Dynamic Sensor Positioning for Robot Workspace Blind Spots
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial robots in manufacturing environments face challenges in detecting objects within undetectable zones due to sensor limitations and workspace configurations, leading to incomplete object accommodation during automated tasks.
Innovation Solution
A method and system that generate a digital workspace model with digital robots and sensors, simulate sensor operations, identify undetectable areas, and selectively position sensors using a transport system to optimize coverage, adjusting their position and orientation based on undetectable areas to achieve a Pareto optimal state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are placed in fixed positions within the workspace, then the system structure is simple and easy to implement, but undetectable zones are created that prevent complete object detection
Solution Approach 1:
The patent implements a dynamic sensor positioning system where sensors are moved along a transport system to different locations within the workspace. The sensor position is adjusted based on detected undetectable zones, transforming the sensor placement from a static configuration to a dynamic one that adapts to coverage requirements, thereby eliminating blind spots without permanently complicating the overall system architecture
Solution Approach 2:
The patent introduces a computing device as an intermediary that coordinates between the sensor, transport system, and robot controller. This intermediary processes sensor data, identifies undetectable zones, and generates commands to reposition sensors, thereby managing the complexity of dynamic positioning through a centralized control layer rather than direct sensor-transport coupling
2Reliability
If multiple sensors are deployed to cover the entire workspace, then detection coverage is improved, but the cost and complexity of the sensor system increases
Solution Approach 1:
Instead of deploying multiple static sensors simultaneously, the system uses a single sensor that dynamically repositions itself to different locations within the workspace. The sensor is moved along a transport system to various positions where undetectable zones are identified, providing comprehensive coverage over time rather than requiring simultaneous coverage from multiple sensors
Solution Approach 2:
The system employs periodic scanning and detection cycles where the sensor repeatedly traverses different areas of the workspace. During each cycle, the sensor detects objects and identifies undetectable zones, then the transport system repositions the sensor to address identified gaps in the next cycle, achieving complete coverage through repeated periodic operations rather than permanent multi-sensor deployment
3Measurement precision
If sensors are repositioned frequently to eliminate undetectable zones, then detection accuracy is improved, but the time required for sensor adjustment and system response increases
Solution Approach 1:
The system performs preliminary detection to identify undetectable zones before executing repositioning operations. The computing device analyzes sensor data, determines areas requiring improved coverage, and only then commands the transport system to move sensors to those specific locations. This preliminary identification step prevents unnecessary repositioning and ensures that time is spent only on corrective actions that improve detection accuracy
Data Source
AI summary
A method includes generating a workspace model having one or more digital robots, one or more digital sensors, and a digital transport system. The method includes simulating, for a task of the one or more digital robots, a sensor operation of the one or more digital sensors within the workspace model based on sensor characteristics of the one or more digital sensors. The method includes identifying, for the task of the one or more digital robots, an undetectable area within the workspace model based on the simulated sensor operation. The method includes selectively positioning, by a transport system, a set of sensors from among the one or more sensors based on the undetectable areas associated with the task.