Modular Time-of-Flight Sensor for Robot Tool Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current safety sensors are inadequate for protecting tool attachments on robots due to size, flexibility, and response time issues, particularly in confined spaces with complex geometries, leading to unsatisfactory protection and potential hazards during human-robot collaboration.
Innovation Solution
A modular system of safe optoelectronic distance sensors with single-photon avalanche diodes and time-of-flight technology, allowing for flexible arrangement and high spatial resolution, which can be dynamically adapted to the tool's geometry and movement, providing precise protection in complex danger zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing safety sensors (laser scanners, light grids) are used to protect tool attachments, then monitoring coverage can be achieved, but the sensors are too large or too heavy to be attached to the robot arm and are too inflexible in terms of protection geometry
Solution Approach 1:
The patent divides the monitoring task into multiple small, independent time-of-flight sensors distributed across the robot arm and tool attachment. Each sensor monitors a specific local area, and together they provide comprehensive coverage. This segmentation allows the system to achieve reliable protection without requiring a single large, inflexible sensor system.
Solution Approach 2:
The patent transitions from traditional 2D laser scanners to 3D spatial monitoring using multiple time-of-flight sensors positioned at different locations and orientations. This multi-dimensional arrangement enables flexible adaptation to complex tool geometries while maintaining compact individual sensor sizes.
2Device complexity
If radial validation from a single sensor origin is used, then monitoring can be implemented, but dead areas arise in the shadow of the tool that have to be covered with additional sensors in a complex manner
Solution Approach 1:
The patent combines multiple time-of-flight sensors at different positions and orientations to create overlapping monitoring fields. This merging of sensor data from multiple perspectives eliminates dead zones and shadow areas that would exist with a single radial sensor, providing complete monitoring coverage without complex additional sensors.
Solution Approach 2:
By distributing sensors in three-dimensional space around the tool attachment rather than using a single origin point, the system creates multiple validation perspectives. This spatial distribution ensures that no dead zones exist in shadow areas, as each region is monitored from multiple angular viewpoints.
3Reliability
If complex safety sensor systems are used to cover complex geometries, then protection can be achieved, but long response times result from complex evaluation of data, resulting in latency in data and signal transmission
Solution Approach 1:
The patent segments the monitoring system into independent time-of-flight sensors that each perform simple distance measurements to predefined safe positions. This segmentation allows parallel processing of multiple sensor data streams without complex cross-sensor evaluation, significantly reducing response time while maintaining accurate protection for complex geometries.
Solution Approach 2:
The patent changes the evaluation parameter from complex 3D spatial analysis to simple distance comparison against predefined safe positions. This parameter simplification enables rapid response times while maintaining protection accuracy for complex tool geometries, as each sensor independently compares its measured distance to its corresponding safe position threshold.
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 solution offers robust, cost-effective, and quick-reacting protection for tool attachments on robots, reducing the risk of injury by effectively covering complex geometries and ensuring precise monitoring with minimal latency, enabling safer human-robot collaboration.
Implementation Method 1
a light receiver (13), in particular a light receiver with at least one array (18) of single-photon avalanche diodes (14)
Implementation Method 2
the control and evaluation unit (10), from which a distance signal representative of the distance between the object and the light sensor is determined from the time between transmission and reception of the light pulse
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Method for monitoring a danger zone (2) and safe optoelectronic distance sensor for monitoring a danger zone (2) on a movable machine part (3) with a protective zone (4), wherein the safe distance sensor (1) is arranged on the movable machine part (3), wherein a tool (5) is arranged on the movable machine part (3), wherein a plurality of distance sensors (1) are arranged modularly and the protective zone (4) is adapted to the tool (5), wherein the distance sensor (1) is a time-of-flight sensor (12), wherein a light receiver (13) of the distance sensor (1) has at least one array (18) of single-photon avalanche diodes (14).