Protected exit from physically restricted robot workspace

Abstract

A robotic system, method, and apparatus for controlling robot operation are disclosed. The robotic system includes: (i) a robot configured to move one or more items within a workspace; (ii) sensors configured to collect sensor data about the workspace; and (iii) one or more processors. The one or more processors are configured to: (a) determine to reset operation of the robot; (b) determine, based at least in part on the sensor data, that a human worker has exited a safeguarded space within the workspace; and (c) resume operation of the robot in response to determining that the human worker has exited the safeguarded space.

Description

CROSS-REFERENCE TO OTHER APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 427,738, filed November 23, 2022, entitled "SAFEGUARDED EXIT FROM PHYSICALLY CONSTRAINED ROBOTIC WORKSPACE," which is incorporated herein by reference for all purposes. [Background technology]

[0002] Robots have been used in manufacturing and other fields to perform tasks, such as tasks in environments that may be unhealthy or otherwise hazardous to humans, tasks that require the application of greater forces than humans can exert, and tasks that require a high degree of precision and consistency over extended periods of time.

[0003] Robotic systems have been utilized to assemble kits, perform sorting and / or singulation, perform line kitting, and to stack or remove items from pallets or other containers.

[0004] Industrial robots are widely used in manufacturing environments to automate various tasks and increase efficiency and productivity. However, the interaction between humans and robots in these situations poses unique safety challenges, particularly during the start-up and restart phases of a robotic system. Safety concerns related to the deployment of industrial robots are crucial given the proximity and potential risks involved for human operators. Traditional safety measures often include utilizing physical barriers, emergency stop buttons, and light curtains to prevent accidents. While these measures mitigate some risks, they do not adequately address the complexities associated with the start-up and restart procedures of robotic systems and can be costly to implement. [Brief explanation of the drawings]

[0005] Various embodiments of the present invention are disclosed in the following detailed description and the accompanying drawings.

[0006] [Figure 1] FIG. 1 illustrates a robotic system according to various embodiments.

[0007] [Figure 2] FIG. 1 illustrates a robotic system with a safeguarded space, according to various embodiments.

[0008] [Figure 3A] FIG. 1 illustrates a robotic system configured to resume operation based at least in part on detecting that a human worker has exited a safeguarded space, according to various embodiments.

[0009] [Figure 3B] FIG. 1 illustrates a robotic system configured to resume operation based at least in part on detecting that a human worker has exited a safeguarded space, according to various embodiments.

[0010] [Figure 4] FIG. 1 illustrates a robotic system configured to resume operation based at least in part on detecting that a human worker has exited a safeguarded space, according to various embodiments.

[0011] [Figure 5] 1 is a flowchart illustrating a method for controlling a robot to resume operation, according to various embodiments.

[0012] [Figure 6] 1 is a flowchart illustrating a method for determining whether conditions for resuming autonomous robot operation are met, according to various embodiments.

[0013] [Figure 7]1 is a flowchart illustrating a method for determining whether conditions for resuming autonomous robot operation are met, according to various embodiments.

[0014] [Figure 8] 1 is a flowchart illustrating a method for controlling a robot to resume operation, according to various embodiments.

[0015] [Figure 9] 1 is a flowchart for controlling a robot to operate in autonomous mode, according to various embodiments.

[0016] [Figure 10] 1 is a flowchart for controlling a robot to operate in autonomous mode, according to various embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0017] The present invention may be embodied in various forms, including as a process, an apparatus, a system, a composition of matter, a computer program product embodied on a computer-readable storage medium, and / or a processor configured to execute instructions stored in and / or provided by a memory coupled to the processor. These embodiments, or any other form the present invention may take, may be referred to herein as technology. In general, the order of steps in a disclosed process may be varied within the scope of the present invention. Unless otherwise noted, components, such as a processor or memory, described as configured to perform a task may be implemented as general components temporarily configured to perform the task at a given time, or as specific components manufactured to perform the task. As used herein, the term “processor” refers to one or more devices, circuits, and / or processing cores configured to process data, such as computer program instructions.

[0018] The following is a detailed description of one or more embodiments of the present invention with reference to figures that illustrate the principles of the invention. While the present invention has been described in connection with such embodiments, it is not limited to any particular embodiment. The scope of the present invention is limited only by the claims, and the present invention includes many alternatives, modifications, and equivalents. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. These details are for the purpose of example, and the present invention may be practiced according to the claims without some or all of these specific details. For simplicity, technical matters that are well known in the art related to the present invention have not been described in detail so as not to unnecessarily obscure the present invention.

[0019] As used herein, a robotic system comprises a combination of hardware and software configured to perform a set of tasks, such as a robotic application (e.g., a robot that performs a particular function). As an example, a robot is deployed in the context of a robotic application.

[0020] In related art systems where the robot is deployed in an industrial robotic environment, the reset needs to be outside the safeguarded space to allow a human to safely activate the reset from a position outside the safeguarded space.

[0021] Industrial safety standards for working with robots in non-collaborative spaces (i.e., spaces where the robot and human are not working simultaneously) require the robot to be placed in an enclosed or otherwise safeguarded space that ensures there is no access by workers unless the robot is stopped.

[0022] For autonomous mobile robots (AMRs) operating in enclosed spaces (such as truck trailers) where communications are absent, unreliable, or limited, the safety reset cannot be located outside the safeguarded space. Furthermore, adding wireless communications from outside the safeguarded space may not be practical or economical, and / or such communication failures may lead to downtime. Conversely, systems in which the control unit is connected to the robot by wires may be impractical.

