin, additional cost savings can be achieved.

[0019] For effective and simple control of the individual sensor elements, the invention also comprises a sensor system in which a plurality of sensor elements are designed to be operated according to the method according to the invention described above, wherein the individual sensor elements can be controlled by a common central unit via a bus system.

[0020] In particular, the sensor system described so far is preferably part of a machine control system for detecting the approach of objects or bodies. The machine control system can be configured such that, upon detecting a potential collision risk, the machine control system switches the machine either to a standby mode or to a safe mode in which the risk of collision is at least reduced.

[0021] Further advantages, features and details of the invention will become apparent from the following description of preferred embodiments and from the drawings.

[0022] This shows in: Fig. 1 to Fig. 4 a sensor system consisting of several sensor elements, in which different electric fields are generated successively in time, in a simplified representation, Fig. 5 a cross section through a sensor element, as in the sensor system according to the Fig. 1 to 4is used, Fig. 6 and Fig. 7 simplified representations to show the formation of electric fields during two successive cycles, Fig. 8 a representation of a sensor system in which dead zones formed between sensor elements are detected and Fig. 9 a simplified circuit diagram of a sensor system according to the invention as a component of a machine control.

[0023] Identical elements or elements with the same function are provided with the same reference numbers in the figures.

[0024] In the Fig. 1 to 4By way of example, four capacitive sensor elements 1a to 1d arranged next to one another are shown in a simplified manner as part of a sensor system 100. In particular, it can be provided that the sensor elements 1a to 1d are arranged on a machine component or a robot in the region of a movable component, such as a gripper arm or the like. The arrangement of the individual sensor elements 1a to 1d can, for example, be effected via adhesive connections on the outer surface of the component. Furthermore, it is mentioned that four sensor elements 1a to 1d are shown merely as an example and for the sake of better clarity. In practice, however, such a sensor system 100 has a multiplicity of such sensor elements 1a to 1d, for example several hundred sensor elements 1a to 1d. The individual sensor elements 1a to 1d do not necessarily all have to be identically designed and / or have the same size.

[0025] Furthermore, several of the sensor elements 1a to 1d can be structurally combined, for example, arranged on a common circuit carrier. The sensor elements 1a to 1d are thus functionally separate units, which, however, do not necessarily have to be structurally separate from one another.

[0026] With regard to the possible construction of such a sensor element 1a (to 1d), reference is now made to the Fig. 5There it can be seen that the sensor element 1a has an (active) electrode element 11 on the side facing the external environment. The thin or flat electrode element 11 can be electrically switched either as a transmitting electrode or as a receiving electrode. For this purpose, the electrode element 11 can be connected to different voltage potentials. On the side facing away from the external environment, a first carrier or intermediate element 12 is connected to the electrode element 11. On the side of the intermediate element 12 facing away from the electrode element 11, a shielding electrode 13 is arranged, which is connected to electrical ground at least at the time of measurement. A second intermediate layer 14 is connected to the shielding electrode 13. The second intermediate layer 14 is connected to a first signal layer 15, which in turn is connected to a third intermediate layer 16.On the side of the third intermediate layer 16 facing away from the first signal layer 15, there is a second signal layer 17 on which electronic components 18 are arranged.

[0027] With reference to the Fig. 1 to 4 A possible mode of operation of the sensor system 100 is explained as follows: First, according to the Fig. 1 The sensor element 1a is connected as a transmitting electrode, while the adjacent sensor elements 1b to 1d are each connected or act as receiving electrodes. This simultaneously creates three electric (alternating) fields 21 to 23, which are Fig. 1are each represented by a single field line. The first electric field 21 is formed between the sensor element 1a and the sensor element 1b. The second electric field 22 is formed between the sensor element 1a and the sensor element 1c. The third electric field 23 is formed between the sensor element 1a and the sensor element 1d. All three electric fields 21 to 23 can be formed by means of a Fig. 1 to 4 be monitored by an evaluation device (not shown) in order to detect, for example, the approach of a hand H to the electrical fields 21 to 23.

[0028] After the formation of the electric fields 21 to 23, the Fig. 2three further electric fields 24 to 26 are formed. The electric fields 24 to 26 are formed by the fact that the sensor element 1b is now operated as a transmitting electrode, while the sensor elements 1a, 1c, and 1d act as receiving electrodes.

