U.S. patent application number 16/372306 was filed with the patent office on 2020-10-01 for proximity detection in fabrication environments having robots.
The applicant listed for this patent is The Boeing Company. Invention is credited to Fei Cai, Kevin Cheng, Farahnaz Sisco.
Application Number | 20200312112 16/372306 |
Document ID | / |
Family ID | 1000005087289 |
Filed Date | 2020-10-01 |
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United States Patent
Application |
20200312112 |
Kind Code |
A1 |
Cheng; Kevin ; et
al. |
October 1, 2020 |
PROXIMITY DETECTION IN FABRICATION ENVIRONMENTS HAVING ROBOTS
Abstract
Systems and methods are provided for reporting proximity in an
assembly environment. One method includes equipping a technician
with a first proximity detector that is wearable, disposing a
second proximity detector at a robot that moves within a cell of
the assembly environment, and directing the first proximity
detector to provide a warning to the technician if a distance
between the first proximity detector and the second proximity
detector is less than a threshold.
Inventors: |
Cheng; Kevin; (Seattle,
WA) ; Sisco; Farahnaz; (Mukilteo, WA) ; Cai;
Fei; (Edmonds, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Boeing Company |
Chicago |
IL |
US |
|
|
Family ID: |
1000005087289 |
Appl. No.: |
16/372306 |
Filed: |
April 1, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G06F 1/163 20130101;
B25J 9/1676 20130101; G08B 21/0225 20130101 |
International
Class: |
G08B 21/02 20060101
G08B021/02; B25J 9/16 20060101 B25J009/16; G06F 1/16 20060101
G06F001/16 |
Claims
2. The method of claim 1 wherein: transmitting comprises:
transmitting a first signal from the first proximity detector to
sensors in the assembly environment; and transmitting a second
signal from the second proximity detector to the sensors.
3. The method of claim 2 further comprising: determining a distance
between the first proximity detector and the second proximity
detector based on the first signal and the second signal.
4. The method of claim 2 wherein: the threshold is a first
threshold, and the method further comprises: directing the robot to
halt if the distance is less than a second threshold that is
smaller than the first threshold.
5. The method of claim 1 further comprising: placing multiple
proximity detectors at the robot, each of the multiple proximity
detectors transmitting a signal that identifies the robot and
distinguishes the proximity detector from other proximity detectors
at the robot; and determining distances between each of the
multiple proximity detectors at the robot and the first proximity
detector.
6. The method of claim 5 further comprising: directing the first
proximity detector to provide a warning to the technician if any of
the distances are less than the threshold.
7. The method of claim 6 further comprising: directing the robot to
halt movement if any of the distances are less than a second
threshold.
8.-16. (canceled)
17. A portion of an aircraft assembled according to the method of
claim 1.
18. A non-transitory computer readable medium embodying programmed
instructions which, when executed by a processor, are operable for
performing a method for reporting proximity in an assembly
environment, the method comprising: equipping a technician with a
first proximity detector that is wearable; disposing a second
proximity detector at a robot that moves within a cell of the
assembly environment; transmitting signals from the proximity
detectors to sensors in the assembly environment that are disposed
outside of the cell; and directing the first proximity detector to
provide a warning to the technician if a distance between the first
proximity detector and the second proximity detector, determined
based on the signals from the proximity detectors, is less than a
threshold while the technician is within the cell.
19. The medium of claim 18 wherein: transmitting comprises:
transmitting a first signal from the first proximity detector to
sensors in the assembly environment; and transmitting a second
signal from the second proximity detector to the sensors.
20. The medium of claim 19 wherein the method further comprises:
determining a distance between the first proximity detector and the
second proximity detector based on the first signal and the second
signal.
21. The medium of claim 19 wherein: the threshold is a first
threshold, and the method further comprises: directing the robot to
halt if the distance is less than a second threshold that is
smaller than the first threshold.
22. The medium of claim 18 wherein the method further comprises:
placing multiple proximity detectors at the robot, each of the
multiple proximity detectors transmitting a signal that identifies
the robot and distinguishes the proximity detector from other
proximity detectors at the robot; and determining distances between
each of the multiple proximity detectors at the robot and the first
proximity detector.
23. The medium of claim 22 wherein the method further comprises:
directing the first proximity detector to provide a warning to the
technician if any of the distances are less than the threshold.
24. The medium of claim 23 wherein the method further comprises:
directing the robot to halt movement if any of the distances are
less than a second threshold.
