Petr Svarny

Petr Svarny, Jakub Rozlivek, Lukas Rustler et al.

The need to guarantee safety of collaborative robots limits their performance, in particular, their speed and hence cycle time. The standard ISO/TS 15066 defines the Power and Force Limiting operation mode and prescribes force thresholds that a moving robot is allowed to exert on human body parts during impact, along with a simple formula to obtain maximum allowed speed of the robot in the whole workspace. In this work, we measure the forces exerted by two collaborative manipulators (UR10e and KUKA LBR iiwa) moving downward against an impact measuring device. First, we empirically show that the impact forces can vary by more than 100 percent within the robot workspace. The forces are negatively correlated with the distance from the robot base and the height in the workspace. Second, we present a data-driven model, 3D Collision-Force-Map, predicting impact forces from distance, height, and velocity and demonstrate that it can be trained on a limited number of data points. Third, we analyze the force evolution upon impact and find that clamping never occurs for the UR10e. We show that formulas relating robot mass, velocity, and impact forces from ISO/TS 15066 are insufficient -- leading both to significant underestimation and overestimation and thus to unnecessarily long cycle times or even dangerous applications. We propose an empirical method that can be deployed to quickly determine the optimal speed and position where a task can be safely performed with maximum efficiency.

Petr Svarny, Michael Tesar, Jan Kristof Behrens et al.

So-called collaborative robots are a current trend in industrial robotics. However, they still face many problems in practical application such as reduced speed to ascertain their collaborativeness. The standards prescribe two regimes: (i) speed and separation monitoring and (ii) power and force limiting, where the former requires reliable estimation of distances between the robot and human body parts and the latter imposes constraints on the energy absorbed during collisions prior to robot stopping. Following the standards, we deploy the two collaborative regimes in a single application and study the performance in a mock collaborative task under the individual regimes, including transitions between them. Additionally, we compare the performance under "safety zone monitoring" with keypoint pair-wise separation distance assessment relying on an RGB-D sensor and skeleton extraction algorithm to track human body parts in the workspace. Best performance has been achieved in the following setting: robot operates at full speed until a distance threshold between any robot and human body part is crossed; then, reduced robot speed per power and force limiting is triggered. Robot is halted only when the operator's head crosses a predefined distance from selected robot parts. We demonstrate our methodology on a setup combining a KUKA LBR iiwa robot, Intel RealSense RGB-D sensor and OpenPose for human pose estimation.