UWB Worker Positioning for Restricted-Zone Robot Shutdown
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Solution Overview
Problem
Industrial accidents frequently occur due to the lack of effective systems for managing entrances and exits in automated industrial environments, where workers are at risk of accidents from malfunctioning equipment or unauthorized access.
Innovation Solution
An accident monitoring system using ultra-wide band (UWB)-based real-time positioning, which includes UWB tags worn by workers and anchors installed around processing lines, sensing temperature, humidity, illuminance, and frequency, and a programmable logic control (PLC) system that stops industrial robots and conveyor belts when workers enter access-limited areas, providing notifications and warnings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If safety sensors are installed at the entrance of the fence to stop the robot when a worker enters, then the worker is protected from robot operation, but the robot may resume operation erroneously or workers may still encounter accidents during maintenance
Solution Approach 1:
The patent replaces traditional mechanical safety sensors with a UWB (Ultra-Wideband) wireless positioning system. The system uses UWB tags attached to workers and anchors installed in the environment to continuously track worker position and communicate with the robot controller, eliminating the need for complex mechanical safety fences and sensors while providing more reliable safety monitoring throughout the entire workspace
Solution Approach 2:
The patent introduces a safety management server as an intermediary that receives position information from UWB anchors, determines whether workers are in unsafe areas, and communicates with the robot controller. This intermediary layer provides centralized safety management and prevents erroneous robot resumption by verifying worker positions before allowing operation to continue
2Reliability
If workers stop robots when entering work sites for minor repair, then safety is improved, but productivity decreases due to delays in the entire process
Solution Approach 1:
The patent implements dynamic safety management where the robot controller receives real-time position data from UWB tags and dynamically adjusts robot operation based on worker location. The system automatically pauses robot operation when workers enter predefined unsafe areas and resumes operation when workers exit these areas, providing safety without requiring manual intervention and maintaining process efficiency
Solution Approach 2:
The system pre-defines unsafe areas and safety zones in the virtual environment before operation begins. The safety management server continuously monitors worker positions against these pre-defined zones and takes preliminary action to pause robot operation before accidents can occur, eliminating the need for reactive stopping by workers
3Ease of operation
If traditional safety sensors are used at fence entrances, then robot operation can be stopped when workers enter, but workers are still at risk during unauthorized access or system malfunction
Solution Approach 1:
The UWB positioning system serves multiple safety functions simultaneously: it tracks worker positions in real-time, identifies unauthorized access to restricted areas, monitors worker proximity to robot workspaces, and provides continuous safety verification. This universal system replaces multiple separate safety mechanisms and provides comprehensive protection throughout the entire workspace rather than just at fence entrances
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
Prevents accidents by ensuring real-time monitoring and control of worker access, enhancing safety and productivity by automatically stopping machinery when workers enter restricted areas and providing alerts for maintenance needs based on environmental conditions.
Implementation Method 1
The UWB tag may transmit a time stamp to each of the plurality of UWB anchors, wherein each of the plurality of UWB anchors transmits the time stamp through the AP to the server, and the server may determine a position of the UWB tag based on a difference between the time stamps received from the plurality of UWB anchors
Data Source
AI summary
An accident monitoring system based on UWB-based real-time positioning comprises a UWB tag, a plurality of UWB anchors installed around a processing line and receiving the worker's position from the UWB tag and sensing predetermined information for the processing line, an AP receiving the worker's position and the predetermined information for from the plurality of UWB anchors, a server receiving the worker's position and the predetermined information for from the AP, storing the worker's position and the predetermined information for, and determining whether the worker is in a preset access-limited area, and a programmable logic control (PLC) box, upon receiving proximity information indicating that the worker is the access-limited area from the server through the AP, controlling to stop the industrial robot, the conveyor belt, and the motor in the processing line.