ENABLING COLLABORATIVE ROBOT APPLICATIONS WITH MACHINE ... · Enabling Collaborative Robot Applications With Machine Vision Technology ISO 10218-1 : Section 5.10.2 Safety -rated monitored

ENABLING COLLABORATIVE ROBOT APPLICATIONS WITH

MACHINE VISION TECHNOLOGY

David L. Dechow FANUC America Corporation

ENABLING COLLABORATIVE ROBOT APPLICATIONS WITH MACHINE VISION

TECHNOLOGY Topics • Overview of collaborative robot technologies • The roles for machine vision • It’s still machine vision - Unique challenges • Applications and future trends

Enabling Collaborative Robot Applications With Machine Vision Technology

COLLABORATIVE ROBOT OVERVIEW

Defining the “collaborative” robot • The COBOT landscape



Safety considerations •ANSI/RIA specifications • ISO/TS 15066 •How they might be implemented



Safety considerations



Safety Considerations • Safety Rated Monitored Stop

• Safe I/O input from safety rated device (scanner or light screen) • Input to DCS enables speed limit of 0 mm/s or 0 deg/s • Robot program can remain in cycle, no e-stop issues • Once the operator leaves the protected area, production can resume with out any

delay for faults to clear or servo power to be re-enabled


ISO 10218-1 : Section 5.10.2 Safety-rated monitored stop The robot shall stop when a human is in the collaborative workspace. The stop function shall comply with 5.4 and 5.5.3. The robot may resume automatic operation when the human leaves the collaborative workspace. Alternatively, the robot may decelerate, resulting in a category 2 stop in accordance with IEC 60204-1. Once stopped, this

standstill shall be monitored by the safety-related control system in accordance with 5.4. Fault of the safety-rated monitored stop function shall result in a category 0 stop.

Note: This can include a monitored category 2 stop function in accordance with IEC 60204-1 provided by an electric power drive system that corresponds to an SOS in accordance with 61800-5-2.


Safety Considerations • Hand Guiding


ISO 10218-1 : Section 5.10.3 Hand Guiding When provided, hand guiding equipment shall be located close to the end effector and shall be equipped with the following: a) An emergency stop complying with 5.5.2 and 5.8.4, and b) An enabling device complying with 5.8.3

The robot shall operate at a safety-rated monitored speed determined by a risk assessment. The speed monitoring function

shall comply with 5.4. If the monitored speed exceeds the determined speed limit, a protective stop shall be issued.


Safety Considerations •Hand Guiding



Safety Considerations • Speed and Separation Monitoring

• “Fenceless” operation


ISO 10218-1 : Section 5.10.4 Speed and separation monitoring The robot shall maintain a determined speed and separation distance from the operator. These functions may be accomplished by integral features or a combination of external inputs. Detection of the failure to maintain the determined speed or separation distance shall result in a protective stop (see 5.5.3). The speed and separation monitoring functions shall comply with 5.4.2.

The robot is simply a component in a final collaborative robot system and is not in itself sufficient for a safe collaborative operation. The collaborative operation applications are dynamic and shall be determined by a risk assessment performed during the application system design. Information for use shall contain direction for implementing speed values and separation distances. ISO 10218-2 shall be used for designing collaborative operations. Additional information will be contained in the future ISO/TS 15066.. The relative speeds of the operator and robot need to be considered when calculating the minimum safe separation distance. Minimum distance requirements can be found in ISO 13855.




18” + Stopping Distance

Operating Space


Operating Space

Semi-Fenceless Concept using DCS Position Check and a Safety Area Scanner

Safety Zone: DCS Zero

Speed Zone

Warning Zone #2: Program

Pause

Warning Zone #1: Speed Override to 250mm/sec




Operating Space

Restricted Space using hard stop

18” (450mm)

Restricted Space w/

18” spacing

Fencing with 18” Spacing from Restricted Space

Zone switches could also be eliminated or reduced if the system integrator’s risk assessment validates

the safety of the system w/o the zone switch.


Fencing with 18” + Stopping Distance Spacing from

Restricted Space

Operating Space

Restricted Space w/ 18” + Stopping

Distance Spacing

Restricted Space using

DCS Position Check

Fencing Requirements using DCS Position Check


Safety Considerations • Power and Force Limiting

• Starting in 2012 it was possible under the RIA and ISO robot standard (RIA R15.06-2012/ISO 10218-1) to have a robot that can work alongside people without traditional guarding.

• However these robots required very special features under the ISO standard. • Specifically operation where contact could occur needed to follow a concept called

‘Power and Force Limited’ robot


ISO 10218-1 : Section 5.10.5 Power and force limiting by inherent design or control The robot shall limit dynamic power output, static force and speed or energy in compliance with 5.4. If any parameter limit is exceeded, a protective stop shall be issued.

The robot is only a component in a final collaborative robot system and alone is not sufficient for a safe collaborative operation. The collaborative operation application shall be determined by a risk assessment performed during the application system design. Information for use shall include details for setting established parameter limits in the controlled robot. ISO 10218-2 shall be used for designing collaborative operations. Additional information will be contained in the future ISO/TS 15066.


Safety Considerations • Power and Force Limiting


Force and power limiting can be achieved by monitoring and stopping robot based on force detected between a robot and operator

Force and power limiting = Contact Stop Stop

Push J2

Push J1

Retract


Applications and limitations • Best uses • Machine tending • Part installation and assembly • Palletizing/packing/depalletizing • Part delivery • Meeting speed and payload

expectations


THE ROLES FOR MACHINE VISION

The two sides of collaboration •Working autonomously or together

• “Safe” robots working in the vicinity of human workers • Robot and human collaboration


THE ROLES FOR MACHINE VISION

More-flexibile automation • Human-like performance means human-like environments

• True collaboration is elusive with respect to machine vision technology

• VGR for the collaborative robot – standard techniques and perhaps much more


IT’S STILL MACHINE VISION

It’s still machine vision… •Similar methods, new challenges

• Ease of use at highest demand • Complex application requirements impact machine vision

implementations • Support tools can ease robot programming • Broader recognition capabilities are at a premium • 3D is more in demand



Some VGR basics • 2D guidance – finding and delivering the object



• Some VGR basics • 3D guidance – now a requirement



Challenges – old and new • Lighting in the collaborative environment • The human interference factor • Handling random parts


APPLICATIONS AND FUTURE TRENDS

Application videos


APPLICATIONS AND FUTURE TRENDS

• What’s next • The market is justifiably constrained by safety demands • More machine vision capability will drive future applications


CONTACT INFORMATION

David L. Dechow Staff Engineer-Intelligent Robotics/Machine Vision FANUC America Corporation

+1 (248) 276-4058 [email protected]

Documents

ENABLING COLLABORATIVE ROBOT APPLICATIONS WITH MACHINE ... · Enabling Collaborative Robot Applications With Machine Vision Technology ISO 10218-1 : Section 5.10.2 Safety -rated monitored