Machine Safety Sensor Architecture for Validated 3D Object Tracking
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Solution Overview
Problem
Current 3D camera systems for industrial safety do not provide precise object localization and tracking due to insufficient computing power in certified safety controllers, limiting their ability to perform complex safety functions like object tracking and hazard mitigation.
Innovation Solution
A safety system comprising a safe sensor for protective field monitoring and a non-safe evaluation unit for object localization, using redundant sensors and plausibility checks to ensure reliable object tracking and hazard assessment, with annotated training data generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a certified safety controller is used to perform complex safety functions like object tracking and localization, then safety compliance is ensured, but computing power is insufficient
Solution Approach 1:
The system divides the safety evaluation function into two segments: a safe sensor performs protective field monitoring and generates safe output signals, while a non-safe evaluation unit performs complex object localization and tracking. This segmentation allows each component to specialize - the safe sensor ensures compliance while the non-safe unit provides computing power for complex functions.
Solution Approach 2:
The safe sensor acts as an intermediary between the non-safe evaluation unit and the machine control system. It receives sensor data from the non-safe unit, performs independent protective field monitoring, and outputs safe signals to the machine. This intermediary ensures that complex evaluations can be performed without compromising safety compliance.
2Power
If a non-safe evaluation unit is used for object localization, then computing power is sufficient, but safety certification is not available
Solution Approach 1:
The safe sensor serves as a mediator that validates the outputs of the non-safe evaluation unit. It independently monitors protective fields and compares results with object localization data, providing safety certification through its certified evaluation without limiting the computing capabilities of the non-safe unit.
Solution Approach 2:
The system implements feedback through plausibility checks where the safe sensor's protective field monitoring results are compared with object localization and tracking data from the non-safe evaluation unit. This feedback mechanism ensures that complex functions are performed safely by continuously validating their outputs.
3Adaptability or versatility
If complex safety functions are implemented, then hazard mitigation capability is improved, but system complexity increases
Solution Approach 1:
The system segments complex safety functions into modular components: protective field monitoring, object detection, localization, and tracking. Each module operates independently with defined interfaces, allowing complex hazard mitigation capabilities to be built from simpler, well-understood building blocks that maintain overall system manageability.
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
Enables complex safety functions like object tracking and hazard mitigation with high reliability and compliance with safety standards by leveraging existing certified safety components for enhanced computing power and data processing.
Implementation Method 1
Optoelectronic sensors are very frequently used in non-contact monitoring for hazard prevention, such as on machinery in industrial environments
Implementation Method 2
In a time-of-flight (TOF) camera, which we will examine in more detail, a scene is illuminated with amplitude-modulated light. The light returning from the scene is received and demodulated at the same frequency used to modulate the transmitted light
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A safety system for securing a machine is described, comprising at least one safe sensor (10) and one non-safe evaluation unit (40). The safe sensor (10) includes a protective field evaluation (42), a safe interface (30), and a non-safe interface for outputting sensor data (44) to the non-safe evaluation unit (40). The non-safe evaluation unit (40) determines the positions of objects (20, 34) located within the detection range (18) by means of a non-safe position evaluation (46) of the sensor data (44). The object positions are validated by monitoring the at least one protective field.