Machining System Operator Safety via Dynamic Speed Control
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Solution Overview
Problem
In machining systems with robots and machine tools, ensuring operator safety without adding new sensors and wiring is challenging, as existing methods require additional sensors for the machine tool, increasing costs and potentially exposing operators to hazards when operation speeds are high.
Innovation Solution
A machining system that includes an operator detecting device to calculate the position of the operator relative to the machine tool or robot, determining operation restrictions based on this position and notifying the respective controllers to adjust the operation speeds of the machine tool and robot, thereby ensuring safety without additional sensors or wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If operation speed of machine tool is increased to improve productivity, then productivity is improved, but operator safety deteriorates when operator enters the area
Solution Approach 1:
The patent applies dynamics by making the operation speed of the machine tool variable rather than fixed. The speed control unit dynamically adjusts the operation speed based on real-time detection of operator presence. When no operator is detected, high speed operation is permitted for maximum productivity. When an operator is detected, the speed is automatically reduced to a safe level. This dynamic adjustment resolves the contradiction between maintaining high productivity and ensuring operator safety.
2Object-affected harmful factors
If operation speed of machine tool is restricted to ensure operator safety, then operator safety is improved, but productivity deteriorates due to reduced operation speed
Solution Approach 1:
The system dynamically adjusts operation speed based on operator presence detection. The speed control unit receives detection results in real-time and modifies the operation speed accordingly. When the detection unit confirms no operator is present, the machine tool operates at high speed for maximum productivity. When an operator is detected, the speed is automatically reduced to ensure safety. This dynamic approach eliminates the need for constant speed restriction while maintaining safety when required.
Solution Approach 2:
The patent implements feedback control where the detection unit continuously monitors operator presence and feeds this information back to the speed control unit. The speed control unit then adjusts the operation speed based on this feedback. This closed-loop feedback mechanism ensures that safety restrictions are applied only when necessary (when operator presence is detected) while maintaining high productivity when the area is clear, resolving the contradiction between safety and productivity.
3Object-affected harmful factors
If sensor is added to machine tool for operation restriction to ensure operator safety, then operator safety is improved, but cost increases due to additional sensor and wiring
Solution Approach 1:
The patent merges the detection function for both the robot area and machine tool area into a single detection unit. This unified detection unit monitors operator presence in the entire working area including both the robot workspace and the machine tool workspace. By combining the detection functions, the system avoids the need for separate sensors and wiring for the machine tool, thereby reducing system complexity and cost while maintaining comprehensive safety coverage.
Solution Approach 2:
The detection unit is designed with multi-functionality to serve both the robot safety system and the machine tool safety system. A single detection unit performs the dual function of detecting operators in the robot work area and the machine tool work area, and provides detection results to both the robot controller and the speed control unit. This universal approach eliminates the need for dedicated sensors for each device, reducing overall system complexity and cost while ensuring comprehensive operator safety.
Data Source
AI summary
When a machining system that includes a machine tool and a robot detects that an operator is present in a dangerous area in the system, a robot controller that controls the robot determines an operation restriction on the machine tool and notifies a numerical controller that controls the machine tool of the determined operation restriction. The numerical controller restricts the operation of the machine tool in accordance with the notified operation restriction.