Multi-Axis Kinematic Safety Control With Real-Time Error Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing multi-axis kinematic systems face challenges in safe operation due to inaccuracies in sensor data and inertial run-on distances, which conventional error calculation methods fail to adequately address, leading to overly conservative safety measures and reduced system availability.
Innovation Solution
A method that calculates compensation values in real-time using predefinable error values, geometric parameters, and current axis values to enhance safety monitoring, allowing for dynamic adaptation of safety functions such as safe zone monitoring, speed monitoring, and orientation monitoring, thereby minimizing unnecessary pessimistic estimations and ensuring accurate safety reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional statistical error calculation methods are used for safety monitoring, then safety reactions can be initiated, but the error allowance is insufficient because mean deviations are calculated rather than worst-case deviations
Solution Approach 1:
The patent applies dynamics by transitioning from static, pre-calculated safety margins to dynamic, real-time compensation values. The controller continuously calculates compensation values based on current axis positions and error propagation, adapting the safety monitoring to the actual kinematic state rather than using fixed conservative estimates throughout operation.
Solution Approach 2:
The patent changes the parameter calculation approach from mean deviations to worst-case deviations through error propagation analysis. By calculating maximum possible errors based on sensor accuracy specifications and kinematic relationships, the system determines appropriate compensation values that reflect actual worst-case scenarios rather than statistical averages.
2Reliability
If general correction values are used without specific kinematic system knowledge, then safety-oriented operation can be maintained, but system availability is unnecessarily reduced due to overly conservative measures
Solution Approach 1:
The patent applies local quality by tailoring the error allowance to specific locations and configurations within the kinematic system. Instead of using uniform conservative correction values, the system calculates specific compensation values for each axis and safety function based on local sensor accuracies, kinematic relationships, and operational parameters, allowing optimized safety monitoring that adapts to local requirements.
Solution Approach 2:
The system dynamically adapts safety parameters based on real-time operational conditions. Compensation values are recalculated as axis positions change, allowing the system to maintain appropriate safety margins while avoiding unnecessarily conservative restrictions that would reduce availability during operations where errors are inherently smaller.
3Measurement precision
If sensor values with inherent inaccuracies are used for safety monitoring, then axis positions can be ascertained, but errors and inertial run-on distances cause inaccuracies in safety function output
Solution Approach 1:
The patent applies preliminary action by pre-specifying sensor accuracy values and error margins for each axis during system configuration. These predetermined error bounds are then used in real-time compensation calculations to account for sensor inaccuracies and inertial effects before they compromise safety monitoring accuracy.
Solution Approach 2:
The system implements feedback through continuous compensation value calculation that incorporates current axis positions and predetermined error values. The controller constantly adjusts safety function parameters based on feedback from actual system state and known error characteristics, maintaining accurate safety monitoring despite inherent sensor inaccuracies.
Data Source
AI summary
A method and an associated controller for safely operating a multi-axis kinematic system by using a safety function are disclosed. The method includes calculating compensation values at the run time of a controller of the multi-axis kinematic system, wherein the calculation is performed based on predefinable error values of respective axes, geometric parameters of the multi-axis kinematic system, and current axis values of the multi-axis kinematic system. The method further includes operating the safety function based on the calculated compensation values.