Proximity detection in robotic manufacturing environments

Abstract

To provide a system and a method for reporting a proximity state in an assembly environment.SOLUTION: A method includes: equipping a technician with a first proximity state detector which is wearable; disposing a second proximity state detector at a robot which moves within a cell of an assembly environment; and directing the first proximity state detector to provide a warning to the technician if a distance between the first proximity state detector and the second proximity state detector becomes less than a threshold.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to the field of assembly, and in particular to human-machine interaction in an assembly environment. [Background technology]

[0002] In assembly environments, it remains desirable to assemble new parts as quickly and efficiently as possible. It is common for some assembly tasks to be performed by automated machines while others are performed by human technicians. To ensure safety, technicians are restricted from entering the operating zone of an automated machine while the machine is operating. This creates a "no-go zone," which can reduce the speed and efficiency with which the technician works and / or result in an undesirable reduction in assembly speed. At the same time, it is not feasible to rely on workers' awareness of nearby automated machines (which would allow automated machines to operate in conjunction with technicians in the same zone). Therefore, automated machines and technicians are restricted to separate usage times if they both use the same zone.

[0003] It would therefore be desirable to have a method and apparatus that takes into account at least some of the above problems, as well as other possible problems. Summary of the Invention

[0004] The embodiments described herein dynamically determine the proximity of a technician to a robot and implement a variety of corrective actions based on the proximity. For example, in a first proximity state, the technician may receive a warning, and in a second proximity state, the robot may be stopped. Additionally, multiple proximity detectors may be placed on the robot to accurately track the location of multiple components on the robot.

[0005] One embodiment is a method for proximity reporting in an assembly environment, the method including equipping a technician with a first wearable proximity detector, disposing a second proximity detector on a robot that moves within a cell of the assembly environment, and instructing the first proximity detector to provide an alert to the technician when a distance between the first proximity detector and the second proximity detector falls below a threshold.

[0006] A further embodiment is a non-transitory computer-readable medium embodying programmed instructions that, when executed by a processor, are executable to implement a method for reporting proximity conditions in an assembly environment, the method including equipping a technician with a first wearable proximity detector, disposing a second proximity detector on a robot that moves within a cell of the assembly environment, and instructing the first proximity detector to provide an alert to the technician when a distance between the first proximity detector and the second proximity detector falls below a threshold.

[0007] A further embodiment is a system for proximity reporting in an assembly environment, the system comprising a first wearable proximity detector and a second proximity detector located on a robot within a cell of the assembly environment; and a proximity state server, the proximity state server including a memory that stores data indicative of a first threshold and a second threshold that is less than the first threshold, and a controller that analyzes the first signal and the second signal to determine a distance between the first proximity state detector and the second proximity state detector, provide a notification to the first proximity state detector when the distance is less than the first threshold, and provide a notification to the second proximity state detector when the distance is less than the second threshold.

[0008] A further embodiment is a system for detecting proximity between a technician and a robot. The system includes a sensor that receives signals indicative of the location of a first proximity detector worn by the technician and the location of a second proximity detector on the robot. The system also includes a proximity server. The proximity server includes a memory that stores the signals and a controller that determines the distance between the first proximity detector and the second proximity detector, directs the first proximity detector to provide a warning to the technician when the distance falls below a first threshold, and directs the robot to stop when the distance falls below a second threshold.

[0009] Other exemplary embodiments (e.g., methods and computer-readable media related to the above-described embodiments) may also be described below. The above-described features, functions, and advantages may be realized individually in various embodiments or may be combined in yet further embodiments, further details of which can be seen with reference to the following description and drawings.

[0010] Some embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which like reference numerals represent the same or similar elements in all the drawings, and in which: [Brief explanation of the drawings]

[0011] [Figure 1] 1 illustrates a proximity status reporting system in an exemplary embodiment. [Figure 2] FIG. 1 is a flow diagram illustrating a method for reporting proximity status in an exemplary embodiment. [Figure 3] FIG. 2 is a diagram of a proximity detector in an exemplary embodiment. [Figure 4] 1 illustrates the distance between proximity detectors in an exemplary embodiment. [Figure 5] 1 illustrates the distance between proximity detectors in an exemplary embodiment. [Figure 6] 1 illustrates the distance between proximity detectors in an exemplary embodiment. [Figure 7] 1 illustrates a technician moving across a cell on a factory floor in an illustrative embodiment. [Figure 8] 1 illustrates a technician moving across a cell on a factory floor in an illustrative embodiment. [Figure 9] 1 illustrates communications sent between a proximity state detector and a proximity state reporting server in an exemplary embodiment. [Figure 10] 1 illustrates communications sent between a proximity state detector and a proximity state reporting server in an exemplary embodiment. [Figure 11] FIG. 1 is a block diagram of a proximity status reporting system in an exemplary embodiment. [Figure 12] FIG. 1 is an illustration of an illustration of an aircraft manufacturing and service method in accordance with an illustrative embodiment; [Figure 13] FIG. 1 is an illustration of a block diagram of an aircraft in an illustrative embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0012] The figures and the following description provide specific and exemplary embodiments of the present disclosure. Thus, it will be appreciated that those skilled in the art may devise various configurations (even if not explicitly described or shown herein) that embody the principles of the present disclosure and are within the scope of the present disclosure. Furthermore, any examples described herein should be construed as being intended to aid in the understanding of the principles of the present disclosure and not as being limited to such specifically recited examples and conditions. Consequently, the present disclosure is not limited to the specific embodiments or examples described below, but rather by the claims and their equivalents.