25.-33. (canceled)
34. A portion of an aircraft assembled according to the method
defined by the instructions stored on the computer readable medium
of claim 18.
35. A system for proximity reporting in an assembly environment,
the system comprising: a first proximity detector that is wearable;
a second proximity detector that is disposed at a robot in a cell
of the assembly environment; sensors in the assembly environment
that are disposed outside of the cell and a proximity server
comprising: a memory storing data indicating a first threshold and
a second threshold that is smaller than the first threshold; and a
controller that analyzes a first signal and a second signal
received by the sensors to determine a distance between the first
proximity detector and the second proximity detector based on the
first signal and the second signal, provides a notification to the
first proximity detector if the distance is less than the first
threshold, and provides a notification to the second proximity
detector if the distance is less than the second threshold while
the first proximity detector is within the cell.
36. The system of claim 35 wherein: the first proximity detector
comprises: a transceiver; and a controller that directs the
transceiver to transmit a first signal to sensors in the assembly
environment, and that warns a technician wearing the proximity
detector, based on a notification received from a proximity
reporting server.
37. The system of claim 35 wherein: the first proximity detector is
implemented within a hat, helmet, glasses, vest, or glove.
38. The system of claim 36 wherein: the second proximity detector
comprises: a transceiver; and a controller that directs the
transceiver to transmit a second signal to the sensors in the
assembly environment, and that directs the robot to halt, based on
a notification received from the proximity reporting server.
39. Fabricating a portion of an aircraft using the system of claim
35.
40. A system for detecting a proximity between technicians and
robots, the system comprising: sensors that receive signals
indicating positions of a first proximity detector worn by a
technician and a second proximity detector at a robot, and that are
disposed outside of a cell occupied by the robot and the
technician; and a proximity server comprising: a memory that stores
the signals; and a controller that determines a distance between
the first proximity detector and the second proximity detector,
directs the first proximity detector to provide a warning to the
technician if the distance is less than a first threshold, and
directs the robot to halt if the distance is less than a second
threshold while the technician is within the cell.
41.-44. (canceled)
45. Fabricating a portion of an aircraft using the system of claim
40.
Description
FIELD
[0001] The disclosure relates to the field of assembly, and in
particular, to human-machine interactions in an assembly
environment.
BACKGROUND
[0002] In an assembly environment, it remains desirable to assemble
new parts as quickly and efficiently as possible. It is not
uncommon for certain assembly tasks to be performed by automated
machines, while other assembly tasks are performed by human
technicians. To ensure safety, technicians are restricted from
entering zones of operation of the automated machines while the
automated machines are operating. This results in "stayout zones"
that may reduce the speed and efficiency at which the technicians
operate, and or may result in slower assembly rates, which is
undesirable. At the same time, it is infeasible to rely on operator
awareness of nearby automated machines or otherwise allow automated
machines to operate in tandem with technicians in the same zone.
Hence, automated machines and technicians are restricted to
separate times of use if they both will be utilizing the same
zone.
[0003] Therefore, it would be desirable to have a method and
apparatus that take into account at least some of the issues
discussed above, as well as other possible issues.
SUMMARY
[0004] Embodiments described herein dynamically determine the
proximity of a technician to a robot, and perform a variety of
corrective measures based on this proximity. For example, within a
first proximity, the technician may receive a warning, and within a
second proximity, the robot may be halted. Furthermore, multiple
proximity detectors may be disposed at a robot to accurately track
the position of multiple components of the robot.
[0005] One embodiment is a method for reporting proximity in an
assembly environment. The method includes equipping a technician
with a first proximity detector that is wearable, disposing a
second proximity detector at a robot that moves within a cell of
the assembly environment, and directing the first proximity
detector to provide a warning to the technician if a distance
between the first proximity detector and the second proximity
detector is less than a threshold.
[0006] A further embodiment is a non-transitory computer readable
medium embodying programmed instructions which, when executed by a
processor, are operable for performing a method for reporting
proximity in an assembly environment. The method includes equipping
a technician with a first proximity detector that is wearable,
disposing a second proximity detector at a robot that moves within
a cell of the assembly environment, and directing the first
proximity detector to provide a warning to the technician if a
distance between the first proximity detector and the second
proximity detector is less than a threshold.
