Manipulator Restricted-Zone Control for Safe Material Refill
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Solution Overview
Problem
Existing robot systems lack effective methods to prevent collisions between manipulators and people or obstacles, and they do not efficiently adapt restricted operation areas based on material availability or operator authentication, leading to potential malfunctions and reduced operation efficiency.
Innovation Solution
A robot system equipped with a lidar sensor, camera, storage unit, and controller that dynamically adjusts the restricted operation area and manipulator speed based on material availability, operator authentication, and obstacle detection, allowing for real-time changes in operation zones and speed adjustments to prevent collisions and optimize efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the restricted region is set to include the inlet of the storage to prevent unauthorized access, then security is improved, but the manipulator's operation efficiency deteriorates due to frequent interruptions when operators need to refill materials
Solution Approach 1:
The restricted region is dynamically adjusted based on material levels. When material is sufficient, the restricted region includes the inlet for security. When material is low, the controller automatically shrinks the restricted region to allow operators to refill without triggering collision stoppage, while still maintaining safety through continuous monitoring
Solution Approach 2:
The system changes the parameter of the restricted region's spatial boundaries based on material availability conditions. The controller monitors material levels and adjusts the restricted region's extent accordingly, transitioning between a larger secure configuration and a smaller operational configuration
2Productivity
If the manipulator operates at high speed to improve productivity, then output is improved, but the risk of collision with persons or obstacles increases
Solution Approach 1:
The manipulator's speed is dynamically adjusted based on real-time detection of persons and obstacles. The controller continuously monitors the environment and modifies the speed parameter accordingly - maintaining high speed when the area is clear and reducing speed when persons or obstacles are detected, thus resolving the contradiction between productivity and safety
Solution Approach 2:
The system uses sensor feedback (lidar, cameras) to continuously monitor the operational environment and adjusts manipulator speed in response to detected conditions. This closed-loop control allows the system to maintain high productivity while automatically responding to safety concerns by reducing speed when necessary
3Reliability
If the restricted region is continuously monitored to prevent collisions, then safety is improved, but the system complexity increases due to multiple sensors and control mechanisms
Solution Approach 1:
The controller serves multiple functions: it manages the restricted region boundaries, processes sensor data from lidar and cameras, controls manipulator speed, and monitors material levels. By consolidating these diverse functions into a single control unit, the system achieves comprehensive safety monitoring without proportionally increasing overall system complexity
Solution Approach 2:
The system merges the detection functions of multiple sensors (lidar, cameras) into a unified monitoring framework controlled by a single controller. This integration allows the system to achieve enhanced safety through multiple sensing modalities while managing complexity through centralized control architecture
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 system effectively prevents collisions by dynamically adjusting operation zones and speeds, ensuring safe and efficient operation of the manipulator, even when material levels are low or when performing maintenance tasks, thereby enhancing operational safety and efficiency.
Implementation Method 1
a lidar sensor configured to detect a person or an obstacle that approaches a restricted region set to include the manipulator
Implementation Method 2
a camera configured to monitor the restricted region and the person or the obstacle that approaches the restricted region
Data Source
AI summary
A robot system can include a main body; a manipulator installed on the main body; a sensor configured to detect an object approaching a restricted region including the manipulator; a camera configured to monitor the restricted region and the object approaching the restricted region; a storage configured to store a material for an operation of the manipulator, the storage including an inlet for receiving the material; a remaining amount sensor configured to detect an amount of the material remaining in the storage; and a controller configured to change the restricted region based on at least one of a result of detection of the remaining amount sensor and image information of the camera, and in response to the sensor detecting that the object is within the restricted region, stop manipulation of the manipulator.