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Kollaborative Industrieroboter werden für produzierende Unternehmen immer kosteneffizienter. Während diese Systeme für den menschlichen Mitarbeiter eine große Hilfe sein können, stellen sie gleichzeitig ein ernstes Gesundheitsrisiko dar, wenn die zwingend notwendigen Sicherheitsmaßnahmen nur unzureichend umgesetzt werden. Herkömmliche Sicherheitseinrichtungen wie Zäune oder Lichtvorhänge bieten einen guten Schutz, aber solch statische Schutzvorrichtungen sind in neuen, hochdynamischen Arbeitsszenarien problematisch.
Im Forschungsprojekt BeyondSPAI wurde ein Funktionsmuster eines Multisensorsystems zur Absicherung solcher dynamischer Arbeitsszenarien entworfen, implementiert und im Feld getestet. Kern des Systems ist eine robuste optische Materialklassifikation, die mit Hilfe eines intelligenten InGaAs-Kamerasystems Haut von anderen typischen Werkstückoberflächen (z.B. Holz, Metalle od. Kunststoffe) unterscheiden kann. Diese einzigartige Eigenschaft wird genutzt, um menschliche Mitarbeiter zuverlässig zu erkennen, so dass ein konventioneller Roboter in Folge als personenbewusster Cobot arbeiten kann.
Das System ist modular und kann leicht mit weiteren Sensoren verschiedenster Art erweitert werden. Es kann an verschiedene Marken von Industrierobotern angepasst werden und lässt sich schnell an bestehenden Robotersystemen integrieren. Die vier vom System bereitgestellten Sicherheitsausgänge können dazu verwendet werden - abhängig von der durchdrungenen Überwachungszone - entweder eine Warnung auszugeben, die Bewegung des Roboters auf eine sichere Geschwindigkeit zu verlangsamen, oder den Roboter sicher anzuhalten. Sobald alle Zonen wieder als „eindeutig frei von Personen“ identifiziert sind, kann der Roboter wieder beschleunigen, seine ursprüngliche Bewegung wiederaufnehmen und die Arbeit fortsetzen.
Entering the work envelope of an industrial robot can lead to severe injury from collisions with moving parts of the system. Conventional safety mechanisms therefore mostly restrict access to the robot using physical barriers such as walls and fences or non-contact protective devices including light curtains and laser scanners. As none of these mechanisms applies to human-robot-collaboration (HRC), a concept in which human and machine complement one another by working hand in hand, there is a rising need for safe and reliable detection of human body parts amidst background clutter. For this application camera-based systems are typically well suited. Still, safety concerns remain, owing to possible detection failures caused by environmental occlusion, extraneous light or other adverse imaging conditions. While ultrasonic proximity sensing can provide physical diversity to the system, it does not yet allow to reliably distinguish relevant objects from background objects.This work investigates a new approach to detecting relevant objects and human body parts based on acoustic holography. The approach is experimentally validated using a low-cost application-specific ultrasonic sensor system created from micro-electromechanical systems (MEMS). The presented results show that this system far outperforms conventional proximity sensors in terms of lateral imaging resolution and thus allows for more intelligent muting processes without compromising the safety of people working close to the robot. Based upon this work, a next step could be the development of a multimodal sensor systems to safeguard workers who collaborate with robots using the described ultrasonic sensor system.
Diese Arbeit präsentiert eine Methode zur zuverlässigen Personendetektion für die Absicherung des Arbeitsbereichs von Industrierobotern. Hierzu wird ein im Nahinfrarotbereich (NIR) arbeitendes aktives Kamerasystem eingesetzt, das durch erweiterte und robuste Hauterkennungseigenschaften besonders dazu geeignet ist, zwischen verschiedensten Materialoberflächen und menschlicher Haut zu unterscheiden. So soll zum einen die Erkennungsleistung gegenüber handelsüblichen, im visuellen Bereich arbeitenden RGB-Kamerasystemen gesteigert werden und gleichzeitig eine „intelligente“ Form des Mutings realisiert werden. Die im Rahmen des Projekts „Sichere Personendetektion im Arbeitsbereich von Industrierobotern durch ein aktives NIR-Kamerasystem (SPAI)“ entwickelte und hier vorgestellte Methode erreicht in einer ersten Variante eine pixelweise Personenerkennungsrate von ca. 98,16%.
The proper use of protective hoods on panel saws should reliably prevent severe injuries from (hand) contact with the blade or material kickbacks. It also should minimize long-term lung damages from fine-particle pollution. To achieve both purposes the hood must be adjusted properly by the operator for each workpiece to fit its height. After a work process is finished, the hood must be lowered down completely to the bench. Unfortunately, in practice the protective hood is fixed at a high position for most of the work time and herein loses its safety features. A system for an automatic height adjustment of the hood would increase comfort and safety. If the system can distinguish between workpieces and skin reliably, it furthermore will reduce occupational hazards for panel saw users. A functional demonstrator of such a system has been designed and implemented to show the feasibility of this approach. A specific optical sensor system is used to observe a point on the extended cut axis in front of the blade. The sensor determines the surface material reliably and measures the distance to the workpiece surface simultaneously. If the distance changes because of a workpiece fed to the machine, the control unit will set the motor-adjusted hood to the correct height. If the sensor detects skin, the hood will not be moved. In addition a camera observes the area under the hood. If there are no workpieces or offcuts left under the hood, it will be lowered back to the default position.
Persons entering the working range of industrial robots are exposed to a high risk of collision with moving parts of the system, potentially causing severe injuries. Conventional systems, which restrict the access to this area, range from walls and fences to light barriers and other vision based protective devices (VBPD). None of these systems allow to distinguish between humans and workpieces in a safe and reliable manner. In this work, a new approach is investigated, which uses an active near-infrared (NIR) camera system with advanced capabilities of skin detection to distinguish humans from workpieces based on characteristic spectral signatures. This approach allows to implement more intelligent muting processes and at the same time increases the safety of persons working close to the robots. The conceptual integration of such a camera system into a VBPD and the enhancement of person detection methods through skin detection are described and evaluated in this paper. Based upon this work, next steps could be the development of multimodal sensor systems to safeguard working ranges of collaborating robots using the described camera system.