[0007] A further embodiment is a system for proximity reporting in
an assembly environment. The system includes a first proximity
detector that is wearable, a second proximity detector that is
disposed at a robot in a cell of the assembly environment, and a
proximity server. The proximity server includes a memory storing
data indicating a first threshold and a second threshold that is
smaller than the first threshold, and a controller that analyzes
the first signal and the second signal to determine a distance
between the first proximity detector and the second proximity
detector, provides a notification to the first proximity detector
if the distance is less than the first threshold, and provides a
notification to the second proximity detector if the distance is
less than the second threshold.
[0008] A further embodiment is a system for detecting a proximity
between technicians and robots. The system includes sensors that
receive signals indicating positions of a first proximity detector
worn by a technician and a second proximity detector at a robot.
The system also includes a proximity server. The proximity server
includes a memory that stores the signals, and a controller that
determines a distance between the first proximity detector and the
second proximity detector, directs the first proximity detector to
provide a warning to the technician if the distance is less than
the first threshold, and directs the robot to halt if the distance
is less than a second threshold.
[0009] Other illustrative embodiments (e.g., methods and
computer-readable media relating to the foregoing embodiments) may
be described below. The features, functions, and advantages that
have been discussed can be achieved independently in various
embodiments or may be combined in yet other embodiments further
details of which can be seen with reference to the following
description and drawings.
DESCRIPTION OF THE DRAWINGS
[0010] Some embodiments of the present disclosure are now
described, by way of example only, and with reference to the
accompanying drawings. The same reference number represents the
same element or the same type of element on all drawings.
[0011] FIG. 1 illustrates a proximity reporting system in an
illustrative embodiment.
[0012] FIG. 2 is a flowchart illustrating a method for reporting
proximity in an illustrative embodiment.
[0013] FIG. 3 is a diagram of a proximity detector in an
illustrative embodiment.
[0014] FIGS. 4-6 depict distances between proximity detectors in an
illustrative embodiment.
[0015] FIGS. 7-8 depict a technician proceeding across a cell of a
factory floor in an illustrative embodiment.
[0016] FIGS. 9-10 illustrate communications transmitted between
proximity detectors and a proximity reporting server in an
illustrative embodiment.
[0017] FIG. 11 is a block diagram of a proximity reporting system
in an illustrative embodiment.
[0018] FIG. 12 is a flow diagram of aircraft production and service
methodology in an illustrative embodiment.
[0019] FIG. 13 is a block diagram of an aircraft in an illustrative
embodiment.
DESCRIPTION
[0020] The figures and the following description provide specific
illustrative embodiments of the disclosure. It will thus be
appreciated that those skilled in the art will be able to devise
various arrangements that, although not explicitly described or
shown herein, embody the principles of the disclosure and are
included within the scope of the disclosure. Furthermore, any
examples described herein are intended to aid in understanding the
principles of the disclosure, and are to be construed as being
without limitation to such specifically recited examples and
conditions. As a result, the disclosure is not limited to the
specific embodiments or examples described below, but by the claims
and their equivalents.
[0021] FIG. 1 is a diagram of proximity reporting system 100 in an
illustrative embodiment. Proximity reporting system 100 comprises
any system operable to dynamically determine distances between
proximity sensors within an assembly environment. Proximity
reporting system 100 has been enhanced to distinguish between
technicians and robots, and to provide warnings and/or other
mitigation based on distances between technicians and robots. This
provides a technical benefit by ensuring the safety of technicians
who work near robots, while also increasing the up-time of robots
within a cell. As used herein, a "cell" comprises any dedicated
workspace or volume in which one or more robots/machines are
intended to operate.
[0022] In this embodiment, proximity reporting system 100 includes
proximity reporting server 110, and sensors 120 (e.g., radio
antennae, transceivers, cameras, etc.). Sensors 120 receive input
from proximity detectors 160, which are disposed within one or more
of cells 132-133 of an assembly environment 130 (e.g., a factory
floor), and hence sensors 120 operate as an interface of proximity
reporting server 110. Proximity detectors 160 are capable of being
worn by one or more technicians 150, and also may be disposed at
portions 142 (e.g., moving components) of robots 140. Robots 140
may comprise robotic arms, Automated Guided Vehicles (AGVs), flex
track machines and other automated devices that move within a cell.
As depicted, a technician 150 is wearing a proximity detector 160
within cell 132, and is at a proximity P from a robot 140 within
cell 133. Furthermore, as depicted, there is presently no
technician or proximity detector within cell 133.
