Voxel-Based Spatial Modeling for Dynamic Robot Safety Envelopes
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Solution Overview
Problem
Current industrial robots lack accurate dynamic modeling, particularly in collaborative human-robot applications, due to limitations in manufacturing tolerances, joint friction, and lack of direct measurable parameters, which hinders safe operation and accurate prediction of robot movements, especially in complex or aperiodic tasks.
Innovation Solution
A safety system that generates and visualizes potential occupancy envelopes (POEs) for both robots and humans, using 3D spatial representations and real-time scanning data, to restrict robot operations and ensure safe separation distances, incorporating simulation and sensor data for dynamic modeling and safety protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional industrial robots are used with fixed trajectories and guarding, then safety is maintained through separation, but workspace collaboration and productivity are constrained
Solution Approach 1:
The patent implements dynamic safety monitoring that continuously tracks robot trajectory deviations in real-time, allowing the safety system to adapt to actual robot movements rather than relying on fixed, conservative safety zones. This enables closer human-robot collaboration while maintaining safety through active monitoring and dynamic response to trajectory errors.
2Measurement precision
If robot accuracy is improved through better manufacturing, then positioning precision increases, but costs and manufacturing complexity increase
Solution Approach 1:
The patent employs feedback mechanisms where sensor data continuously monitors actual robot position and compares it to the planned trajectory. The system calculates deviations and uses this information to dynamically adjust safety parameters and warnings, achieving high positioning accuracy through active correction rather than relying solely on manufacturing precision.
Solution Approach 2:
The patent replaces reliance on mechanical manufacturing precision with electronic/software-based trajectory monitoring and correction systems. By using sensors, controllers, and computational algorithms to detect and compensate for positioning errors, the system achieves high accuracy without requiring extremely tight manufacturing tolerances.
3Reliability
If robot stopping distance is reduced for safety, then response time to hazards decreases, but dynamic performance and speed are limited
Solution Approach 1:
The patent implements preliminary safety actions by continuously monitoring trajectory deviations and issuing warnings before actual hazards occur. The system detects potential safety issues early in the robot's movement cycle, allowing operators to take preventive actions before the robot reaches hazardous positions, thereby maintaining high speeds while ensuring safety.
Data Source
AI summary
Systems and methods for spatially modeling a three-dimensional object are disclosed. In some embodiments, a disclosed method comprises: obtaining a polygon mesh including polygons representing a surface of an object; converting the polygon mesh into a triangle mesh including first triangles; subdividing the triangle mesh into a subdivided triangle mesh including second triangles, wherein the subdivided triangle mesh is overlaid with a voxel grid including a set of voxels; generating a point collection including a plurality of points each corresponding to a voxel in the voxel grid; and generating, based on the point collection and the voxel grid, at least one of: a surface point cloud representation, a surface voxel representation, or a volume voxel representation of the object.