3D Workspace Safety Monitoring With Dynamic Safe Zones
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Solution Overview
Problem
Conventional guarding systems in industrial environments are insufficiently granular to reliably monitor dynamic workspaces where humans and machinery interact, leading to potential safety hazards due to the complexity of configuring 3D sensor systems and the need for precise calculation of safe zones around moving machinery and humans.
Innovation Solution
A system that uses distributed sensors to dynamically monitor and classify workspace regions as occupied, unoccupied, or unknown, with real-time modeling of machinery and human trajectories, allowing for the identification of potentially occupied spaces and the generation of safe zones without requiring discrete speed limitations, thereby reducing the designated off-limits area for humans.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional guarding systems are used to ensure safety, then safety is improved, but workspace efficiency and accessibility deteriorate due to large restricted areas
Solution Approach 1:
The monitoring space is segmented into multiple sub-zones based on risk levels, allowing different machinery operations in different regions. High-risk areas have stricter controls while low-risk areas allow greater human access, optimizing both safety and productivity
Solution Approach 2:
The system dynamically adjusts safe zones and machinery speed limitations based on real-time human position and behavior. When no humans are present, machinery operates at full speed; when humans approach, speed is reduced or motion is paused, eliminating the need for constant conservative speed limitations
2Measurement precision
If 3D sensor systems are configured to monitor dynamic workspaces, then monitoring precision is improved, but system complexity increases due to the need for precise calculation of safe zones
Solution Approach 1:
Safe zones are pre-calculated and stored in the system before operation begins. When humans enter the workspace, the system quickly retrieves and applies the appropriate pre-computed safe zones rather than calculating them in real-time, reducing computational complexity while maintaining precision
Solution Approach 2:
The patent introduces an intermediary processing layer that simplifies the complex 3D spatial calculations by using pre-defined safe zone models and lookup tables, making the system more manageable while preserving monitoring precision
3Reliability
If discrete speed limitations are imposed on machinery, then safety is improved, but productivity deteriorates due to reduced operational flexibility
Solution Approach 1:
The system replaces fixed discrete speed limitations with dynamic speed adjustment based on real-time conditions. Machinery speed is continuously adapted according to human proximity and behavior, allowing full operational flexibility when safe while maintaining safety when humans are present
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 safety by dynamically adjusting safe zones and allowing machinery to operate closer to humans while maintaining safety, reducing the need for conservative speed limitations and minimizing the area restricted to humans, thus improving workspace efficiency and safety.
Implementation Method 1
3D LIDAR
Implementation Method 2
3D time-of-flight cameras
Data Source
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AI summary
Systems and methods monitor a workspace for safety purposes using sensors distributed about the workspace. The sensors are registered with respect to each other, and this registration is monitored over time. Occluded space as well as occupied space is identified, and this mapping is frequently updated.