Robot Dynamic Safety Zones for Continuous Workspace Operation
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Solution Overview
Problem
Existing robot safe zone systems are inadequate as they are static and do not adapt to changing operational conditions, potentially leading to unnecessary robot halts or unsafe operations when humans or objects enter the zone.
Innovation Solution
A dynamic safe zone system that uses sensors and real-time data to adjust the size and shape of the safety zone based on the robot's motion profile, external inputs, and system parameters, allowing the robot to continue operating safely by modifying its motion pathways and safe zones dynamically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a static safe zone is used for robot operation, then safety boundaries are clearly defined, but the robot must halt operation when humans or objects enter the zone, reducing productivity
Solution Approach 1:
The patent implements dynamic safe zones that automatically adjust their boundaries based on real-time robot motion states. When the robot is stationary or moving slowly, the safe zone expands to ensure safety. When the robot is moving quickly or performing critical operations, the safe zone contracts to allow continuous operation. This dynamic adjustment resolves the contradiction by making the safety boundary adaptive rather than fixed.
Solution Approach 2:
The system changes the spatial parameters of the safe zone based on robot velocity, acceleration, and task criticality. The safe zone radius is dynamically modified according to motion profile parameters, allowing the robot to maintain operation during human proximity when motion parameters indicate low risk, while expanding protection when parameters indicate high risk.
2Reliability
If a large static safe zone is established, then safety margins are maximized, but the robot's workspace is restricted and productivity decreases
Solution Approach 1:
The safe zone dynamically contracts and expands based on robot motion characteristics. During high-speed movements or critical operations, the safe zone minimizes to preserve workspace. During low-speed movements or when the robot is stationary, the safe zone expands to maximize safety margins. This temporal-spatial adaptation allows the robot to access previously restricted workspace areas when safety conditions permit.
3Productivity
If the safe zone is reduced to increase workspace, then productivity improves, but safety risks increase when humans are nearby
Solution Approach 1:
The system modulates safe zone parameters based on real-time monitoring of robot velocity, acceleration, direction, and task type. When motion parameters indicate low risk (slow speed, controlled movement), the safe zone contracts to maximize workspace utilization. When parameters indicate high risk (high speed, uncontrolled movement), the safe zone expands to ensure safety. This parameter-based adaptation resolves the safety-productivity tradeoff.
4Productivity
If a dynamic safe zone system is implemented, then robot operation continuity is improved, but system complexity increases due to real-time adjustments
Solution Approach 1:
The dynamic safe zone system continuously monitors robot motion parameters (velocity, acceleration, position) and task state, using this feedback to automatically adjust safe zone boundaries in real-time. The controller receives sensor data, evaluates risk based on motion profiles, and modifies the safe zone accordingly, creating a closed-loop control system that balances safety and productivity without requiring complex manual intervention.
Data Source
AI summary
A robot is disclosed which includes a dynamic safety zone feature capable of defining a space around the robot to be monitored to provide safe operating conditions for personnel or property. The dynamic safe zones can be a volume around one or more moving components of the robot. Such dynamic safe zones can be scaled depending on the nature of the operation (fast moving robot having a larger dynamic safety zone). Multiple different zones can be used in some embodiments. The zones can further be scaled depending on the nature of the sensors used in the operation of the robot. Multiple different moving components can have different dynamic safety zones.