Robotic Line Kitting Safety Stops for Human Intervention
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Solution Overview
Problem
Robotic line kitting systems face challenges in ensuring safe operation around human workers, as existing safety mechanisms often result in productivity losses due to sudden halts and inefficient handling of items, particularly when detecting human presence in the workspace.
Innovation Solution
Implementing a robotic line kitting system with a safety circuit that includes sensors and a controlled safety stop mechanism, allowing for a two-step deceleration and resumption of operations, along with dynamic zone management and task scheduling to avoid human-robot collisions and ensure safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional safety mechanisms are used to detect human presence and rapidly halt robotic operations, then safety of human workers is improved, but robot productivity and throughput deteriorate due to periods of non-operation
Solution Approach 1:
The robotic system dynamically adjusts its operational state based on human presence detection. When a human is detected in the workspace, the system transitions from full-speed operation to a controlled two-step deceleration sequence, then to a halted state. This dynamic response allows the system to maintain high productivity during normal operation while ensuring safety when humans are present, resolving the contradiction between continuous productivity and safety-responsive halting.
Solution Approach 2:
The system performs preliminary detection of human presence in the workspace before executing any robotic operations. This advance detection allows the control system to proactively adjust operational parameters, initiate deceleration sequences, or halt operations before potential safety incidents occur. The preliminary action of detecting and responding to human presence prevents the need for sudden emergency stops, thereby maintaining productivity while ensuring safety.
2Reliability
If robotic operations are halted rapidly upon detecting human presence, then safety response time is improved, but item handling quality deteriorates due to sudden stops causing damage or dropping
Solution Approach 1:
The system executes preliminary actions in the form of a two-step deceleration sequence before coming to a complete halt. The first deceleration step reduces speed to a intermediate level, and the second step brings the robot to a stop. This preliminary deceleration action allows the robotic system to respond safely to human presence while maintaining item handling quality, as items are gently lowered or secured during the controlled deceleration rather than being dropped from sudden stops.
Solution Approach 2:
The controlled two-step deceleration mechanism acts as a cushioning measure that prevents the harmful effects of sudden stops. By gradually reducing velocity through two distinct deceleration phases, the system cushions the impact that would otherwise occur during emergency halts, thereby protecting items from damage or dropping while still achieving rapid safety response.
3Adaptability or versatility
If human workers are allowed to load stacks and remove output stacks in the same workspace as robotic operations, then operational flexibility is improved, but safety risk increases due to potential collisions between humans and robots
Solution Approach 1:
The robotic system continuously monitors the workspace for human presence through sensor feedback. When humans are detected loading input stacks or removing output stacks, the system receives feedback signals and automatically adjusts its operational parameters or halts operations in the affected zones. This feedback mechanism enables human workers to operate flexibly in the shared workspace while the robotic system responds in real-time to maintain safety, preventing collisions between humans and robots.
Data Source
AI summary
A robotic line kitting system is disclosed. In various embodiments, a sensor reading associated with a force sensor associated with a robotic instrumentality comprising the robotic line kitting system is received. It is determined based at least in part on the sensor reading that a condition requiring human intervention has been detected. A task to be performed by a human worker to correct the condition is scheduled.