Bracket-Mounted Proximity Detection for Obscured Robot Assembly
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Solution Overview
Problem
In assembly environments, the separation of human technicians and automated machines due to safety concerns leads to reduced efficiency and assembly speed, as technicians are restricted from zones where automated machines operate, and it is difficult to detect their presence when obscured by large parts.
Innovation Solution
A proximity reporting system using wearable and machine-mounted proximity detectors, along with sensors and a server, that dynamically sense and report distances between technicians and machines, providing warnings if they are within a threshold distance, and adjusts detection modes to account for obscuring objects, ensuring safety and increased machine uptime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If technicians are restricted from zones where automated machines operate, then safety is improved, but assembly speed and efficiency deteriorate
Solution Approach 1:
A proximity detection system acts as an intermediary between technicians and automated machines, enabling their coexistence in the same zone by continuously monitoring distances and providing warnings when thresholds are approached, thus eliminating the need for physical zone separation
Solution Approach 2:
The system provides real-time feedback to technicians about their proximity to automated machines through warnings and alerts, allowing them to adjust their movements and maintain safe distances while working in the same zone, thereby improving both safety and efficiency
2Productivity
If automated machines and technicians share the same zone, then productivity is improved, but safety risks increase due to difficulty in detecting technician presence
Solution Approach 1:
The proximity detection system serves multiple functions simultaneously: it detects technician presence, measures distances, provides safety warnings, and enables collaborative work, making it a universal solution that addresses both safety and productivity concerns in shared zones
3Productivity
If technicians work in zones with automated machines, then assembly rate is improved, but detection of technician presence becomes difficult when obscured by large parts
Solution Approach 1:
The system replaces visual/mechanical line-of-sight detection methods with electronic proximity sensors that can detect technicians through large parts and obstacles, eliminating the detection difficulties caused by obscuring objects while enabling higher assembly rates
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
The system ensures the safety of technicians working near machines while maintaining assembly efficiency by accurately detecting their proximity and preventing collisions, even when obscured by large parts, thus enhancing collaboration between humans and machines in the same workspace.
Implementation Method 1
operating sensors at the bracket to directly detect a location of a first proximity detector worn by a technician and a location of a second proximity detector at the robot
Data Source
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AI summary
Systems (100) and methods (1100) are provided for proximity detection in a fabrication environment. One embodiment is a method (1100) for reporting proximity in an assembly environment (130). The method (1100) includes inserting (1102) an arm (1026) of a bracket (1020) into an interior (1004) of a part (1000) that is held by a cradle (1010), and that is worked upon by a robot (140, 1030, 1250), placing (1104) indexing features (1016) at the bracket (1020) into contact with indexing features (1023) of the cradle (1010), operating (1106) sensors (120, 1028, 1270) at the bracket (1020) to directly detect a location of a first proximity detector (160, 300, 410, 1260) worn by a technician (150, 920) and a location of a second proximity detector (162, 300, 420, 430, 1290) at the robot (140, 1030, 1250), and directing (1108) the first proximity detector (160, 300, 410, 1260) to provide a warning to the technician (150, 920) if a distance between the first proximity detector (160, 300, 410, 1260) and the second proximity detector (162, 300, 420, 430, 1290) is less than a threshold.