Device for monitoring an area at a machine

The invention relates to a device for monitoring a detection range on a working medium.

Such work equipment generally form systems such as machinery, equipment or vehicles, which may pose hazards to persons within a hazardous area by working movements. Devices of the type mentioned are used to secure such danger areas, in which by means of such a device, the penetration of objects in a detection area, which covers the respective danger area as completely as possible, is detected. In particular, such devices are used to secure machines such as press brakes, cutting machines or punching machines. These machines have a first machine part, which performs working movements against a second machine part. In a press brake, the first machine part consists of an upper tool, which can be moved in the vertical direction on a second machine part forming the lower tool to perform a bending operation.

In order to exclude hazards to persons, the apron must be monitored in front of the upper tool or generally in front of the first machine part in order to stop the machine immediately in the event of an intervention by a person in this danger zone.

From DE 197 172 99 A1 a protective device for monitoring such a danger zone is known.

This protective device has an optical sensor arrangement, which is formed by a light barrier or a light barrier arrangement, which is moved along with the first machine part. The bar of each photocell has a transmit light emitting transmitter and an associated receiver mounted on opposite edges of the first machine part. The transmitted light beams emitted by the or each transmitter run parallel to the lower edge of the first machine part running along a straight line and, with the free area of ​​protection, hit unhindered on the associated receiver. In the case of an object intervention in the protected area, at least the beam path of a light barrier is interrupted, whereupon the working movement performed by the first machine part is interrupted.

In order for the protected area covered by the light barrier or the light barrier arrangement to cover the danger zone of the machine as completely as possible, the received signal is required for the transmitted light beams of the or each light barrier to run at a certain safety distance from the lower edge of the first machine part. To set this safety distance, a further light barrier is provided, the transmitted light rays are at the level of the lower edge of the first machine part. During an adjustment procedure, the optical sensor arrangement on the first machine part is displaced until a beam interruption is registered at the light barrier provided for the adjustment. Thereafter, the sensor assembly is slightly moved again in the opposite direction until the beam interruption at this light barrier is just canceled.

A disadvantage of this protective device is, on the one hand, that with this a danger zone can be monitored only at certain points along the beam axes of the transmitted light beams of the light barriers. This is particularly problematic when small object sizes, such as fingers of a hand or the like must be delektiert to ensure adequate personal protection. A further disadvantage is that the light barriers must be set in an adjustment to a safety distance to the first machine part to monitor the desired danger area, which is cumbersome and time consuming.

Finally, it is disadvantageous that this protective device in machines designed as press brakes, by means of which three-dimensional workpieces are produced by folding, not or only to a limited extent can be used. This is based on the fact that in the case of the fold of such a workpiece, a workpiece side can block the beam path of the light barriers of the protective device, so that object detection is no longer possible in this case.

The invention has for its object to provide a system which ensures the most complete and safe monitoring of hazardous areas of equipment.

To solve this problem, the features of claim 1 are provided. Advantageous embodiments and expedient developments of the invention are described in the subclaims.

The device according to the invention serves to monitor a detection area on a working medium. This device has a light beam emitting illumination unit for illuminating the detection area. Likewise, the device according to the invention includes a camera for determining zweidimerisionaler images of the detection area. The camera has a linear arrangement of receiving elements whose output signals are evaluated in an evaluation unit. For each receiving element, a distance value from the light transit time of the light beams emitted by the illumination unit and reflected back from the detection area is determined. With the evaluation at least one guided to the working means switching output is controlled, so that the working fluid is only set in operation, if there is no object in the detection area.

A significant advantage of the device according to the invention is that with the camera by evaluating the output signals of the receiving elements not only a presence control of objects can be carried out, but in addition a depth information is obtained by the distance measurements performed. This gives a two-dimensional image of objects within the detection area. It is particularly advantageous that an object detection within the detection range can be performed without performing a reference image comparison. In particular, objects can be reliably detected against a background, the object detection being largely independent of environmental influences such as the nature of the background or extraneous light.

The device according to the invention can be used in particular for monitoring hazardous areas on machines in which a first machine part executes working movements against a second machine part. Such machines can be designed in particular as cutting machines or as punching machines. Furthermore, such machines may be designed as press brakes, wherein the first machine part is formed by an upper tool, which is movable relative to a stationary lower tool forming the second machine part. The advantage here is that by attaching the device according to the invention in the region of the first machine part, in the case of a press brake in the region of the upper tool, the entire danger zone can be monitored to the lower tool. It is particularly advantageous in this case that movements of workpieces to be machined do not lead to a blockage of the beam path of the light beams of the device according to the invention, so that even when guiding workpieces in the danger area object detection is ensured by means of the device within the detection range.