[0013] FIG. 1 is a diagram of a proximity reporting system 100 in one example embodiment. The proximity reporting system 100 includes any system operable to dynamically determine the distance between proximity sensors in an assembly environment. The proximity reporting system 100 has been enhanced to distinguish between technicians and robots and to provide warnings and / or other mitigation measures based on the distance between the technician and robot. This benefits the technology by ensuring the safety of technicians working near robots and increasing the uptime of robots within a cell. As used herein, "cell" includes any dedicated workspace or space intended for one or more robots / machines to operate within.

[0014] In this embodiment, the proximity reporting system 100 includes a proximity reporting server 110 and a sensor 120 (e.g., a wireless antenna, a transceiver, a camera, etc.). The sensor 120 receives input from a proximity detector 160 located within one or more cells 132-133 of an assembly environment 130 (e.g., a factory floor). Thus, the sensor 120 acts as an interface to the proximity reporting server 110. The proximity detector 160 may be attached to one or more technicians 150 or may also be located on a portion 142 (e.g., a moving component) of a robot 140. The robot 140 may comprise a robotic arm, an automated guided vehicle (AGV), a flex track machine, or other automated device moving within the cell. As shown, the technician 150 is wearing the proximity detector 160 within the cell 132 and is in proximity state P from the robot 140 within the cell 132. Additionally, as shown, there are no technicians or proximity detectors present in cell 133 at this time.

[0015] The controller 112 of the proximity status reporting server 110 determines the location of each of the proximity status detectors 160 based on signals from the proximity status detectors 160. If one or more of the technician's proximity status detectors 160 come closer to the proximity status detectors 160 of the robot 140 than a predetermined threshold stored in memory 114, the controller 112 may provide an alert. The controller 112 may be implemented, for example, as a custom circuit, as a hardware processor executing programmed instructions, or some combination thereof.

[0016] The proximity reporting system 100 enables human-machine collaboration by providing a double safety measure: the robot 140 and technician 150 are equipped with transceivers to communicate their location, which can then be compared to each other. Based on this comparison, different levels of warning / action (e.g., to warn the human and / or stop the robot) are provided to ensure safety when humans and robots work together in the same cell / zone.

[0017] Exemplary details of the operation of proximity condition reporting system 100 will now be described in conjunction with the flow diagram of Figure 2. In this embodiment, it is assumed that technician 150 of Figure 1 intends to enter cell 132 where robot 140 is operating. The robot may be assembling / joining composite and / or metal parts used in an aircraft, for example.

[0018] 2 is a flow diagram illustrating a method 200 for reporting proximity conditions in one example embodiment. The steps of method 200 are described with reference to the proximity condition reporting system of FIG. 1, but one skilled in the art will recognize that method 200 may be implemented in other systems. The steps of the flow diagrams described herein are not exhaustive and may include other steps not shown. The steps described herein may also be performed in an alternative order.

[0019] In step 202, technician 150 is equipped with a first proximity detector (e.g., one or more of proximity detectors 160). The first proximity detector may be wearable so that the technician can carry it in a hands-free manner. For example, the proximity detector may be attached to the technician's headwear (e.g., a helmet), attached to clothing worn by technician 150 with a hook-and-loop (e.g., Velcro) material, placed in the technician's pocket, in the form of a pendant or smart watch worn by technician 150, sewn or glued to clothing worn by technician 150, implemented as smart safety glasses that provide a visual alert, an audible alert, a vibrating alert, or any combination thereof, or equipped by other means.

[0020] In step 204, a second proximity detector is placed on a portion 142 of a robot 140 that moves within the assembly environment 130. This may include installing multiple proximity detectors 160 on each robot 140 in the cell (e.g., on or within each robot) and may be performed during initial setup and calibration of the robot 140 before maintenance or inspection is required. In some embodiments, the second proximity detector is coupled to the robot's 140 power supply and in communication with the robot's 140 controller. With the first and second proximity detectors in place, a technician 150 enters the cell 132 (e.g., to perform inspection, assembly assistance, or maintenance). At this time, the robot 140 within the cell 132 may continue to operate.

[0021] In step 206, the first proximity detector transmits a first signal to sensors 120 in the assembly environment 130 (e.g., sensors 120 located outside the cell 132, sensors 120 located inside the cell 132, sensors 120 located on the robot 140, etc.). In one embodiment, the first signal comprises an ultra-wideband (UWB) radio signal that provides a unique identifier for the first proximity detector that distinguishes the first proximity detector from other proximity detectors 160 in the assembly environment 130. The first proximity detector may be associated with a particular technician, as indicated in the memory 114 of the proximity reporting server 110. In a further embodiment, the first signal further identifies the technician or robot to which the first proximity detector is attached. In yet another embodiment, the first signal is transmitted over multiple different radio bands or communication channels. In some embodiments, the first signal may be transmitted as a visual code by a light-emitting diode (LED). Transmitting the first signal over multiple separate communication channels provides a technical benefit of ensuring that the signal can be received and processed by sensor 120. The first signal may be transmitted continuously or periodically (e.g., once or multiple times per second).

[0022] In step 208, the second proximity detector transmits a second signal to the sensor 120. The second signal uniquely identifies the second proximity detector and may be transmitted in a similar manner as the first signal and over the same channel. The first and second signals are received by the sensor 120 and provided to the proximity reporting server 110 for analysis.

