3D Sensor Auto-Configuration for Safe Object Tracking Zones
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Solution Overview
Problem
Current 3D sensor configuration processes for secure object tracking in safety technology are complex, time-consuming, and prone to errors, particularly in industrial environments where high safety standards must be met, such as EN 13849 and IEC 61496, making them difficult to automate and requiring manual intervention.
Innovation Solution
An automated method for configuring a 3D sensor system that identifies a reference surface, such as the ground level, to define a detection area using 3D image processing and filtering techniques, allowing for the identification of moving objects and expanding the detection area to include sloping parts, with user confirmation and iterative refinement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual configuration of protective fields is used, then safety requirements are met, but configuration complexity and time consumption increase significantly
Solution Approach 1:
The system automatically performs configuration tasks by detecting the work area boundaries and generating protective fields without manual intervention. The control unit autonomously processes 3D sensor data to define the detection zone and configure safety parameters, eliminating the need for complex manual setup while maintaining safety compliance
Solution Approach 2:
The system performs preliminary detection of the work area boundaries and automatically configures protective fields before actual operation begins. By pre-defining the detection zone and safety parameters based on initial scanning, the system prepares the safety configuration in advance, avoiding complex real-time adjustments during operation
2Reliability
If manual configuration of protective fields is used, then safety requirements are met, but commissioning time increases
Solution Approach 1:
The system autonomously completes the entire configuration process by automatically detecting work area boundaries, calculating protective field parameters, and setting safety zones without requiring operator intervention. This self-configuring capability dramatically reduces commissioning time while ensuring safety standards are met through automated compliance checks
Solution Approach 2:
The system performs all necessary configuration measurements and calculations during an initial automated scanning phase before operational use. By completing boundary detection and protective field definition in advance through automatic processes, the system eliminates time-consuming manual configuration steps during commissioning
3Measurement precision
If manual configuration in CAD program is used, then detection zone can be defined, but error probability increases
Solution Approach 1:
The system replaces manual mechanical configuration processes with automated optical sensing and computational processing. The 3D sensor and control unit automatically measure and calculate detection zone boundaries based on real-world geometry, eliminating human errors associated with manual CAD drawing and configuration while maintaining high measurement precision through automated data processing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Simplifies the configuration process, reduces user complexity, and enhances safety by automating the detection area definition, reducing commissioning time and error rates, ensuring compliance with safety standards by accurately tracking moving objects and preventing accidents.
Implementation Method 1
A time-of-flight (TOF) camera, for example, illuminates a scene with amplitude-modulated light. The light returning from the scene is received and demodulated at the same frequency that is also used to modulate the transmitted light (lock-in method). After repeated measurements with different relative phase positions between the signals for the transmit-side modulation and the receive-side demodulation, the time-of-flight-related absolute phase shift between the transmitted and received signals can be determined. This phase shift is proportional to the object distance in the scene.
Data Source
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AI summary
A method for the automatic configuration of a 3D sensor (10) for safe object tracking is described, in which at least one 3D image is acquired with the 3D sensor (10), a detection area (34) within a detection range (18) of the 3D sensor (10) is defined based on the at least one 3D image, within which safety-relevant objects (36) can move, and the object tracking is restricted to the detection area (34). In this process, corresponding image points are identified in the at least one 3D image of a reference surface (40), in particular the ground plane, and the detection area (34) is defined based on these image points.