Camera-Based Safety Zones for Automated Machines
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Solution Overview
Problem
Existing safety systems for automated machines require large safety distances to ensure protection, which is inefficient in terms of space usage and flexibility, especially in environments where multiple machines need to be closely arranged, and are not suitable for non-fail-safe machines.
Innovation Solution
A device and method that define two protection zones, one internal to monitor the machine's movement and another external to detect foreign objects, allowing for reduced safety distances without compromising safety, using a camera system to evaluate images and trigger safety functions if either zone is breached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional protective devices (safety fences, light barriers) are used to safeguard automated machines, then safety protection is achieved, but the required space around the machine increases and device complexity increases
Solution Approach 1:
The patent replaces mechanical protective devices (safety fences, light barriers) with a camera-based vision system that uses image processing to detect foreign objects. The camera system captures images of the hazardous area, and algorithmic processing determines whether objects are present, eliminating the need for physical barriers and reducing the space required around the machine.
Solution Approach 2:
The patent creates a virtual model of the hazardous area through camera imaging and image processing. Instead of using physical barriers to define the protection zone, the system creates a digital representation (copy) of the workspace and monitors it for foreign objects, allowing safety monitoring without physical enclosures.
2Reliability
If traditional protective devices are used to safeguard automated machines, then safety protection is achieved, but device complexity and installation complexity increase
Solution Approach 1:
The patent replaces complex mechanical and optical protective devices with a camera-based system that uses software algorithms for foreign object detection. The camera system with image processing capabilities simplifies the hardware requirements while maintaining safety protection, reducing both installation and maintenance complexity.
3Reliability
If large safety distances are defined around automated machines, then safety protection is ensured, but flexibility in machine arrangement and human-machine interaction decreases
Solution Approach 1:
The patent implements dynamic monitoring of the hazardous area using a camera system that continuously captures images and processes them to detect foreign objects. This dynamic approach allows the safety zone to be virtually defined rather than physically fixed, enabling flexible machine arrangements and better human-machine interaction while maintaining safety protection.
Solution Approach 2:
The patent transitions from two-dimensional physical safety barriers to three-dimensional virtual monitoring zones captured by the camera system. By using vision technology to create a volumetric understanding of the hazardous area, the system allows flexible spatial arrangements while maintaining comprehensive safety coverage.
Data Source
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AI summary
An apparatus for safeguarding a monitoring area, in which an automatically operating machine is disposed, comprises: (i) a sensor unit including a camera system for producing images of the monitoring area; (ii) a configuration unit for defining first and second protection areas; and (iii) an evaluation unit for triggering a safety-related function. The first protection area is at a first distance from the machine and the second protection area is at a second greater distance from the machine. The sensor unit monitors both the first protection area and the second protection area. The evaluation unit analyzes the images produced by the camera system so as to evaluate both (i) whether a machine element of the machine enters the first protection area as well as (ii) whether a foreign object enters the second protection area. The evaluation unit triggers the safety-related function if at least one of these events occurs.