[0023] In step 210, the controller 112 of the proximity reporting server 110 determines the distance between the first proximity detector and the second proximity detector based on the first and second signals. This may be done by referencing information stored in memory 114 indicating the location of each sensor, triangulating the first location of the first proximity detector and the second location of the second proximity detector based on the strength of the signals received by each sensor 120, and determining the amount of separation between the first and second locations. The memory 114 may store the signals from the sensors 120 as part of this process. In further embodiments in which the sensors 120 include cameras, the angles of the cameras and stereoscopic devices or techniques may be used to determine the location. In further embodiments, the controller 112 may select which proximity detectors to determine the distance between. For example, controller 112 may selectively refrain from determining distance between proximity detectors located on multiple technicians, between proximity detectors located on the same entity (e.g., the same technician, the same robot, etc.), between proximity detectors located on multiple robots (e.g., in situations where existing collision avoidance technology for the robots has already prevented collisions), etc. This may increase the likelihood that controller 112 will perform the most appropriate distance determination (i.e., most likely to enhance safety). In yet another embodiment, motion detection techniques may be used on distance data obtained over time to determine the current speed and / or direction of a technician or robot.

[0024] After the distance is determined, the controller 112 determines whether the distance is below a first threshold in step 212. The distance thresholds described herein may be statically defined for each robot, or may be dynamically defined as the robot continues to operate based on the motions indicated in the robot's NC program and / or the robot's position in the NC program. For example, if the robot's future path predicts that the robot will be closer to the technician, the threshold may be increased to ensure a faster warning.

[0025] If the distance is not below the first threshold, the technician 150 is away from the robot 140. Therefore, the robot 140 may continue operating. Thus, processing continues at step 210. Alternatively, if the distance is below the first threshold at step 212, then at step 214, the controller 112 (e.g., via the sensor 120) instructs the first proximity detector to provide a warning to the technician 150. The operating environment within the cell 132 may include visual, audible, and / or other stimuli that may relax the technician 150's senses. Thus, the warning may be generated to stimulate multiple senses (e.g., with a bright light, a vibrating movement, and / or a distinctive sound). The warning may also take the form of an audio warning that sounds, depending on the technician's location relative to the robot, such as "Stop moving," "Don't move left," "Don't move south," or similar phrases. The warning is a cue to the technician 150 to promote increased awareness and vigilance. In further embodiments, the warning may be implemented in the form of a flashing light on the technician's helmet, glasses, or gloves, or as a flashing light or siren on the robot.

[0026] In step 216, the controller 112 also determines whether the distance between the first proximity detector and the second proximity detector is below a second threshold. If the distance is below the second threshold, the controller 112 instructs the robot 140 to stop in step 218. This provides a technical benefit by ensuring that the technician remains safe even if the technician approaches an actively operating robot. This provides a further technical benefit because each robot itself does not need to include dedicated sensors and logic to avoid the technician.

[0027] Method 200 may be performed substantially simultaneously and asynchronously for multiple sets of proximity detectors. For example, method 200 may be performed multiple times to identify additional distances between a technician's proximity detector and an additional robot's proximity detector. This allows proximity detection to be performed for all relevant entities in a manufacturing cell (or even across the entire factory floor).

[0028] FIG. 3 is a diagram of a proximity detector 300 in an exemplary embodiment. The proximity detector 300 may be used as the proximity detector 160 (see FIG. 1). The proximity detector 300 includes a controller 310, a memory 320, and a primary transceiver 330, as well as a secondary transceiver 340. The primary transceiver 330 and the secondary transceiver 340 operate using different frequency ranges (or different communication modalities, such as optical and radio) to transmit signals from the proximity detector 300. Thus, if one frequency range experiences interference or noise, the other transceiver remains capable of providing signals in another frequency range. The proximity detector 300 also includes a vibration generator 360 (e.g., a piezoelectric element, a vibration motor, etc.) and a speaker 350. The controller 310 may activate one or both of these elements when generating an alert to attract a technician's attention. In further embodiments, the proximity detector 300 may generate an alarm in the ophthalmic device worn by the technician 150, triggering a flashing light, other visual input, or vibration to provide a warning. For example, an audible alert may be generated by a portion of the ophthalmic device near the technician's temple, particularly at the temple end. In further embodiments, the ophthalmic device includes smart safety glasses with visual, audible, or vibratory alerts, or any combination thereof. In some embodiments, Bluetooth technology is utilized, where the technician wears a base station that can communicate with a wearable device, such as a hat, helmet, gloves, glasses, vest, etc., that implements the proximity detector. In this embodiment, the proximity detector 300 also includes a battery 370 and a sensor 380. The sensor 380 detects the battery level (e.g., by measuring the voltage at the battery 370). The sensor 380 may report the battery level to the controller 310. If the battery level falls below a desired value, the controller 310 may generate a battery level warning through the speaker 350 and / or the vibration generator 360. The proximity detector 300 may further include a button 390.By pressing the button 390, the first proximity detector may be operable to issue a command to remotely stop any robots 140 that are in the same cell as the technician 150.

[0029] In further embodiments, battery level information may be reported to the proximity status reporting server 110. Each cell may be associated with a predetermined battery level. This may be a battery level that is desired to ensure that the proximity status detector 300 continues to operate while a technician is performing inspection or maintenance within that cell. Upon entering a cell (e.g., determined based on the triangulated location of the proximity status detector 300), the controller 112 may compare the current battery level with the desired battery level for that cell. The controller 112 may further instruct the proximity status detector 300 to generate an alert if the battery level is below the predetermined battery level when the technician attempts to enter the cell. The proximity status reporting server 110 may further estimate the expected time the technician will remain within the cell 132 (where the technician is located) and instruct the proximity status detector 300 to generate a battery level alert if the battery level drops below the expected battery level at this point in the inspection or maintenance process.

