Worldwide innovation: Newly developed ultrasonic sensor makes Industry 4.0 safe

The requirements of reliable workpiece safety or tool safety are high. The effect of force and pressure on a human who touches the mandrel on a gripper or cordless screwdriver exceed the maximum permissible limit value for the ISO/TS 15066 standard. The screwdriver protection must therefore be contactless. At the same time, the automatic operating process must not be impaired. 

Mayser’s and KUKA’s collaborative solution is based on using ultrasonic sensors. The new development ultrasonic safety contactlessly detects both humans and objects, regardless of dirt, extraneous noise, air flows and moisture. The special characteristics of Mayser’s ultrasonic sensors are the two very small ultrasonic transducers that are flexibly and geometrically positioned independent of the electronics. They can be placed directly on the robot or grabber and extensively and reliably monitor their surroundings. The transducers can also be locally arranged. The sensors take measurements in an elliptical sound field and detect even the smallest objects. A teach-in function also enables the system to learn the complete measuring environment as a standard environment. The system thus only responds to deviations from the target state.  

The reliable ultrasonic sensor is a unique development globally as it is approved for personnel safety thanks to its two channels. This was crucial for KUKA to get involved in the joint advance development with Mayser regarding tool safety for a KUKA LBR iiwa.

The two transducers of ultrasonic safety create two protection fields around the robot. The larger protection field allows faster movement by the tool arm. If the screwdriver comes close to a workpiece, the smaller protection field is activated. The robot movement then slows down so that a person can be detected in time and thus to exclude any contact with the tool. Collaboration between robot and humans is possible without any danger. 

Mayser’s and KUKA’s solution for the KUKA LBR iiwa provides a complete system for making Cobot workplaces safe and thus improved ergonomics for employees. These can be effectively supported for difficult work. Higher robot speeds and cycle times are also possible. Thanks to the certification of the failsafe, dual-channel ultrasonic safety according to ISO 13849-1:2015 category 3 PL d, the global novelty is approved for personnel safety from February 2017.