Robot Tool Sensor Shell for Hazard Zone Monitoring
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Solution Overview
Problem
Existing safety sensors fail to adequately secure tools on robots, particularly those with sharp or rotating parts, due to their small size, varied geometries, and fast movement, leading to increased injury risks even with force-limited robots, which prevents robots from receiving a CE mark for intrinsic safety.
Innovation Solution
A sensor system comprising distance sensors and a control unit, with a disk-shaped housing and fastening system that forms a protected field shell, ensuring secure fastening and monitoring of hazardous zones, using a fastening system with adapters that allow flexible attachment to robots and tools, and inherently safe design to prevent manipulation and forward forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing safety sensors are used to monitor hazardous zones, then the robot can operate with force limitation, but the tools with sharp or rotating parts remain inadequately secured, increasing injury risk
Solution Approach 1:
The protective function is segmented into multiple independent distance sensors arranged in a holder, each monitoring a specific sector of the hazardous zone. This segmentation allows comprehensive coverage of the tool's movement path while maintaining individual sensor reliability
Solution Approach 2:
A dedicated holder structure serves as an intermediary component between the robot's movable machine part and the distance sensors. This holder provides a stable mounting platform that ensures consistent sensor positioning and orientation, improving the reliability of hazard zone monitoring
2Area of stationary object
If multiple distance sensors are arranged to form a protected field shell, then coverage of hazardous zone is improved, but device complexity increases
Solution Approach 1:
Multiple distance sensors are merged into a single integrated holder structure that is mounted on the movable machine part. This combining approach maintains comprehensive hazardous zone coverage while reducing the number of separate mounting operations and simplifying the overall system structure
Solution Approach 2:
The holder structure serves multiple functions: it provides mounting for multiple distance sensors, ensures proper positioning and orientation, and creates a stable platform that works with various tool configurations. This multi-functionality reduces the need for additional specialized components
3Reliability
If the holder has a disk-shaped housing with round surfaces, then safety is improved by eliminating corners, but manufacturing complexity increases
Solution Approach 1:
The holder housing is designed with a disk shape featuring round surfaces and curved transitions instead of sharp corners. This curved geometry eliminates injury risks from corners while maintaining structural integrity. The design uses standard machining operations to create the curved surfaces, making the increased safety requirement compatible with conventional manufacturing processes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enhances work safety and throughput by securely monitoring hazardous zones, minimizing collision risks, and allowing direct human-robot collaboration, while being adaptable to various tool geometries and robot configurations, ensuring compliance with safety standards like EN/IEC 61496 and EN 13849.
Implementation Method 1
distance sensors (8) for monitoring a hazardous zone
Data Source
AI summary
A system having a sensor system comprising distance sensors for monitoring a hazardous zone at a movable machine part having at least one protected zone, wherein a tool is arranged at the movable machine part, wherein the distance sensors are arranged at a holder at the movable machine part, wherein a plurality of distance sensors are arranged, with the detection beams of the distance sensors forming a protected field shell, wherein the holder has the distance sensors, with the holder having a disk-shaped housing, with the disk-shaped housing having round surfaces and not having any corners at the outer surfaces, with the system comprising a fastening system, the fastening system comprises one of a first fastening adapter and a second fastening adapter at which the holder is respectively arranged for fastening the holder to the movable machine part.