3D Occupancy Envelope Control for Safe Human-Robot Workspaces
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Solution Overview
Problem
Conventional industrial robots pose safety risks due to limited accuracy and dynamic modeling, particularly in collaborative human-robot applications, where precise control of robot trajectories and safe separation distances are crucial to prevent injuries, but existing methods like guarding and sensor systems are inadequate for complex and dynamic work environments.
Innovation Solution
A safety system that models potential occupancy envelopes (POEs) of robots and humans in a 3D workspace, using sensors and simulation to dynamically compute and visualize safe and unsafe regions, restricting robot operation to ensure safe separation distances and prevent collisions, and continuously updates these models based on real-time scanning data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional guarding methods (cages, light curtains) are used to ensure safety, then safety is improved, but workspace flexibility and productivity are reduced
Solution Approach 1:
The patent replaces physical guarding mechanisms (cages, light curtains) with a computational safety system that uses sensors, simulation, and real-time monitoring to predict robot occupancy and enforce safety zones. This substitution eliminates the need for physical barriers while maintaining safety, thereby improving workspace flexibility and productivity.
Solution Approach 2:
The safety system dynamically adjusts safety zones and robot speed limits based on real-time human presence and predicted robot trajectories. Instead of static guarding, the system continuously updates potential occupancy envelopes and modifies operational constraints accordingly, allowing maximum productivity when humans are absent while ensuring safety when they are present.
2Productivity
If robot speed and acceleration are increased to improve productivity, then productivity is improved, but safety risks increase due to longer stopping distances
Solution Approach 1:
The system performs preliminary simulation of robot trajectories to compute potential occupancy envelopes before the robot executes movements. By predicting future positions and stopping distances in advance, the system can proactively slow the robot or establish safety zones before hazardous situations arise, allowing high speeds during safe operations while preventing accidents.
Solution Approach 2:
The safety system continuously monitors robot position, speed, and acceleration, and compares actual trajectories against simulated potential occupancy envelopes. When deviations or potential hazards are detected, the system provides feedback to adjust robot speed and acceleration in real-time, enabling high productivity during normal operation while automatically reducing speed when safety margins are approached.
3Manufacturing precision
If robot accuracy is improved through better manufacturing and control, then positioning accuracy is improved, but system complexity and cost increase
Solution Approach 1:
The patent introduces a computational intermediary layer that includes simulation software and sensor systems. This intermediary compensates for robot positioning inaccuracies by predicting potential occupancy envelopes that account for manufacturing tolerances and control errors. Rather than requiring extremely precise robots, the system uses computational modeling to establish safety margins, thereby achieving safety without excessive robot precision or system complexity.
Data Source
AI summary
Various embodiments for enforcing safe operation of machinery performing an activity in a three-dimensional (3D) workspace includes computationally generating a 3D spatial representation of the workspace; computationally mapping 3D regions of the workspace corresponding to space occupied by the machinery and a human; and based thereon, restricting operation of the machinery in accordance with a safety protocol during physical performance of the activity.