[0023] Based on signals from proximity detectors 160, controller
112 of proximity reporting server 110 determines the location of
each proximity detector 160. If proximity detectors 160 for one or
more technicians are closer than predefined thresholds stored in
memory 114 to a proximity detector 160 at a robot 140, then
controller 112 may provide a warning. Controller 112 may be
implemented, for example, as custom circuitry, as a hardware
processor executing programmed instructions, or some combination
thereof.
[0024] Proximity reporting system 100 enables human-machine
collaboration by providing dual safety paths. That is, the robots
140 and technicians 150 are equipped with transceivers to
communicate their locations, and these locations may be compared to
each other. Based on this comparison, different levels of
warning/remediation are provided (e.g., to warn humans and/or
shutdown robots) in order to ensure safety when humans and robots
work together in the same cell/zone.
[0025] Illustrative details of the operation of proximity reporting
system 100 will be discussed with regard to the flowchart of FIG.
2. Assume, for this embodiment, that a technician 150 of FIG. 1 is
planning on entering a cell 132 where robots 140 are presently
operating. For example, the robots may be assembling/joining
composite parts and/or metal parts for use in an aircraft.
[0026] FIG. 2 is a flowchart illustrating a method 200 for
reporting proximity in an illustrative embodiment. The steps of
method 200 are described with reference to proximity reporting
system 100 of FIG. 1, but those skilled in the art will appreciate
that method 200 may be performed in other systems. The steps of the
flowcharts described herein are not all inclusive and may include
other steps not shown. The steps described herein may also be
performed in an alternative order.
[0027] In step 202, a technician 150 is equipped with a first
proximity detector (e.g., one or more of proximity detectors 160).
The first proximity detector is wearable in that it may be carried
on the technician in a hands-free manner. For example, the
proximity detector may be added to headwear (e.g., a helmet) of the
technician, may be equipped by hook-and-loop fastener (e.g.,
Velcro) fabric to clothing worn by the technician 150, may be
placed in a pocket of the technician, may be in the form of a
pendant or smart wrist watch worn by the technician 150, may be
sewn or bonded to clothing worn by the technician 150, may be
implemented as smart safety glasses that provide visual, audio or
vibratory warnings or any combination thereof, or may be equipped
via other means.
[0028] In step 204, a second proximity detector is disposed at a
portion 142 of a robot 140 that moves within assembly environment
130. This may comprise placing multiple proximity detectors 160 at
(e.g., disposed on or within) each robot 140 within the cell, and
may be performed during initial setup and calibration of the robots
140 before maintenance or inspection is desired. In some
embodiments, the second proximity detector is coupled with the
power supply of the robot 140, and communicates with a controller
of the robot 140. With the first proximity detector and second
proximity detector in place, the technician 150 proceeds into the
cell 132 (e.g., to perform inspections, assist with assembly or
maintenance). During this time, robots 140 within the cell 132 may
continue to operate.
[0029] In step 206, the first proximity detector transmits a first
signal to sensors 120 in the assembly environment 130 (e.g.,
sensors 120 disposed outside of the cell 132, inside of the cell
132, at the robot 140, etc.). In one embodiment, the first signal
comprises an UltraWide Band (UWB) radio signal that provides a
unique identifier for the first proximity detector that
distinguishes it from other proximity detectors 160 in assembly
environment 130. The first proximity detector may be associated
with a specific technician indicated in memory 114 of proximity
reporting server 110. In a further embodiment, the first signal
also explicitly recites the technician or robot to which the first
proximity detector is attached. In still further embodiments, the
first signal is transmitted over multiple different radio bands or
channels of communication. The first signal may even be transmitted
via a Light Emitting Diode (LED) as a visual code in certain
embodiments. Transmitting the first signal via multiple distinct
channels of communication provides a technical benefit of ensuring
that the signal can be received and processed by sensors 120. The
first signal may be transmitted continuously or periodically (e.g.,
once or multiple times per second).
[0030] In step 208, the second proximity detector transmits a
second signal to the sensors 120. The second signal uniquely
identifies the second proximity detector, and may be transmitted
via the same channels and in a similar manner to the first signal.
The first signal and the second signal are received at sensors 120,
and the signals are provided to proximity reporting server 110 for
analysis.
