Robot Workspace Sensor Placement for Blind Zone Reduction
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Solution Overview
Problem
Industrial robots in workspaces often have undetectable zones due to sensor limitations and workspace configurations, which hinder their ability to accommodate objects effectively.
Innovation Solution
A method and system that generate a digital workspace model with defined robot poses and sensor characteristics, simulate sensor operations, and identify undetectable areas, optimizing sensor placement to reduce these zones by adjusting sensor configurations and layouts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are placed in the workspace to detect objects, then object detection capability is improved, but undetectable zones remain due to sensor limitations and workspace configuration
Solution Approach 1:
The patent introduces multiple pose scenarios (different spatial dimensions and configurations) to analyze sensor coverage. By evaluating sensor performance across multiple robot poses and sensor orientations, the system identifies undetectable zones from multiple dimensional perspectives, enabling comprehensive coverage optimization that addresses blind spots in the workspace.
Solution Approach 2:
The patent performs preliminary simulation of sensor operations across multiple pose scenarios before actual deployment. By pre-identifying undetectable zones through virtual simulation and analysis, the system can optimize sensor placement and configuration in advance, preventing detection gaps before they occur in real operations.
2Reliability
If multiple sensors are added to cover undetectable zones, then detection coverage is improved, but system complexity and cost increase
Solution Approach 1:
The patent evaluates sensor coverage across multiple pose scenarios, which represents an excessive analysis beyond a single pose. This comprehensive simulation approach allows the system to identify the minimum necessary sensor configuration that achieves adequate coverage across all scenarios, avoiding both insufficient and excessive sensor deployment.
Solution Approach 2:
The patent optimizes sensor parameters (placement location, orientation, type) based on simulation results from multiple pose scenarios. By adjusting these parameters systematically, the system achieves optimal detection coverage with the appropriate number of sensors, balancing coverage requirements against system complexity and cost.
Data Source
AI summary
A method includes generating a workspace model having one or more robots and a plurality of image sensors, defining a plurality of pose scenarios of the one or more robots, and defining sensor characteristics of the plurality of image sensors. The method includes, for each of the plurality of pose scenarios, simulating a sensor operation of the plurality of image sensors within the workspace model based on the sensor characteristics and identifying an undetectable area within the workspace model based on the simulated sensor operation. The method includes performing a sensor placement control based on the undetectable areas associated with each of the plurality of pose scenarios.