[0030] In yet another embodiment, the proximity status reporting server 110 may determine that a proximity status detector has not transmitted a signal for more than a predetermined period of time (e.g., 1 second, 10 seconds, 30 seconds, 1 minute, etc.). In response to this determination, the proximity status reporting server 110 may send a stop command to all robots located in the cell where the proximity status detector was last detected. This provides safety in the event of an unexpected power loss to the proximity status detector and allows a technician to safely exit the cell in the event of a total battery loss or device failure.

[0031] Additional proximity detectors (such as those located on the robot 140) may be equipped without vibration generators, batteries, battery sensors, and / or speakers. Such proximity sensors may be attached directly to the power source of the robot to which they are attached and may have a controller that communicates directly with the controller of the robot 140 to which they are attached.

[0032] 4 to 6 illustrate the distances between proximity detectors 410, 420, and 430 in an exemplary embodiment. Each of proximity detectors 410, 420, and 430 may be used as proximity detector 160 (see FIG. 1) or configured as proximity detector 300 (see FIG. 3). In this embodiment, proximity detector 410 is assumed to be located on a technician (e.g., technician 150 shown in FIG. 1) entering a cell (e.g., cell 132 or 133 shown in FIG. 1). As shown in FIG. 4, the technician is moving toward proximity detector 420 located on a first robot (e.g., robot 140 shown in FIG. 1 or robot 710 shown in FIG. 7) and proximity detector 430 located on a second robot (e.g., robot 140 shown in FIG. 1 or robot 720 shown in FIG. 7). The robots to which proximity detectors 420 and 430 are attached are also moving in different directions. As the technician and robot move, the distance between proximity detector 410 and proximity detectors 420 and 430 decreases until proximity detector 420 is within distance D2, as shown in Figure 5. This causes proximity detector 410 to issue a warning. In Figure 6, continued movement of the technician and robot has brought proximity detector 420 within distance D1 and proximity detector 430 within distance D2. Proximity detector 410 continues to issue a warning, and the robot to which proximity detector 420 is attached is stopped. Stopping the robot may include impeding its movement, disabling it, moving it into a "safety" pose or other retracted state, or actively moving the robot away from the technician.

[0033] 7-8 show a technician 150 moving across a cell 132 on the factory floor in one example embodiment. In this embodiment, robot 710 and robot 720 each include proximity detectors 160 located on different parts that can move to different locations (e.g., on the robot's end effector or on the robot's base). For example, the proximity detectors 160 attached to the robots may each be installed at different stiffnesses in the robot's kinematic chain. As technician 150 moves through space 740 of cell 132, the robots are turned off and then turned back on. For example, as shown in FIG. 7, robot 710 may be deactivated to stop working on part 730 while the technician moves through cell 132, and then robot 710 may be reactivated to perform work on part 730 while robot 720 is deactivated, as shown in FIG. 8. 8, the robot 720 is stopped (e.g., by ceasing all motion or by returning to a home / retracted position) as the technician 150 approaches the robot 720. However, as the technician 150 moves further away from the robot 710, the robot 710 is reactivated.

[0034] 9-10 illustrate communications sent between a proximity detector and a proximity reporting server in an exemplary embodiment. FIG. 9 illustrates a communication 900 of a signal transmitted by a proximity detector. This communication may be packetized according to a known wireless protocol (e.g., according to the IEEE 802.11 protocol, Bluetooth, etc.) and received via the sensor 120 or otherwise modulated to carry information. According to FIG. 9, communication 900 includes a master ID indicating the robot or person to which the proximity detector is attached. Communication 900 also includes a device ID that uniquely distinguishes the proximity detector from other proximity detectors on the same person or robot. Communication 900 also reports the battery level of the proximity detector that generated the communication. FIG. 10 illustrates a communication 1000 that may be provided to the proximity detector by the proximity reporting server 110. In this embodiment, communication 1000 includes a notification. The communication 1000 includes an identifier assigned to the device, an identifier assigned to the proximity detector, and an instruction provided to the proximity detector. Exemplary instructions may include an alert, a stop operation instruction, a resume operation instruction, and the like. For example, when the distance of a proximity detector on a robot falls below a first threshold, a first notification (e.g., a warning notification) may be provided to a proximity detector worn by a technician, while a second notification (e.g., a stop notification) may be provided to a second proximity detector that is at a distance below a second threshold that is less than the first threshold.

[0035] example The following examples describe further processes, systems, and methods in the context of a proximity status reporting system.

[0036] 11 is a block diagram of a proximity reporting system, according to an exemplary embodiment. As shown in FIG. 11, manufacturing cell 1100 includes robot 1150. Robot 1150 is mounted to base 1110 and includes controller 1152. Controller 1152 directs the operation of actuators 1112, 1114, and 1116 to reposition rigid bodies 1120 and 1130 (e.g., according to a numerical control (NC) program), which in turn repositions end effector 1132. The combination of actuators 1112, 1114, and 1116 and rigid bodies 1120 and 1130 (including end effector 1132) forms kinematic chain 1154.

