Robot Arm Sensor Positioning for Stable Operator Monitoring
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Solution Overview
Problem
Existing operating devices for industrial settings, such as collaborative robots and sensor-based safety systems, face limitations in versatility and cost-effectiveness, particularly in high-production volume environments, and struggle to provide adequate safety monitoring for operators.
Innovation Solution
An operating device equipped with a robot arm and a positioning system that maintains a constant orientation for presence sensors, ensuring effective monitoring volumes are maintained regardless of the arm's movement, using a four-bar linkage mechanism or a gyroscope system to keep sensors aligned with the work space, allowing for flexible and efficient safety monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple presence sensors are positioned around the device to create monitoring areas, then operator safety monitoring is improved, but device complexity and reconfiguration requirements increase when tasks change
Solution Approach 1:
The patent combines multiple presence sensors into a single integrated sensor unit mounted on the robot arm. This single unit performs the monitoring function that would otherwise require multiple separate sensors positioned around the device, thereby reducing complexity while maintaining safety monitoring capability.
Solution Approach 2:
The sensor unit is mounted on the robot arm itself, allowing it to move dynamically with the arm throughout the working area. This dynamic positioning enables the single sensor unit to cover the entire monitoring area that would otherwise require multiple fixed sensors, eliminating reconfiguration needs when tasks change.
2Reliability
If collaborative robots with multiple sensor systems are used for continuous human-machine interaction, then safety and interaction capability are improved, but cost and system complexity increase significantly
Solution Approach 1:
The patent extracts only the essential safety monitoring function from complex collaborative robot systems. By using a single presence sensor unit mounted on the robot arm, it provides the necessary safety monitoring capability without the additional complexity of force sensors, proximity sensors, contact sensors, and other interaction means found in full collaborative robot systems.
Solution Approach 2:
The invention uses a simpler, more cost-effective sensor solution compared to expensive collaborative robot systems. The single presence sensor unit provides adequate safety monitoring without requiring the investment in multiple sophisticated sensor systems and complex control software needed for full human-machine interaction capabilities.
3Adaptability or versatility
If presence sensors are mounted on the robot arm to create a mobile monitoring area, then adaptability is improved, but monitoring effectiveness and operator safety are reduced
Solution Approach 1:
The patent replaces the inadequate mechanical mounting approach with a properly engineered sensor unit that has an extended detection range. This allows the sensor to maintain effective monitoring coverage even when mounted on the moving robot arm, overcoming the limitations of previous mobile sensor implementations.
Solution Approach 2:
The invention changes the detection parameters of the presence sensor to ensure adequate monitoring effectiveness. By using a sensor with extended detection capabilities, the system maintains reliable safety monitoring despite the mobile mounting position, addressing the effectiveness issues of earlier mobile sensor solutions.
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 enhances safety monitoring by maintaining consistent sensor orientation during robot arm movements, improving versatility and reducing complexity and costs, thereby addressing the limitations of existing technologies in ensuring operator safety in dynamic industrial environments.
Implementation Method 1
using a four-bar linkage mechanism or a gyroscope system to keep sensors aligned with the work space
Implementation Method 2
using a four-bar linkage mechanism or a gyroscope system to keep sensors aligned with the work space
Data Source
Figure 1
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Figure 4
AI summary
Described herein is an operating device configured to operate in a work space (L), comprising: - a robot arm (10), which comprises a succession of arm elements (10i) mounted on one another in a rotatable way about respective axes of rotation (Xi) and which carries an operating unit (12) on its end; and - at least one presence sensor (14) prearranged for detecting the presence of an operator. The device is characterized in that it includes a positioning system, comprising a support (22) by which the at least one presence sensor (14) is carried and which is mounted on an arm element (1011) of the robot arm, according to a pre-set orientation and in such a way as to be orientable with respect to the arm element (1011), and wherein the positioning system further comprises a positioning unit (24; 44; 54) prearranged for rotating the support (22) with respect to the arm element (1011), as a result of a movement of the robot arm (10), so as to keep the pre-set orientation of the support (22) unchanged.