Dual-Processor Robot Safety Control for State and Link Faults
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Solution Overview
Problem
Current robot control systems fail to ensure high functional safety and safety integrity, particularly in environments where robots interact with humans, as they lack effective mechanisms to monitor and respond to deviations in robot states and data link interruptions.
Innovation Solution
A system comprising two processors and a control unit that utilize algorithms to check robot states against prescribed state spaces, generating stop signals to transition the robot to a safe state upon deviations, with the second processor monitoring the first processor's algorithm execution and interrupting the data link if faults are detected, ensuring consistent safety checks and transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single processor is used to control the robot, then the device complexity is low, but the functional safety and reliability are insufficient
Solution Approach 1:
The control system is segmented into two independent processors (first processor and second processor), each executing safety checks independently. This segmentation allows redundant verification of robot states without requiring a completely complex centralized system, thereby improving reliability while managing complexity through modular architecture.
Solution Approach 2:
Each processor is assigned specific safety check functions with localized responsibilities. The first processor handles primary safety monitoring while the second processor provides independent verification. This local quality approach ensures that each component performs its specific safety function efficiently, contributing to overall system reliability without unnecessary complexity.
2Reliability
If redundant safety checks are implemented, then the reliability is improved, but the processing time and response speed increase
Solution Approach 1:
The system performs preliminary safety checks by continuously monitoring robot states against predefined state spaces before hazardous conditions develop. The processors proactively verify state validity in advance, allowing the system to maintain high reliability while responding quickly to actual deviations when they occur.
Solution Approach 2:
When a safety violation is detected, the system immediately transitions to a safe state without unnecessary intermediate processing steps. The redundant checks are designed to skip unnecessary verification steps once a violation is confirmed, ensuring rapid response time while maintaining the benefit of preliminary redundant monitoring.
3Reliability
If the data link is continuously monitored, then the reliability is improved, but the use of energy increases
Solution Approach 1:
The data link monitoring is implemented using periodic health checks rather than continuous monitoring. The system periodically verifies data link integrity between processors and the control unit, maintaining reliable communication detection while significantly reducing energy consumption compared to continuous monitoring approaches.
Data Source
AI summary
A system for controlling a robot. The system includes: an interface that provides data DAT(t) captured by one or more sensors, wherein the data DAT(t) indicate a current state ZUS(t) of the robot, a first processor that is connected to the interface and that is set up to use a first algorithm to check, on the basis of the data DAT(t) and a prescribed state space Z, which indicates exclusively permitted states of the robot, whether it holds that: ZUS(t)ϵZ, wherein in the event of: ZUS(t)∉Z a first stop signal Sig1 is generated, a unit, connected to the first processor via a data link, for generating a second stop signal Sig2, which generates the second stop signal Sig2 when the unit receives the first stop signal Sig1 or when the unit establishes that the data link is interrupted, a second processor, connected to the interface and the first processor or only to the first processor, that is set up to use a second algorithm to check, on the basis of the data DAT(t) and a prescribed state space Z′ or a boundary for the state space Z′, whether it holds that: ZUS(t)ϵZ′, wherein in the event of ZUS(t)∉Z′ the second processor prompts an interruption unit to interrupt the data link between the first processor and the unit, and a control unit, connected to the unit, for controlling the robot, which control unit controls/regulates the robot into a prescribed safe state when the second stop signal Sig2 is present.