[0031] In step 210, controller 112 of proximity reporting server
110 determines a distance between the first proximity detector and
the second proximity detector based on the first signal and the
second signal. This may be performed by consulting information
stored in memory 114 indicating a position of each sensor,
triangulating a first position of the first proximity detector and
a second position of the second proximity detector based on the
strength of signals received at each sensor 120, and determining an
amount of separation between the first position and the second
position. Memory 114 may store signals from the sensors 120 as a
part of this process. In further embodiments wherein the sensors
120 comprise cameras, the angle of each camera, and stereoscopic
equipment or techniques may be used in order to determine position.
In further embodiments, controller 112 may select which proximity
detectors to determine distances between. For example, controller
112 may selectively forego distance determinations between
proximity detectors located on technicians, proximity detectors
located on the same entity (e.g., the same technician, the same
robot, etc.), proximity detectors located on robots (e.g., in
circumstances where existing collision avoidance technologies for
the robots already prevent collisions), etc. This may increase the
rate at which controller 112 may perform distance determinations
which are most relevant (i.e., most likely to enhance safety). In
still further embodiments, motion detection techniques may be used
on distance data acquired over time to determine the current speed
and/or direction of a technician or robot.
[0032] After the distance has been determined, in step 212
controller 112 determines whether the distance is less than the
first threshold. The distance thresholds described herein may be
statically defined on a per-robot basis, or may be dynamically
determined based on movements indicated in an NC program for the
robot, and/or a position of the robot within the NC program as the
robot continues to operate. For example, if a path of a robot in
the future is expected to cause the robot to reduce its distance to
a technician, the threshold may be increased to ensure that a
warning is issued more quickly.
[0033] If the distance is not less than the first threshold, then
the technician 150 is far away from the robot 140. Therefore, the
robot 140 may continue operations. Processing therefore continues
to step 210. Alternatively, if the distance is less than the first
threshold in step 212, then in step 214, controller 112 directs the
first proximity detector (e.g., via sensors 120) to provide a
warning to the technician 150. The operating environment within the
cell 132 may include visual, auditory, and/or other stimuli that
may dull the senses of the technician 150. Therefore, the warning
may be generated to stimulate multiple senses (e.g., via bright
light, vibratory motion, and or distinctive sounds). The warning
may even take the form of a verbal warning stating "halt movement
forward," "do not move to the left," "do not move south," or
similar phrases, depending on the location of the technician
relative to the robot. The warning is a cue for the technician 150
that encourages increased awareness and caution. In further
embodiments, the warning may be implemented in the form of a
flashing light on the helmet, glasses, or gloves of the technician,
or as a flashing light or siren at the robot.
[0034] In step 216, controller 112 also determines whether the
distance between the first proximity detector and the second
proximity detector is less than a second threshold. If the distance
is less than the second threshold, then in step 218 controller 112
directs the robot 140 to halt. This provides a technical benefit by
ensuring that the technician remains safe, even when they move
close to an actively operating robot. This also provides a
technical benefit because it does not require each robot to include
its own dedicated technician avoidance sensors and logic.
[0035] Method 200 may be performed for multiple sets of proximity
detectors substantially concurrently and asynchronously. For
example, method 200 may be performed multiple times to determine
additional distances between a proximity detector at a technician
and proximity detectors at additional robots. This enables
proximity detection to be performed for all relevant entities
within a manufacturing cell, or even across an entire factory
floor.
[0036] FIG. 3 is a diagram of a proximity detector 300 in an
illustrative embodiment. Proximity detector 300 includes a
controller 310, memory 320, and a primary transceiver 330 as well
as a secondary transceiver 340. Primary transceiver 330 and
secondary transceiver 340 operate using different frequency ranges
(or modalities of communication, such as optical vs. radio) in
order to transmit a signal from proximity detector 300. Thus, if
one frequency range experiences interference or noise, the other
transceiver may still provide the signal at another frequency
range. Proximity detector 300 also includes vibration generator 360
(e.g., a piezoelectric element, a vibrational motor, etc.), and
speaker 350. When generating a warning, controller 310 may activate
one or both of these elements to draw the attention of a
technician. In further embodiments, proximity detector 300 may
generate an alert at eyewear worn by the technician 150 to cause
flashing lights, other visual input, or vibrations that provide a
warning. For example, an audio warning may be generated by portions
of eyewear located proximate to the temples of a technician and in
particular the ends of the temples. In further embodiments, the
eyewear comprises smart safety glasses with visual, audio or
vibratory warnings or any combination thereof. In some embodiments,
Bluetooth technology is utilized, wherein the technician wears a
base station in communication with wearable devices such as hats,
helmets, gloves, glasses, vests, etc. that implement proximity
detectors. In this embodiment, proximity detector 300 also includes
battery 370 and sensor 380. Sensor 380 detects a battery level
(e.g., by measuring voltage at battery 370). Sensor 380 may report
this battery level to controller 310. If the battery level is below
a desired value, then controller 310 may generate a battery level
warning via speaker 350 and/or vibration generator 360. Proximity
detector 300 may further include a button 390. Pressing button 390
may operate the first proximity detector to issue a command to
remotely halt robots 140 that are within the same cell as the
technician 150.