[0037] A proximity condition detector 1190 is attached to the robot 1150 and is communicatively coupled to the controller 1152. The proximity condition detector 1190 includes a controller 1192 that generates signals that are processed by the proximity condition reporting server 1180 and further includes a memory 1194. To provide redundancy and reduce the likelihood of signals being subject to interference, signals are transmitted via a primary transceiver 1196 and / or a secondary transceiver 1198. The signals transmitted from the proximity condition detector 1190 are received at the sensor 1170.

[0038] Proximity detector 1160 is worn by a technician within manufacturing cell 1100. Proximity detector 1160 includes a controller 1161 that generates signals and a memory that stores instructions for generating and interpreting the signals. Proximity detector 1160 also includes a primary transceiver 1163 and a secondary transceiver 1164. A speaker 1165 and a vibration generator 1166 are used to generate alerts for the technician, and a battery 1167 provides mobile power. A sensor 1168 reports the battery level to controller 1161 for interpretation.

[0039] Referring more particularly to the drawings, embodiments of the present disclosure may be described in terms of aircraft manufacturing and service in method 1200 as shown in Figure 12 and in terms of aircraft 1202 as shown in Figure 13. During pre-production, method 1200 may include specification and design 1204 of the aircraft 1202 and material procurement 1206. During production, component and subassembly manufacturing 1208 and system integration 1210 of the aircraft 1202 occurs. The aircraft 1202 may then undergo certification and delivery 1212 and be placed into service 1214. While in operation by a customer, the aircraft 1202 is scheduled for periodic maintenance and service 1216, which may include modification, reconfiguration, refurbishment, etc. Apparatus and methods embodied herein may be used in any suitable stage or stages of the manufacturing and maintenance described in method 1200 (e.g., specification and design 1204, materials procurement 1206, component and subassembly manufacturing 1208, systems integration 1210, certification and delivery 1212, operation 1214, maintenance and service 1216) and / or in any suitable components of aircraft 1202 (e.g., airframe 1218, systems 1220, interior 1222, propulsion system 1224, electrical system 1226, hydraulic system 1228, environmental system 1230).

[0040] Each process of method 1200 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). As used herein, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, a leasing company, a military organization, a service organization, etc.

[0041] 13 , aircraft 1202 produced by method 1200 may include an airframe 1218 having a number of systems 1220 and an interior 1222. Examples of systems 1220 include one or more of a propulsion system 1224, an electrical system 1226, a hydraulic system 1228, and an environmental system 1230. Any number of other systems may also be included. While an aerospace example is shown, the principles of the present invention may be applied to other industries, such as the automotive industry.

[0042] As already described above, apparatus and methods embodied herein may be used in any one or more stages of manufacturing and service described in method 1200. For example, components or subassemblies corresponding to component and subassembly manufacturing 1208 may be fabricated or manufactured in a manner similar to components or subassemblies manufactured during the service life of aircraft 1202. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized in subassembly manufacturing 1208 and system integration 1210, for example, by significantly streamlining the assembly of aircraft 1202 or significantly reducing the cost of aircraft 1202. Similarly, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the service life of aircraft 1202 (for example, but not limited to, in maintenance and service 1216). For example, techniques and systems described herein may be used in material procurement 1206, component and subassembly manufacturing 1208, system integration 1210, operation 1214, and / or maintenance and service 1216, and / or may be used in airframe 1218 and / or interior 1222. Such techniques and systems may also be utilized in systems 1220, including, for example, propulsion system 1224, electrical system 1226, hydraulic system 1228, and / or environmental system 1230.

[0043] In one embodiment, a part comprises a portion of the airframe 1218 and is manufactured in component and subassembly manufacturing 1208. The part may then be assembled into an aircraft in system integration 1210 and then utilized in service 1214 until wear renders the part unusable. The part may then be discarded and replaced with a newly manufactured part in maintenance and service 1216. Novel components and methods may be utilized throughout component and subassembly manufacturing 1208 to facilitate inspection and maintenance of the system that manufactures the new parts.

[0044] Any of the various control elements (e.g., electrical components or electronic components) shown in the figures or described herein may be implemented as hardware, processor-implemented software, processor-implemented firmware, or some combination thereof. For example, an element may be implemented as dedicated hardware. Dedicated hardware elements may be referred to as "processors," "controllers," or some similar terminology. When provided by a processor, functionality may be provided by a single dedicated processor, by a single shared processor, or by multiple individual processors, some of which may be shared. Furthermore, explicit use of the terms "processor" or "controller" should not be construed as referring only to hardware capable of executing software, but may implicitly include, without limitation, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuitry, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random access memory (RAM), non-volatile storage, logic, or any other physical hardware element or module.

[0045] Also, a control element may be implemented as instructions executable by a processor or computer to perform the function of the element. Some examples of instructions are software, program code, and firmware. When executed by a processor, the instructions are executable to instruct the processor to perform the function of the element. The instructions may be stored in a storage device readable by the processor. Some examples of storage devices are digital or solid-state memory, magnetic storage media such as magnetic disks and magnetic tapes, hard drives, or optically readable digital data storage media.

[0046] Additionally, the present disclosure includes examples according to the following clauses:

[0047] Clause 1. A method for reporting proximity in an assembly environment, comprising: equipping a technician with a wearable first proximity detector; disposing a second proximity detector on a robot that moves within a cell of the assembly environment; and instructing the first proximity detector to provide an alert to the technician when a distance between the first proximity detector and the second proximity detector falls below a threshold; method.

[0048] Clause 2. The method of clause 1, further comprising transmitting a first signal from a first proximity detector to sensors in the assembly environment and transmitting a second signal from a second proximity detector to those sensors.

