Robot Safety Management via Light Curtain Zone Monitoring
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Solution Overview
Problem
In robot systems, the need for frequent human intervention to supply work to robots reduces productivity due to time and effort spent unlocking physical locks, and existing safety management technologies either compromise safety or are inefficient.
Innovation Solution
A safety management method and system that sets a third space where both workers and robots can enter, with monitoring boundaries to detect crossings and presence, restricting robot operation when simultaneous detection occurs and canceling the alert state only when both monitoring boundaries and the third space return to non-detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a safety fence with physical lock is used to separate worker area and robot area, then worker safety is ensured, but productivity is reduced due to time and effort required for unlocking
Solution Approach 1:
The patent replaces the mechanical physical lock system with an optical monitoring system using light curtains and control logic. The light curtains detect the presence of workers or robots in restricted zones, and the control system automatically manages robot operation states (stop, alert, or normal operation) based on detection results, eliminating the need for manual locking and unlocking operations
Solution Approach 2:
The patent introduces a control system as an intermediary between the worker area and robot area. This control system receives signals from light curtains, processes the information according to predetermined logic, and generates appropriate control signals for the robot, thereby mediating the interaction between human and robot operations without requiring direct physical intervention
2Productivity
If monitoring systems are implemented to detect worker presence in robot area, then productivity is improved by reducing locking time, but safety reliability may be compromised if detection is inaccurate
Solution Approach 1:
The patent divides the monitoring space into multiple distinct zones using separate light curtains (first light curtain for worker area boundary, second light curtain for robot area boundary, third light curtain for intermediate zone). Each light curtain independently monitors its specific zone, and the control system integrates information from all zones to make comprehensive safety decisions, ensuring accurate detection through distributed monitoring
Solution Approach 2:
The patent implements a closed-loop feedback system where light curtains continuously provide presence/absence information to the control system, which then adjusts robot operation in real-time. The system constantly monitors the states of all light curtains and modifies robot behavior based on current detection results, ensuring both safety and productivity through dynamic adaptation
3Adaptability or versatility
If a third space is created where both worker and robot can enter, then flexibility is improved, but complexity of monitoring system increases
Solution Approach 1:
The patent segments the workspace into three distinct areas (worker area, third space, robot area) using two sets of light curtains. The first light curtain monitors the boundary between worker area and third space, while the second light curtain monitors the boundary between robot area and third space. This segmentation allows independent monitoring of each zone while maintaining overall system coordination
Solution Approach 2:
The patent implements dynamic monitoring logic that adapts robot operation based on real-time detection states. When only one light curtain detects presence, the robot operates normally; when both light curtains detect presence simultaneously, the robot stops and alerts are generated. This dynamic response strategy simplifies the control logic despite the complex spatial configuration
Data Source
AI summary
A safety management method sets a third space that both a worker and a robot can enter between a first space in which the worker is present and a second space in which the robot is disposed; sets, between the first space and the third space and between the second space and the third space, respectively, boundaries for monitoring crossing thereof; monitors the presence/absence of the robot or the worker in the third space; when a state of crossing of one boundary and a state of the worker or the robot in the third space are simultaneously switched to “detection”, restricts the operation of the robot, when crossing of another boundary is detected; and not restricts the operation of the robot when the state of crossing of the one boundary and the state of the worker or the robot in the third space are simultaneously switched to “non-detection”.