Proximity Sensor Safety System for Industrial Robots
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Solution Overview
Problem
Current safety systems for machine-controlled handling appliances, such as industrial robots, often require cumbersome mechanical fences and complex sensor systems, which hinder flexibility and increase costs, especially in portable applications where the danger area changes frequently.
Innovation Solution
A safety sensor system utilizing non-contacting proximity sensors, including ultrasound and microwave sensors, to monitor the working area and adjust safety zones dynamically, allowing for flexible and selective area monitoring without the need for physical barriers, and integrating with existing safety controllers to manage robot operations based on detected presence and position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical fences and switches are used to bound the danger area, then operator safety is ensured, but flexibility and ease of operation deteriorate due to the need to reconfigure fences when robot position changes
Solution Approach 1:
The patent replaces mechanical fences and physical barriers with an optical sensor system consisting of safety sensor, transmitter, and receiver. This substitution eliminates the need for mechanical reconfiguration when robot positions change, while maintaining safety through optical monitoring of the danger area.
Solution Approach 2:
The safety system dynamically adapts to changing robot positions by using optical sensors that can detect objects in the danger area regardless of robot location. The system automatically adjusts its monitoring coverage without requiring physical reconfiguration, enabling flexible robot movement while maintaining safety.
2Reliability
If mechanical fences are installed to protect the danger area, then safety is improved, but device complexity and installation effort increase
Solution Approach 1:
The patent replaces complex mechanical fence structures with a simpler optical sensor-based system. The safety sensor, transmitter, and receiver create a virtual barrier through optical fields rather than physical structures, significantly reducing system complexity and installation requirements.
Solution Approach 2:
The patent extracts the essential safety function from the mechanical fence structure, isolating the core protective capability into an optical sensing system. This extraction eliminates unnecessary mechanical components while preserving the safety function.
3Adaptability or versatility
If light grids or light fences are used instead of mechanical fences, then flexibility is improved, but device complexity increases due to additional sensors and evaluation units
Solution Approach 1:
The patent merges the functions of multiple components (safety sensor, transmitter, receiver, and evaluation unit) into an integrated system. The safety sensor directly communicates with the robot control unit, eliminating the need for separate complex evaluation units and reducing overall system complexity.
Solution Approach 2:
The optical sensor system serves multiple functions: it monitors the danger area, detects objects, determines positions, and interfaces with the robot control unit. This multi-functionality reduces the need for separate specialized components, simplifying the overall system.
4Reliability
If isolating protective devices are installed, then safety is ensured, but ease of operation deteriorates due to restricted access and interaction with the machine
Solution Approach 1:
The patent replaces physical isolating barriers with an optical monitoring system that does not restrict access. Operators can freely approach and interact with the robot while the optical sensors continuously monitor for safety concerns, eliminating the need for physical fences or guard gates.
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 solution simplifies safety monitoring, reduces operational complexity, and allows for flexible robot operation by eliminating the need for mechanical fences, enhancing safety and reducing costs while maintaining maximum operator safety, even in portable applications.
Implementation Method 1
A safety sensor system which has non-contacting proximity sensors, by means of which a safety-relevant part of the working area of the handling appliance is covered by detection areas of the proximity sensors
Implementation Method 2
A safety sensor system utilizing non-contacting proximity sensors, including ultrasound and microwave sensors, to monitor the working area
Data Source
AI summary
An apparatus and method is disclosed for protection of a machine-controlled handling appliance having moving parts, having a safety sensor system for detection of objects in the working area of the handling appliance, having a safety controller which interacts with the handling appliance controller and in the process controls safety-relevant handling appliance functions as a function of signals from the safety sensor system. The safety sensor system has non-contacting proximity sensors so that a safety-relevant part of the working area of the handling appliance is covered by the detection areas of the proximity sensors.