Robotic Palletizing Zone Detection for Operator Safety
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Solution Overview
Problem
Existing automatic robotic palletizing installations face productivity limitations while ensuring operator safety, as they require operators to enter enclosures for tasks like quality control, leading to machine downtime and the need for complex restart procedures.
Innovation Solution
The installation employs detection means to delimit multiple zones within the enclosure, allowing continuous robot operation while ensuring safety by independently managing the presence of operators and pallets, using sensors and cameras to control robot modes without stopping the entire machine, and simplifying restart processes by eliminating the need for manual arming and detection activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the detection means are positioned at a height greater than the height of an empty pallet, then the robot can operate continuously without stopping for pallet presence detection, but the ability to detect pallet presence is reduced
Solution Approach 1:
The detection system is segmented into two independent parts: detection means positioned at height to monitor zones without detecting pallets, and separate means (sensors) positioned to detect pallet presence. This segmentation allows each subsystem to perform its specific function optimally without interference.
Solution Approach 2:
The patent introduces an intermediary detection system that bridges the gap between the high-positioned detection means and pallet presence detection needs. The intermediary sensors detect pallet presence and provide this information to the control system, which then modulates the robot's operation accordingly without requiring the main detection means to be repositioned.
2Reliability
If the robot operates in multiple zones with different operating modes, then operator safety is improved, but the system complexity increases
Solution Approach 1:
The robot's operating mode is made dynamic and adaptive based on operator position within the enclosure. The control system continuously monitors operator position and automatically adjusts the robot's operating mode (normal mode, slow mode, or stopped) accordingly. This dynamic adaptation ensures safety without requiring complex manual intervention or system reconfiguration.
Solution Approach 2:
The system implements continuous feedback loops where detection means monitor operator position in real-time, and the control system receives this feedback to automatically adjust robot operation. This closed-loop feedback mechanism ensures operator safety while maintaining relatively simple system architecture through automated decision-making.
3Reliability
If the entire machine is shut down for safety when an operator enters the enclosure, then operator safety is ensured, but productivity is reduced due to complete shutdown and restart procedures
Solution Approach 1:
Instead of applying a uniform safety shutdown to the entire machine, the patent implements local quality control by allowing different operating modes in different zones of the enclosure. When an operator enters, only the specific zone where the operator is located is affected, while other zones can continue normal operation. This localized approach maintains safety while preserving overall productivity.
Solution Approach 2:
The system applies partial action by modulating robot operation rather than completely shutting down. Depending on operator position, the robot may continue at normal speed, operate in slow mode, or stop temporarily. This partial action approach provides sufficient safety protection without the excessive measure of complete shutdown, thereby maintaining productivity.
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
This solution enhances productivity by minimizing machine stops and downtime, ensuring operator safety without requiring the machine to be made safe, and improves ergonomics by simplifying operator interactions and adhering to safety standards.
Implementation Method 1
detection means which detect the presence of an element in said closed enclosure said operator intervention station
Data Source
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AI summary
The invention relates to an automatic automated installation in which at least one robot (2) is used in at least one mode of operation in at least one work zone (3). The installation comprises a closed space (1) equipped with at least one door (4) offering access to at least one operator intervention work station (6) which is situated in said work zone (3) of said robot, and means (7) for detecting the presence of an element (25; 26) in said closed space (1) at said operator intervention work station (6). The detection means (7) are arranged in said closed space (1) to delimit at least two zones (8, 9, 10) and are also associated with means (21) for control of said at least one mode of operation of the robot (2), each zone (8, 9, 10) being associated with one mode of operation of the robot (2). The detection means (7) are positioned a predetermined height from a floor (18) of said space (1), said height being greater than the height of an empty pallet (12).