Laser-Optical Detection With Dynamic Power for Safe Robot Setup
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Solution Overview
Problem
Laser-optical detection systems used in robotic workstations cannot operate safely in set-up mode without being switched off or significantly reducing laser power, limiting their functionality and requiring manual intervention for tasks like adjusting robot paths or testing programs.
Innovation Solution
A method and system that include a sensor unit to detect a person's approach and transmit a signal to reduce the laser projector's maximum irradiation intensity and adjust camera exposure parameters, allowing the system to continue operating with reduced power and maintaining detection quality during set-up mode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the laser projector operates at full irradiation intensity to maintain detection quality, then object detection accuracy is improved, but operator safety is compromised when a person approaches during set-up mode
Solution Approach 1:
The laser projector's irradiation intensity is made dynamically adjustable based on real-time detection of operator proximity. The control device receives signals from the sensor unit and automatically adjusts the laser power between full intensity (for detection accuracy) and reduced intensity (for operator safety), resolving the contradiction between measurement precision and safety
Solution Approach 2:
A feedback loop is established where the sensor unit continuously monitors the workspace for operator presence, transmits signals to the control device, which then adjusts the laser projector's irradiation intensity accordingly. This closed-loop feedback system enables automatic adaptation of laser power to maintain both detection accuracy and operator safety
2Object-affected harmful factors
If the laser power is reduced to a safe level when a person approaches, then operator safety is improved, but detection quality and system functionality deteriorate
Solution Approach 1:
The system dynamically adjusts laser irradiation intensity based on operator proximity detection. When no operator is present, full power is maintained for optimal detection. When an operator approaches, power is reduced to safe levels, and the camera exposure parameters are simultaneously adjusted to maintain detection quality despite reduced laser intensity
Solution Approach 2:
The system changes multiple parameters in response to operator proximity: the laser projector's irradiation intensity is reduced to safe levels, and the camera's exposure parameters (such as exposure time or gain) are adjusted to compensate for the reduced light intensity, thereby maintaining detection accuracy while ensuring operator safety
3Object-affected harmful factors
If the laser-optical detection system is switched off during set-up mode to ensure safety, then operator safety is improved, but system functionality and productivity are reduced
Solution Approach 1:
Instead of switching the system off, the laser projector operates in a dynamic power mode, automatically adjusting irradiation intensity based on operator proximity. This allows the system to remain fully functional during set-up mode while ensuring safety through automatic power reduction when operators are present
Solution Approach 2:
The sensor unit provides continuous feedback about operator presence to the control device, which automatically adjusts laser power levels. This feedback mechanism enables the system to maintain full functionality when safe and automatically protect operators without requiring manual shutdown, thereby preserving productivity while ensuring safety
4Measurement precision
If the camera exposure parameters are adjusted to compensate for reduced laser intensity, then detection quality is maintained, but system complexity increases
Solution Approach 1:
The control device merges multiple control functions into a single unit: it receives signals from the sensor unit, controls the laser projector's irradiation intensity, and adjusts the camera's exposure parameters. This integration simplifies the overall system architecture by consolidating control logic in one device rather than requiring separate control systems for each component
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 safe operation near the laser-optical detection system during set-up mode by reducing laser power and adjusting camera exposure parameters, ensuring operator safety while maintaining object detection accuracy and system functionality.
Implementation Method 1
a laser projector which is designed to emit laser light of predetermined patterns in a predetermined wavelength range with a predetermined irradiation intensity
Implementation Method 2
a camera which is designed to optically detect the pattern reflected on the object, which is projected onto the object by the laser projector
Data Source
AI summary
A method and a laser-optical detection system including a laser projector, a camera, a control device which is designed and configured to actuate the laser projector and the camera in order to determine features of the object, and a sensor unit. The control device is configured such that, as a function of the characterizing signal obtained by the sensor unit relating to an approach or the presence of a person in a critical spatial proximity to the laser projector, the exposure parameters of the camera are adjusted as a function of the reduced maximum irradiation intensity of the laser projector in relation to the current irradiation intensity of the laser projector. A robotic workstation includes a laser optical detection system of this type.