Contactless Distance Sensing With Virtual Beams for Machine Safeguarding
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Solution Overview
Problem
Existing machine safety systems, particularly in human-robot collaboration environments, face challenges in accurately recognizing objects and preventing accidents due to inaccuracies in distance sensor measurements and environmental modeling.
Innovation Solution
A contactless distance sensor system that moves with the machine, using multiple virtual distance measuring beams to compare actual measurement values with predicted values, enhancing object recognition accuracy and robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single virtual distance measuring beam is used for object detection, then the system is simple to implement, but measurement accuracy deteriorates due to deviations in pose and surface model
Solution Approach 1:
The single distance measuring beam is segmented into multiple virtual distance measuring beams (first virtual beam and at least one further virtual beam with offset). Each beam provides an independent measurement path, and the system evaluates whether actual measured values are compatible with virtual measured values from multiple beams simultaneously, thereby improving object detection accuracy while managing system complexity through structured segmentation.
2Adaptability or versatility
If distance thresholds are adjusted to create a flexible protective dome, then adaptability improves, but reliability deteriorates due to deviations between assumed and actual line of sight
Solution Approach 1:
The system transitions from a single-line measurement approach to a multi-dimensional evaluation by introducing offset virtual beams that create a volumetric measurement space. Instead of relying on a single distance threshold that may be affected by line-of-sight deviations, the system evaluates compatibility across multiple spatial dimensions (multiple beams with different offsets), thereby maintaining adaptability while significantly improving reliability at edge positions.
Data Source
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AI summary
A method for safeguarding a machine (10) is described, in which objects (18) in a working area (20, 22) of the machine (10) are detected by a moving non-contact distance sensor (12) with at least one distance measuring beam (14) measuring an actual measurement for a distance, generating a first virtual distance measuring beam (28) that simulates the distance measuring beam (14), and comparing the actual measurement with its first virtual measurement. At least one further virtual distance measuring beam (30) is generated with an offset (32) to the first virtual distance measuring beam (28), and a further virtual measurement is calculated. The actual measurement is then compared with the virtual measurements to determine if they are compatible.