Fraunhofer Institute for Factory Operation
and Automation IFF
Fraunhofer Institute for Factory Operation
and Automation IFF

Technologies for Safe Robot Applications

Flexible and human-centered work and manufacturing environments make it necessary to do away with the strict separation of humans and robots (for instance, by safety fencing). Open cooperation and collaboration permits combining humans’ strengths, such as flexibility, cognitive skills, experiential knowledge and sensorimotor skills, with robots’ advantages, such as 24/7 use, high precision and payload capacity. Such human-robot collaboration in a shared workspace necessitates keeping people safe.

© Fraunhofer IFF, Stefan Deutsch

Fraunhofer IFF researches and develops technologies for standard-compliant detection of dangerous situations between humans and robots (such as proximity or collision). The ISO/TS 15066 guidelines on speed and separation monitoring require monitoring of compliance with separation distances. The advantage of such collaboration is the ability to use not only small and midsize robots but also large and heavy-duty robots safely alongside humans. Dynamic adjustment of the requisite safety distances as a function of the current robot configuration (including joint positions and speeds) minimizes the robot’s space requirements and maximizes the workspace for humans.

We developed a system for this that continuously determines the necessary safety distances between humans and robotic systems (robots, tools, workpieces, etc.) in real time, in compliance with ISO/TS 15066. This system employs current joint positions and speeds and the robot’s current payload capacity and factors in the robot’s braking distance and stopping time to determine safety distances. This results in minimal and dynamic safety distances.

Effective technologies are needed to monitor required safety distances. Fraunhofer IFF is researching different designs, methods and sensor systems that each have their strengths and advantages in different applications and under different general conditions. Among others, these are:

  • optical sensor systems, such as projector and camera-based systems and purely camera-based systems (area scan and time-of-flight cameras),
  • touch sensors as (large-area) tactile flooring with spatial resolution,
  • proximity detection by capacitive sensing systems right on robots,
  • AI systems that analyze collaborative workspaces, including detection of people and their actions, and
  • projected visualization systems that visualize active/inactive warning and safety zones and additional information (robot states, process and more).

We additionally develop touch, high resolution and flexible sensors that cover entire robot surfaces as a tactile skin, detecting contact between robots and humans.

We are also researching inherently safe kinematics that are flexible and very lightweight, designed to move safely at reduced speeds, such as the mechatronic implementation of an elephant trunk.

The development of new safety technologies and components to implement flexible and innovative collaborative workspaces is one of our main research specializations at Fraunhofer IFF.

Our services:

  • Design and development of innovative sensor technologies and systems to implement open collaborative workspaces
  • Extensive knowledge and experience in the field of optical and touch sensor systems (patented technologies and systems)
  • Implementation of visualization systems that display safety, process and robot information
  • Completion of feasibility studies and building of demonstrators

Technologies

© Fraunhofer IFF, Stefan Deutsch

Projection and camera-based technology

We have developed projection and camera-based technology for monitoring workspaces that offers safety and interaction options, 3D environment detection, and worker assistance in human-robot collaboration scenarios. This technology is characterized by fast response times, short safety distances, independence from external light, and high availability.

© Fraunhofer IFF

Tactile sensor technology for safe human-robot collaboration

Tactile sensor systems modeled on the human sense of touch enable the detection of contact and pressure distribution and are used in human-machine interactions, process monitoring, and precise gripping. We develop customized tactile sensor systems ranging from prototypes to complex systems, with main applications in tactile floors, robot skins, and grippers.

© Fraunhofer IFF

Visualization systems

We research and develop software and hardware solutions that enable the visualization of a wide variety of information in the human environment. In addition to work environments in the context of human-robot collaboration (e.g., industry, medicine), we also address areas of human life such as nursing care.

© Fraunhofer IFF

AI-based methods for detecting people and their actions

Camera-based detection of people and AI-based prediction of their actions has made significant progress in recent years. We develop solutions to leverage the potential of such AI systems in new areas, such as human-technology interaction in industry, medicine, and healthcare.

References

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Optical workspace monitoring of MRK workstations

In the EU project “FourByThree,” we developed a technology for optical workspace monitoring that improves safety, interaction possibilities, 3D environment detection, and worker assistance in human-robot cooperation scenarios. This solution, based on projector and camera technology, projects dynamic safety zones and reduces extraneous light influences, thereby increasing availability and adaptability in various industrial environments.

 

© Fraunhofer IFF, Stefan Deutsch

Safe human-robot collaboration with heavy-duty robots in industrial applications

In the SAPARO project, we developed an innovative sensor and visualization system that enables dynamic safety zones based on robot movements and tactile floors for safe human-robot cooperation with heavy-duty robots.

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Tactile sensor systems for safe collision detection in human-robot interaction

We developed a cost-effective, robust, and customizable tactile sensor system for robotics that reliably detects collisions in human-robot collaboration and immediately stops the robot to ensure human safety. The TAKSENS project included the development, validation, and demonstration of the technical feasibility and economic potential of this technology.

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Stationary industrial robots as an assistance system for the production of die-casting molds

The STROBAS project developed an assistance system for processing die-casting molds based on an industrial robot. With its load capacity and precision, this system supports workers in physically demanding tasks. The innovative safety technologies developed at the Fraunhofer IFF rule out any danger to humans.

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Semi-automated shell end assembly through the integration of collaborative lightweight robots

In the AGREED project, industry and research partners worked together to develop modular systems that take human-robot collaboration (HRC) into account in order to intelligently automate and accelerate manufacturing and testing processes in shell end assembly.

Dynamic workspace monitoring, interaction functionality, and information visualization on a woodworking machine

In this project, on behalf of a leading global manufacturer of woodworking machines, novel technologies were developed to ensure personal safety and to implement interaction functionalities and information visualization, and these were integrated into a processing machine.

© Fraunhofer IFF

Collimated lighting system for large-area and safe monitoring of MRK workstations in heavy-duty robotics

The KOLI-BOT project designed and implemented a novel, active sensor system for workspace monitoring in large-scale and heavy-duty robotics. A collimated lighting unit was developed for this purpose, which enables a monitoring system developed at the Fraunhofer IFF to be used cost-effectively to cover even large workspaces.

Safe collaboration between humans and large-scale robots thanks to camera-monitored LED array floor modules

The SIMBA project is developing a new type of active sensor system for monitoring workspaces in the field of large-scale and heavy-duty robotics. The system is based on LED flooring which, in combination with camera technology, enables the cost-effective and functionally safe monitoring of large workspaces.

Uses

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Human-technology interaction in the care sector

We research and develop technologies that are universally available to people in assisted living facilities, record their current living situations, and provide situation-specific support. This particularly involves making everyday life easier through comfort functions and detecting emergency situations such as falls.

 

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Tactile sensor systems for reliable collision detection

In applications involving human-robot interaction, tactile sensor systems are an important key technology for monitoring and limiting the forces of interaction between humans and robots.

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Tactile sensor systems in pressure-sensitive floor coverings

By integrating tactile sensor systems into floor coverings, forces acting on the floor can be detected with spatial resolution. Floor coverings equipped in this way can detect both stationary and moving objects.

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