Robotic Line Kitting Safety Circuit for Two-Step Stops
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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 abrupt stops and reduced throughput.
Innovation Solution
Implementing a safety circuit with a controlled two-step stop process and dynamic zone management, allowing robots to adjust their operation based on human presence, using sensors and visual displays to ensure safe transit and operation, and scheduling human intervention when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional safety mechanisms are used to detect human presence and halt robotic operations, then safety of human workers is improved, but robot productivity and throughput deteriorate due to abrupt stops
Solution Approach 1:
The patent implements dynamic safety zones that can be actively entered or exited by humans, allowing the robotic system to adapt its operation dynamically. When a safety zone is actively entered (detected by sensors), the robot halts; when exited, the robot resumes operation. This dynamic approach replaces static safety mechanisms with adaptive control, maintaining safety while minimizing unnecessary productivity losses.
Solution Approach 2:
The system continuously monitors the status of safety zones through sensors and provides feedback to the control system. This feedback loop enables real-time detection of human presence and automatic adjustment of robotic operations. The control system receives ongoing information about zone status and accordingly adjusts robot behavior, creating a responsive safety mechanism that only halts operations when truly necessary.
2Reliability
If safety zones are implemented with active entry detection, then safety is improved by allowing selective robotic halting, but device complexity increases due to additional sensors and control mechanisms
Solution Approach 1:
The workspace is segmented into multiple independent safety zones, each monitored by its own sensors. This segmentation allows the system to manage complexity by dividing the monitoring task into smaller, manageable units. Each zone operates independently, and the control system processes zone status individually, making the overall system more manageable and maintainable despite the added complexity.
Solution Approach 2:
The safety zone system serves multiple functions: it detects human presence, determines active entry status, controls robotic halting, and provides visual feedback through indicators. By consolidating these functions into a unified safety zone management system, the patent reduces overall system complexity compared to having separate mechanisms for each function.
3Reliability
If robotic operations are halted frequently for safety, then safety of human workers is improved, but loss of time increases due to repeated stoppages
Solution Approach 1:
The robotic system operates dynamically, halting only when a safety zone is actively entered and resuming immediately when the zone is exited. This dynamic response minimizes idle time by keeping the robot operational during periods when no human is present in safety zones, thereby reducing overall productivity loss while maintaining safety.
Solution Approach 2:
The system maintains continuous useful action by allowing robotic operations to proceed uninterrupted during periods when safety zones are not actively entered. The robot continues its productive work without unnecessary stoppages, and only halts when truly required for safety reasons, thus maximizing the continuity of useful action and minimizing time loss.
Data Source
AI summary
A robotic line kitting system is disclosed. In various embodiments, a signal associated with an unsafe condition is received via a communication interface. In response to the signal, a controlled operation to reduce a speed of movement of a robotic instrumentality is performed prior to a safety stop of the robotic instrumentality being triggered.