[0023] Techniques are disclosed for safely resetting a robotic system without the need for wired or wireless communication with the robotic system from outside the safeguarded space. In various embodiments, a reset button or other manually actuated control is provided, for example, on or near the robot. A human actuates the reset. A safety (e.g., laser) scanner field or other safety-compliant scanning / monitoring structure or device is utilized to detect human exit from the safeguarded space or to determine when the safeguarded space is completely empty. The robotic system resumes operation after actuation of the reset button or other manually actuated control based on an indication that the human has been determined to have exited the safeguarded space.

[0024] In some embodiments, the reset button is located within the safeguarded space (e.g., on the robot or within close proximity of the robot). In conventional installations, the reset is typically located outside the safeguarded space, as currently required by existing consensus standards. Various other related art installations may include a reset button within the safeguarded space, but such systems start a predetermined timer when the reset button is pressed, and a human must press a second button outside the safeguarded space within the predetermined time counted by the timer.

[0025] As disclosed herein, a scanner field is used to enable a reset to be within the safeguarded space and still comply with safety standards or other requirements. The scanner field includes one or more detection fields from which a sensor system captures data, and the system detects a human and / or determines whether the human has moved outside the safeguarded space or moved a sufficient distance outside the safeguarded space. As an example, the scanner field includes a first detection field and a second detection field. The first detection field and the second detection field may at least partially overlap. In some embodiments, the system utilizes sensor data captured for each of the first detection field and the second detection field in connection with determining that the human has left the safeguarded space.

[0026] Various embodiments are disclosed that provide a robotic system, method, and apparatus for controlling the operation of a robot. The robotic system includes: (i) a robot configured to move one or more items within a workspace; (ii) sensors configured to collect sensor data related to the workspace; and (iii) one or more processors. The one or more processors are configured to: (a) determine to reset the operation of the robotic arm; (b) determine, based at least in part on the sensor data, that a human worker has exited a safeguarded space within the workspace; and (c) resume the operation of the robot in response to determining that the human worker has exited the safeguarded space.

[0027] In some embodiments, multiple safety scanner fields are defined and utilized to monitor the approach of a person to a hazard (such as a moving robot) and slow or stop the hazard when a person approaches. In some embodiments, the same fields may be repurposed to implement the reset techniques disclosed herein.

[0028] In some embodiments, the system determines whether a human has entered the detection field based on a determination that the state of the detection field has changed from an unattended state to an attended state, and conversely, the system determines whether a human has exited the detection field based on a determination that the state of the detection field has changed from an attended state to an unattended state.

[0029] 1 is a diagram illustrating a robotic system according to various embodiments. In some embodiments, system 100 performs at least a portion of process 400 of FIG. 4, process 500 of FIG. 5, process 600 of FIG. 6, process 700 of FIG. 7, and / or process 800 of FIG. 8.

[0030] In various embodiments, once the robot is stopped (e.g., upon detecting the approach of a human operator), the system requires that a reset button or other manually activated control be activated and that the human operator be detected as having left the safeguarded space to resume operation. Before activating the reset control, the human may be trained and required to ensure that no other humans or other hazards are present within the safeguarded space, e.g., to slowly exit the space within a predetermined time period to activate the reset. The system may detect that the human has entered a first field near the robot, then entered a second field further from the robot, then at least partially entered the first field, then exited the first field, and then exited the second field (which extends further from the robot than the first field), after which autonomous operation of the robot resumes.

[0031] In the illustrated example, system 100 includes a robot 105 deployed within a workspace. The workspace may be limited / enclosed by walls 120, 125, etc. Within the workspace, robot 105 may be controlled to perform tasks related to items within the workspace. Various tasks may be performed. For example, various types of systems may be deployed, such as a singulation system for performing singulation tasks, a kitting system for performing kitting tasks, and / or a palletization system for performing palletizing tasks.

[0032] As shown, the robot 105 is controlled to palletize items onto a pallet 115. For example, the robot 105 picks items from a source location (e.g., a table 110, a conveyor, a shelf, etc.). The robot 105 is controlled to perform tasks in an autonomous mode (e.g., without human intervention except when the system is reset or reconfigured). The robot 105 may be controlled by a control system (not shown). The system 100 includes a sensor system that the system 100 utilizes to collect sensor data about the workspace.

[0033] In some embodiments, the sensor system includes one or more 2D cameras, 3D (e.g., RGBD) cameras, infrared sensors, light curtains, and other sensors. The system 100 uses the sensor data captured by the sensor system to generate a three-dimensional view of the workspace (or a portion of the workspace, such as a pallet and a stack of items on the pallet). The system 100 can use the sensor data to generate a model of a safeguard that corresponds to, includes, or may be contained within the workspace. A safeguard may be a space in which the presence of a human worker influences whether the robot 105 operates in autonomous mode. For example, when a human worker is not present within the safeguard, the robot 105 operates freely and autonomously to perform tasks related to items within the workspace. The control system uses the safeguard sensor data to detect the presence of a human. In response to determining that a human worker is present within the safeguard, the control system causes the robot 105 to pause or otherwise cease operation in autonomous mode. The control system monitors the safeguarded space and, in response to detecting that a human worker has left the safeguarded space or determining that no human workers remain in the safeguarded space, can cause the robot 105 to resume operation in autonomous mode. The system 100 can further monitor the movement / position of the human worker using sensor data.

