Robot Safety Device with Kinematic Assembly for Collision Detection
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Solution Overview
Problem
Current safety systems for industrial robots are inadequate in detecting collisions between end effectors and objects, particularly those requiring force transmission, as they either restrict functionality or fail to reliably detect collisions with defined forces, especially in applications like ultrasonic welding where sensor elements interfere with vibration properties.
Innovation Solution
A safety device with a locking arrangement that forms a rigid connection between the robot and end effector, utilizing kinematics and sensor elements to detect collisions and transmit forces, including magnetic, optical, and mechanical sensors, and a clamping device to secure the end effector, allowing for precise force transmission and reduced risk of injury.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensor elements are mounted on the robot arm to detect collisions, then collision detection capability is improved, but the end effector cannot be enclosed without impairing its functionality
Solution Approach 1:
The patent introduces an intermediary kinematic assembly with connecting arrangements between the robot arm and end effector. This assembly includes sensor elements that detect collisions without being part of the end effector itself, allowing the end effector to maintain its original functionality while enabling collision detection through the intermediary structure.
Solution Approach 2:
The safety device is segmented into separate components: a robot section, an end effector section, and connecting arrangements with sensor elements. This segmentation allows the end effector to remain functionally independent while the connecting arrangements provide collision detection capability without interfering with end effector operations.
2Ease of operation
If spring elements are used for collision detection, then flexible mounting of end effector is improved, but the system can only be used where the end effector is supported by a workpiece
Solution Approach 1:
The connecting arrangement is designed with universal applicability through the orthogonal displacement paths and rigid connection capability. The system can detect collisions in multiple directions and configurations, making it suitable for various end effector types and applications beyond just workpiece-supported scenarios, including ultrasonic welding and other force transmission applications.
3Reliability
If a pneumatic element is used to detect collisions, then reliable collision detection is improved, but the end effector can essentially only be subjected to tensile stress
Solution Approach 1:
The patent replaces the pneumatic element with a mechanically-based connecting arrangement featuring rigid connections and orthogonal displacement paths. This mechanical system can detect collisions reliably while accommodating various force transmission modes including compression, tension, and lateral forces, enabling applications like ultrasonic welding that require defined contact pressure.
4Force
If the end effector is rigidly fixed to the robot, then force transmission is improved, but collision detection becomes difficult
Solution Approach 1:
The patent applies local quality by creating a rigid connection between the robot arm and end effector for force transmission, while simultaneously incorporating sensor elements in the connecting arrangements to detect collisions. The rigid connection maintains force transmission capability, while the localized sensor elements provide collision detection without compromising the rigid connection.
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
Enables reliable detection and prevention of collisions with defined forces, reducing the risk of injury and improving operational safety in applications like ultrasonic welding by maintaining the functionality of end effectors while ensuring safety standards are met.
Implementation Method 1
the at least one sensor element generates sensor data based on magnetic effects
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a safety device (1) for collision monitoring of an end effector (3) that is or can be brought into operative contact with a robot (2). The safety device (1) has at least one kinematic assembly (4) with a robot section (5), a connecting arrangement (6), and an end effector section (7). The safety device (1) is fixed/fixable to the robot (2) by means of the robot section (5) of the kinematic assembly (4). The end effector (3) can be fixed to the end effector section (7) of the at least one kinematic assembly (4). The end effector section (7) is mounted to the robot section (5) by means of the connecting arrangement (6) of the at least one kinematic assembly (4) such that the end effector section (7) can be displaced relative to the robot section (5) at least along a displacement path.The safety device (1) has at least one sensor element (16, 17, 18) by means of which a displacement of the end effector section (7) relative to the robot section (5) can be detected, so that a collision of the end effector (3) with an object (37) that has a motion vector differing from that of the robot section (5) can be determined. The safety device (1) has a locking arrangement (19, 20, 21) by means of which a rigid connection between the end effector section (7) and the robot section (5) can be formed, so that a rigid connection between the robot (2) and the end effector (3) can be formed.