工业机器人主动安全作业方法与应用

doi:10.3901/JME.2025.15.174

机械工程学报 ›› 2025, Vol. 61 ›› Issue (15): 174-184.doi: 10.3901/JME.2025.15.174

• 人-机器人协作 • 上一篇

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工业机器人主动安全作业方法与应用

吕鸿昊^1,2,3, 诸正杰^1,2, 程宇航^2,4, 何平^2,4, 汪若菡^1,2, 陈富国^3,5, 杨华勇^1,2, 杨赓^1,2,3, 董娜^3,5

1. 浙江大学机械工程学院杭州 310058;
2. 浙江大学流体动力基础件与机电系统全国重点实验室杭州 310027;
3. 电力装备制造及智能运维机器人浙江省工程研究中心杭州 310058;
4. 浙江大学工程师学院杭州 310058;
5. 东方电气长三角(杭州)创新技术研究院有限公司杭州 310011

收稿日期:2024-12-31 修回日期:2025-06-02 发布日期:2025-09-28
作者简介:吕鸿昊，男，1996年出生，助理研究员，博士后。主要研究方向为人机安全交互。E-mail：lvhonghao@zju.edu.cn;董娜(通信作者)，女，1980年出生，博士，教授级高工。主要研究方向为机器人自动化焊接，高效焊接和智能制造。E-mail：dongna@dongfang.com
基金资助:
国家自然科学基金(52375031,52405038); 中国电子学会-腾讯 Robotics X犀牛鸟专项研究计划; 国家资助博士后研究人员计划B档(GZB20240654); 中国博士后科学基金面上(2024M762812);中国博士后科学基金; 浙江省博士后科研(一等资助)(ZJ2024013); 浙江省科技厅“尖兵领雁+X”研发攻关计划(2024C04057(CSJ));浙江省科技厅“尖兵”“领雁”研发攻关计划(2023C01045)资助项目。

Proactive Safety Techniques and Applications for Industrial Robots

Lü Honghao^1,2,3, ZHU Zhengjie^1,2, CHENG Yuhang^2,4, HE Ping^2,4, WANG Ruohan^1,2, CHEN Fuguo^3,5, YANG Huayong^1,2, YANG Geng^1,2,3, DONG Na^3,5

1. School of Mechanical Engineering, Zhejiang University, Hangzhou 310058;
2. The State Key Laboratory of Fluid Power and Mechatronic Systems, Zhejiang University, Hangzhou 310027;
3. Zhejiang Engineering Research Center of Robotics in Electric Equipment Manufacturing and Intelligent Operation-Maintenance, Hangzhou 310058;
4. Polytechnic Institute of Zhejiang University, Hangzhou 310058;
5. Dongfang Electric (Hangzhou) Innovation Institute Co., Ltd., Hangzhou 310011

Received:2024-12-31 Revised:2025-06-02 Published:2025-09-28

摘要/Abstract

摘要： 当前工业生产制造场景下，机器人感知单一、缺乏智能交互策略，导致安全事故频发，轻则致伤重则致死。面向未来工厂智能制造场景下的多源感知及安全交互需求，提出一种工业机器人“在体感知”与“离体感知”相结合的主动安全作业系统。通过大范围视觉监控、近距离迫近感知以及碰撞检测构建多源感知系统，对机器人作业环境中的操作者与机器人之间的接近信号及接触信号处理分析，设计人机共享控制策略，实现机器人的主动安全作业规划；进一步划分传感器检测范围，设计卡尔曼滤波多源融合方法构建机器人多级感知信号处理以及分级安全交互策略，并设计对应的模拟碰撞实验验证多源融合数据的有效性。所研发的工业机器人主动安全作业系统现已在东方电气集团冲击式转轮水斗机器人电弧增材平台，以及大型分盘式水轮机座环机器人焊接平台试装试用。应用结果表明，所提出的多源融合主动安全作业方法，充分结合各传感器在不同的感知区域的优势，为全空间、全场景下的人机交互提供感知能力和安全响应，显著提升了工业机器人系统的安全作业能力。

关键词: 人机安全, 迫近感知, 工业机器人, 主动安全, 人本智造

Abstract: In current industrial manufacturing scenarios, robots often suffer from limited perception and lack intelligent interaction strategies, leading to frequent safety accidents, ranging from minor injuries to fatalities. To address the multi-source perception and safety interaction needs in future smart factories, a proactive safety operation concept for industrial robots is proposed, combining on-body and off-body perception. The system is built using a multi-source sensory network, which integrates wide-area visual monitoring, close-range proximity sensing, and collision detection. These technologies process and analyze proximity and contact signals, allowing for the design of shared human-robot control strategies and proactive safety operation planning. Furthermore, after dividing the sensor detection ranges, a Kalman filter-based multi-source fusion method is employed to process the multi-level perception signals and design tiered safety interaction strategies. The proactive safety system developed in this study has been integrated and tested in various platforms of Dongfang electric group, including the shock-type turbine water-wheel robot arc additive manufacturing platform and the large-diameter disc turbine rotor welding platform. The results demonstrate that the proposed multi-source fusion proactive safety method effectively combines the advantages of different sensors in various perception zones, providing perceptual capabilities and safety responses for human-robot interaction in full-space and full-scenario environments. This significantly enhances the safety and operational capability of industrial robot systems.

Key words: human-robot interaction safety, proximity sensing, industrial robots, proactive safety, human-centered smart manufacturing

中图分类号:

TP242

吕鸿昊, 诸正杰, 程宇航, 何平, 汪若菡, 陈富国, 杨华勇, 杨赓, 董娜. 工业机器人主动安全作业方法与应用[J]. 机械工程学报, 2025, 61(15): 174-184.

Lü Honghao, ZHU Zhengjie, CHENG Yuhang, HE Ping, WANG Ruohan, CHEN Fuguo, YANG Huayong, YANG Geng, DONG Na. Proactive Safety Techniques and Applications for Industrial Robots[J]. Journal of Mechanical Engineering, 2025, 61(15): 174-184.

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工业机器人主动安全作业方法与应用

Proactive Safety Techniques and Applications for Industrial Robots

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