[0049] Clause 3. The method of clause 2, further comprising determining a distance between the first proximity detector and the second proximity detector based on the first signal and the second signal.

[0050] Clause 4. The method of clause 2 or 3, further comprising instructing the robot to stop if the threshold is a first threshold and the distance falls below a second threshold that is less than the first threshold.

[0051] Clause 5. The method of any one of clauses 1 to 4, further comprising: providing a plurality of proximity detectors on the robot, each of the plurality of proximity detectors transmitting a signal that identifies the robot and distinguishes the proximity detector from other proximity detectors on the robot; and determining a distance between each of the plurality of proximity detectors on the robot and the first proximity detector.

[0052] Clause 6. The method of clause 5, further comprising instructing the first proximity detector to provide an alert to a technician if any of the distances falls below a threshold.

[0053] Clause 7. The method of clause 5 or 6, further comprising instructing the robot to stop movement if any of the distances falls below a second threshold.

[0054] Clause 8. The method of any one of clauses 1 to 7, further comprising: disposing a third proximity detector on a portion of a further robot moving within the cell; transmitting a third signal from the third proximity detector to a sensor in the assembly environment; determining a further distance between the first proximity detector and the third proximity detector based on the first signal and the third signal; and instructing the first proximity detector to provide an alert to a technician if the further distance falls below a first threshold.

[0055] Clause 9. The method of clause 8, further comprising instructing the robot to stop if the further distance falls below a second threshold.

[0056] Clause 10. The method of any one of clauses 1 to 9, further comprising operating the first proximity detector to provide a battery level warning to a technician if the technician attempts to enter the cell when the battery level of the first proximity detector is below a predetermined battery level.

[0057] Clause 11. The method of clause 10, further comprising determining a battery level in the first proximity detector and determining that the battery level is below a predetermined battery level, the predetermined battery level varying based on the cell the technician is attempting to enter.

[0058] Clause 12. A method according to any one of clauses 1 to 11, wherein determining the distance includes determining a first position of a first proximity detector based on a first signal transmitted by the first proximity detector, determining a second position of a second proximity detector based on a second signal transmitted by the first proximity detector, and determining a distance between the first position and the second position.

[0059] Clause 13. The method of clause 12, wherein determining the first location is performed by triangulation based on the strength of signals received at each of a plurality of sensors in the assembly environment.

[0060] Clause 14. A method as described in clause 12 or 13, wherein transmitting the first signal is performed in the first proximity detector by operating a first transceiver to provide the first signal within a first frequency range and by operating a second transceiver to provide the first signal within a second frequency range.

[0061] Clause 15. The method of any one of clauses 1 to 14, wherein the warning includes vibration, flashing light, and sound on the proximity detector.

[0062] Clause 16. The method of any one of clauses 1 to 15, further comprising operating the first proximity detector to issue a command to remotely stop a robot that is in the same cell as the technician.

[0063] Clause 17. A part of an aircraft assembled in accordance with the method described in any one of clauses 1 to 16.

[0064] Clause 18. A non-transitory computer readable medium embodying programmed instructions, which when executed by a processor, are executable to perform a method for reporting proximity conditions in an assembly environment, wherein a technician is equipped with a wearable first proximity condition detector and a second proximity condition detector is disposed on a robot moving within a cell of the assembly environment, the method including instructing the first proximity condition detector to provide an alert to the technician when a distance between the first proximity condition detector and the second proximity condition detector falls below a threshold; Medium.

[0065] Clause 19. A non-transitory computer readable medium embodying programmed instructions that, when executed by a processor, are executable to perform a method for reporting proximity conditions in an assembly environment, the method including equipping a technician with a wearable first proximity detector, disposing a second proximity detector on a robot that moves within a cell of the assembly environment, and instructing the first proximity detector to provide an alert to the technician when a distance between the first proximity detector and the second proximity detector falls below a threshold; Medium.

[0066] Clause 20. The medium of clause 18 or 19, wherein the method further includes transmitting a first signal from a first proximity detector to sensors in the assembly environment and transmitting a second signal from a second proximity detector to those sensors.

[0067] Clause 21. The medium of clause 20, wherein the method further includes determining a distance between the first proximity detector and the second proximity detector based on the first signal and the second signal.

[0068] Clause 22. The medium of clause 20 or 21, wherein the threshold is a first threshold, and the method further comprises instructing the robot to stop if the distance falls below a second threshold that is less than the first threshold.

[0069] Clause 23. The medium of any one of clauses 18 to 22, wherein the method further includes: installing a plurality of proximity detectors on the robot, each of the plurality of proximity detectors transmitting a signal that identifies the robot and distinguishes the proximity detector from other proximity detectors on the robot; and determining a distance between each of the plurality of proximity detectors on the robot and the first proximity detector.

[0070] Clause 24. The medium of clause 23, wherein the method further includes instructing the first proximity detector to provide an alert to a technician if any of the distances fall below a threshold.

[0071] Clause 25. The medium of clause 23 or 24, wherein the method further comprises instructing the robot to stop movement if any of the distances falls below a second threshold.

[0072] Clause 26. The medium of any one of clauses 18 to 25, wherein the method further includes disposing a third proximity detector on a portion of a further robot moving within the cell, transmitting a third signal from the third proximity detector to a sensor in the assembly environment, determining a further distance between the first proximity detector and the third proximity detector based on the first signal and the third signal, and instructing the first proximity detector to provide an alert to a technician if the further distance falls below a first threshold.

