Articulated Arm Collision Avoidance via Operator Position Detection

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Solution Overview

Problem

Existing robotic devices in manufacturing environments are not adequately equipped to operate in close proximity to human operators while performing automated inspections, posing risks of impact and requiring lock-out procedures to prevent accidents.

Innovation Solution

A human-centric robot system with an articulated arm, sensors, and a 3D scanner that can determine the position of both the operator and the object, adjusting its movement to avoid contact and perform inspections, allowing for safe and efficient operation near humans.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional robotic devices are used in manufacturing environments, then automated inspection and manufacturing precision are improved, but the risk of impact with human operators increases and requires lock-out procedures

Engineering Contradiction:

Improveautomated inspection precisionVSAvoidrisk of impact with human operators

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent introduces sensors as intermediary devices that detect human operators and transmit information to the robot controller. This intermediary system enables the robot to perceive human presence and adjust its behavior accordingly, resolving the contradiction between maintaining automated inspection capabilities and preventing harmful impacts on operators

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent implements a feedback loop where sensors continuously monitor the environment for human operators, the controller processes this information to assess collision risk, and the robot adjusts its speed or trajectory in response. This closed-loop feedback system enables real-time adaptation to human presence while maintaining automated inspection functions

Inventive Principle:

Principle #23Feedback

2Object-affected harmful factors

If lock-out procedures are implemented to prevent robot impact, then safety is improved, but productivity and ease of operation deteriorate due to disabled robot functionality

Engineering Contradiction:

Improvesafety from robot impactVSAvoidrobot operational availability

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The patent transforms the static lock-out procedure into a dynamic safety system. Instead of completely disabling the robot when humans are present, the system dynamically adjusts robot behavior based on real-time sensor data, allowing the robot to continue operating at reduced speed or modified trajectory while maintaining safety, thus preserving productivity

Inventive Principle:

Principle #15Dynamics

3Ease of operation

If human-centric robots with sensors are used to operate near humans, then safety and ease of operation are improved, but device complexity increases

Engineering Contradiction:

Improveability to operate near human operatorsVSAvoidrobot system complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent applies multi-functionality by using the same sensor system for multiple purposes: detecting human operators for safety, and potentially for inspection tasks. This universal approach allows the robot to handle both safety monitoring and manufacturing functions with integrated systems, reducing the need for separate specialized components

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables cost-effective and reliable automated inspection of objects in manufacturing, reducing the risk of human-robot collisions and minimizing errors by allowing robots to operate safely in close proximity to operators, thereby reducing scrap and rework costs.

Implementation Method 1

A three-dimensional (3D) scanner is configured in operation to determine three-dimensional coordinates of a surface of an object

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 2

each of the arm segments having a transducer. An electronic circuit is configured in operation to determine a position and orientation of the end effector

Methodology Applied

Scientific EffectTransducer conversion:

Implementation Method 3

At least one sensor measures in operation a position of an operator

Methodology Applied

Scientific EffectSensor detection:

Data Source

PatentUS10546167B2System and method of operating a manufacturing cell

Publication Date: 2020.01.28 FARO TECHNOLOGIES INC

AI summary

A system and method for operating a manufacturing cell is provided. The system includes an articulated arm having a plurality of arm segments, each of the arm segments having a transducer. An end effector is coupled to an end of the articulated arm. An electronic circuit is configured in operation to determine a position and orientation of the end effector. A sensor measures in operation a position of an operator. A tool is removably coupled to the end effector. A three-dimensional (3D) scanner is configured in operation to determine three-dimensional coordinates of a surface of an object, the 3D scanner being removably coupled to the end effector. A controller determines when the operator is within a predetermined distance of the articulated arm and altering a speed or a movement of the articulated arm to avoid contact or reduce the impact of contact between the operator and the articulated arm.