Robot Safety Zone Configuration Using Distance-Based Gap Detection
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Solution Overview
Problem
Current manual configuration of safety functions for robot devices is cumbersome and time-consuming, failing to adapt automatically to changes in the robot's application or environment, leading to inefficient and costly production processes.
Innovation Solution
A method for automatically generating a safety function configuration for a robot device by obtaining distance information between its moving parts and the environment, comparing it with a minimum gap criterion, and dynamically adjusting safety zones based on this information to account for crushing and free impact hazards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual configuration of safety functions is performed, then safety parameters can be set, but the process is cumbersome and time-consuming
Solution Approach 1:
The robot device automatically configures its own safety functions by detecting environmental features and determining contact hazards without manual intervention. The system performs self-assessment of crushing and clamping hazards based on detected objects and spatial relationships, eliminating the need for manual safety configuration while ensuring appropriate safety parameters are applied.
Solution Approach 2:
The patent replaces manual mechanical configuration processes with automated sensor-based detection and computational analysis. Sensors detect environmental features and objects, and a processing system automatically determines hazard types and configures safety functions, substituting the manual mechanical process with an automated sensing-computing-actuating system.
2Reliability
If manual safety configuration is performed, then safety zones can be defined, but they cannot automatically adapt to changes in robot application or environment
Solution Approach 1:
The safety configuration becomes dynamic and adaptive by continuously detecting environmental features and objects using sensors. The system automatically updates safety zone definitions and contact hazard assessments based on real-time environmental changes, such as newly installed features or modified workspace layouts, ensuring safety parameters remain appropriate without manual reconfiguration.
Solution Approach 2:
The system implements feedback loops where sensors continuously monitor the environment for changes in objects, features, or spatial relationships. Based on this feedback, the processing system automatically re-evaluates contact hazards and adjusts safety function configurations accordingly, maintaining adaptability to environmental changes while ensuring ongoing safety compliance.
3Reliability
If different safety measures are applied for crushing and free impact, then risk mitigation is improved, but the complexity of identifying and distinguishing contact hazards increases
Solution Approach 1:
The patent segments the hazard identification process into distinct analytical components: detecting environmental features, identifying objects in the workspace, determining spatial relationships, and classifying contact hazard types (crushing vs. clamping). This segmentation allows the complex overall task to be broken down into manageable automated steps, each handled by specific sensor types and processing algorithms.
Solution Approach 2:
The system performs preliminary detection and classification of environmental features and objects before safety configuration is needed. By pre-identifying potential hazard sources and their characteristics, the system prepares the information necessary for automatic safety parameter selection, reducing the complexity of real-time hazard assessment while ensuring accurate risk mitigation measures are applied.
Data Source
AI summary
A method for automatically setting up a safety function configuration for a robot device includes obtaining a distance information between at least one moving part of the robot device and a defined position point in an environment of the robot device; comparing the distance information with a minimum gap criterion that defines a minimum distance between the at least one moving part of the robot device and the defined position point in the environment of the robot device, determining automatically a corresponding safety function configuration for the robot device in a dedicated workspace area depending on a deviation of the distance information and the minimum gap criterion.