LiDAR Detection System for Machine Safety

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Solution Overview

Problem

Current safety systems for machine operators, such as guards and light curtains, face limitations including interference with visibility, complex wiring, high maintenance needs, and inaccurate detection of human presence, leading to unnecessary machine shutdowns.

Innovation Solution

A LiDAR detection system utilizing overhead and/or surrounding LiDAR sensors to create a 3D image of the environment, accurately detecting human presence and transmitting alerts to ensure safe operation of machines by reducing the need for complex wiring and multiple sensors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If light curtains are used to detect human presence, then safety detection is provided, but complex wiring and multiple sensors are required

Engineering Contradiction:

Improvesafety detectionVSAvoidwiring complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple sensor functions into a single LiDAR unit that performs both human detection and distance measurement. The LiDAR sensor integrates the light source, receiver, and scanning mechanism into one compact device, eliminating the need for separate transmitter and receiver units required by traditional light curtains.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The LiDAR sensor serves multiple functions simultaneously: it detects human presence, measures distance, and creates 3D environmental mapping. This multi-functionality replaces the specialized but separate components needed for traditional light curtain systems, reducing overall system complexity while maintaining safety detection capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If light curtains are used for safety protection, then human detection is provided, but unnecessary machine shutdowns occur

Engineering Contradiction:

Improvehuman detection accuracyVSAvoidmachine operation continuity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the simple binary light blockage detection with a LiDAR-based 3D spatial mapping system. This substitution enables the system to distinguish between human presence and other objects blocking light paths, providing contextual awareness that prevents false alarms and unnecessary shutdowns.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The LiDAR system introduces an intermediary 3D environmental map as a mediator between raw sensor data and safety decisions. This intermediate representation allows the system to process spatial information contextually, determining whether a detected object is indeed a human in a hazardous zone before triggering a shutdown.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If guards are used to prevent access to hazardous areas, then safety is provided, but visibility is interfered with

Engineering Contradiction:

Improvesafety protectionVSAvoidvisibility

Core Design Contradiction:

ReliabilityVSIllumination intensity

Solution Approach 1:

The patent replaces physical guards with a LiDAR-based detection system that operates optically. Instead of using physical barriers that block light and visibility, the system uses LiDAR to detect human presence and transmit alerts, maintaining full visibility while providing safety protection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If interlocked guards are used, then machine shutdown is enforced, but extensive wiring and maintenance are required

Engineering Contradiction:

Improvemachine shutdown enforcementVSAvoidwiring requirements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical and electrical interlocked guard system with a LiDAR-based optical detection system. Instead of using physical barriers with tripping mechanisms and complex wiring, the system uses LiDAR to detect human presence and communicate with the machine control system, significantly reducing wiring requirements and maintenance needs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The LiDAR system provides a 360-degree field of vision, accurately differentiates human presence from non-human objects, and reduces unnecessary shutdowns by allowing machines to operate safely when humans are not in hazardous zones, thus enhancing safety measures beyond conventional systems.

Implementation Method 1

a receiver structured to receive the light reflected and roundtrip data of the light

Methodology Applied

Scientific EffectLight Reflection: Reflection

Implementation Method 2

a receiver structured to receive the light reflected and roundtrip data of the light

Methodology Applied

Scientific EffectTime of Flight: Time of Flight

Data Source

PatentUS20250012924A1Lidar detection system and method for machine safety

Publication Date: 2025.01.09 STOLLE MACHINERY CO LLC

AI summary

A LIDAR (Light Detection and Ranging) detection system for use with a machine includes a LiDAR sensor disposed overhead and structured to scan and create at least one of a three-dimensional (3D) image or a 3D point map of a machine and surroundings thereof, and (ii) a controller communicatively coupled to the LiDAR sensor and structured to collect data including at least one of the 3D image or the 3D point map from the LiDAR sensor, analyze the data, and detect a human, and determine if a detected human is in the vicinity of a hazardous zone associated with the machine.