3D Workspace Monitoring for Human-Robot Collision Separation
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Solution Overview
Problem
Existing safety monitoring systems for shared workspaces between humans and robots are inadequate in dynamically accounting for the presence and movement of both humans and robots, as well as objects they may be carrying, particularly in dynamic environments where objects and tools change frequently, leading to potential collisions and safety hazards.
Innovation Solution
A system and method utilizing three-dimensional sensors and a safety control system that includes a CPU, memory, and analysis module to monitor the workspace, cluster and label objects, and adjust robot movements based on real-time data to maintain safe separation distances, accounting for objects carried by both humans and robots without preprogramming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If three-dimensional sensors are used to accurately monitor relative distance between human and robot, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent embeds multiple functional components within the sensor system including three-dimensional sensors, processors, and safety control systems in a nested architecture. The sensor system contains processors that analyze sensor data, which in turn control robot motion commands, creating a hierarchical nested structure that improves measurement precision while managing complexity through organized integration.
Solution Approach 2:
The sensor system is designed to perform multiple functions: detecting human presence, measuring relative distances, identifying objects carried by human or robot, and triggering safety responses. This multi-functional approach consolidates what would otherwise require separate systems into a single integrated sensor platform, improving measurement capabilities without proportionally increasing complexity.
2Device complexity
If a static light curtain defines the safety zone, then device complexity is reduced, but adaptability to dynamic workplace deteriorates
Solution Approach 1:
The patent transitions from static light curtain boundaries to dynamic safety zones that continuously adapt based on real-time sensor data. The system monitors human position, robot position, and object locations to dynamically recalculate and adjust safety zone boundaries, allowing the system to adapt to moving targets and changing workspace conditions while maintaining safety.
Solution Approach 2:
The system implements continuous feedback loops where sensors monitor the workspace environment, processors analyze the data to detect human presence and object locations, and the safety zone is continuously adjusted based on this feedback. This closed-loop control enables the safety zone to adapt dynamically to changing conditions without requiring complex manual reconfiguration.
3Device complexity
If preprogramming is used to account for objects carried by robot, then device complexity is reduced, but adaptability to changing objects deteriorates
Solution Approach 1:
The system employs automatic object detection and identification capabilities that eliminate the need for preprogramming specific object types. The three-dimensional sensors and image processing algorithms automatically detect, classify, and track objects carried by the human or robot, allowing the system to adapt to any object type without manual configuration or preprogramming.
Solution Approach 2:
The patent replaces manual preprogramming approaches with automated sensor-based detection and image processing systems. Instead of mechanically configuring the system for specific objects through programming, the system uses optical and spatial sensing to automatically identify and account for objects, substituting mechanical/configuration complexity with sensor-based adaptability.
4Adaptability or versatility
If safety zone boundaries are constantly adjusted based on real-time position, then adaptability is improved, but loss of time for processing and response increases
Solution Approach 1:
The system performs preliminary calculations and preparations for safety zone adjustments based on predicted human and robot trajectories. By anticipating future positions and pre-calculating safety zone boundaries, the system reduces the processing time required for real-time adjustments while maintaining adaptability to dynamic conditions.
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
Enhances safety by dynamically adapting to changing conditions in the workspace, preventing collisions, and optimizing robot movement efficiency by accurately detecting and accounting for various objects, thereby prioritizing human safety without unduly restricting robot performance.
Implementation Method 1
three-dimensional optoelectronic sensors or other suitable equipment able to monitor three-dimensional space, such as stereo cameras and time-of-flight cameras
Data Source
AI summary
The disclosure relates to systems and methods for ensuring human safety in a workspace shared with a robot or other dangerous machinery. The system includes one or more sensors arranged to monitor the workspace. Data from each of the sensors is acquired and analyzed to determine the positioning and spatial relationship between the human and machine, along with any respective objects that either or both may be carrying as they each move throughout the workspace. The captured data is analyzed to mitigate potential collisions between the human and the machine in the workspace, including potential collisions that may be caused by the respective objects carried by the human or machine.