Industrial Robot Brake Release Sequencing for Safe MwoDP Activation
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Solution Overview
Problem
Existing industrial robot systems lack robustness in activating the Movement without Drive Power (MwoDP) mode, as they are prone to unintentional activation due to operator error or hardware defects, posing safety risks.
Innovation Solution
A method for controlling industrial robots that enters the MwoDP mode only in response to safely generated signals, using a sequence of first and second safe release signals, along with actuator-selection data received via an arbitrary input means, to enhance safety and reduce the risk of unintentional activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single button press on the GUI is used to release brakes, then the operation is simple and fast, but the risk of unintentional activation increases significantly
Solution Approach 1:
The system requires the operator to press the Enable switch before the Caution button becomes active for brake release. This preliminary action ensures intentional activation by establishing a predefined sequence where the Enable switch must be engaged first, creating a barrier against accidental activation while maintaining operational efficiency.
Solution Approach 2:
The brake release function is divided into two distinct safe input means: the Enable switch and the Caution button. This segmentation requires two separate intentional actions to complete the brake release operation, reducing the probability of unintentional activation while preserving ease of operation through a streamlined two-step process.
2Device complexity
If the GUI uses non-safety-certified hardware and software, then the cost and complexity are reduced, but the risk of erroneous signals increases
Solution Approach 1:
The patent introduces a safety certification layer that mediates between the non-safety-certified GUI hardware/software and the safety-critical brake release function. This intermediary safety mechanism validates signals before execution, allowing the use of cost-effective non-safety-certified components while ensuring signal accuracy and preventing erroneous activations.
Solution Approach 2:
The safety-critical validation logic is extracted from the main GUI control system and implemented as a separate safety certification mechanism. This extraction allows the primary GUI to remain simple and cost-effective while isolating the safety functions that require rigorous validation, thereby reducing overall system complexity while maintaining reliability.
3Ease of manufacture
If mechanical buttons are used for input, then the interface is simple and robust, but the mechanical components become significant error sources
Solution Approach 1:
The patent replaces traditional mechanical buttons with a touch-sensitive interface that uses electrical fields instead of mechanical contact. This substitution eliminates wear, contact resistance, and mechanical failure modes while maintaining interface simplicity and robustness. The touch interface detects finger proximity through electrical field changes, providing reliable input signals without mechanical components.
Data Source
AI summary
A method of controlling an industrial robot, including a robot controller, a programming interface, which is separate from the robot controller, and a robot manipulator with a plurality of actuators. The method includes: receiving a first release signal via a first safe input means; receiving actuator-selection data, which indicates one or more of the actuators, via an arbitrary input means at the programming interface; receiving a second release signal via a second safe input means at the programming interface after having received the actuator-selection data; and, in response to determining that the first and second release signals are still received, causing the actuators indicated by the actuator-selection data to enter a movement-without-drive-power mode.