Movable Machine Part Safeguarding With Adaptive Distance Beams
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Solution Overview
Problem
Conventional safety systems for collaborative robots and machines face limitations in dynamically protecting dangerous areas, particularly during complex tasks like gripping and processing, due to the need for complex setup processes and restricted orthogonal approaches, which lack flexibility and fail to adapt to changing environments.
Innovation Solution
A method involving non-contact distance sensors that adjust their protective beams based on the 3D topography of the workspace, allowing for continuous adaptation of distance thresholds and beam lengths to ensure safety without requiring extensive teaching processes, enabling flexible protection in dynamic environments and non-orthogonal approaches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional security sensors (laser scanners, light curtains) are used to monitor large open areas, then safety coverage is achieved, but the system cannot adapt to complex geometries and dynamic workspaces
Solution Approach 1:
The patent applies dynamics by making the protective bell dynamic rather than static. The distance sensor moves with the machine part, and the protective bell's extent is continuously adjusted based on the distance to the work surface and workpiece. This allows the safety monitoring area to adapt to complex geometries and dynamic workspaces, resolving the contradiction between adaptability and system complexity.
Solution Approach 2:
The distance sensor serves multiple functions: it monitors the work surface distance, defines the protective bell extent, and triggers safety responses. This multi-functionality eliminates the need for separate sensors for different safety zones, reducing system complexity while maintaining high adaptability to various workspace geometries.
2Adaptability or versatility
If a fixed protective bell is used around the tool, then safety monitoring is provided, but it triggers false safety responses during approach movements and cannot adapt to changing distances
Solution Approach 1:
The protective bell's extent is dynamically adjusted based on the distance to the work surface and workpiece. During approach movements, the bell contracts to avoid false triggering, while maintaining full protection when the tool is positioned. This dynamic behavior eliminates false safety responses while preserving reliable safety monitoring.
Solution Approach 2:
The patent changes the parameter of the protective bell's spatial extent based on the distance to the workpiece. By continuously adjusting this parameter according to real-time distance measurements, the system adapts to changing work conditions without triggering false safety responses, while maintaining reliable protection when needed.
3Reliability
If distance thresholds are adjusted during approach movements, then safety is maintained, but complex learning processes are required to teach switching points
Solution Approach 1:
The system performs self-service by automatically determining the protective bell extent based on real-time distance measurements to the work surface and workpiece. No external teaching or programming of switching points is required - the system autonomously adjusts safety parameters based on sensor feedback, eliminating complex learning processes while maintaining reliable safety during approach movements.
Solution Approach 2:
The distance sensor provides continuous feedback about the distance to the work surface and workpiece. This feedback is used by the control system to automatically adjust the protective bell extent and trigger appropriate safety responses. The closed-loop feedback mechanism eliminates the need for pre-programmed switching points, reducing setup complexity while ensuring reliable safety.
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
This approach simplifies the protection system, reducing the need for complex learning procedures and allowing easy adaptation to changing work environments, enhancing safety and operational efficiency by ensuring the protective beams are always sufficient without triggering false safety reactions.
Implementation Method 1
at least one non-contact distance sensor which moves together with the machine part... measures distances along several lines of sight
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A method for safeguarding a movable machine part (10) of a machine is described, wherein at least one non-contact distance sensor (12a-b) moving with the machine part (10) measures a distance value along several lines of sight (14) and compares the measured distance values with at least one adjustable distance threshold to decide whether a safety-related reaction of the machine is initiated. The topography of the machine's environment (20, 22, 32) is recorded, and a maximum distance to the environment (20, 22, 32) is determined for each line of sight (14) based on the topography. The at least one distance threshold is then adjusted based on this maximum distance.