Dynamic Robot Safety Zones for Automated Vehicle Entry

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Solution Overview

Problem

Conventional robotic systems face downtime and reduced efficiency due to fixed safety zones that are triggered by the presence of automated vehicles within the robot's safety area, leading to unnecessary termination of robot operations for safety reasons.

Innovation Solution

A robotic system with a dynamic safety zone adjustment mechanism, where the robot controller detects the entry of automated vehicles and adjusts the robot safety zone by merging, substituting, or muting parts of the safety zone using vehicle sensor data to allow vehicles to operate within the robot's safety area without interrupting the robot's operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a fixed robot safety zone is used to ensure safety, then safety is improved, but robot operation is terminated when vehicles enter the zone, leading to reduced productivity

Engineering Contradiction:
ImprovesafetyVSAvoidrobot operation continuity
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent applies the dynamics principle by transforming the fixed, static safety zone into a dynamic safety zone that automatically adjusts its boundaries based on the presence and position of automated vehicles. The controller receives vehicle position data from vehicle sensors and dynamically modifies the safety zone parameters in real-time, allowing the safety zone to expand or contract as vehicles enter or leave the robot workspace, thereby maintaining safety while preventing unnecessary operation terminations

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent implements parameter changes by modifying the safety zone parameters (such as zone boundaries, detection sensitivity, or exclusion areas) based on vehicle presence. When a vehicle enters the workspace, the controller changes the safety zone parameters to exclude the vehicle from triggering safety stop conditions, while maintaining strict safety monitoring in other areas. This parameter adaptation allows continuous operation during vehicle presence while preserving safety standards

Inventive Principle:
Principle #35Parameter changes

2Reliability

If safety sensors are used to detect objects in the safety zone, then safety control is improved, but unnecessary termination of robot operation occurs when vehicles are detected

Engineering Contradiction:
Improvesafety controlVSAvoiddowntime
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The patent introduces an intermediary mechanism in the form of a controller that mediates between the vehicle sensors and the robot safety control system. The controller receives data from vehicle sensors, determines whether detected objects are vehicles or other objects, and selectively applies different safety responses. This intermediary layer prevents direct triggering of safety stops by vehicles while maintaining full safety monitoring capability for other objects in the workspace

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent implements feedback by continuously monitoring vehicle position through vehicle sensors and using this feedback information to dynamically adjust safety zone parameters. The controller receives real-time position feedback from vehicles and automatically adjusts the safety zone configuration accordingly, creating a closed-loop system that adapts safety parameters based on current workspace conditions rather than using fixed, overly conservative settings

Inventive Principle:
Principle #23Feedback

Data Source

PatentUS11992954B2Safe operation of a robotic system
Publication Date: 2024.05.28 ABB (SCHWEIZ) AG
  • US11992954B2 patent drawing
  • US11992954B2 patent drawing
  • US11992954B2 patent drawing

AI summary

A robotic system includes: at least one robot; a robot controller for controlling an operation of the at least one robot; a robot sensor system with at least one robot sensor, the robot sensor system being coupled to the robot controller to detect a presence of an object in a robot safety zone, which robot safety zone at least partially surrounds the at least one robot; and at least one automated vehicle for supplying the at least one robot. The at least one vehicle has at least one vehicle sensor for detecting a presence of an object in a vehicle safety zone, which vehicle safety zone at least partially surrounds the at least one vehicle. The robot controller determines an entry of the at least one vehicle into the robot safety zone. The robot controller adjusts at least a part of the robot safety zone.