Robot Casing Haptics and Proximity Sensing for Safe Collaboration
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Solution Overview
Problem
Existing robotic systems face challenges in human-robot collaboration due to inefficiencies and safety issues, including error-triggering and the inability to effectively distinguish between humans and non-human objects, leading to potential hazards such as bumping and clamping.
Innovation Solution
The system incorporates movable parts with actuators, force limiting sensors, and casing elements equipped with vibration sensors and joint position detection, allowing for speed and force monitoring, haptic feedback, and proximity detection to prevent collisions and enhance user interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If proximity or touch sensors are used to detect humans, then safety is improved, but error-triggering occurs and detection precision deteriorates when distinguishing between humans and non-human objects
Solution Approach 1:
The robot system divides the detection function into multiple specialized sensors: proximity sensors for early warning, touch sensors for contact detection, and force limiting sensors for force monitoring. Each sensor type handles specific detection tasks, improving overall reliability while reducing false triggers compared to using a single sensor type for all detection purposes.
Solution Approach 2:
The system changes detection parameters by using multiple sensor types with different detection principles (optical, mechanical, force-based) rather than relying on a single sensor type. This allows the system to adjust detection sensitivity and thresholds for different sensor types, improving precision in distinguishing between human and non-human objects while maintaining safety.
2Reliability
If the robot stops motion when speed or force limits are exceeded, then safety is improved, but productivity deteriorates due to motion interruptions
Solution Approach 1:
The robot system performs preliminary actions by continuously monitoring speed and force parameters before dangerous situations occur. The control unit proactively adjusts motion parameters and prepares stopping sequences when approaching safety limits, rather than reacting only after limits are exceeded. This reduces abrupt interruptions and maintains smoother operation flow, improving productivity while ensuring safety.
Solution Approach 2:
The system implements continuous feedback loops where sensors monitor speed, force, and position in real-time, and the control unit continuously adjusts motion commands based on this feedback. This closed-loop control allows the robot to operate close to safety limits without exceeding them, maximizing productivity while maintaining safety through dynamic adjustment rather than conservative static speed limits.
3Reliability
If multiple sensors and safety systems are added to the robot, then safety and detection capability are improved, but device complexity increases
Solution Approach 1:
The robot system merges multiple sensor types (proximity, touch, force) and safety functions into an integrated control unit that manages all safety-related operations. The control unit consolidates data from multiple sensors and coordinates safety responses in a single processing core, reducing the complexity that would arise from having separate control systems for each sensor type while maintaining comprehensive safety coverage.
Solution Approach 2:
The control unit is designed as a universal safety system that handles multiple functions: proximity detection coordination, touch sensor processing, force limiting control, speed monitoring, and emergency stopping. This multi-functional approach consolidates what would otherwise require multiple specialized control units, reducing overall system complexity while providing comprehensive safety coverage across all robot operations.
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
Enhances safety and efficiency in human-robot collaboration by preventing collisions through precise motion control and providing haptic guidance, improving user interaction and productivity.
Implementation Method 1
a sensor configured to detect a vibration generated by a vibration sensor for performing a proximity detection or a contact detection to an external object
Data Source
AI summary
A robot system comprising movable parts, a casing element, a force limiting sensor, a joint position sensor, and one or more processors, wherein the casing element comprises a vibration actuator. Multiple embodiments are introduced for the implementation of the casing element include haptic warning and proximity sensing. Furthermore, means to use the casing element to guide the robot and generate haptic effect by the vibration actuator to assist the user in a human-robot collaboration and/or guiding function are also disclosed.