3D Protected Zone Control for Human-Robot Hazard Monitoring
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Solution Overview
Problem
Current robot motion planning systems fail to effectively integrate safety protocols when humans are present in the workspace, leading to potential hazards such as crushing and shear injuries, and do not efficiently adapt to dynamic conditions, compromising both safety and productivity.
Innovation Solution
A system comprising sensors and a control and evaluation unit that generate a spatially dynamic protected zone around hazardous robot parts, using 3D data to localize humans and adjust movement parameters, including speed and trajectory planning, to prevent collisions and ensure safe human-robot collaboration by adding buffer zones and restricting joint angles, and employing adaptive kinematic adjustments based on real-time human presence and movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robot operates with high speed and productivity in an industrial workspace, then productivity is improved, but safety hazards increase when humans are present in the same workspace
Solution Approach 1:
The monitored workspace is segmented into multiple spatial zones (first spatial zone, second spatial zone, third spatial zone) with different safety levels. The hazard zone is divided into monitored zones and protected zones, allowing the robot to operate at high speed in protected zones while implementing safety measures only where humans are present, thus maintaining productivity while reducing overall safety hazards.
Solution Approach 2:
A sensor system acts as an intermediary between the robot and humans in the workspace. The sensor detects human presence and transmits information to the control unit, which then adjusts robot behavior accordingly. This intermediary enables automatic safety management without reducing robot productivity, as the system dynamically adapts based on real-time detection.
2Reliability
If the robot implements strict safety protocols and monitoring zones when humans are present, then safety is improved, but productivity decreases due to movement restrictions
Solution Approach 1:
The protected zone and safety boundaries are dynamically adjusted based on real-time human position and robot motion state. When the robot is stationary or moving slowly, the protected zone is smaller, allowing higher productivity. When the robot moves rapidly or humans approach, the protected zone expands automatically, maintaining safety without unnecessarily restricting productivity during safe operating conditions.
Solution Approach 2:
The system changes safety parameters (protected zone size, boundary location, monitoring intensity) based on operating conditions such as robot speed, human distance, and workspace configuration. This allows the system to maintain high productivity during safe operations while implementing strict safety protocols only when necessary, resolving the contradiction between safety and productivity.
3Reliability
If the protected zone is expanded to completely surround the hazardous part of the robot, then safety boundary coverage is improved, but robot movement freedom deteriorates
Solution Approach 1:
The protected zone is dynamically configured based on the robot's current motion state, human position, and task requirements. When the robot is stationary or performing low-risk operations, the protected zone is minimized to maintain movement freedom. When the robot executes high-speed movements or humans are nearby, the protected zone automatically expands to ensure complete safety coverage, thus resolving the contradiction between coverage and freedom.
4Measurement precision
If the system continuously monitors the workspace with high-resolution 3D sensors, then detection precision is improved, but energy consumption increases
Solution Approach 1:
The sensor system operates periodically rather than continuously, adjusting the monitoring frequency and resolution based on risk levels. When humans are far from the robot or the robot is stationary, monitoring intensity is reduced. When humans approach or the robot moves rapidly, the sensor increases sampling rate and resolution, maintaining high detection precision only when necessary and reducing energy consumption during low-risk periods.
Data Source
AI summary
A system for monitoring a hazard zone of a robot having at least one sensor having at least one spatial monitored zone for monitoring the hazard zone, and a control and evaluation unit, and a robot controller for controlling the movements of at least one hazardous part of the robot, wherein the robot controller and the control and evaluation unit are electronically connected to one another by means of at least one interface, wherein the sensor is configured to cyclically transmit 3D data of the monitored zone to the control and evaluation unit, wherein the sensor and the control and evaluation unit are further configured to generate at least one spatial protected zone in the monitored zone, wherein the control and evaluation unit is configured to localize persons in the monitored zone of the sensor with reference to the 3D data and to determine their distance from the hazardous part of the robot, wherein the control and evaluation unit is configured to arrange the spatial protected zone such that the spatial protected zone completely surrounds and includes the hazardous part of the robot and a surface of the protected zone forms an outer safety boundary, wherein the location of the safety boundary is fixable in dependence on a distance, on a direction of movement and/or a movement speed of the person with respect to the hazardous part of the robot, and wherein the robot controller is configured to freely move the hazardous part of the robot within the protected zone.