[0034] In the illustrated example, the sensor system includes cameras 130, 132, 134, and 136. The sensor system also includes sensors (such as 138, 140, 142, and / or 144) that may be utilized to detect when a human worker enters the protected space in which the robot 105 operates (e.g., within a confined space such as the space defined by walls 120, 125, or a space such as a trailer during loading / unloading, etc.). By way of example, sensors 138 and 140 may be sensors included in a light curtain.

[0035] In some embodiments, the sensor system includes sensors for detecting a human worker within a detection field. A single sensor may be utilized to detect a human worker within a series of consecutive detection fields. For example, a multi-field sensor may be utilized to detect human movement through multiple successive detection fields. In some embodiments, one or more sensors configured to collect sensor data for the various detection fields have a refresh rate of 200 ms or less.

[0036] In some embodiments, the sensor system includes one or more active or passive sensors configured to acquire sensor data related to a series of detection fields (e.g., a series of consecutive detection fields). As an example, the sensor includes a transponder and a receiver for acquiring the sensor data related to the detection fields.

[0037] According to various embodiments, the system enables the robot 105 to resume autonomous operation in response to activating a reset control and determining, after activation of the reset control, that all human operators have left the safeguarded space. The reset control may be a reset button or other control located on or near the robot 105. The system may determine that all human operators have left the safeguarded space by monitoring the first and second detection fields and detecting movement of human operators through the first detection field, into the second detection field, and out the rear of the second detection field (e.g., at the distal end of the second detection field relative to the robot 105). The system may consider a human operator to have exited the safeguarded space upon exiting the second detection field (e.g., without re-entering the first detection field).

[0038] The safe start-up and restart mechanisms of various embodiments increase overall safety by addressing critical stages of the robot's operation, reducing the likelihood of accidents and injuries during start-up and restart procedures.

[0039] In some embodiments, system 100 adapts to dynamic changes in the environment to ensure the robot is started or restarted under conditions that minimize risk and optimize operational efficiency. The implementation of real-time monitoring capabilities allows system 100 to respond quickly to unexpected situations, providing a proactive approach to safety during critical operational phases. System 100's fail-safe mechanisms (e.g., pausing or halting the robot's 105 operation during autonomous operation) help minimize downtime by quickly halting operation in the presence of potential risks and enable efficient troubleshooting and resolution.

[0040] In some embodiments, the system disables the robot's autonomous operation upon detecting the presence of a human within the safeguarded space. Using sensor data collected by multiple sensors and real-time detection algorithms (e.g., the system generates a model of the safeguarded space and / or detection field to monitor human movement), the system identifies the intrusion of a human worker into a designated detection field (e.g., the safeguarded space) and triggers an immediate shutdown of autonomous robot functions to prevent a potential collision or accident. After this protected state, various embodiments incorporate a reset controller within the safeguarded space that, when activated, initiates a systematic reassessment of the environment. The system intelligently resumes autonomous operation upon detecting that a human worker has entered a first detection field (e.g., into the front / proximal portion of the first detection field), moved into a second detection field, and then exited the second detection field (e.g., via the rear portion of the second detection field), ensuring seamless and safe integration of robot tasks with human activities. This safety protocol not only prioritizes the well-being of human workers but also promotes efficient and safe collaboration between humans and robots in industrial environments.

[0041] 2 is a diagram illustrating a robotic system with a safeguarded space, according to various embodiments. In some embodiments, system 200 performs at least a portion of process 400 of FIG. 4, process 500 of FIG. 5, process 600 of FIG. 6, process 700 of FIG. 7, and / or process 800 of FIG. 8.

[0042] In the illustrated example, system 300 defines safeguarded space 210 by including three solid walls 205 (e.g., walls of a shipping trailer / container) and an open wall protected by a safety field of scanners. System 200 uses sensor data to detect when a human worker exits safeguarded space 210 and scanner field 215, such as to move to the rear of trailer 220 adjacent to the open wall. In some embodiments, scanner field 215 and safeguarded space 210 at least partially overlap. For example, safeguarded space 210 may include scanner field 215.

[0043] System 200 prevents autonomous operation of the robot upon detecting a human operator within safeguarded space 210. A predetermined protocol is implemented to resume autonomous operation. For example, the system enables autonomous operation only upon completion of the predetermined protocol. In some embodiments, the predetermined protocol includes: (i) activation of reset controller 225 within safeguarded space 210, such as by a human operator; and (ii) for one or more human operators within safeguarded space 210 (e.g., for all human operators), (a) the human operator enters a first detection field within scanner field 215, (b) the human operator enters a second detection field within scanner field 215, and (c) the human operator exits the second detection field (e.g., to enter the rear of trailer 220). The predetermined protocol may further include detecting that the human operator has exited the second detection field before exiting, and preferably after entering, the second detection field when the first and second detection fields at least partially overlap.

[0044] 3A and 3B illustrate a robotic system configured to resume operation based at least in part on detecting that a human worker has exited a safeguarded space. In some embodiments, system 200 performs at least a portion of process 400 of FIG. 4, process 500 of FIG. 5, process 600 of FIG. 6, process 700 of FIG. 7, and / or process 800 of FIG. 8.

[0045] To arm the robot and resume autonomous mode, the human worker checks to ensure the trailer (e.g., safeguarded space) is free of, for example, other workers or other hazards, activates a reset control (e.g., presses a reset button that may be present within the safeguarded space), and walks (e.g., slowly) out of the trailer. A field is used to invisibly monitor the human worker as they leave, and the system arm the robot and / or resumes operation in autonomous mode once the worker exits the safeguarded space. For example, the system enables the robot to resume operation in autonomous mode. In some embodiments, the system controls a brief sound and / or a flashing light to be emitted within the workspace before the robot resumes autonomous operation.