[0073] Clause 27. The medium of clause 26, wherein the method further includes instructing the robot to stop if the further distance falls below a second threshold.

[0074] Clause 28. The medium of any one of clauses 18 to 27, wherein the method further includes operating the first proximity detector to provide a battery level warning to a technician if the technician attempts to enter the cell when the battery level of the first proximity detector is below a predetermined battery level.

[0075] Clause 29. The medium described in Clause 28, wherein the method further includes determining a battery level in the first proximity detector and determining that the battery level is below a predetermined battery level, the predetermined battery level varying based on the cell the technician is attempting to enter.

[0076] Clause 30. The medium of any one of clauses 18 to 29, wherein determining the distance includes determining a first position of a first proximity detector based on a first signal transmitted by the first proximity detector, determining a second position of a second proximity detector based on a second signal transmitted by the first proximity detector, and determining a distance between the first position and the second position.

[0077] Clause 31. The medium of clause 30, wherein determining the first location is performed by triangulation based on the strength of signals received at each of a plurality of sensors within the assembly environment.

[0078] Clause 32. The medium of clause 30 or 31, wherein transmitting the first signal is performed in the first proximity detector by operating a first transceiver to provide the first signal within a first frequency range, and by operating a second transceiver to provide the first signal within a second frequency range.

[0079] Clause 33. The medium of any one of clauses 18 to 32, wherein the warning includes both vibration and sound at the proximity detector.

[0080] Clause 34. The medium of any one of clauses 18 to 33, wherein the method further includes operating the first proximity detector to issue a command to remotely stop a robot that is in the same cell as the technician.

[0081] Clause 35. A portion of an aircraft assembled in accordance with a method defined by instructions stored on a computer-readable medium according to any one of clauses 18 to 34.

[0082] Clause 36. A system for proximity reporting in an assembly environment, comprising: a wearable first proximity detector; a second proximity detector disposed on a robot within a cell of the assembly environment; and a proximity reporting server, the proximity reporting server comprising: a memory that stores data indicative of a first threshold and a second threshold that is less than the first threshold; and a controller that analyzes the first and second signals to determine a distance between the first proximity detector and the second proximity detector, and to provide a notification to the first proximity detector when the distance falls below the first threshold and to provide a notification to the second proximity detector when the distance falls below the second threshold. system.

[0083] Clause 37. The system described in Clause 36, wherein the first proximity state detector comprises a transceiver and a controller that instructs the transceiver to transmit a first signal to a sensor in the assembly environment and alerts a technician wearing the first proximity state detector based on a notification received from the proximity state reporting server.

[0084] Clause 38. The system of clause 36 or 37, wherein the first proximity detector is implemented in a hat, helmet, glasses, vest, or glove.

[0085] Clause 39. A system described in any one of clauses 36 to 38, wherein the second proximity state detector comprises a transceiver and a controller that instructs the transceiver to transmit a second signal to a sensor in the assembly environment and instructs the robot to stop based on a notification received from the proximity state reporting server.

[0086] Clause 40. A system as described in any one of clauses 36 to 39, further comprising a sensor for receiving signals indicative of the position of a first proximity detector worn by the technician and the position of a second proximity detector on the robot.

[0087] Clause 41. The system of clause 40, wherein the sensor provides a signal to a proximity state server.

[0088] Clause 42. The system of clause 41, wherein the sensor is selected from the group consisting of a wireless antenna, a transceiver, and a camera.

[0089] Clause 43. A system described in any one of clauses 40 to 42, wherein the controller triangulates a first position of the first proximity detector and a second position of the second proximity detector based on the strength of the signal received at each sensor, and determines the amount of separation between the first position and the second position.

[0090] Clause 44. Manufacture of a part of an aircraft using a system according to any one of clauses 36 to 43.

[0091] Clause 45. A system for detecting proximity between a technician and a robot, comprising: a sensor that receives signals indicative of the location of a first proximity detector worn by the technician and the location of a second proximity detector on the robot; and a proximity server that has a memory that stores the signals and a controller that determines the distance between the first proximity detector and the second proximity detector, instructs the first proximity detector to provide a warning to the technician when the distance falls below a first threshold, and instructs the robot to stop when the distance falls below a second threshold. system.

[0092] Clause 46. The system of clause 45, wherein the sensor provides a signal to a proximity state server.

[0093] Clause 47. The system of clause 46, wherein the sensor is selected from the group consisting of a wireless antenna, a transceiver, and a camera.

[0094] Clause 48. The system of any one of clauses 45 to 47, wherein the first proximity detector is implemented in a hat, a helmet, glasses, a vest, or gloves.

[0095] Clause 49. A system described in any one of clauses 45 to 48, wherein the controller triangulates a first position of the first proximity detector and a second position of the second proximity detector based on the strength of the signal received at each sensor, and determines the amount of separation between the first position and the second position.

[0096] Clause 50. Manufacturing of a part of an aircraft using a system according to any one of clauses 45 to 49.

[0097] Although specific embodiments are described herein, the scope of the disclosure is not limited to such specific embodiments. The scope of the disclosure is defined by the following claims and any equivalents thereof.

