3D Workcell Safety Monitoring With Sensor Validation Alerts
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Solution Overview
Problem
Industrial machinery safety systems, particularly those using 3D sensors, face challenges in configuration and continuous monitoring due to complex data streams and environmental variations, which can lead to safety hazards if not properly calibrated and maintained.
Innovation Solution
A system that continuously monitors the workspace using 3D image sensors, performs initial calibration and registration, and tracks static and moving elements, with environmental sensors to ensure accurate data and performance, and includes self-detection modules for errors and performance issues, issuing alerts or shutting down machinery if conditions are unsafe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If 3D sensors are used for workspace monitoring, then measurement precision and safety monitoring capability are improved, but device complexity and difficulty of detecting and measuring increase
Solution Approach 1:
The safety system is segmented into multiple independent monitoring channels, each responsible for specific safety functions. The controller divides complex safety monitoring into separate evaluation routines for different hazard types, allowing each component to be simpler while maintaining overall high precision through coordinated operation of multiple specialized subsystems
Solution Approach 2:
The controller acts as an intermediary between the complex 3D sensor data and the safety decision-making process. It processes raw sensor data through calibration routines and intermediate evaluation steps, transforming complex measurements into reliable safety signals that trigger appropriate machinery responses without requiring the entire system to handle full complexity simultaneously
2Reliability
If continuous monitoring is implemented, then reliability of safety system is improved, but use of energy and device complexity increase
Solution Approach 1:
The system implements periodic safety evaluations at controlled intervals rather than truly continuous monitoring. The controller performs safety checks at regular cycles, evaluating sensor data periodically to maintain high reliability while reducing peak energy consumption compared to uninterrupted real-time analysis of all sensor streams
Solution Approach 2:
The monitoring system maintains continuous readiness to detect hazards while managing energy consumption through efficient data processing. Once safety conditions are established, the system maintains continuous monitoring capability but processes data in optimized batches, ensuring uninterrupted safety coverage while minimizing energy waste through efficient use of processing resources
3Measurement precision
If calibration and registration processes are performed, then measurement precision is improved, but loss of time and device complexity increase
Solution Approach 1:
The system performs calibration and registration as preliminary actions during initial setup before normal operation begins. By completing these time-consuming precision tasks beforehand, the system establishes accurate measurement baselines that can be maintained throughout operation without repeatedly losing time to recalibration, thus improving ongoing measurement precision while accepting upfront time investment
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 accurately tracking changes and maintaining optimal sensor operation, thus enabling safe human-robot collaboration.
Implementation Method 1
3D depth sensors have been recently employed in various machine-guarding applications for providing guarding improvement. Examples of the 3D depth sensors include 3D time-of-flight cameras
Implementation Method 2
two-dimensional (2D) LIDAR sensors that use active optical sensing to detect the minimum distance to an obstacle along a series of rays emanating from the sensors
Data Source
AI summary
This Application regards a system for continuously monitoring a workcell during operation of industrial machinery. The system includes a safety system, a monitoring system, and a controller. The safety system includes a sensor and supporting software or hardware for acquiring image data associated with the workcell. The monitoring system is for detecting a parameter value associated with the safety system. And the controller is configured to determine whether the image data is valid based at least in part on the detected parameter value, and cause an alert to be issued responsive to determining that the image data is invalid.