[0046] In the illustrated example, system 300 comprises a confined space, such as a trailer 305. System 300 further comprises a robot 310 configured to autonomously perform tasks within the confined space, such as to load / unload items to / from trailer 305.

[0047] In some embodiments, system 300 includes a reset control (e.g., reset button 315). The reset control may be deployed within the safeguarded space and activated by a human worker (e.g., human 350) when the human worker is within the safeguarded space. For example, human 350 may press reset button 315. In some embodiments, activation of the reset control initiates a protocol in which the system monitors the workspace (e.g., safeguarded space) and determines whether all human workers have exited the safeguarded space. Upon determining that no additional humans are present within the safeguarded space, system 300 allows robot 310 to resume autonomous operation.

[0048] System 300 further includes a sensor system, which in the illustrated example includes sensors 320 and / or cameras 325. The sensor system collects sensor data about the safeguarded space. For example, as shown, sensor 320 collects sensor data about first detection field 330 and second detection field 335. In some embodiments, first detection field 330 and second detection field 335 at least partially overlap, e.g., are designed with overlap area 340.

[0049] After activating the reset control (eg, pressing reset button 315), persons 350 and 355 exit the safeguarded space, as shown in FIG. 3B.

[0050] In response to activation of the reset control, the system implements a protocol to monitor for the exit of humans from the safeguarded space. After the reset control is activated, system 300 uses sensor data (e.g., collected by sensors 320) to determine whether all humans have exited the safeguarded space, such as based on determining that a human entered first detection field 330, then entered second detection field 335 (e.g., in overlap area 340), then exited first detection field 330 (e.g., the human is in a non-overlapping portion of the second detection field), and then exited second detection field 335 (e.g., via the rear of second detection field 335, such as by leaving a trailer, which is a confined space).

[0051] 3A and 3B are described in the context of a set of overlapping detection fields. In other embodiments, the set of detection fields may not overlap. For example, a system may include a series of consecutive detection fields (e.g., two or more consecutive fields that do not overlap).

[0052] FIG. 4 illustrates a robotic system configured to resume operation based at least in part on detecting that a human worker has exited a safeguarded space, according to various embodiments.

[0053] To arm the robot and resume autonomous mode, the human operator checks to ensure the trailer (e.g., safeguarded space) is free of, for example, other operators or other hazards, activates a reset control (e.g., presses a reset button that may be present within the safeguarded space), and walks (e.g., slowly) out of the trailer. A field is used to invisibly monitor the human operator as they leave, and the system arm the robot and / or resumes operation in autonomous mode once the human operator exits the safeguarded space. The system may determine that the human operator has exited the safeguarded space based at least in part on determining that the human operator is in a designated exit zone.

[0054] In some embodiments, the system has multiple consecutive detection fields. Each consecutive detection field is successively farther away from the robot. For example, if the system has three consecutive detection fields, the first detection field is the closest detection field to the robot, the second detection field is second-closest to the robot (e.g., the second detection field is adjacent to the first detection field), and the third detection field is third-closest to the robot (or farthest from the robot). In some embodiments, none of the multiple consecutive detection fields overlap with one another. In some embodiments, two or more of the consecutive detection fields overlap with another detection field.

[0055] In the depicted example, system 400 comprises a confined space, such as a trailer 405. System 400 further comprises a robot 410 configured to autonomously perform tasks within the confined space, such as to load / unload items to / from trailer 405.

[0056] In some embodiments, system 400 includes a reset control (e.g., reset button 415). The reset control may be deployed within the safeguarded space and activated by a human worker (e.g., human 450) when the human worker is within the safeguarded space. For example, human 450 may press reset button 415. In some embodiments, activation of the reset control initiates a protocol in which the system monitors the workspace (e.g., safeguarded space) and determines whether all human workers have exited the safeguarded space. Upon determining that no additional humans are present within the safeguarded space, system 400 enables robot 410 to resume autonomous operation.

[0057] The human operator who presses the reset button is the last person remaining in the safeguarded space. For example, the human operator may be trained to check the safeguarded space to ensure that there are no other human operators or objects within the safeguarded space that could interfere with the robot. In some embodiments, the system includes a sensor system (e.g., a camera, etc.) for detecting the human operator within the safeguarded space. In response to receiving an indication that the reset control has been activated, the system may verify that only one human operator is present within the safeguarded space (e.g., the human operator who pressed the reset control button within the safeguarded space).

[0058] System 400 further includes a sensor system, which in the illustrated example includes sensor 420. The sensor system collects sensor data about the safeguarded space. In the illustrated example, sensor 420 collects sensor data about a first detection field 430, a second detection field 435, and a third detection field 440. In some embodiments, first detection field 430, second detection field 435, and third detection field 440 do not overlap.

[0059] The sensor data collected by the sensor 420 may be utilized to detect when a human worker is exiting a safeguarded space or detection field based on the system 400 determining that the human worker is moving such that the human worker is continuously moving through a continuous detection field.

[0060] In some embodiments, the sensor 420 is a multi-field sensor. A single sensor 420 may be used to collect sensor data for the first detection field 430, the second detection field 435, and the third detection field 440 (e.g., to detect a human within the detection field). The sensor 420 may be implemented as a passive or active sensor. The system 400 may confirm that the human worker has exited the safeguarded space based on determining, based on the sensor data, that the human worker is in a designated exit zone. The designated exit zone may be a predetermined space outside the safeguarded space. Referring to the illustrated example, the designated exit zone may be a space farther from the robot than the third detection field 440.

