Collaborative Robot Safety via Dynamic Gap Calculation
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Solution Overview
Problem
Collaborative robots face design constraints due to the need for intrinsic safety measures, which limit design freedom, and existing functional safety systems struggle to prevent finger catching between the robot's arms and end effector without imposing unnecessary restrictions.
Innovation Solution
A collaborative robot system with a robot controller that calculates the posture and position of the robot and end effector using link parameters and basic shapes to determine potential finger catching scenarios, allowing for dynamic adjustment of safety modes to prevent collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If intrinsic safety measures are implemented (such as securing large space between arms), then safety is improved, but design freedom is reduced
Solution Approach 1:
The patent replaces mechanical intrinsic safety measures (physical spacing constraints) with a computational system. The robot controller calculates real-time gap distances between robot components using posture information and basic shapes, substituting physical design constraints with software-based monitoring and detection capabilities.
Solution Approach 2:
The patent implements dynamic safety monitoring where the robot controller continuously calculates gap distances between arms and end effectors based on real-time posture data. This dynamic calculation allows the safety assessment to adapt to changing robot configurations without requiring fixed physical spacing, enabling both safety and design flexibility.
2Reliability
If functional safety measures are activated to prevent finger catching, then safety is improved, but operational restrictions are imposed
Solution Approach 1:
The patent applies partial action by implementing safety monitoring only in specific critical zones where finger catching is possible (between arms and between arm and end effector). The catching determination device selectively monitors these partial areas rather than imposing restrictions on the entire workspace, allowing normal operation in safe zones while providing enhanced safety in危险 zones.
Solution Approach 2:
The patent performs preliminary calculation of gap distances using basic shapes before actual finger catching can occur. The robot controller proactively determines potential catching risks by calculating gaps between basic shapes of robot components, enabling preventive safety measures rather than reactive responses.
3Measurement precision
If basic shapes and gap calculations are used to determine catching potential, then detection accuracy is improved, but computational complexity increases
Solution Approach 1:
The patent creates simplified geometric copies (basic shapes) of the robot's arms and end effectors for calculation purposes. Instead of performing complex calculations with detailed 3D models, the system uses simplified basic shapes that replicate the essential geometry, reducing computational complexity while maintaining sufficient accuracy for safety detection.
Solution Approach 2:
The patent transforms the complexity management by changing parameters from detailed geometric models to simplified basic shape parameters. The catching determination device works with fundamental geometric parameters of basic shapes rather than complex surface geometries, reducing computational burden while preserving the ability to detect catching risks accurately.
Data Source
AI summary
A collaborative robot system has a catching determination device. The catching determination device sets basic shapes, which encompasses a main body shape or a shape of an end effector, and calculates gaps or contacts between the basic shapes on the basis of the basic shapes, a posture of the robot, and a position of the end effector, thereby determining whether there is a possibility of a finger of an operator to be caught between arms of the robot or between the arm and the end effector.