[0029] Subsequently, according to the Fig. 3 Three electric fields 27 to 29 are again formed. The sensor element 1c is operated as a transmitting electrode, while the sensor elements 1a, 1b and 1d act as receiving electrodes.

[0030] Finally, according to the Fig. 4 three electric fields 30 to 32 are generated, with the sensor elements 1a, 1b and 1c acting as receiving electrodes, while the sensor element 1d acts as transmitting electrode.

[0031] The electric fields 21 to 32 can then be adjusted according to the sequence of figures in the Fig. 1 to 4be trained again, or in a reverse order, or alternatively in any order.

[0032] In the Figs. 6 and 7 Another operating mode of the sensor system 100 is shown using six sensor elements 1a to 1f. To clarify which of the sensor elements 1a to 1f acts as a transmitting electrode or as a receiving electrode, the sensor elements 1a to 1f acting as receiving electrodes are designated E1 to E6, while a sensor element acting as a transmitting electrode is designated S.

[0033] Based on the Fig. 6 It can be seen that at a first point in time, the sensor element 1f acts as a transmitting electrode S, while the adjacent sensor element 1a acts as a receiving electrode E1. An electric field 33 is formed between the two sensor elements 1a and 1f. Subsequently, according to the Fig. 7The functioning of the two sensor elements 1a and 1f is reversed, such that the sensor element 1a now acts as the transmitting electrode S, while the sensor element 1f acts as the receiving electrode E6. An electric field 34 is formed between the two sensor elements 1a and 1f.

[0034] In the Fig. 8shows how, when using six sensor elements 1a to 1f, an object in the form of a hand H approaching between the two sensor elements 1a and 1f is detected. What is important here is that when the hand H approaches from a direction in which an electric field 35 formed between the sensor elements 1a and 1f is not changed, the approach of the hand H to the sensor system 100 is detected by a change in the electric fields 36 and 37 between the sensor elements 1f and 1b and 1f and 1c. The two electric fields 38 and 39 between the sensor element 1f and the sensor element 1d or the sensor element 1e, for example, also do not change when the hand H approaches the sensor system 100.

[0035] In the Fig. 9The structure and arrangement of the sensor system 100 is further explained. In particular, it can be seen that a plurality of sensor elements 1a to 1n are connected or coupled in the manner of a chain via a common bus line 101 to a central unit 102 acting as a control device. The voltage supply to the individual sensor elements 1a to 1n is also provided via the central unit 102 via connecting lines 103, 104. Furthermore, there are serial connections 105, 106 for data exchange both between the individual sensor elements 1a to 1n and between the sensor element 1a and the central unit 102. The central unit 102 is connected to a machine control 110, which, when an object or person approaches, operates the machine, for example, in a safe mode or shuts it down. Furthermore, the central unit 102 can be configured via a computer 115.

[0036] It is also mentioned that the detection of the approach of an object or a person in the sensor elements 1a to 1f can be realized by an analog, digital or mixed analog / digital circuit. Furthermore, it is mentioned that, in contrast to the representation of the Fig. 5 the sensor elements 1a to 1f can also be designed or realized by either, as in the Fig. 5 shown, each electrode 11 is assigned a separate sensor element 1a to 1f or a separate substrate, or that several electrodes 11 of the sensor elements 1a to 1f are arranged on a common substrate.

[0037] The layer structure of a sensor element 1a to 1f can also be different from that shown in the Fig. 5shown. For example, it may be possible not to provide any further electrode elements besides the active electrode element 11. A bias electrode may also be arranged or connected, for example, between the electrode element 11 and the shielding electrode 13. Furthermore, it may be provided that one electrode element 11 is designed only as a transmitting electrode or receiving electrode. Furthermore, it may be provided that the sensor system 100 described so far or the sensor elements 1a to 1f are also arranged, for example, in housing shells (made of plastic) of an industrial robot or a machine. The electronic components can be arranged on the same substrate as the electrode elements, or - at least some of the components - on a structurally separate circuit carrier.

[0038] A further acceleration of the measuring process can be achieved by operating one or more sensor elements 1a to 1n acting as transmitting electrodes simultaneously with different transmitting frequencies, and by simultaneously detecting the different transmitting frequencies by the sensor elements 1a to 1n acting as receiving electrodes, for example by using filters.

