Robot Safeguarding System for Human-Robot Collision Avoidance
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Solution Overview
Problem
In manufacturing environments, the close cooperation between humans and robots is hindered by the need for large safety distances due to the risk of injury from high-speed robotic movements, leading to unnecessary interruptions in the robot's work mode.
Innovation Solution
A method and apparatus that utilize a safeguarding system with sensors, prediction units, and collision monitoring to identify potential intersections between a person's action range and the robot's movable part, allowing the robot to switch to a safety mode only when a collision is imminent, thereby reducing the need for excessive safety distances and maintaining efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large safety distances are established to prevent collision risk, then person safety is improved, but robot productivity deteriorates due to unnecessary work mode interruptions
Solution Approach 1:
The safety distance is made dynamic rather than static. The system continuously monitors person position and robot movement, adjusting the effective safety distance in real-time based on actual collision risk. When no person is detected in the danger zone, the robot operates at full speed with effectively zero safety distance. When a person enters the action range, the safety distance dynamically increases to allow safe deceleration. This resolves the contradiction by eliminating unnecessary safety margins while maintaining protection when needed.
Solution Approach 2:
The system implements continuous feedback through sensors that monitor person position, body posture, and robot movement. This feedback enables real-time assessment of collision risk and dynamic adjustment of safety measures. The feedback loop allows the robot to maintain high-speed operation when safe, while automatically reducing speed or stopping when a person enters the action range, thus resolving the contradiction between continuous safety and productivity.
2Productivity
If robot moves at high speed to maintain productivity, then productivity is improved, but person safety deteriorates due to increased collision risk
Solution Approach 1:
The robot speed is made dynamic rather than constant. The system adjusts robot velocity in real-time based on detected person position and predicted collision risk. When the workspace is clear, the robot operates at maximum speed for optimal productivity. When a person enters the action range or exhibits movement indicating potential collision, the speed dynamically reduces to safe levels. This resolves the contradiction by enabling high-speed operation when safe while automatically reducing speed when person safety is at risk.
Solution Approach 2:
The system performs preliminary safety assessment by continuously monitoring person position and predicting potential collision scenarios before they occur. By detecting person entry into the action range in advance, the system can begin deceleration sequences early, allowing the robot to maintain high-speed operation longer while still ensuring safety. This preliminary detection and preparation resolves the contradiction by enabling sustained high-speed operation without compromising safety response capability.
3Productivity
If safety distance is reduced to improve robot efficiency, then productivity is improved, but the risk of injury in case of sudden person movement increases
Solution Approach 1:
The system implements real-time feedback monitoring of person position, body posture, and movement characteristics. This continuous feedback enables the system to detect when a person enters the action range or exhibits sudden movements, immediately triggering speed reduction or stopping. The feedback mechanism allows the robot to operate with minimal effective safety distance while maintaining safety through active monitoring and rapid response, resolving the contradiction between reduced safety distance and injury risk.
Solution Approach 2:
The system replaces passive mechanical safety distances with active sensor-based monitoring and control. Instead of relying on fixed physical barriers or large safety zones, the system uses sensors, prediction algorithms, and real-time control to dynamically manage collision risk. This substitution allows the robot to operate efficiently with minimal physical safety margins while maintaining safety through intelligent detection and response, resolving the contradiction between reduced safety distance and injury prevention.
Data Source
AI summary
A method for controlling a robot, which is designed to be operated in a working mode, in which a part of the robot is moved at a speed at which there is a risk of injury to a person. The working mode is deactivated if a safety device detects that the person has entered an action region of the displaceable part. The aim is to make close cooperation possible between the person and the robot. A sensor unit determines a position and a posture of the person while the person is outside the action region of the part. A prediction unit determines an action region of the person. A collision monitoring unit monitors whether the two action regions overlap. The robot can optionally be switched from the working mode into a safety mode.