Robot Safety System Using Simulation Image Comparison
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Solution Overview
Problem
Existing robot safety systems fail to effectively address issues related to camera malfunctions or misalignments, leading to potential collisions and increased costs due to the need for multiple cameras and complex adjustments, while also risking blind spots and inaccurate distance calculations.
Innovation Solution
A robot system that uses a camera to generate a current position model of the robot, compares it with a simulation image to detect the robot's presence, and ensures safety by adjusting operation speed or stopping the robot if the camera fails to detect it correctly, thereby reducing costs and preventing collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple cameras are used to monitor the robot and prevent erroneous detection, then detection reliability is improved, but system cost and device complexity increase
Solution Approach 1:
The patent creates a virtual copy of the robot's appearance and position through simulation image generation. The simulation image generation unit creates a rendered image of what the robot should look like from the camera's perspective, based on robot model data and current position data. This virtual copy is then compared with the actual camera image to verify detection accuracy, eliminating the need for multiple physical cameras while maintaining high detection reliability
Solution Approach 2:
The patent introduces a simulation image as an intermediary between the actual robot and the camera detection system. Instead of directly comparing multiple camera feeds, the system generates a simulated camera view from robot model data and uses this intermediate representation to verify whether the camera is correctly detecting the robot, thereby reducing system complexity while maintaining reliability
2Reliability
If multiple cameras are deployed around the robot to ensure comprehensive monitoring, then safety coverage is improved, but adjustment complexity and system cost increase
Solution Approach 1:
The system generates a virtual representation of the camera's view through simulation image generation. By rendering what the camera should see based on the robot model and camera position data, the system creates a complete safety coverage model without needing multiple physical cameras, thereby eliminating the adjustment complexity associated with positioning and calibrating multiple devices
3Device complexity
If a single camera is used to monitor the robot, then system cost is reduced, but detection reliability and safety monitoring capability deteriorate
Solution Approach 1:
The patent compensates for using a single camera by creating a virtual copy of the robot's appearance and position through simulation. The simulation image generation unit renders an image of the robot as it should appear from the camera's perspective, and this virtual copy is compared with the actual camera capture to verify detection reliability, thereby maintaining high safety monitoring capability with simplified hardware
4Adaptability or versatility
If camera position or posture changes occur, then adaptability to new conditions is improved, but monitoring capability and safety detection deteriorate
Solution Approach 1:
The system dynamically updates the simulation image based on current robot position data and camera position data. When the camera position or posture changes, the simulation image generation unit recalculates and regenerates the expected robot appearance from the new camera perspective, allowing the system to adapt to position changes while maintaining accurate monitoring capability through continuous verification against the updated simulation
Data Source
AI summary
To provide a robot system capable of ensuring safety while giving consideration to the occurrence of a trouble in image capture means. A robot system with a camera for monitoring a robot comprises: current position model generation means that generates a current position model for the robot based on current position data about the robot and robot model data about the robot; simulation image generation means that generates a simulation image of the robot viewed from the direction of the camera based on set position data about the camera, set position data about the robot, and the current position model; detection means that compares the simulation image and a monitoring image acquired from the camera to detect the robot in the monitoring image; and safety ensuring means that ensures the safety of the robot system if the detection means does not detect the robot in the monitoring image.