Modular Robot Position Sensing for Fail-Safe Collision Avoidance
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Solution Overview
Problem
Modular robots face challenges in ensuring fail-safe position detection of movable elements, particularly when modules from different manufacturers are combined, leading to inconsistent and unreliable collision avoidance systems that fail to meet safety standards.
Innovation Solution
A method that combines multiple position detection systems, including a position probe with a transponder, to create a combined fail-safe position detection system, allowing for wireless transmission of position coordinates and ensuring independence from manufacturer-specific controls, thereby enhancing operational safety and compliance with safety regulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple position detection systems are combined to achieve fail-safe detection, then reliability is improved, but device complexity increases
Solution Approach 1:
The position detection system is divided into multiple independent channels (first simple position detection and second simple position detection) that operate separately but are combined for fail-safe detection. Each channel can be independently implemented by different module controllers, allowing parallel development and reducing individual channel complexity while achieving overall system reliability through diversity.
Solution Approach 2:
The combined fail-safe position detection system serves multiple functions: it provides position information for normal operation control, enables collision detection and avoidance, and offers redundancy for safety-critical applications. The system can accommodate different detection technologies (e.g., optical sensors, encoders, transponders) within a unified architecture that works across modules from different manufacturers.
2Adaptability or versatility
If modules from different manufacturers are combined, then adaptability is improved, but reliability deteriorates due to inconsistent position detection
Solution Approach 1:
A higher-level controller acts as an intermediary that receives position data from multiple independent module controllers and simple position detection systems. This intermediary combines the data streams and implements the fail-safe detection logic, bridging the gap between heterogeneous modules with different native detection systems and providing a unified reliable position signal for the entire modular robot system.
Solution Approach 2:
The system transforms position detection from a manufacturer-specific hardware dependency to a standardized data interface problem. By accepting various input formats from different manufacturers and normalizing them through the higher-level controller, the system changes the parameter representation to a common format that enables consistent fail-safe detection across all modules regardless of their original detection technology.
3Reliability
If dual-channel diverse detection is implemented, then reliability is improved, but ease of operation worsens
Solution Approach 1:
The dual-channel position detection systems are designed to be self-diagnosing and self-validating. Each channel independently monitors its own operation and can detect failures or inconsistencies in itself or the other channel. The system automatically switches to safe states or alerts operators only when actual failures occur, rather than requiring constant manual verification, thus maintaining ease of operation while ensuring reliability.
Data Source
AI summary
The application relates to a method for operating a modular robot (MDR), wherein the robot comprises a first module (MD1) as an automated guided vehicle (AGV) and a second module (MD2) as a robot arm, wherein the first module (MD1, AGV) has a first controller (CT1) which has a first fail-safe position sensing (PS1) for the movable element (MEL1) of the first module (MD1, AGV), wherein the second module (MD2, robot arm) has a first and a second simple position sensing (PR1, PR2) of the at least one movable element (MEL2) of the second module (MD2), wherein a second fail-safe position sensing (PS2) is combined from the first and the second simple position sensing (PR1, PR2) of the at least one movable element (MEL2) of the second module (MD2).and wherein a combined fail-safe position sensing (PSC) for the modular robot (MDR) is combined or determined from the first fail-safe position sensing (PS1) and the second fail-safe position sensing (PS2). The invention also relates to a modular robot (MDR), a collision protection system (CPS), and a corresponding computer program product (CPP).