[0037] In further embodiments, battery level information may be
reported to proximity reporting server 110. Each cell may be
associated with a predetermined battery level. This may be the
battery level desired in order to ensure that proximity detector
300 continues to operate while a technician performs inspections or
maintenance within that cell. Upon entry to the cell (e.g., as
determined based on a triangulated location of the proximity
detector 300), controller 112 may compare the current battery level
to that desired for the cell. Controller 112 may further direct the
proximity detector 300 to generate a warning if the battery level
is below the predetermined battery level when the technician
attempts to enter the cell. Proximity reporting server 110 may
further estimate a period of time during which a technician is
expected to remain in the cell 132 that they currently occupy, and
instruct proximity detector 300 to generate a battery level warning
if the battery level drops below a battery level expected at this
point in time during the inspection or maintenance process.
[0038] In still further embodiments, proximity reporting server 110
may determine that a proximity detector has not transmitted a
signal for longer than a predefined duration (e.g., one second, ten
seconds, thirty seconds, one minute, etc.). In response to this
determination, proximity reporting server 110 may transmit a halt
instruction to all robots located in the cell that the proximity
detector was last detected in. This ensures safety in the event of
an unexpected power loss to a proximity detector, and enables the
technician to safely exit the cell even in the event of total
battery loss or device failure.
[0039] Additional proximity detectors, such as those disposed at a
robot 140, may be equipped without vibration generators, batteries,
battery sensors, and/or speakers. Such proximity sensors may be
directly attached to a power source of the robot that they are
attached to, and may have controllers which directly communicate
with a controller of the robot 140 to which they are mounted.
[0040] FIGS. 4-6 depict distances between proximity detectors in an
illustrative embodiment. Assume, for this embodiment, that
proximity detector 410 is located at a technician who is moving
within a cell. The technician is moving towards a proximity
detector 420 disposed at a first robot, and a proximity detector
430 disposed at a second robot as shown in FIG. 4. The robots to
which proximity detectors 420 and 430 are attached are also moving,
and in different directions. As the technician and the robots move,
the distance between proximity detector 410 and proximity detectors
420 and 430 decreases, until proximity detector 420 is within a
distance D2, as shown in FIG. 5. This causes the proximity detector
410 to emit a warning. In FIG. 6, the technician and robots have
continued to move, bringing proximity detector 420 within a
distance D1, and bringing proximity detector 430 within a distance
D2. The warning continues to emanate from proximity detector 410,
and the robot to which proximity detector 420 is attached, is
halted. Halting the robot may comprise preventing the robot from
moving, deactivating the robot, causing the robot to move into a
"safety" pose or other retracted state, or having the robot
actively move away from the technician.
[0041] FIGS. 7-8 depict a technician proceeding across a cell 132
of a factory floor in an illustrative embodiment. In this
embodiment, robot 710 and robot 720 each include proximity
detectors 160 disposed at different portions of the robot (e.g., at
an end effector of the robot, at a base of the robot, etc.) which
may move to different locations. For example, the proximity
detectors 160 attached to the robots may each be placed on a
different rigid body within a kinematic chain of the robot. As the
technician 150 proceeds through volume 740 of cell 132 the robots
turn off and then back on. For example, as shown in FIG. 7, robot
710 deactivates and halts work on part 730 while the technician
proceeds within the cell 132, and then as shown in FIG. 8, robot
710 may reactivate to perform work on part 730, while robot 720
deactivates. That is, because technician 150 has moved close to
robot 720 in FIG. 8, robot 720 has been shut down (e.g., by halting
all motion, or returning to a home/retracted position. However,
because technician 150 has moved further away from robot 710, robot
710 is reactivated.
