Robot Collision Detection Device Using Acceleration Monitoring
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Solution Overview
Problem
Existing collaborative robots (cobots) lack sufficient sensitivity in their internal safety features, often requiring moderate force to trigger a stop, which can result in unintended collisions with fragile objects or people before the robot is halted.
Innovation Solution
A collision detection device is introduced, comprising an accelerometer and processor circuitry that monitors acceleration values and triggers a safety stop if abnormal acceleration is detected, independent of the robot's control system, and can also include a microphone to detect sound-based collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If internal safety features require moderate force to trigger a stop, then the robot can maintain operational stability and avoid false stops, but the robot lacks sensitivity and may collide with fragile objects or people before stopping
Solution Approach 1:
The safety system is segmented into multiple independent detection layers: accelerometer-based collision detection, force sensor monitoring, and traditional light curtain systems. Each layer operates independently with its own threshold criteria, allowing the system to achieve high sensitivity through the most sensitive layer while maintaining overall reliability through cross-validation and layered protection.
Solution Approach 2:
The system changes the detection parameter from moderate force thresholds to acceleration-based detection with much lower thresholds. By monitoring acceleration changes rather than direct force application, the system can detect subtle collisions and vibrations that would trigger false stops in traditional force-based systems, while still maintaining operational stability through intelligent signal processing and contextual analysis.
2Reliability
If the robot uses traditional light curtains and physical barriers, then safety is maintained, but the system complexity increases and automation is reduced
Solution Approach 1:
The system replaces mechanical light curtains and physical barriers with an intelligent sensor-based detection system. Accelerometers, force sensors, and microphones work together to detect collisions and abnormal forces, eliminating the need for complex mechanical safety infrastructure. This substitution maintains safety while significantly reducing system complexity and improving automation.
Solution Approach 2:
The robot equips itself with embedded sensors and detection capabilities within its own structure, enabling self-monitoring and self-protection. The accelerometers and force sensors are integrated into the robot's mechanical structure, allowing it to detect collisions and trigger safety stops autonomously without external safety systems or human intervention, thereby reducing overall system complexity.
3Productivity
If the robot operates at high speed, then productivity increases, but the impact of unintended collisions increases
Solution Approach 1:
The system performs preliminary detection of abnormal acceleration and force changes before full-speed operation can cause damage. By continuously monitoring acceleration and force parameters at high sampling rates, the system can detect the onset of a collision and trigger an emergency stop in advance, preventing the high-speed robot from impacting objects or people while maintaining high productivity during normal operation.
Solution Approach 2:
The system prepares safety mechanisms in advance by maintaining ready-state monitoring and detection systems that can immediately respond to collision threats. The accelerometers and force sensors are pre-positioned and calibrated to detect abnormal forces, creating a protective buffer that prevents high-speed collisions from causing harm while allowing the robot to operate at high speeds during normal tasks.
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 provides more sensitive collision detection, allowing for quicker robot stops and preventing damage or injury by triggering a safety stop before or during collisions, enhancing safety and reducing unintended impacts.
Implementation Method 1
A collision detection device is introduced, comprising an accelerometer and processor circuitry that monitors acceleration values
Implementation Method 2
can also include a microphone to detect sound-based collisions
Data Source
AI summary
Apparatus and methods to reduce impact of robot collision and/or avoid robot collision are described herein. An example collision detection device includes a housing to be coupled to an automated robot, a sensor in the housing, a relay in the housing, the relay to be electrically coupled to a safety circuit of the automated robot, and circuitry in the housing. The circuitry is to determine a parameter value based a signal from the sensor, compare the parameter value to a threshold value, and, in response to the parameter value satisfying the threshold value, trigger the relay to stop the automated robot.