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In the presented project, new approaches for the prevention of hand movements leading to hazards and for non-contact detection of fingers are intended to permit comprehensive and economical protection on circular saws. The basic principles may also be applied to other machines with manual loading and/or unloading. Two new detection principles are explained. The first is the distinction between skin and wood or other material by spectral analysis in the near infrared region. Using LED and photodiodes it is possible to detect fingers and hands reliable. With a kind of light curtain the intrusion into the dangerous zone near the blade can be prevented. The second principle is video image processing to detect persons, arms and fingers. In the first stage of development the detection of upper limb extremities within a defined hazard area by means of a computer based video image analysis is investigated.
At previous SIAS conferences, we presented a novel opto-electronic safety sensor system for skin detection at circular saws jointly developed with the Institute for Occupational Safety and Health of the German Social Accident Insurance (IFA). This work now presents the development results of our consecutive research on a prototype of a sensor system for more general production machine applications including robot workplaces. The system uses offthe shelf LEDs and photodiodes in combination with dedicated optics and a microcontroller system to implement a so-called spectral light curtain.
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%.