Robot Control Device for Cooperative Work Safety
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Solution Overview
Problem
Existing cooperative robot systems either require safety fences that slow down work or stop robots frequently to ensure worker safety, leading to decreased efficiency and safety due to unintentional contact and complex advance preparations for safety sensor setups.
Innovation Solution
A robot system with a control device that includes a stopping section, position recording, position distribution generation, and speed changing sections to minimize robot stops by recording and analyzing stopping positions and adjusting operating speeds based on these records, allowing simultaneous worker and robot operation without advance preparations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a safety fence is installed between worker and robot, then worker safety is ensured, but work speed decreases
Solution Approach 1:
The invention extracts the safety function from the physical safety fence and relocates it to the robot control system through external force detection. The robot controller detects external forces applied to the robot and automatically stops the robot when the force exceeds a threshold, eliminating the need for safety fences while maintaining worker safety.
Solution Approach 2:
The invention replaces the mechanical safety fence system with an electronic control system that uses external force sensors and software algorithms. The robot controller monitors external forces and uses decision logic to determine when to stop, substituting mechanical barriers with intelligent control.
2Reliability
If robot is stopped when external force is detected, then worker safety is ensured, but work efficiency decreases due to frequent stops
Solution Approach 1:
The invention applies different response strategies based on the characteristics of external force events. For brief, low-magnitude forces typical of unintentional contact, the robot continues operating. For sustained or high-magnitude forces indicating intentional contact, the robot stops. This localized differentiation of safety responses reduces unnecessary stops while maintaining safety.
Solution Approach 2:
The invention uses a threshold-based approach where the robot stops only when external force exceeds a predetermined threshold level. This partial action approach ensures safety for significant contacts while allowing normal operation during minor disturbances, avoiding excessive stopping.
3Reliability
If predetermined region is defined using safety sensor, then robot can be stopped in that region to ensure safety, but advance preparation becomes complicated and time-consuming
Solution Approach 1:
The robot control system automatically detects external forces and determines when to stop without requiring pre-defined safety regions or complex sensor setups. The system serves itself by using its own motion data and external force measurements to make safety decisions, eliminating the need for advance preparation of safety zones.
Solution Approach 2:
The invention eliminates the need for preliminary definition of safety regions by using real-time external force detection during robot operation. The safety control is established dynamically based on actual conditions rather than pre-configured zones, simplifying setup.
Data Source
AI summary
A control device of a robot system includes a position recording section that records a stopping position of a robot when the robot has been stopped by a stopping section, and a position distribution generation section that generates a distribution of the stopping positions of the robot recorded by the position recording section. The control device further includes a speed changing section that automatically changes an operating speed of the robot in accordance with the generated stopping position distribution of the robot.