Disc-Shaped Sensor Holder for Robot Safety Monitoring
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Solution Overview
Problem
Current safety solutions for robots in confined spaces with sharp or hot tools and workpieces are inadequate, as they fail to effectively protect against injuries from the tool's movement or geometry, especially in environments where mechanical barriers are not feasible.
Innovation Solution
A sensor system with distance sensors mounted on a holder with a disc-shaped housing and adaptive fastening adapters, providing a comprehensive and inherently safe protective field with rounded surfaces, connected to an evaluation unit for real-time monitoring and safety signal generation, ensuring safe human-robot interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large number of distance sensors are arranged on the movable machine part to form a comprehensive protective field, then the safety coverage is improved, but the device complexity increases
Solution Approach 1:
The distance sensors are integrated into a holder that is mounted on the movable machine part, creating a nested structure where sensors are contained within the holder assembly. This modular nesting approach allows comprehensive sensor coverage while managing system complexity through hierarchical organization of components.
Solution Approach 2:
The holder serves multiple functions: it provides structural support for the distance sensors, offers a standardized mounting interface on the movable machine part, and creates a compact assembly that simplifies installation. This multi-functionality reduces the need for separate components, thereby managing complexity while maintaining safety coverage.
2Stability of the object's composition
If the holder is equipped with fastening adapters for secure mounting, then the mechanical stability is improved, but the device complexity increases
Solution Approach 1:
The fastening adapters are integrated directly into the holder structure, merging the mounting function with the sensor housing. This combination eliminates the need for separate mounting brackets or attachment mechanisms, thereby improving mechanical stability while avoiding additional complexity from separate components.
Solution Approach 2:
The holder features a disc-shaped housing with round surfaces and no corners on the outer surfaces. This curved geometry provides inherent mechanical stability through distributed stress distribution while simplifying the overall structure compared to angular designs with multiple joints and connection points.
3Object-affected harmful factors
If the holder has a disc-shaped housing with round surfaces, then the safety against injuries is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The holder features a disc-shaped housing with round surfaces and no corners on the outer surfaces. This curved geometry eliminates sharp edges and corners that could cause injuries, while the disc shape provides a simple, robust form that is relatively tolerant to manufacturing variations compared to complex angular geometries.
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 sensor system effectively monitors the danger zone around the robot, preventing collisions by detecting violations of the protective field and issuing safety signals to stop or slow down the robot, thereby minimizing the risk of injury and ensuring compliance with safety standards like EN/IEC 61496 and EN13849.
Implementation Method 1
The distance sensors (2) are non-contact distance measuring distance sensors (2), the sensors (2) have a detection beam (9) for detecting objects in the surveillance area
Implementation Method 2
with the detection beams (9) of the distance sensors (2) forming a protective field (10)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Sensor system (1) with distance sensors (2) for monitoring a danger zone (3) on a movable machine part (4) with at least one protective zone (5), wherein a tool (6) and/or a workpiece is arranged on the movable machine part (4), wherein the distance sensors (2) are arranged on a holder (7) on the movable machine part (4), wherein a plurality of distance sensors (2) are arranged, wherein the detection beams (9) of the distance sensors (2) form a protective field (10), wherein the holder (7) has receptacles (11) for the distance sensors (2), wherein a first mounting adapter (12) is arranged on the holder (7) for attaching the holder (7) to the movable machine part (4) and a second mounting adapter (13) is arranged on the holder (7) for attaching the tool (6) to the holder (7), and a disc-shaped housing (14) is located between the mounting adapters (12, 13) of the holder (7). exhibitswherein the disc-shaped housing (14) has round surfaces (15) and no corners on the outer surfaces.