Virtual Protective Sheath Adaptation for Movable Machine Parts
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Solution Overview
Problem
Current safety technologies for machines, especially in human-robot collaboration, are inflexible and require specific adjustments for each application and process sequence, limiting their adaptability to environmental changes and process variations, and often result in overly protective and inefficient safety measures.
Innovation Solution
A method for dynamically adapting the geometry of a virtual protective shell around a moving machine part using non-contact distance sensors, where the position and orientation of measuring beams can be adjusted, and additional sensors provide real-time data for adjusting the protective field based on the tool, workpiece, or environment, allowing for situational and flexible safety responses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional safety sensors and fixed protective fields are used, then safety monitoring is provided, but the system lacks flexibility and adaptability to different applications and process variations
Solution Approach 1:
The protective field geometry is made dynamically adjustable through multiple distance sensors that can be selectively activated and positioned. The system transitions from fixed protective fields to dynamically configurable virtual protective shells that adapt to different tools, workpieces, and process sequences without requiring permanent reconfiguration or multiple dedicated safety systems.
Solution Approach 2:
A single safety system with multiple distance sensors serves multiple applications and process variations. The system can monitor different tools, workpieces, and environmental conditions using the same hardware infrastructure, eliminating the need for separate safety systems for each application while maintaining adaptability through selective sensor activation and geometric configuration.
2Adaptability or versatility
If fixed protective fields are programmed for specific applications, then safety monitoring is provided, but manual reconfiguration is required for each new application
Solution Approach 1:
The system performs self-configuration by automatically determining the geometry and position of the virtual protective shell based on real-time data from distance sensors, tool characteristics, workpiece dimensions, and environmental conditions. This eliminates the need for manual programming and reconfiguration for each new application, as the system autonomously adapts to the current operational context.
Solution Approach 2:
The system continuously receives feedback from multiple distance sensors monitoring the positions of tools, workpieces, and environmental objects. This feedback is used to dynamically adjust the protective field geometry and ensure appropriate safety monitoring without requiring manual intervention or pre-programming for each specific application scenario.
3Area of stationary object
If multiple distance sensors are used to monitor different areas, then coverage is improved, but system complexity and cost increase
Solution Approach 1:
The monitoring area is divided into multiple zones, each monitored by individual distance sensors. Each sensor independently monitors a specific sector or region, and the system integrates data from all sensors to create a comprehensive virtual protective shell. This segmentation allows extensive coverage while maintaining manageable system complexity through modular sensor deployment and independent zone monitoring.
Solution Approach 2:
Multiple distance sensors are merged into a unified safety system that creates a single integrated virtual protective shell. The system combines data from all sensors to form a comprehensive protective geometry, allowing extensive monitoring coverage to be achieved through a coordinated sensor network rather than multiple independent systems, thereby reducing overall complexity.
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
This approach enhances the intelligence and flexibility of safety systems, reducing manual intervention and ensuring maximum safety and productivity by automatically adjusting the protective field in response to changing conditions without pre-defined settings, thus improving machine safety in close human-machine cooperation.
Implementation Method 1
at least one non-contact distance sensor moving with the machine part... This sensor is preferably an optoelectronic distance sensor
Data Source
Figure 1~2
Figure 3a~4b
Figure 5
AI summary
A method for safeguarding a movable machine part of a machine (10) is described, wherein at least a part of the movable machine part is safeguarded by a protective sheath (16) by initiating a safety-related reaction of the machine (10) when an object (18) engages the protective sheath (16), wherein the protective sheath (16) is supported by at least one non-contact distance sensor (12) moving with the machine part, which measures several distance values with multiple measuring beams (14), and wherein the geometry of the protective sheath (16) is determined by the origin and orientation of the measuring beams (14) as well as distance thresholds for the respective measuring beams (14). The protective sheath (16) is adapted by changing the origin and/or orientation of the measuring beams (14).