[0039] With regard to the evaluation method of the electric fields 21 to 38, it is mentioned that a comparison of the measured value change of each electric field 21 to 38 or key figures calculated therefrom can be made with an upper or lower limit value for each electric field 21 to 38, wherein if the value is exceeded or undershot, the machine control 110 is transferred to a safe state. It can also be concluded that an object or person is dynamically approaching if the change in a measured value of an electric field 21 to 38 occurs faster than a predetermined limit value. By including the measured values ​​from neighboring sensor elements 1a to 1n and processing them with suitable algorithms to check the plausibility of the measured values ​​or, in the case of sensor elements 1a to 1n that are not in a fixed spatial relationship to one another, to reliably detect safety-critical approaches.

[0040] With regard to possible applications, in addition to the use in industrial plants or industrial robots, it is mentioned that such a sensor system 100 can also be installed, for example, in a body part of a motor vehicle, such as a bumper, in order to fulfill, for example, assistance and safety functions.

Claims

1. Method for operating a sensor system (100) having at least three sensor elements (1a to 1n) which can be attached to the surface of machines or components, wherein the sensor elements (1a to 1n) each have an electrode (11) for forming electric fields (21 to 39), wherein the electrodes (11) can be connected to a different electrical potential in such a way that the electrodes (11) act as a transmitting electrode (S) or as a receiving electrode (E1 to E6), wherein the electric fields (21 to 39) change during the approach of and / or in the event of contact with an object, wherein the sensor elements (1a to 1n) are controlled in succession in a certain temporal or local order by a control device (102), and wherein either at least two electric fields (21 to 39) are formed at the same time between a first sensor element (1a to 1n) acting as a transmitting electrode (S) and two second sensor elements (1a to 1n) acting as a receiving electrode (E1 to E6) or between two first sensor elements (1a to 1n) acting as a transmitting electrode (S) and a second sensor element (1a to 1n) acting as a receiving electrode (E1 to E6), characterized in that the sensor elements (1a to 1n) are arranged in areas of the machine that are of different relevance with respect to a risk of collision, and in that, according to the relevance of the areas, some electric fields (21 to 39) are formed at the same time and other electric fields (21 to 39) are formed in temporal succession, the relevant areas being monitored by means of electric fields (21 to 39) formed at the same time.

2. Method according to Claim 1, characterized in that all sensor elements (1a to 1n) that do not act as a transmitting electrode (S) are simultaneously connected as a receiving electrode (E1 to E6).

3. Method according to Claim 1 or 2, characterized in that at least two sensor elements (1a to 1n), preferably arranged directly next to each other, are connected in temporal succession as a transmitting electrode (S), and in that preferably the sensor element (1a to 1n) respectively previously acting as a transmitting electrode (S) is connected as a receiving electrode (E1 to E6).

4. Method according to one of Claims 1 to 3, characterized in that measurement signals from electric fields (21 to 39) arranged spatially close to each other are compared with measurement signals from electric fields (21 to 39) arranged spatially far apart from each other by means of an algorithm.

5. Method according to one of Claims 1 to 4, characterized in that a plurality of sensor elements (1a to 1n) acting as a receiving electrode (E1 to E6) and / or a plurality of sensor elements (1a to 1n) acting as a transmitting electrode (S) are electrically interconnected.

6. Method according to one of Claims 1 to 5, characterized in that, in a first step, an electric field (21 to 39) formed between two sensor elements (1a to 1n) is generated by operating a first sensor element (1a to 1n) as a transmitting electrode (S) and a second sensor element (1a to 1n) as a receiving electrode (E1 to E6), and in that, in a second step, the electric field (21 to 39) is generated by operating the second sensor element (1a to 1n) as a transmitting electrode (S) and the first sensor element (1a to 1n) as a receiving electrode (E1 to E6).

7. Method according to one of Claims 1 to 6, characterized in that, when operating a plurality of sensor elements (1a to 1n) as a transmitting electrode (S), they are operated at different frequencies.

8. Method according to Claim 7, characterized in that at least one sensor element (1a to 1n) is connected as a receiving electrode (E1 to E6), and in that the at least one sensor element (1a to 1n) acting as a receiving electrode (E1 to E6) is designed to distinguish the different frequencies, in particular by using filters.

9. Sensor system (100) comprising a plurality of sensor elements (1a to 1n) which are designed to carry out a method according to one of Claims 1 to 8, wherein the sensor elements (1a to 1n) can be controlled by a common control device (102) via a bus system (101).

10. Sensor system according to Claim 9, characterized in that the sensor system (100) is part of a machine controller for detecting the approach of objects.