[0061] In another embodiment, two or more of the first detection field 430, the second detection field 435, and the third detection field 440 overlap.

[0062] After activating the reset control (eg, pressing reset button 415), human worker 450 exits the safeguarded space, such as by moving through a continuous detection field.

[0063] In some embodiments, system 400 implements a protocol to monitor human exit from the safeguarded space in response to activation of the reset control. After the reset control is activated (e.g., by the last remaining human in the safeguarded space), system 400 uses sensor data (e.g., collected by sensor 420) to determine whether all humans have exited the safeguarded space, such as based on detecting human workers moving continuously through the detection field. For example, system 400 uses sensor data 420 to determine that a human worker exits a first detection field 430 (e.g., the detection field closest to robot 410), then exits a second detection field 435 (e.g., the detection field next closest to robot 410), then exits first detection field 430 (e.g., the human is in a non-overlapping portion of the second detection field), then exits second detection field 435 (e.g., via the rear of second detection field 435), and then exits third detection field 440 (e.g., by leaving the trailer, which is a confined space, and entering a designated exit, etc.).

[0064] Diagram 500 is a flowchart illustrating a method for controlling a robot to resume operation, according to various embodiments. In some embodiments, process 500 is performed, at least in part, by system 100 of FIG. 1 and / or system 300 of FIGS. 3A and 3B.

[0065] In step 505, the system decides to reset the operation of the robot. In some embodiments, the system decides to reset the operation of the robot in response to determining that a reset control has been activated, such as by detecting a reset button within the safeguarded space being pressed.

[0066] In step 510, the system acquires sensor data about the robot workspace. The system collects sensor data about the safeguarded space. The sensor data may include data about one or more detection fields. The one or more detection fields may be monitored to verify that a human worker has exited the safeguarded space.

[0067] In step 515, the system determines whether a human worker has exited the safeguarded space of the robot workspace. In some embodiments, the system analyzes sensor data for one or more detection fields in connection with determining whether a human worker has exited the safeguarded space. In step 515, the system may invoke process 700 of FIG. 7 or process 800 of FIG. 8.

[0068] In response to determining that no human workers (e.g., all human workers) have exited the safeguarded space, process 500 returns to step 510, and process 500 repeats steps 510-515 until no more humans are in the safeguarded space (e.g., including any humans who have entered the safeguarded space since the reset control was activated). Conversely, in response to determining that no human workers have exited the safeguarded space, process 500 proceeds to step 500.

[0069] At step 520, the system resumes operation of the robot. For example, in response to determining that the safeguarded space is completely clear of humans, the system enables (e.g., configures, authorizes, etc.) the robot to operate in an autonomous mode to perform a corresponding task within the workspace (e.g., singulation, palletization, or kitting of items).

[0070] At step 525, a determination is made as to whether process 500 is complete. In some embodiments, process 500 is determined to be complete in response to a determination that there are no additional robotic systems to monitor / control, that the robot has completed a series of tasks autonomously, that a user has stopped the robot's operation, that an administrator or other user has indicated that process 500 is paused or stopped, etc. In response to a determination that process 500 is complete, process 500 ends. In response to a determination that process 500 is not complete, process 500 returns to step 505.

[0071] 6 is a flowchart illustrating a method for determining whether conditions for resuming autonomous robot operation are met, according to various embodiments. In some embodiments, process 600 is performed, at least in part, by system 100 of FIG. 1 and / or system 300 of FIGS. 3A and 3B.

[0072] In step 605, the system obtains an indication that determines whether autonomous operation is to be performed. In some embodiments, the system indication that determines whether autonomous operation is to be performed (e.g., continued / resume) corresponds to or is generated in response to a reset control being actuated.

[0073] In step 610, the system acquires sensor data, which may include acquiring sensor data for multiple detection fields, which may be monitored to detect the presence / movement of human workers.

[0074] In step 615, the system determines whether a set of autonomous operation conditions is met. The set of autonomous operations may be predefined. For example, the set of operations may correspond to a protocol to be executed before autonomous operation is resumed. In some embodiments, the system invokes process 700 or process 800.

[0075] In response to determining that the set of autonomous operation conditions is not satisfied, process 600 returns to step 610, and the process repeats steps 610-615 until the set of autonomous operation conditions is satisfied. For example, the system may continue to monitor the safeguarded space (e.g., collect sensor data) and determine whether or not a human is present in the safeguarded space. Conversely, if the system determines that the set of autonomous operation conditions is satisfied, process 600 proceeds to step 620.

[0076] In step 620, the system provides an indication that it is capable of performing autonomous operation. For example, the system may provide the indication to another system, service, or process that invoked process 600. The system may provide the indication to a control system that controls the robot to perform a series of tasks autonomously.

[0077] At step 625, a determination is made as to whether process 600 is complete. In some embodiments, process 600 is determined to be complete in response to a determination that there are no additional robotic systems to monitor / control, that the robot has completed a series of tasks autonomously, that a user has stopped the robot's operation, that an administrator or other user has indicated that process 600 is paused or stopped, etc. In response to a determination that process 600 is complete, process 600 ends. In response to a determination that process 600 is not complete, process 600 returns to step 605.

[0078] 6 is a flowchart illustrating a method for determining whether conditions for resuming autonomous robot operation are met, according to various embodiments. In some embodiments, process 700 is performed, at least in part, by system 100 of FIG. 1 and / or system 300 of FIGS. 3A and 3B.