[0042] FIGS. 9-10 illustrate communications transmitted between
proximity detectors and a proximity reporting server in an
illustrative embodiment. FIG. 9 illustrates a communication 900 for
a signal transmitted by a proximity detector. The communication may
be packetized according to a well-known wireless protocol (e.g., in
accordance with an IEEE 802.11 protocol, in accordance with
Bluetooth, etc.) and received via sensors 120, or may otherwise be
modulated to carry information. According to FIG. 9, communication
900 includes a master ID indicating the robot or person to which it
is attached. Communication 900 also includes a device ID that
uniquely distinguishes the proximity detector from other proximity
detectors at the same person or robot. Communication 900 further
reports a battery level for the proximity detector that generated
the communication. FIG. 10 depicts a communication 1000 that may be
provided to a proximity detector by proximity reporting server 110.
In this embodiment, communication 1000 comprises a notification.
Communication 1000 includes an identifier for the device it is
directed to, an identifier for the proximity detector that it is
directed to, and an instruction provided to the proximity detector.
Example instructions may include a warning, an instruction to halt
operations, an instruction to resume operations, and others. For
example, a first notification (e.g., a notification to warn) may be
provided to a proximity detector worn by a technician if a distance
of a proximity detector at a robot is less than a first threshold,
while a second notification (e.g., a notification to halt) may be
provided to the second proximity detector of the distance is less
than a second threshold which is smaller than the first
threshold.
EXAMPLES
[0043] In the following examples, additional processes, systems,
and methods are described in the context of proximity reporting
system.
[0044] FIG. 11 is a block diagram of a proximity reporting system
in an illustrative embodiment. As shown in FIG. 11, manufacturing
cell 1100 includes robot 1150. Robot 1150 is attached to base 1110,
and includes controller 1152. Controller 1152 directs the
operations of actuators 1112, 1114, and 1116, in order to
reposition rigid bodies 1120 and 1130 (e.g., in accordance with a
Numerical Control (NC) program). This also repositions end effector
1132. The combination of actuators 1112, 1114, and 1116, and rigid
bodies 1120 and 1130 (including end effector 1132) form kinematic
chain 1154.
[0045] Proximity detector 1190 is mounted to robot 1150, and is
coupled for communication with controller 1152. Proximity detector
1190 includes controller 1192, which generates signals for
processing by proximity reporting server 1180, and further includes
memory 1194. Signals are transmitted via primary transceiver 1196
and/or secondary transceiver 1198 in order to provide redundancy
and reduce the potential for the signal to be interfered with.
Signals transmitted from proximity detector 1190 are received at
sensors 1170.
[0046] Proximity detector 1160 is worn by a technician within
manufacturing cell 1100. Proximity detector 1160 includes
controller 1161, which generates signals, memory 1162, which stores
instructions for generating and interpreting signals. Proximity
detector 1160 further includes primary transceiver 1163 and
secondary transceiver 1164. Speaker 1165 and vibration generator
1166 are used to generate warnings for the technician, and battery
1167 provides mobile power. Sensor 1168 reports battery levels to
controller 1161 for interpretation.
[0047] Referring more particularly to the drawings, embodiments of
the disclosure may be described in the context of aircraft
manufacturing and service in method 1200 as shown in FIG. 12 and an
aircraft 1202 as shown in FIG. 13. During pre-production, method
1200 may include specification and design 1204 of the aircraft 1202
and material procurement 1206. During production, component and
subassembly manufacturing 1208 and system integration 1210 of the
aircraft 1202 takes place. Thereafter, the aircraft 1202 may go
through certification and delivery 1212 in order to be placed in
service 1214. While in service by a customer, the aircraft 1202 is
scheduled for routine work in maintenance and service 1216 (which
may also include modification, reconfiguration, refurbishment, and
so on). Apparatus and methods embodied herein may be employed
during any one or more suitable stages of the production and
service described in method 1200 (e.g., specification and design
1204, material procurement 1206, component and subassembly
manufacturing 1208, system integration 1210, certification and
delivery 1212, service 1214, maintenance and service 1216) and/or
any suitable component of aircraft 1202 (e.g., airframe 1218,
systems 1220, interior 1222, propulsion system 1224, electrical
system 1226, hydraulic system 1228, environmental 1230).
