Wearable Robot Proximity Detection for Shared Assembly Cells
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Solution Overview
Problem
In assembly environments, the separation of automated machines and human technicians due to safety concerns leads to reduced efficiency and assembly rates, as they cannot operate simultaneously in the same zone without risking safety.
Innovation Solution
A proximity reporting system that uses wearable proximity detectors for technicians and detectors on robots to dynamically determine their proximity, providing warnings and halting robot operations when thresholds are breached, ensuring safety while allowing coexistence in the same zone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If technicians are restricted from entering zones of operation of automated machines, then safety is improved, but assembly speed and efficiency deteriorate
Solution Approach 1:
The system dynamically adjusts the operational state of automated machines based on real-time technician proximity. When a technician enters a predefined distance threshold, the system transitions the machine from operational to halted state, and vice versa. This dynamic adjustment allows the system to adapt safety measures to actual conditions rather than maintaining static restrictions.
Solution Approach 2:
The system continuously monitors technician location using detectors and provides feedback to control the operational state of automated machines. The control unit receives proximity information and adjusts machine operation accordingly, creating a closed-loop feedback system that balances safety and productivity based on real-time conditions.
2Reliability
If automated machines and technicians are restricted to separate times of use, then safety is improved, but productivity and assembly rates deteriorate
Solution Approach 1:
The system enables dynamic sharing of workspace between technicians and automated machines through real-time proximity monitoring. Instead of restricting access to separate time periods, the system allows simultaneous presence by dynamically adjusting machine operation based on detected proximity, enabling both parties to utilize the same zone as needed.
3Reliability
If proximity monitoring systems are implemented, then safety and coexistence are improved, but device complexity increases
Solution Approach 1:
The system uses universal detectors that can identify both technicians and automated machines and determine their proximity. The same detection mechanism serves multiple purposes: detecting presence, determining proximity, and triggering appropriate safety responses, reducing the need for multiple specialized systems.
Data Source
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AI summary
Systems (100) and methods (200) are provided for reporting proximity in an assembly environment (130). One method (200) includes equipping (202) a technician (150) with a first proximity detector (160, 300, 410, 1160) that is wearable, disposing (204) a second proximity detector (160, 300, 420, 430, 1190) at a robot (140, 710, 720, 1150) that moves within a cell (132, 133, 1100) of the assembly environment (130), and directing (214) the first proximity detector (160, 300, 410, 1160) to provide a warning to the technician (150) if a distance between the first proximity detector (160, 300, 410, 1160) and the second proximity detector (160, 300, 420, 430, 1190) is less than a threshold.