Safety Zone Monitoring With 3D Sensing and Person Classification
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Solution Overview
Problem
Current safety monitoring systems for handling devices, such as industrial robots, are prone to failures due to environmental changes and require manual reset, often relying on incomplete scanning methods like horizontal plane scanning or light barriers, which are not reliable for safe human-robot collaboration.
Innovation Solution
A monitoring device with multiple sensor units, including 3D cameras and vital signal detectors, that continuously monitor a safety area, classify objects as persons or non-persons, and control the handling device to switch between safe and working states based on accurate detection data, minimizing downtime and eliminating the need for manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If light barriers or horizontal plane scanning are used for safety monitoring, then the device complexity is reduced, but the reliability of safety detection deteriorates
Solution Approach 1:
The safety monitoring system is segmented into multiple independent sensor units, each responsible for detecting specific parameters (distance, velocity, acceleration). This segmentation allows each sensor to focus on a specific measurement task, improving overall detection reliability while maintaining manageable system complexity through modular architecture.
Solution Approach 2:
The system transitions from traditional two-dimensional horizontal plane scanning to three-dimensional spatial monitoring by adding vertical dimension detection capabilities. Multiple sensor units are positioned at different heights and angles to provide comprehensive coverage of the safety zone, eliminating blind spots and improving detection reliability without proportionally increasing complexity.
2Reliability
If comprehensive safety monitoring with multiple sensor units is implemented, then the reliability of safety detection is improved, but the device complexity increases
Solution Approach 1:
Each sensor unit is designed with multi-functionality, capable of detecting multiple parameters (distance, velocity, acceleration) simultaneously. This universal design reduces the total number of sensor units needed compared to having separate dedicated sensors for each parameter, thereby improving reliability through comprehensive monitoring while controlling system complexity.
Solution Approach 2:
Multiple sensor units are merged into a coordinated monitoring system with centralized evaluation. The sensors work together as an integrated unit, sharing data and coordinating their detection coverage. This merging approach achieves comprehensive safety monitoring through collaboration rather than through individual complex sensors, balancing reliability improvement with complexity management.
3Reliability
If manual reset and reactivation procedures are required for safety systems, then the ease of operation is reduced, but the reliability of safety monitoring is improved
Solution Approach 1:
The safety monitoring system incorporates self-diagnosis and automatic reset capabilities. When a fault or safety event occurs, the evaluation unit automatically analyzes the situation, determines whether reset is safe, and reactivates the handling device without requiring manual intervention. This self-service approach maintains high reliability through continuous monitoring while dramatically improving ease of operation by eliminating manual reset procedures.
Solution Approach 2:
The system implements continuous feedback loops where sensor data is constantly evaluated against safety criteria. When safety conditions are violated, immediate feedback triggers automatic response actions. When conditions return to safe states, feedback mechanisms automatically initiate reset procedures. This closed-loop feedback system ensures reliable safety monitoring while enabling automatic operation recovery without manual intervention.
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 provides reliable and cost-effective safety monitoring, reducing false alarms and downtime by accurately detecting persons and maintaining safe operating states without requiring a special safety officer, ensuring efficient operation of handling devices.
Implementation Method 1
a first sensor unit (9), in particular a 3D camera, for detecting an object entering the safety area (5)
Implementation Method 2
a second sensor unit (11), in particular a sensor unit for detecting vital signals, for determining additional data about an object that has entered the safety area (5)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Automated production installations require safety monitoring, in particular when said production installations are collaborating with people. The invention relates to a monitoring device for the safety monitoring of a handling device (2), wherein the handling device (2) has a safety zone (5). The handling device (2) has a safe operating state and a working state, wherein in the working state, the handling device (2) is designed to carry out a handling step, comprising a first sensor unit (9), a second sensor unit (11), and an evaluation module (8). The first sensor unit (9) is designed to detect the entry of an object into the safety zone (5) and to provide said entry to the evaluation module (8) as first sensor data. The evaluation module (8) is designed to actuate the handling device (2) based on the first sensor data, to assume the safe operating state as soon as an entry into the safety zone (5) was detected. The second sensor unit (11) is designed to monitor the safety zone (5) by sensors, and upon entry of the object into the safety zone, to determine additional data for the object, and to provide the same to the evaluation module (8). The evaluation module (8) is designed to classify the object as a person (3) or a non-person, based on the additional data, wherein the evaluation module (8) is designed to actuate the handling device (2), based on the additional data, and to assume the working state if the object was classified as a non-person.