3D Workspace Monitoring for Worker-Robot Protection Area Switching
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Solution Overview
Problem
Designing a working environment where a worker and an industrial robot can coexist safely is challenging due to the need for multiple photoelectric safety devices and complex installation considerations, especially when multiple common areas overlap.
Innovation Solution
A monitoring system with two 3D cameras and a monitoring device that sets and switches between worker and robot protection areas using a CPU, ROM, RAM, and communication interface, allowing safe coexistence by limiting robot motion when either the worker or robot enters a designated protection area, thus preventing collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photoelectric safety devices are installed for each common area to detect intrusion, then worker and robot collision prevention is improved, but device complexity and installation difficulty increase
Solution Approach 1:
The patent merges multiple photoelectric safety devices into a single integrated monitoring system that uses a camera and image processing to monitor multiple common areas simultaneously. Instead of installing separate photoelectric devices for each overlapping work area, the system combines detection functions into one unified装置 that processes visual information from the entire workspace.
Solution Approach 2:
The patent replaces mechanical photoelectric safety devices with an optical monitoring system using a camera and image processing algorithms. The system substitutes physical photoelectric sensors with visual field analysis, where the camera captures images and the processor identifies worker and robot positions and predicts collision risks through image processing rather than direct photoelectric detection.
2Reliability
If photoelectric safety devices are installed with appropriate safety distance, then worker protection is improved, but working space flexibility decreases
Solution Approach 1:
The patent transitions from one-dimensional photoelectric detection to three-dimensional spatial monitoring using a camera system. By capturing images and processing them to create spatial awareness of worker and robot positions, the system monitors protection distances in three-dimensional space rather than relying on fixed one-dimensional photoelectric zones, enabling flexible working space design while maintaining safety.
Solution Approach 2:
The patent implements dynamic safety monitoring where protection areas and safety distances are not fixed but adapt in real-time based on worker and robot positions. The system continuously updates the monitored protection area based on current locations detected in images, allowing the safety zones to move and adjust dynamically rather than being static predetermined zones.
3Reliability
If multiple photoelectric safety devices are installed for multiple common areas, then collision detection coverage is improved, but loss of time for system setup and design increases
Solution Approach 1:
The patent creates a universal monitoring system that can detect and monitor multiple common areas simultaneously with a single setup. The camera and image processing system serves multiple functions: detecting worker position, detecting robot position, calculating protection areas, and monitoring multiple overlapping work zones all through one unified system rather than requiring separate detection systems for each area.
Solution Approach 2:
The patent performs preliminary calculation of protection areas based on robot work speeds and sizes before actual operation. The system pre-establishes the relationship between robot parameters and required protection distances, allowing the monitoring system to be configured once with these parameters and then automatically adapt to different scenarios without requiring time-consuming redesign for each new common area or robot configuration.
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
Facilitates the design of a working environment with overlapping work areas by reducing the need for safety fences and lowering facility costs, ensuring worker and robot safety through effective area management and motion control.
Implementation Method 1
a three-dimensional detection unit that detects a position of the worker and a position of the robot in the work area
Data Source
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AI summary
A monitoring system, a monitoring device, and a monitoring method that can facilitate designing of a working environment are provided. Positions of a worker and a robot in a three-dimensional space are specified, at least one protection area to secure safe work of the worker and the robot is set, whether at least one of the worker and the robot intrudes into the protection area is determined, the motion of the robot is limited when at least one of the worker and the robot intrudes into the protection area, a protection area for executing the determination is being switched from multiple set protection areas, and it is possible to set the protection area when the worker works in a common area in which a work area of the worker and a work area of the robot overlap and set the protection area when the robot works in the common area.