Claims

1. A method (200) for reporting proximity conditions in an assembly environment (130), comprising: Equipping (202) a technician (150) with a wearable first proximity detector (160, 300, 410, 1160); disposing (204) a second proximity detector (160, 300, 420, 430, 1190) on a robot (140, 710, 720, 1150) moving within a cell (132, 133, 1100) of said assembly environment (130); transmitting a signal from the first proximity detector (160, 300, 410, 1160) and the second proximity detector (160, 300, 420, 430, 1190) to a sensor (120, 1170) located outside the cell (132, 133, 1100) in the assembly environment (130); instructing (214) the first proximity detector (160, 300, 410, 1160) to provide an alert to the technician (150) when a distance (D1) between the first proximity detector (160, 300, 410, 1160) and the second proximity detector (160, 300, 420, 430, 1190), determined based on the signal, falls below a threshold while the technician (150) is within the cell (132, 133, 1100); and operating the first proximity detector (160, 300, 410, 1160) to provide a battery level warning to the technician (150) when the technician (150) attempts to enter the cell (132, 133, 1100) when the battery level of the first proximity detector (160, 300, 410, 1160) is below a predetermined battery level that varies based on the cell the technician (150) is attempting to enter. Method (200).

2. Transmitting the signal comprises: transmitting (206) a first signal from the first proximity detector (160, 300, 410, 1160) to the sensor (120, 1170); and transmitting (208) a second signal from the second proximity detector (160, 300, 420, 430, 1190) to the sensor (120, 1170).

3. 3. The method (200) of claim 2, further comprising determining (210) the distance (D1) between the first proximity detector (160, 300, 410, 1160) and the second proximity detector (160, 300, 420, 430, 1190) based on the first signal and the second signal.

4. the threshold is a first threshold, 4. The method (200) of claim 2 or 3, further comprising instructing (218) the robot (140, 710, 720, 1150) to stop when the distance falls below a second threshold that is less than the first threshold.

5. providing a plurality of proximity detectors (160, 300, 420, 430, 1190) on said robot (140, 710, 720, 1150), each of said plurality of proximity detectors (160, 300, 420, 430, 1190) transmitting a signal that identifies said robot (140, 710, 720, 1150) and distinguishes said proximity detector (160, 300, 420, 430, 1190) from other proximity detectors (160, 300, 420, 430, 1190) on said robot (140, 710, 720, 1150); The method (200) of any one of claims 1 to 4, further comprising determining (210) a distance (D1, D2) between each of the plurality of proximity detectors (160, 300, 420, 430, 1190) on the robot (140, 710, 720, 1150) and the first proximity detector (160, 300, 410, 1160).

6. disposing a third proximity detector (160, 300, 430, 1190) on a portion (142) of a further robot (140, 720, 1150) moving within said cell (132, 133, 1100); transmitting a third signal from the third proximity detector (160, 300, 430, 1190) to a sensor (120, 1170) in the assembly environment (130); determining a further distance between the first proximity detector (160, 300, 410, 1160) and the third proximity detector (160, 300, 430, 1190) based on the first signal and the third signal; The method (200) of claim 5, when described in or dependent on any one of claims 2 to 4, further comprising instructing (214) the first proximity detector (160, 300, 410, 1160) to provide an alert to the technician (150) if the further distance falls below a first threshold.

7. Determining the distance (210) determining a first position of the first proximity detector (160, 300, 410, 1160) based on a first signal transmitted by the first proximity detector (160, 300, 410, 1160); determining a second position of the second proximity detector (160, 300, 420, 430, 1190) based on a second signal transmitted by the second proximity detector (160, 300, 420, 430, 1160); and determining a separation between the first position and the second position.

8. The method (200) of any one of claims 1 to 7, further comprising: the first proximity detector (160, 300, 410, 1160) having a button, and when the button is pressed, operating the first proximity detector (160, 300, 410, 1160) to issue a command to remotely stop a robot (140, 710, 720, 1150) in the same cell (132, 133, 1100) as the technician (150).

9. A system (100) for detecting proximity between a technician (150) and a robot (140, 710, 720, 1150) in a cell (132, 133, 1100), comprising: a sensor (120, 1170) located outside the cell (132, 133, 1100) for receiving a signal indicative of the position of a first proximity detector (160, 300, 410, 1160) worn by the technician (150) and the position of a second proximity detector (160, 300, 420, 430, 1190) on the robot (140, 710, 720, 1150); A proximity status reporting server (110, 1180), A memory (114) for storing said signal; and a proximity state reporting server (110, 1180) comprising a controller (112) for determining a distance between the first proximity state detector (160, 300, 410, 1160) and the second proximity state detector (160, 300, 420, 430, 1190) based on the signal, instructing the first proximity state detector (160, 300, 410, 1160) to provide a warning to the technician (150) when the distance falls below a first threshold, and instructing the robot (140, 710, 720, 1150) to stop when the distance falls below a second threshold, the second threshold being less than the first threshold, while the first proximity state detector (160, 300, 410, 1160) is within the cell (132, 133, 1100); the first proximity detector (160, 300, 410, 1160) is operative to provide a battery level warning to the technician (150) when the technician (150) attempts to enter the cell (132, 133, 1100) when the battery level of the first proximity detector (160, 300, 410, 1160) is below a predetermined battery level that varies based on the cell the technician (150) is attempting to enter; System (100).

10. The system (100) of claim 9, wherein the sensor (120, 1170) provides the signal to the proximity state reporting server (110, 1180).

11. 11. The system (100) of claim 9 or 10, wherein the controller (112) triangulates a first position of the first proximity detector (160, 300, 410, 1160) and a second position of the second proximity detector (160, 300, 420, 430, 1190) based on the strength of the signal received at each sensor (120, 1170) and determines the amount of distance between the first position and the second position.

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