Collaborative Robot Proximity Sensing for Speed and Force Limiting
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Solution Overview
Problem
Existing robotic systems for human-robot collaboration (HRC) lack effective safety measures to accommodate for error-triggering scenarios, switching between collaborative speeds, and protection when humans apply force, leading to potential harm.
Innovation Solution
A robot system incorporating a motion control module, safety control module with speed monitoring, power and force limiting (PFL) functions, and proximity sensors to monitor and adjust robot speed and force based on proximity detection, integrating PFL and proximity sensing for safe HRC.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the robot operates at high speed to improve productivity, then productivity increases, but safety risks to nearby humans increase
Solution Approach 1:
The robot system dynamically adjusts its operating speed based on real-time proximity detection. When objects or humans are detected within safe distances, the robot automatically reduces speed or stops. This dynamic speed adjustment allows the robot to maintain high productivity during normal operation while ensuring safety when humans are nearby, resolving the contradiction between speed and safety
Solution Approach 2:
The system implements continuous feedback through proximity sensors that monitor the robot's environment. The safety control module receives real-time data about nearby objects and humans, processes this information, and adjusts robot operation accordingly. This closed-loop feedback mechanism enables the robot to respond immediately to potential safety hazards while maintaining efficient operation during normal conditions
2Area of stationary object
If the robot operates in close proximity to humans to reduce physical footprint, then space utilization improves, but safety risks increase
Solution Approach 1:
The proximity sensors continuously scan the environment ahead of the robot's movement, detecting objects and humans before the robot reaches them. This preliminary detection allows the safety control module to prepare stopping or speed-reduction commands in advance, enabling the robot to operate safely in close proximity to humans without requiring large safety buffers
Solution Approach 2:
The robot implements dynamic speed and position adjustment based on real-time proximity measurements. When humans are detected within safe distances, the robot automatically modifies its trajectory and speed to maintain safety margins. This dynamic adaptation allows efficient use of workspace while ensuring human safety through continuous environmental awareness and responsive control
3Object-affected harmful factors
If power and force limiting functions are added to limit bumping force, then safety improves, but device complexity increases
Solution Approach 1:
The patent combines multiple safety functions into an integrated safety control module. The proximity sensing, speed monitoring, and power/force limiting functions are merged into a single coordinated system rather than separate independent systems. This integration reduces overall system complexity while maintaining comprehensive safety coverage, as the module shares common sensors, processors, and control mechanisms across multiple safety functions
Solution Approach 2:
The safety control module is designed as a multi-functional unit that performs proximity detection, speed monitoring, and power/force limiting through coordinated operation of shared sensors and actuators. The same proximity sensors and motor control mechanisms serve multiple safety purposes simultaneously, reducing the need for dedicated components for each safety function and thereby limiting overall device complexity while providing comprehensive safety
Data Source
AI summary
A robot system for human-robot collaboration is disclosed that includes one or more proximity sensing elements disposed on the movable parts of the robot, joint position sensing sensors, and a safety control module connects the proximity sensing element and joint position sensing sensors and monitors the speed of the robot and the proximity distance to the objects and stop the robot safely when speed exceed the set limit. The safety control module switches the safety status of the robot when a set proximity distance threshold is triggered. Then, multiple embodiments of the safety status triggered by proximity sensing are introduced for different processes of the human-robot collaboration, includes separation monitoring, force limiting for bumping, and manipulation of the robot. Furthermore, embodiments of utilizing different types of sensors to implement the proximity sensing elements are also disclosed.