Potential Occupancy Envelopes for Safe Robot Workspace Control
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Solution Overview
Problem
Conventional industrial robots pose safety risks due to limited accuracy and dynamic modeling, especially in collaborative human-robot applications, where precise control of robot trajectories is essential to prevent injuries. Existing safety systems rely on incomplete dynamic models and require complex monitoring configurations, limiting flexibility and efficiency.
Innovation Solution
A system utilizing safety-rated and non-safety-rated components in robot controllers, with a workspace-level monitoring system that generates and updates potential occupancy envelopes (POEs) for both robots and humans, enabling real-time adjustments to ensure safe operation by constraining robot movements within defined zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional industrial robots are used with traditional safety systems (cages, light curtains), then safety is improved, but workspace flexibility and productivity are worsened due to constrained collaborative use
Solution Approach 1:
The patent replaces mechanical safety systems (cages, light curtains) with a computational safety system that uses dynamic modeling, simulation, and real-time monitoring of robot trajectories. The safety determination is achieved through software-based collision risk assessment rather than physical barriers, enabling collaborative human-robot workspaces without traditional safety constraints.
Solution Approach 2:
The patent implements dynamic safety assessment by continuously simulating robot trajectories and updating collision risk evaluations in real-time. The safety system adapts to changing workspace conditions, human positions, and robot motions, allowing flexible collaborative operation while maintaining safety through dynamic rather than static protection methods.
2Productivity
If robot arms with large inertia are used to increase strength and speed, then productivity is improved, but stopping distance and response time are worsened
Solution Approach 1:
The patent performs preliminary safety assessment by simulating complete robot trajectories before execution. The system evaluates collision risks at all points along the planned path and identifies stopping points in advance, allowing the robot to decelerate smoothly at predetermined locations rather than requiring abrupt stops, thereby reducing actual stopping distances while maintaining high-speed operation.
Solution Approach 2:
The patent implements real-time feedback by continuously monitoring robot position, velocity, and acceleration against the simulated trajectory. The safety system compares actual robot state with predicted state, and when deviations indicate potential collision risks, the system triggers corrective actions to adjust robot motion, enabling precise control of high-inertia robot arms with reduced stopping distances.
3Measurement precision
If dynamic simulation and real-time monitoring are implemented to improve safety accuracy, then collision risk detection is improved, but computational load and system complexity are worsened
Solution Approach 1:
The patent creates a computational copy (digital twin) of the robot system that mirrors the physical robot's dynamics, kinematics, and workspace. This virtual model allows real-time simulation and safety assessment without requiring complex physical sensors or modification of the actual robot hardware. The digital twin captures essential dynamics for collision risk evaluation while keeping the physical system simple.
Solution Approach 2:
The patent implements a unified computational platform that performs multiple functions: trajectory simulation, collision risk assessment, safety determination, and real-time monitoring. This multi-functional system consolidates what could be separate complex subsystems into a single integrated safety determination module, reducing overall system complexity while maintaining high measurement precision through comprehensive dynamic analysis.
Data Source
AI summary
Various embodiments for enforcing safe operation of machinery performing an activity in a three-dimensional (3D) workspace includes computationally generating a 3D spatial representation of the workspace; computationally mapping 3D regions of the workspace corresponding to space occupied by the machinery and a human; and based thereon, restricting operation of the machinery in accordance with a safety protocol during physical performance of the activity.