Robot Control System Using Distance Measurement for Safety
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Solution Overview
Problem
Conventional robot control systems using portable wireless operation panels face safety hazards due to the risk of delayed robot stoppage during low-quality wireless communication and the inability to detect when the operator is too far away from the robot, leading to potential unsafe operations.
Innovation Solution
A robot control system that includes a control device, a portable wireless operation panel, a distance measuring unit, and a warning generator, which measures the distance between the robot and the operation panel and emits warnings or stops the robot when the distance exceeds a predetermined threshold, regardless of communication quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wireless communication is used for portable operation panel, then operator mobility and ease of operation are improved, but safety deteriorates due to inability to detect operator distance from robot
Solution Approach 1:
The system continuously measures the distance between the portable operation panel and the robot using radio wave intensity detection, and provides feedback by issuing warnings when the distance exceeds a predetermined threshold. This closed-loop feedback mechanism ensures operator safety while maintaining wireless mobility.
2Reliability
If robot stops when wireless communication quality degrades, then safety is improved, but productivity deteriorates due to unnecessary stoppages in areas with inherently poor communication
Solution Approach 1:
The system distinguishes between local communication quality characteristics and actual safety conditions by measuring radio wave intensity specifically at the operator's position relative to the robot. This allows the system to adapt safety thresholds to local environmental conditions rather than applying uniform stoppage criteria, thereby maintaining productivity in areas with inherently poor communication while ensuring safety where needed.
3Reliability
If distance measurement function is added to detect operator position, then safety is improved, but device complexity increases
Solution Approach 1:
The system utilizes the existing radio wave transmission infrastructure for control purposes and leverages the inherent properties of radio wave propagation for distance measurement. By using the control radio waves themselves for dual purposes (control and distance measurement), the system avoids adding separate dedicated measurement hardware, thereby implementing safety functionality with minimal increase in device complexity.
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
This solution enhances safety by ensuring the robot is stopped when the operation panel moves beyond a safe distance, preventing unsafe operations and reducing the risk of accidents.
Implementation Method 1
by monitoring the intensity of radio waves between the controller and the teaching device
Data Source
AI summary
The robot control system includes: a control device for controlling a machine; a portable wireless operation panel for performing wireless communication with the control device to control the machine; a distance measuring unit for measuring the distance between the machine and the portable wireless operation panel; and a warning generator that emits a warning to the operator or stops the machine when the distance between the machine and the portable wireless operation panel exceeds a predetermined threshold value.