3D Workcell Safety Monitoring With Calibration and Sensor Feedback
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Solution Overview
Problem
Industrial machinery safety systems, particularly those using 3D sensors, face challenges in configuration, data processing, and continuous monitoring, which can lead to safety hazards and inefficiencies in human-robot collaboration due to complex data streams and environmental variations.
Innovation Solution
A safety system that continuously monitors the workspace using 3D image sensors, performs initial calibration and registration, and tracks volumetric and surface representations to ensure accurate tracking, with environmental sensors to monitor temperature and humidity, and a controller to analyze data for consistency and issue alerts for potential safety hazards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If 3D sensors are used for workspace monitoring, then measurement precision and adaptability are improved, but device complexity and difficulty of detecting and measuring increase
Solution Approach 1:
The system performs initial calibration and registration of 3D sensors to the workspace before operation, storing reference data about static elements. This preliminary action establishes a baseline for continuous monitoring, reducing the complexity of real-time analysis by comparing current sensor data against pre-established references.
Solution Approach 2:
The patent segments the workspace into distinct static and dynamic elements, and further divides monitoring into multiple parameter categories (position, temperature, humidity, sensor health). This segmentation allows the complex monitoring task to be broken into manageable, independent analysis streams.
2Reliability
If continuous monitoring of safety system parameters is implemented, then reliability is improved, but use of energy and device complexity increase
Solution Approach 1:
The system implements continuous monitoring of workspace conditions and sensor health parameters without interruption during machinery operation. This continuous action ensures safety reliability by detecting hazards immediately, while the system is designed to maintain this continuous monitoring at efficient energy levels through optimized sensor operation and data processing.
Solution Approach 2:
The monitoring system continuously feeds back parameter values to the controller, which compares them against target objectives and issues alerts when deviations occur. This feedback mechanism ensures reliability by maintaining awareness of system state while allowing the system to operate efficiently within normal parameter ranges without constant active intervention.
3Measurement precision
If environmental sensors are added to monitor temperature and humidity, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The system uses a multi-functional sensor platform that integrates 3D imaging sensors with environmental sensors (temperature, humidity). This universal sensor system performs multiple monitoring functions simultaneously - workspace geometry detection, environmental condition monitoring, and sensor health tracking - reducing overall system complexity compared to separate dedicated systems for each function.
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
Ensures reliable and continuous monitoring of the workspace and safety system performance, preventing safety hazards by detecting errors and maintaining optimal operational conditions, thereby enhancing human-robot collaboration and productivity.
Implementation Method 1
3D time-of-flight cameras
Data Source
AI summary
Systems and methods for continuously monitoring a workcell during operation of industrial machinery are disclosed. The system may comprise a safety system that includes at least one sensor and supporting software and/or hardware for acquiring image data associated with the workcell; a monitoring system for detecting a parameter value associated with the safety system; and a controller configured to determine a status of the safety system based at least in part on the detected parameter value and cause an alert to be issued if the status of the safety system does not satisfy a target objective.