[0079] In some embodiments, process 700 provides protocols to be executed / met to enable / control the robot to operate in autonomous mode. Process 700 may be executed for each human worker detected entering the safeguarded space.

[0080] In step 705, the system obtains an indication that determines whether the conditions for resuming autonomous operation are met. For example, process 700 is called by step 615 of process 600.

[0081] In step 710, the system acquires sensor data.

[0082] In step 715, the system determines whether a human worker has entered the first detection field, e.g., based on sensor data about the first detection field. In response to determining that a human worker has not entered the first detection field, process 700 returns to step 710, and process 700 repeats steps 710-715 until the system determines that a human worker has entered the first detection field. Conversely, in response to determining that a human worker has entered the first detection field, process 720 proceeds to step 720.

[0083] At step 720, the system determines whether a human worker has entered the second detection field, e.g., based on sensor data about the second detection field. The second detection field may overlap with the first detection field so that a user is not required to exit the first detection field before entering the second detection field. In response to determining that a human worker has not entered the second detection field, process 700 proceeds to step 725, where the system acquires sensor data, and process 700 repeats steps 720-725 until the system determines that a human worker has entered the second detection field. Conversely, in response to determining that a human worker has entered the second detection field, process 700 proceeds to step 730.

[0084] At step 730, the system determines whether the human worker has exited the first detection field, e.g., based on sensor data about the first detection field. In response to determining that the human worker has not exited the first detection field, process 700 proceeds to step 735 where the system acquires sensor data, and process 700 repeats steps 730-735 until the system determines that the human worker has exited the first detection field. Conversely, in response to determining that the human worker has exited the first detection field, process 700 proceeds to step 740.

[0085] At step 740, the system determines whether the human worker has exited the second detection field, e.g., based on sensor data about the second detection field. In response to determining that the human worker has not exited the second detection field, process 700 proceeds to step 745 where the system acquires sensor data, and process 700 repeats steps 740-745 until the system determines that the human worker has exited the second detection field. Conversely, in response to determining that the human worker has exited the second detection field, process 700 proceeds to step 750.

[0086] In step 650, the system provides an indication that the conditions for resuming autonomous operation have been met. For example, the system may provide the indication to another system, service, or process that invoked process 700. The system may provide the indication to a control system that controls the robot to autonomously perform a series of tasks.

[0087] At step 755, a determination is made as to whether process 700 is complete. In some embodiments, process 700 is determined to be complete in response to a determination that there are no more robotic systems to be deployed or configured, that there are no more safety systems to be configured or calibrated, that the deployed robotic systems have been successfully configured, an administrator or other user indicates that process 700 is paused or stopped, etc. In response to a determination that process 700 is complete, process 700 ends. In response to a determination that process 700 is not complete, process 700 returns to step 705.

[0088] 8 is a flowchart illustrating a method for controlling a robot to resume operation, according to various embodiments. In some embodiments, process 800 is performed, at least in part, by system 100 of FIG. 1 and / or system 300 of FIGS. 3A and 3B.

[0089] At step 805, the system obtains an indication that determines whether conditions for resuming autonomous operation are met. For example, process 700 is called by step 615 of process 600. At step 810, the system obtains sensor data. At step 815, the system detects that a human has exited the safeguarded space through the front of the first detection field and the rear of the second detection field. At step 820, the system determines whether any additional humans are present in the safeguarded space. In response to determining that one or more additional humans are present in the safeguarded space, process 800 returns to step 810, and process 800 repeats steps 810-820 until no additional humans are present in the safeguarded space. Conversely, in response to determining that no additional humans are present in the safeguarded space, process 800 proceeds to step 825. At step 825, the system provides an indication that the workspace is ready for resuming operation of the robot in autonomous mode. For example, the system may provide an indication to another system, service, or process that invoked process 800. The system may provide an indication to a control system that controls the robot to autonomously perform a series of tasks. At step 830, a determination is made as to whether process 800 is complete. In some embodiments, process 800 is determined to be complete in response to a determination that there are no additional robotic systems to monitor / control, that the robot has completed a series of tasks autonomously, that a user has stopped the robot's operation, that an administrator or other user has indicated that process 800 is paused or stopped, etc. In response to a determination that process 800 is complete, process 800 ends. In response to a determination that process 800 is not complete, process 800 returns to step 805.

[0090] 9 is a flowchart for controlling a robot to operate in an autonomous mode, according to various embodiments. In some embodiments, process 900 is performed, at least in part, by system 100 of FIG. 1 and / or system 300 of FIGS. 3A and 3B.

[0091] In step 905, the system operates the robot in autonomous mode.

[0092] In step 910, the system acquires sensor data. The system acquires the sensor data from a sensor system including a plurality of sensors configured to detect information about the workspace. In some embodiments, the sensor system includes a first subset for acquiring sensor data for a first detection field and a second subset for a second detection field. The first detection field and the second detection field may at least partially overlap.

[0093] In step 915, the system determines whether a human has been detected within the safeguarded space of the robot workspace.

[0094] In response to determining that a human has not been detected within the safeguarded space, process 900 returns to step 910, and process 900 repeats steps 910-915 until the system detects a human within the safeguarded space. While process 900 repeats steps 910-915, the robot may continue to operate in autonomous mode. In response to determining that a human has been detected within the safeguarded space, process 900 proceeds to step 920.

[0095] In step 920, the system stops the robot's motion.

[0096] At step 925, the system obtains reset data. In some embodiments, the reset data includes data indicating whether a reset control has been activated. For example, the reset data may be generated in response to a reset button being pressed or other such reset control being activated. The system may monitor for receipt of the reset data.

