Robot Speed Control for Human-Robot Collaboration
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Solution Overview
Problem
In production systems, the need for simultaneous human and robot collaboration in the same area is hindered by safety concerns, as existing methods either limit robot efficiency or compromise human safety due to the requirement for separate operation areas.
Innovation Solution
A production system with a controller that allows for a cooperative task area where both humans and robots can operate, with speed limitations and defined robot entry-prohibited zones to ensure safety, and operational modes that adjust based on task requirements to maximize efficiency and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stopper is used to limit the movement range of the robot, then the protection area for human entry is obtained, but the operation area of the robot becomes smaller and robot efficiency deteriorates
Solution Approach 1:
The patent applies dynamics by making the robot's movement characteristics adaptable based on the operator's presence. The controller dynamically adjusts the robot's maximum movement speed and acceleration/deceleration rates depending on whether an operator is detected in the cooperative task area. When no operator is present, the robot operates at full speed for maximum efficiency. When an operator is detected, the robot automatically reduces its speed parameters to ensure safety while still allowing operation in the cooperative area, thus resolving the contradiction between safety and efficiency.
2Adaptability or versatility
If the stopper is removed to change the protection area, then the robot operation area can be expanded, but the protection area cannot be changed during robot operation
Solution Approach 1:
The system dynamically adjusts the protection area and robot operation parameters based on real-time detection of operator presence, eliminating the need for physical stopper adjustments. The controller automatically modifies the robot's movement speed limits and acceleration/deceleration rates according to the defined cooperative task area boundaries, allowing flexible adaptation during operation without setup time loss.
3Adaptability or versatility
If the human enters the movement range of the robot, then collaborative tasks can be performed, but the human and robot cannot simultaneously perform tasks in the same area
Solution Approach 1:
The patent enables simultaneous human-robot collaboration by dynamically controlling the robot's movement characteristics based on operator presence detection. When an operator enters the cooperative task area, the controller automatically reduces the robot's maximum movement speed and acceleration/deceleration rates to safe levels, allowing both to work in the same space. This dynamic speed adjustment maintains safety while enabling collaborative tasks that were previously impossible.
4Productivity
If the robot operates at full speed, then productivity is maximized, but the risk to human safety increases when human and robot share the same area
Solution Approach 1:
The system dynamically adjusts the robot's speed parameters based on the operator's presence in the cooperative task area. The controller monitors the area and automatically modifies the robot's maximum movement speed, acceleration, and deceleration rates. When no operator is present, the robot operates at full speed for maximum productivity. When an operator is detected, the robot automatically reduces its speed parameters to predetermined safe levels, thus eliminating the contradiction between speed and safety.
Data Source
AI summary
A production system in which a human and a robot may simultaneously perform a cooperative task in the same area while ensuring human's safety. A robot is positioned at one side of a working table, and an operator is positioned at the other side of the working table. The reachable area of the operator is limited by the working table. An area of the working table is divided into an area where only the operator may perform a task, an area where only the robot may perform a task, and an area where both the operator and the robot may enter. In a cooperation mode, the maximum movement speed of a component of the robot is limited lower than when the component of the robot is outside the cooperative task area, and, the motion of the robot is limited so that the robot does not enter a robot entry-prohibited area.