Manipulator Control System Safety Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial robots require complex and costly safety measures for manual control due to high safety standards, which can be cumbersome and expensive, and existing solutions do not effectively separate safety and control functionalities.
Innovation Solution
Separating safety and control functionalities by using a lower-security-level operating device for manual control and a higher-security-level protective device for ensuring safety, allowing non-safe technology to be used for manual control when the operator is outside the impermissible area, with the protective device monitoring the presence of personnel and ensuring operational reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a handheld programming device with three-stage enabling button is used to meet safety standards, then safety is improved, but device complexity and cost increase
Solution Approach 1:
The patent divides the safety control system into two separate components: a simple operating device for manual control and a protective device for safety monitoring. The operating device can be a standard PC or PDA without safety certifications, while the protective device (such as a protective fence with monitored door) handles all safety functions. This segmentation allows the operating device to remain simple and inexpensive while safety requirements are met through the separate protective device.
Solution Approach 2:
The patent extracts the safety functionality from the operating device and places it in a separate protective device. The operating device is taken out of the safety-critical path, allowing it to be designed without safety certifications. The protective device independently monitors the protective area and controls the manipulator's operation, separating safety concerns from operational control.
2Reliability
If secure technology with redundancy and diversity is used for safe detection and transmission, then safety is improved, but device complexity and cost increase
Solution Approach 1:
The patent segments the control system into an operating device for command input and a protective device for safety monitoring. The protective device implements the secure detection and transmission with redundancy and diversity, while the operating device remains simple. This segmentation concentrates the complexity of secure technology only where it is needed for safety-critical functions.
Solution Approach 2:
The protective device acts as an intermediary between the operator and the manipulator. It receives control commands from the operating device, monitors the protective area, and only allows manipulator operation when the area is clear. This intermediary role enables the use of simple operating devices while maintaining high safety standards through the protective device's secure technology.
3Reliability
If a protective device with monitored protective door is used, then safety is improved, but ease of operation decreases
Solution Approach 1:
The protective device automatically monitors the protective area and manages safety without requiring manual intervention from the operator. The system self-service includes automatic detection of the protective door status, continuous monitoring of the protective area, and automatic control of manipulator operation based on area clearance. This automation maintains safety while minimizing operational complexity.
Data Source
Figure 1
AI summary
The method involves manually controlling a manipulator i.e. six axis industrial robot (1), by a low safety level personal computer (4), which is connected to a control cabinet (2) of the manipulator. A permissible state is monitored by a higher safety level protective device e.g. safety fence (3), safety door (3.1) and make contact (3.2), which is connected to the cabinet. An action prescribed by the personal computer is executed by the manipulator until the protective device communicates the permissible state to the cabinet, where the action includes movement of the manipulator. Independent claims are also included for the following: (1) an arrangement for safely controlling a manipulator (2) a computer program having instructions for safely controlling a manipulator (3) a computer program product having instructions for safely controlling a manipulator.