Dynamic Robot Safe Zones With Real-Time Human Motion Forecasting
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Solution Overview
Problem
Current safety systems for industrial environments with interacting humans and machinery require precise programming of safe zones, which can be cumbersome and conservative, limiting the workspace's usability due to discrete speed limitations and the need for reconfiguration with changes in robot programs or workspace layouts.
Innovation Solution
A system that dynamically models robot geometry and forecasts both robot and human trajectories in real-time, continuously updating safe zones based on sensed objects, eliminating the need for pre-programmed zones and allowing proportional speed adjustments, thus enhancing safety and workspace efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If discrete speed limitations and pre-programmed safe zones are used, then safety is ensured, but workspace usability is limited and reconfiguration is required when robot programs or workspace layouts change
Solution Approach 1:
The patent implements dynamic speed adjustment based on real-time distance monitoring between robot and human. Instead of discrete speed limits, the robot continuously adjusts its speed proportionally to the detected distance, allowing flexible adaptation to changing workspace conditions without requiring reconfiguration when programs or layouts change
Solution Approach 2:
The system continuously monitors the distance between the robot and human operator in real-time and uses this feedback to dynamically adjust robot speed. This closed-loop feedback mechanism enables the system to adapt to changing conditions automatically, eliminating the need for pre-programmed safe zones and manual reconfiguration
2Reliability
If conservative speed limitations are applied, then safety is maintained, but productivity is reduced due to unnecessary speed reductions
Solution Approach 1:
The patent changes the speed parameter dynamically based on the detected distance to the human operator. Instead of applying a fixed conservative speed limit, the system adjusts the speed parameter continuously according to real-time conditions, allowing maximum productivity when safe and reduced speed only when necessary
3Reliability
If pre-programmed safe zones are configured, then safety boundaries are established, but device complexity increases due to programming and reconfiguration requirements
Solution Approach 1:
The system performs self-service by automatically establishing safety boundaries through real-time distance monitoring and dynamic speed adjustment. Instead of requiring external programming of safe zones and manual reconfiguration when conditions change, the system autonomously adapts to new situations, significantly reducing programming complexity and setup time
Data Source
AI summary
Systems and methods for determining safe zones in a workspace calculate safe actions in real time based on all sensed relevant objects and on the current state of the machinery (e.g., a robot) in the workspace. Various embodiments forecast, in real time, both the motion of the machinery and the possible motion of a human within the space, and continuously update the forecast as the machinery operates and humans move in the workspace.