[0097] At step 930, the system determines whether an indication to perform a reset has been received. In response to determining that an indication to perform a reset has not been received, process 900 returns to step 925, and process 900 repeats steps 925-930 until the system determines that an indication to perform a reset has been received. Conversely, in response to determining that an indication to perform a reset has been received, process 900 proceeds to step 935.

[0098] In step 935, the system determines whether or not a human is present in the safeguarded space. For example, the system determines whether or not a human has exited the safeguarded space, such as after a reset control (e.g., a reset button) has been activated.

[0099] In response to determining that a human is present in the safeguarded space, process 900 proceeds to step 940 where additional sensor data is obtained. The additional sensor data may include sensor data for the first detection field and sensor data for the second detection field. Process 900 repeats steps 935-940 until the system determines that a human is not present in the safeguarded space. In response to determining that a human is not present in the safeguarded space, process 900 proceeds to step 945.

[0100] In step 945, the system causes the robot to resume autonomous operation.

[0101] At step 950, a determination is made as to whether process 900 is complete. In some embodiments, process 900 is determined to be complete in response to a determination that there are no additional robotic systems to monitor / control, that the robot has completed a series of tasks autonomously, that a user has stopped the robot's operation, that an administrator or other user has indicated that process 900 is paused or stopped, etc. In response to a determination that process 900 is complete, process 900 ends. In response to a determination that process 900 is not complete, process 900 returns to step 905.

[0102] 10 is a flowchart for controlling a robot to operate in an autonomous mode, according to various embodiments. In some embodiments, process 1000 is performed, at least in part, by system 100 of FIG. 1 and / or system 400 of FIG. 4.

[0103] In step 1005, the system obtains an indication that the robotic system has been paused or initialized.

[0104] In step 1010, the system obtains reset data. In some embodiments, the reset data includes data indicating whether a reset control has been activated. For example, the reset data may be generated in response to a reset button being pressed or other such reset control being activated. The system may monitor for receipt of the reset data.

[0105] At step 1015, the system determines whether an indication to perform a reset has been received. In some embodiments, the system determines whether a reset control has been actuated. For example, the system determines whether a reset button within the safeguarded space (e.g., reset button 415 of system 400) has been pressed.

[0106] In response to determining at step 1015 that an indication to perform a reset has not been received, process 1000 returns to step 1010, and process 1000 repeats steps 1010-1015 until the system determines that an indication to perform a reset has been received. Conversely, in response to determining that an indication to perform a reset has been received, process 1000 proceeds to step 1020.

[0107] In step 1020, the system determines whether the human has exited the first detection field. In some embodiments, the first detection field corresponds to the detection field closest to the robot. The system may have multiple successive detection fields, with successive detection fields being progressively farther away from the robot.

[0108] In response to determining that the human has not exited the first detection field, process 1000 proceeds to step 1025 where the system acquires sensor data, and process 1000 repeats steps 1015-1020 until the system determines that the human has exited the first detection field. Conversely, in response to determining that the human has exited the first detection field, process 1000 proceeds to step 1030.

[0109] In step 1030, the system determines whether the human has exited the next field of detection. In some embodiments, the next field corresponds to a detection field adjacent to the first field of detection and further away from the robot.

[0110] In response to determining that the human has not exited the next detection field, process 1000 proceeds to step 1035 where the system acquires sensor data, and process 1000 repeats steps 1020-1030 until the system determines that the human has exited the next detection field. Conversely, in response to determining that the human has exited the next detection field, process 1000 proceeds to step 1040.

[0111] In step 1040, the system determines whether the system has another detection field. For example, the system determines whether the successive detection fields include another detection field in succession. As another example, the system determines whether the successive detection fields include a detection field that is at a greater distance from the robot than the detection field from which the human previously exited.

[0112] In response to the system determining that there is another detection field, process 1000 proceeds to step 1045 where the system receives sensor data, and process 1000 repeats steps 1030-1040 until the system determines that there is no more detection field. Conversely, in response to determining that there is no more detection field, process 1000 proceeds to step 1050.

[0113] In step 1050, the system determines whether a human is in a designated exit zone. The designated exit zone may be a predetermined space within which the system can safely resume autonomous operation when a human is present. For example, the designated exit zone is outside the safeguarded space.

[0114] In response to determining that a human is not in the designated exit zone, process 1000 proceeds to step 1055 where the system acquires sensor data. Process 1000 then returns to step 1040, and process 1000 repeats steps 1040-1050. Conversely, in response to determining that a human is in the designated exit zone, process 1000 proceeds to step 1060.

[0115] In step 1060, the system causes the robot to resume autonomous operation.

[0116] At step 1065, a determination is made as to whether process 1000 is complete. In some embodiments, process 1000 is determined to be complete in response to a determination that there are no additional robotic systems to monitor / control, that the robot has completed a series of tasks autonomously, that a user has stopped the robot's operation, that an administrator or other user has indicated that process 1000 is paused or stopped, etc. In response to a determination that process 1000 is complete, process 1000 ends. In response to a determination that process 1000 is not complete, process 1000 returns to step 1005.

[0117] In various embodiments, the techniques disclosed herein may be used to safely reset and resume autonomous operation by a robotic system without (necessarily) having the ability to communicate with the robot from outside the safeguarded space.

[0118] In some examples described herein, a safety scanner field is used to detect and determine when a human worker who has actuated a reset button or other control has left the safeguarded space, although in other examples, other safety-compliant structures and / or techniques may be used, such as continuous light curtains, additional physically depressed or actuated controls located at locations along the egress route, computer vision and associated logic, and / or other structures and techniques.

