Robot TCP Supervision With Hose-Like Tolerance Zones
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Solution Overview
Problem
The existing methods for supervising robots result in a significant reduction of their operational workspace due to the need for a large buffer zone around the safety zone, as they require a long follow-on distance to stop, which can extend into the safety zone, posing a risk to persons in the working range.
Innovation Solution
Defining a hose-like tolerance zone along the movement path that is outside the safety zone, with its width being anti-proportional to the desired movement speed, allowing for continuous verification of the actual Tool Center Point (TCP) position within this zone, and initiating an immediate stop if it exceeds the tolerance zone limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a safety zone with buffer zone is used to ensure robot safety, then safety is improved, but the operational workspace is reduced
Solution Approach 1:
The system performs preliminary verification of the robot's actual position against the tolerance zone before the robot completes its movement. By continuously verifying position data and detecting deviations early, the system can initiate stopping actions before the robot enters the safety zone, eliminating the need for a large buffer zone and preserving operational workspace while maintaining safety.
2Reliability
If a large buffer zone is created around the safety zone, then safety is improved, but the follow-on distance increases
Solution Approach 1:
The system continuously verifies the robot's actual position against the programmed movement path and tolerance zone, creating a feedback loop. When a deviation is detected, the system provides feedback to initiate a stop command. This real-time feedback mechanism allows for early detection and immediate response, reducing the follow-on distance required to stop the robot while maintaining safety.
3Reliability
If the robot movement is stopped immediately upon exceeding tolerance zone, then safety is improved, but the response time requirement increases
Solution Approach 1:
The system performs preliminary verification of position data continuously during robot movement, rather than waiting for the robot to complete its motion or enter a buffer zone. By detecting deviations early and initiating stop commands immediately upon exceeding the tolerance zone, the system minimizes the response time required while maintaining safety.
Data Source
Figure 1~2
Figure 3
AI summary
The invention is related to a method for supervising a robot (12, 62) having a robot controller (14) which is foreseen to control a movement of the robot (12, 62) according to data of a predefined movement program, comprising the following steps: providing a movement program defining at least a given movement path (22, 42, 64) for a tool center point (TCP) of the robot (12, 62), defining a tolerance zone (24, 52, 66) around the movement path (22, 42, 64), moving the robot (12, 62) with its TCP running along the movement path (22, 42, 64) according to the movement program, continuously determining the actual position of the TCP, continuously verifying whether the actual TCP position is within the tolerance zone (24, 52, 66), stopping of the robot movement in the case that the actual TCP is outside (46) the tolerance zone (24, 52, 66). The tolerance zone (24, 52, 66) is extending in a hose-like manner along the movement path (22, 42, 64).