Modular Sensorized Covering for Industrial Robots
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Solution Overview
Problem
Current solutions for enhancing safety between human operators and automated devices, such as robots, in industrial settings face challenges with complex installation and removal of safety coverings, and operational inefficiencies due to laborious maintenance processes.
Innovation Solution
A modular, sensorized covering system for automated devices that integrates contact and proximity sensors, featuring a load-bearing structure with elastically yielding material and quick-coupling mechanisms for easy installation and removal, allowing independent operation of modules and adaptive safety responses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensorized covering is integrated on the movable structure of the manipulator, then safety monitoring capability is improved, but installation and removal complexity increases
Solution Approach 1:
The covering is divided into multiple modular sections that can be independently installed and removed. Each module contains integrated sensors and can be attached separately to the manipulator structure, simplifying the overall installation process while maintaining comprehensive safety monitoring coverage.
Solution Approach 2:
The covering serves multiple functions simultaneously: it provides mechanical protection, integrates safety sensors for monitoring, and enables easy installation/removal through standardized interfaces. This multi-functionality reduces the need for separate components and simplifies the overall system.
2Reliability
If contact sensors and proximity sensors are integrated in the covering, then active safety monitoring is improved, but device complexity increases
Solution Approach 1:
Contact sensors and proximity sensors are merged into a single integrated covering structure. The covering itself becomes the sensor platform, eliminating the need for separate sensor mounting structures and reducing overall system complexity while maintaining comprehensive safety monitoring capabilities.
Solution Approach 2:
The covering uses flexible material that can be embedded with sensors. This flexible shell approach allows sensors to be integrated directly into the covering layers, simplifying the sensor system architecture while enabling comprehensive safety monitoring through both contact and proximity detection.
3Object-affected harmful factors
If the covering is made with elastically yielding material, then passive safety is improved, but sensor detection precision may deteriorate
Solution Approach 1:
Sensors are nested within layered covering structures that include elastically yielding materials. The sensor-containing layer is positioned within or alongside the cushioning layer, allowing the elastic material to absorb impact energy while the sensors remain positioned to detect contact and proximity events with adequate precision.
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 solution provides enhanced safety and ease of maintenance by enabling efficient detection of human proximity and contact, allowing for adaptive safety measures and reducing the complexity of installation and maintenance processes.
Implementation Method 1
coated with soft materials... elastically yielding material... foam covering... energy absorbing foam
Implementation Method 2
a current flowing between one of the electrodes of the first series and an adjacent electrode of the second series is proportional to a thickness of the deformable layer
Implementation Method 3
current flowing... is proportional to a thickness of the deformable layer
Data Source
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AI summary
A sensorized covering, prearranged for covering at least part of a movable structure of an automated device, has contact sensor means (C) and proximity sensor means (P), and comprises a plurality of covering modules that includes one or more sensorized covering modules (24) which integrate respective contact sensor means (C) and proximity sensor means (P). Each sensorized covering module (24) comprises a plurality of active layers (61-63, 66, 68) and of passive layers (60, 64, 65, 67) that includes: - a load-bearing structure (40) of a rigid or semi-rigid material having a predetermined shape, - a cushioning layer (60) formed with elastically yielding material, associated to an outer side of the lead bearing structure (40), - a piezoresistive contact sensor (P) above the cushioning layer (60), which includes a piezoresistive layer (62) set between a lower electrically conductive layer (61) and an upper electrically conductive layer (63), - a lower covering layer (64) and an upper covering layer (65), between which the piezoresistive contact sensor (P) is set, which are formed with electrically insulating material, - a capacitive proximity sensor (P), set above the piezoresistive contact sensor (C), that includes a first electrically conductive layer (66) and a second electrically conductive layer (68) between which an intermediate layer of electrically insulating material (67) is arranged. - an outer covering layer (69) above the capacitive proximity sensor (P), preferably formed with electrically insulating material.