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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.