Fenceless Robot Conveyance With Zone-Based Human Safety Sensing

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Solution Overview

Problem

Conventional human-safe robot technologies are limited by restrictions on speed and payload capacity, making them unsuitable for applications requiring higher payloads and speeds to meet production demands.

Innovation Solution

A fenceless conveyance system and method that uses a robot with an end effector to move items between a source and destination, equipped with trajectory planning, touch sensors, and proximity sensors to ensure safe operation without traditional safety fencing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional human-safe robot technologies are used, then safety is improved, but speed and payload capacity are restricted

Engineering Contradiction:

ImprovesafetyVSAvoidspeed and payload capacity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces traditional mechanical safety fencing with an optical sensing system consisting of proximity sensors and touch sensors. This substitution allows the robot to operate at higher speeds and payloads while maintaining safety through electronic detection and response mechanisms rather than physical barriers.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system implements continuous feedback through proximity sensors that detect human presence and touch sensors that detect contact with the robot or end effector. This feedback loop enables real-time monitoring and immediate response, allowing higher operational speeds while maintaining safety through dynamic adjustment based on sensor input.

Inventive Principle:

Principle #23Feedback

2Reliability

If safety fencing is used to delineate robot cell, then safety is improved, but production floor space and equipment costs increase

Engineering Contradiction:

ImprovesafetyVSAvoidproduction floor space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent extracts and removes the physical safety fencing from the system, replacing it with sensor-based detection. This elimination of mechanical barriers reduces production floor space requirements while maintaining safety through electronic monitoring and response systems.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Physical mechanical fencing is replaced with optical and electronic sensing systems. This substitution eliminates the need for large enclosed robot cells, reducing floor space requirements while maintaining safety through sensor-based detection and control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If physical containment is used, then safety monitoring is improved, but equipment complexity and maintenance costs increase

Engineering Contradiction:

Improvesafety monitoringVSAvoidsafety equipment

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Complex mechanical safety fencing and physical containment systems are replaced with simpler electronic sensor systems. The proximity and touch sensors provide safety monitoring with fewer moving parts and lower maintenance requirements compared to mechanical barriers.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent removes complex safety fencing infrastructure and replaces it with integrated sensor systems that are part of the robot's control architecture. This extraction simplifies the overall system while maintaining safety monitoring capabilities.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Enables the robot to move items at higher speeds and with greater payloads while maintaining safety, reducing the need for costly safety equipment and production floor space, and improving efficiency in manufacturing processes.

Implementation Method 1

a touch sensor configured to detect a contact between an external object and a surface of the robot or a surface surrounding the end effector

Methodology Applied

Scientific EffectContact detection:

Implementation Method 2

a proximity sensor configured to detect a person in proximity to the robot

Methodology Applied

Scientific EffectProximity detection:

Data Source

PatentUS12220808B2Method and setup for fenceless robotics

Publication Date: 2025.02.11 MAGNA POWERTRAIN AG & CO KG

AI summary

A fenceless system and method for automatically moving one or more items between a structure at a source location and a destination using a robot is provided. The system comprises a robot having an end effector to selectively grasp an item. A trajectory planning controller directs the robot to move the item between a source location and a destination. A touch sensor detects a contact between an external object and a surface of the robot or a surface surrounding the end effector; and a proximity sensor detects a person in proximity to the robot. A vision sensor detects a location and orientation of items to be moved. The robot moves in proximity to a person without a safety fence preventing the person from contacting the robot. The system adjusts a speed of the robot in response to detecting a person in one of a plurality of zones around the robot.