[0119] In some examples, the robotic systems disclosed herein are located in shipping containers, truck trailers, or other walled spaces, although the techniques disclosed herein may be used in other contexts, such as caves, barns, recesses, or other physically enclosed spaces.

[0120] Various example embodiments described herein are described with reference to flowcharts. While the examples may include some steps performed in a particular order, according to various embodiments, various steps may be performed in different orders and / or various steps may be combined into a single step or performed in parallel.

[0121] Although the above-described embodiments have been described in some detail for ease of understanding, the invention is not limited to the details provided. There are many alternative ways of implementing the invention. The disclosed embodiments are illustrative and are not intended to be limiting.

Claims

1. 1. A robotic system comprising: a robot configured to move one or more items within a workspace; a sensor configured to collect sensor data about the workspace; one or more processors; Equipped with the one or more processors: determining a reset of the robot's movement; determining, based at least in part on the sensor data, that a human worker has exited a safeguarded space within the workspace; The system is configured to resume operation of the robot in response to determining that the human worker has exited the safeguarded space.

2. 10. The robotic system of claim 1, wherein the one or more processors are further configured to pause operation of the robot in response to determining that an operator has entered a safeguarded space within the workspace.

3. The system of claim 1 , wherein the sensors comprise a first subset of sensors and a second subset of sensors having overlapping detection fields.

4. The system of claim 1 , wherein the sensor comprises a plurality of sensors that collect sensor data for different detection fields in a series of detection fields.

5. 10. The system of claim 1, the sensors comprising a first subset of sensors capturing sensor data for a first detection field and a second subset of sensors capturing sensor data for a second detection field; The system, wherein the first detection field and the second detection field at least partially overlap.

6. 2. The system of claim 1, wherein determining that the human worker has exited a safeguarded space within the workspace comprises: determining, based at least in part on the sensor data, that the human worker has exited a set of detection fields.

7. 7. The system of claim 6, the series of detection fields are consecutive detection fields; The system, wherein determining that the human worker has exited the series of detection fields comprises determining that the human worker has successively exited the successive detection fields.

8. 8. The system of claim 7, wherein determining that the human worker has exited the series of detection fields comprises: determining that the human worker has exited the first detection field; determining that the human worker has exited a second detection field in response to determining that the human worker has exited the first detection field; The system, wherein the first detection field is closer to the robot than the second detection field.

9. 2. The system of claim 1, wherein determining that the human worker has exited a safeguarded space within the workspace comprises: determining that the human worker has entered a first detection field; determining that the human worker entered a second detection field after entering the first detection field; determining that the human worker has exited the first detection field after entering the second detection field; determining that the human worker has exited the second detection field after exiting the first detection field.

10. 10. The system of claim 9, wherein determining that the human worker has entered the second detection field comprises determining that the human worker has moved from a rear portion of the first detection field to a front portion of the second detection field.

11. 10. The system of claim 9, wherein in response to determining that the human worker has exited the first detection field and then the second detection field, the robot is controlled to resume operation if no additional humans are present within the safeguarded space.

12. The system of claim 9 , wherein the second detection field is farther from the robot than the first detection field.

13. 10. The system of claim 1, wherein operation of the robot resumes after determining that the human operator has exited a last detection field in a series of consecutive detection fields without another operator entering the safeguarded space after the human operator has exited a first detection field.

14. 10. The system of claim 1, wherein operation of the robot is resumed in response to determining that the human worker is present within a predetermined designated exit zone that is located farther from the robot than a last detection field in a series of consecutive detection fields.

15. 10. The system of claim 1, wherein the decision to reset the operation of the robot is based at least in part on a reset button in the workspace being activated before the human worker exits the safeguarded space.

16. 16. The system of claim 15, wherein the button is on the robot or within a predetermined distance from the robot.

17. 10. The system of claim 1, wherein the one or more processors are further configured to perform image analysis on the sensor data to detect humans within the workspace.

18. 10. The system of claim 1, wherein at least some of the plurality of sensors operate at a refresh rate of 200 ms or less.

19. 10. The system of claim 1, wherein the robot resumes operation in response to determining that the human worker has exited the safeguarded space without another human worker entering the safeguarded space before the robot resumes operation.

20. 10. The system of claim 1, wherein the one or more processors further comprise: determining, based at least in part on the sensor data, that the human worker has entered the safeguarded space within the workspace while the robot is controlled to move an item within the workspace; The system is configured to stop operation of the robot in response to determining that the human worker has entered the safeguarded space.

21. 10. The system of claim 1, wherein resuming operation of the robot comprises controlling the robot to operate in an autonomous mode to move the item within the workspace.

22. The system of claim 1 , wherein the robot comprises a robot with an end effector configured to grasp an item.

23. 1. A method comprising: acquiring sensor data from sensors regarding a workspace for a robot configured to move one or more items; determining a reset of the robot's movement; determining, based at least in part on the sensor data, that a human worker has exited a safeguarded space within the workspace; resuming operation of the robot in response to determining that the human worker has exited the safeguarded space; A method comprising:

24. A computer program product embodied in a non-transitory computer-readable medium, computer instructions for acquiring sensor data from sensors regarding a workspace for a robot configured to move one or more items; computer instructions for determining a reset of the robot's motion; computer instructions for determining, based at least in part on the sensor data, that a human worker has exited a safeguarded space within the workspace; computer instructions for resuming operation of the robot in response to determining that the human worker has exited the safeguarded space; A computer program product comprising:

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