Robot Safety Cover with Movable Sensor-Integrated Shield
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Solution Overview
Problem
Existing industrial robot safety covers are not adequately safe, functional, or constructively simple for use in open environments with human operators, as they often impair performance and are not effectively designed to detect operator proximity.
Innovation Solution
A safety cover with a movable portion equipped with proximity and contact sensors, allowing the robot to adjust its position to ensure safety without hindering performance, and a controller that automatically adjusts the robot's speed or stops it when detecting human presence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a safety cover is added to surround the operative unit, then safety is improved, but device complexity increases
Solution Approach 1:
The safety cover is divided into a fixed portion rigidly connected to the support frame and a movable portion movably mounted on the support frame. This segmentation allows the movable portion to be independently controlled and equipped with sensors, providing safety functionality without requiring the entire cover to be complex and movable.
2Reliability
If the safety cover completely surrounds the operative unit, then safety is improved, but operational performance deteriorates
Solution Approach 1:
The movable portion of the safety cover is designed to move between a lowered position that surrounds the operative unit and a raised position that uncovers it. This dynamic configuration allows the system to switch between safety mode (cover lowered) and operational mode (cover raised), eliminating the trade-off between safety and performance.
3Reliability
If proximity sensors and contact sensors are added to the safety cover, then safety is improved, but device complexity increases
Solution Approach 1:
The safety cover serves multiple functions: it provides physical protection when lowered, acts as a sensor platform for detecting human proximity and contact, and functions as a movable barrier controlled by the controller. By integrating sensor mounting capabilities into the cover structure itself, the system achieves enhanced safety without adding separate complex sensor assemblies.
4Ease of operation
If the movable portion is made lightweight, then ease of operation is improved, but strength deteriorates
Solution Approach 1:
The movable portion of the safety cover can be constructed using lightweight materials such as plastic or metal sheeting, which provide sufficient structural strength for safety coverage while being easily movable. The thin-walled construction reduces weight for easy actuation by the positioning device, yet maintains adequate strength to provide protective enclosure and support sensor mounting.
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 a high degree of safety, maintains performance, and is constructively simple and efficient, allowing the robot to operate safely and effectively in open environments without limiting its operational range.
Implementation Method 1
both the fixed portion and the movable portion of said safety cover have a collaborative outer structure, equipped with proximity sensors and/or contact sensors, such as to enable the functional assembly to be used in cooperation and in close proximity with one or more human operators
Implementation Method 2
both the fixed portion and the movable portion of said safety cover have a collaborative outer structure, equipped with proximity sensors and/or contact sensors
Implementation Method 3
a controller that automatically adjusts the robot's speed or stops it when detecting human presence
Data Source
AI summary
A functional assembly for an industrial robot includes a safety cover which selectively covers an operative unit or robot end effector. The cover includes a fixed portion and a movable portion which selectively moves relative to the fixed portion. The movable portion selectively moves to cover or uncover a portion of the operative unit for the operative unit to function for its intended purpose. The operative unit can move in two directions orthogonal to the movement of the cover movable portion allowing the operative unit to travel or reach to the full footprint of the cover. The safety cover may include sensors to detect objects in close proximity to the safety cover to slow or stop the robot or functional assembly.