A vehicle assembly system includes a vehicle chassis of a vehicle; at least one object sensor mounted to the vehicle chassis, where the at least one object sensor generates sensor data based on at least one detected object; a vehicle controller mounted to the vehicle chassis and configured to receive the sensor data from the at least one object sensor, where, during assembly, the vehicle controller is configured with production control software that enables the vehicle controller to generate production object data from the sensor data, monitor for a safety event based on the production object data, and generate a safety event signal in response to detecting the safety event; and a safety controller configured to receive the safety event signal from the vehicle controller and alter a movement of a surveilled machine corresponding to the safety event.

Embodiments of the present invention determine the configuration of a workpiece and whether it is actually being handled by a monitored piece of machinery, such as a robot. The problem solved by the invention is especially challenging in real-world factory environments because many objects, most of which are not workpieces, may be in proximity to the machinery. Accordingly, embodiments of the invention utilize semantic understanding to distinguish between workpieces that may become associated with the robot and other objects (and humans) in the workspace that will not, and detect when the robot is carrying a workpiece.

A system having a sensor system comprising distance sensors for monitoring a hazardous zone at a movable machine part having at least one protected zone, wherein a tool is arranged at the movable machine part, wherein the distance sensors are arranged at a holder at the movable machine part, wherein a plurality of distance sensors are arranged, with the detection beams of the distance sensors forming a protected field shell, wherein the holder has the distance sensors, with the holder having a disk-shaped housing, with the disk-shaped housing having round surfaces and not having any corners at the outer surfaces, with the system comprising a fastening system, the fastening system comprises one of a first fastening adapter and a second fastening adapter at which the holder is respectively arranged for fastening the holder to the movable machine part.

Systems and methods monitor a workspace for safety purposes using sensors distributed about the workspace. The sensors are registered with respect to each other, and this registration is monitored over time. Occluded space as well as occupied space is identified, and this mapping is frequently updated. Based on the mapping, a constrained motion plan of machinery can be generated to ensure safety.

A method, system, and one or more computer-readable storage media for controlling a robot in the presence of a moving object are provided herein. The method includes capturing a number of frames from a three-dimensional camera system and analyzing a frame to identify a connected object. The frame is compared to a previous frame to identify a moving connected object (MCO). If an unexpected MCO is in the frame a determination is made if the unexpected MCO is in an actionable region. If so, the robot is instructed to take an action.

A robot system can include a main body; a manipulator installed on the main body; a sensor configured to detect an object approaching a restricted region including the manipulator; a camera configured to monitor the restricted region and the object approaching the restricted region; a storage configured to store a material for an operation of the manipulator, the storage including an inlet for receiving the material; a remaining amount sensor configured to detect an amount of the material remaining in the storage; and a controller configured to change the restricted region based on at least one of a result of detection of the remaining amount sensor and image information of the camera, and in response to the sensor detecting that the object is within the restricted region, stop manipulation of the manipulator.

Systems and methods monitor a workspace for safety purposes using sensors distributed about the workspace. The sensors are registered with respect to each other, and this registration is monitored over time. Occluded space as well as occupied space is identified, and this mapping is frequently updated.

Systems and methods for determining safe zones in a workspace calculate safe actions in real time based on all sensed relevant objects and on the current state of the machinery (e.g., a robot) in the workspace. Various embodiments forecast, in real time, both the motion of the machinery and the possible motion of a human within the space, and continuously update the forecast as the machinery operates and humans move in the workspace.

Various embodiments for enforcing safe operation of machinery performing an activity in a three-dimensional (3D) workspace includes computationally generating a 3D spatial representation of the workspace; computationally mapping 3D regions of the workspace corresponding to space occupied by the machinery and a human; and based thereon, restricting operation of the machinery in accordance with a safety protocol during physical performance of the activity.

Various embodiments for enforcing safe operation of machinery performing an activity in a three-dimensional (3D) workspace includes computationally generating a 3D spatial representation of the workspace; computationally mapping 3D regions of the workspace corresponding to space occupied by the machinery and a human; and based thereon, restricting operation of the machinery in accordance with a safety protocol during physical performance of the activity.