[0048] Each of the processes of method 1200 may be performed or
carried out by a system integrator, a third party, and/or an
operator (e.g., a customer). For the purposes of this description,
a system integrator may include without limitation any number of
aircraft manufacturers and major-system subcontractors; a third
party may include without limitation any number of vendors,
subcontractors, and suppliers; and an operator may be an airline,
leasing company, military entity, service organization, and so
on.
[0049] As shown in FIG. 13, the aircraft 1202 produced by method
1200 may include an airframe 1218 with a plurality of systems 1220
and an interior 1222. Examples of systems 1220 include one or more
of a propulsion system 1224, an electrical system 1226, a hydraulic
system 1228, and an environmental system 1230. Any number of other
systems may be included. Although an aerospace example is shown,
the principles of the invention may be applied to other industries,
such as the automotive industry.
[0050] As already mentioned above, apparatus and methods embodied
herein may be employed during any one or more of the stages of the
production and service described in method 1200. For example,
components or subassemblies corresponding to component and
subassembly manufacturing 1208 may be fabricated or manufactured in
a manner similar to components or subassemblies produced while the
aircraft 1202 is in service. Also, one or more apparatus
embodiments, method embodiments, or a combination thereof may be
utilized during the subassembly manufacturing 1208 and system
integration 1210, for example, by substantially expediting assembly
of or reducing the cost of an aircraft 1202. Similarly, one or more
of apparatus embodiments, method embodiments, or a combination
thereof may be utilized while the aircraft 1202 is in service, for
example and without limitation during the maintenance and service
1216. For example, the techniques and systems described herein may
be used for material procurement 1206, component and subassembly
manufacturing 1208, system integration 1210, service 1214, and/or
maintenance and service 1216, and/or may be used for airframe 1218
and/or interior 1222. These techniques and systems may even be
utilized for systems 1220, including, for example, propulsion
system 1224, electrical system 1226, hydraulic 1228, and/or
environmental system 1230.
[0051] In one embodiment, a part comprises a portion of airframe
1218, and is manufactured during component and subassembly
manufacturing 1208. The part may then be assembled into an aircraft
in system integration 1210, and then be utilized in service 1214
until wear renders the part unusable. Then, in maintenance and
service 1216, the part may be discarded and replaced with a newly
manufactured part. Inventive components and methods may be utilized
throughout component and subassembly manufacturing 1208 in order to
facilitate inspection and maintenance for systems that manufacture
new parts.
[0052] Any of the various control elements (e.g., electrical or
electronic components) shown in the figures or described herein may
be implemented as hardware, a processor implementing software, a
processor implementing firmware, or some combination of these. For
example, an element may be implemented as dedicated hardware.
Dedicated hardware elements may be referred to as "processors",
"controllers", or some similar terminology. When provided by a
processor, the functions may be provided by a single dedicated
processor, by a single shared processor, or by a plurality of
individual processors, some of which may be shared. Moreover,
explicit use of the term "processor" or "controller" should not be
construed to refer exclusively to hardware capable of executing
software, and may implicitly include, without limitation, digital
signal processor (DSP) hardware, a network processor, application
specific integrated circuit (ASIC) or other circuitry, field
programmable gate array (FPGA), read only memory (ROM) for storing
software, random access memory (RAM), non-volatile storage, logic,
or some other physical hardware component or module.
[0053] Also, a control element may be implemented as instructions
executable by a processor or a computer to perform the functions of
the element. Some examples of instructions are software, program
code, and firmware. The instructions are operational when executed
by the processor to direct the processor to perform the functions
of the element. The instructions may be stored on storage devices
that are readable by the processor. Some examples of the storage
devices are digital or solid-state memories, magnetic storage media
such as a magnetic disks and magnetic tapes, hard drives, or
optically readable digital data storage media.
[0054] Although specific embodiments are described herein, the
scope of the disclosure is not limited to those specific
embodiments. The scope of the disclosure is defined by the
following claims and any equivalents thereof. cm 1. A method for
reporting proximity in an assembly environment, the method
comprising: [0055] equipping a technician with a first proximity
detector that is wearable; [0056] disposing a second proximity
detector at a robot that moves within a cell of the assembly
environment; [0057] transmitting signals from the proximity
detectors to sensors in the assembly environment that are disposed
outside of the cell; and [0058] directing the first proximity
detector to provide a warning to the technician if a distance
between the first proximity detector and the second proximity
detector, determined based on the signals from the proximity
detectors, is less than a threshold while the technician is within
the cell.
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