For the protection of persons and objects, the working means is put out of operation by means of the device according to the invention when an object intervention is registered in the surveillance area. In the simplest case, the deactivation of the working medium takes place when any object penetrates into the detection area.

In an advantageous embodiment of the invention, a distinction is made between safety-critical objects and non-safety-critical objects. Non-safety-critical objects can be formed, for example, by workpieces to be machined, machine parts, stationary building parts and the like. Such non-safety-critical objects generally do not pose a hazard to persons. Thus, a deactivation of the working medium caused by the detection of such non-safety-critical objects would mean an unnecessary downtime and thus a reduction in the availability of the working medium.

Appropriately, the contours and possibly also the paths of such non-safety-critical objects are taught in a teach-in process. Then, during the operating phase subsequent to the learning process, all objects which do not correspond to the taught non-safety-critical objects are classified as safety-critical objects, so that their detection within the detection range leads to a deactivation of the working medium. This ensures the highest level of security in the monitoring of the detection area, since only the previously learned non-safety-critical objects do not lead to deactivation of the work equipment when entering the detection area.

In general, a deactivation of the working medium via the device according to the invention can take place when an object or especially a safety-critical object is detected within the entire detection range.

Alternatively, protection zones and non-safety-critical areas can also be defined within the detection area, with only object detections in the non-safety-critical areas not leading to the deactivation of the work equipment. Such hiding of areas increases the availability of work equipment, as unnecessary downtime due to shutdown commands due to object detection in these areas is avoided.

The device according to the invention is used in particular in the field of personal protection. In order to fulfill the required safety level, the sensor unit of the device is expediently designed to be self-confident, in which a self-fault check is carried out in the sensor unit. The advantage here is that the sensor unit in this case can have a single-channel structure. In contrast, the evaluation unit next to the sensor unit preferably has a two-channel structure.

The invention will be explained below with reference to the drawings. Show it:<dl id="dl0001"><dt>FIG. 1:</dt><dd>Schematic representation of the optical components of an apparatus for detecting objects.</dd><dt>FIG. 2:</dt><dd>Block diagram of the device according to FIG. 1</dd><dt>FIG. 3:</dt><dd>Time diagrams for distance determination according to the pulse transit time method for the device according to FIG. 1.</dd><dt>FIG. 4:</dt><dd>Arrangement of a device according to Figures 1 and 2 on a press brake.<ul id="ul0001" list-style="none"><li>a) Cross section through the press brake</li><li>b) top view of the press brake without workpiece to be machined</li><li>c) top view of the press brake with workpiece to be machined</li></ul></dd></dl>

FIG. 1 schematically shows the optical components of a device 1 for monitoring a detection region 2 on a working means. The working means, not shown in Figure 1 is formed by a machine, a plant or the like. Through operations that are performed with the working fluid, a danger zone arises in the area of ​​the working fluid, which is monitored by the device 1 within the detection area 2.

The optical components of the device 1 form a sensor unit consisting of a lighting unit 3 and a camera 4. In the present case, the lighting unit 3 has a transmitter 5 designed as a laser diode, which emits light beams 6. Alternatively, the transmitter 5 may be formed by a light emitting diode. Furthermore, the illumination unit 3 can also have arrangements of a plurality of laser diodes or light-emitting diodes. The illumination unit 3 has, as a further component, a transmitter optics 7 arranged downstream of the transmitter 5. With the transmission optics 7 beam shaping of the light beams 6 takes place in such a way that the detection area 2 to be monitored is completely illuminated with the light beams 6.

The camera 4 has a linear arrangement of receiving elements. In the present case, the camera 4 has a CMOS chip 8 with a linear array of receiving elements. Alternatively, the camera 4 may have a corresponding CCD chip.

The camera 4 further has a CMOS chip 8 upstream receiving optical system 9. By means of the receiving optics 9, the light beams 6 reflected back from the detection area 2 are focused onto the receiving elements of the CMOS chip 8.

FIG. 2 shows a block diagram of the device 1 according to FIG. 1. The transmitter 5 of the illumination unit 3 and the camera 4 are connected to a two-channel evaluation unit 10, which in the present case is formed by two identical mutually monitoring computer units 11, 11 '.

With the evaluation unit 10, on the one hand, the lighting unit 3 is activated. On the other hand, in the evaluation unit 10, the evaluation of the output signals of the receiving elements of the camera 4th In this case, for the determination of two-dimensional images of the detection area 2 or of objects arranged in the detection area 2, distance values ​​are continuously determined from the light transit time of the light beams 6 emitted by the illumination unit 3 and reflected back from the detection area 2.

To the evaluation unit 10, an output circuit 12 having a switching output 13 and a warning output 14 is connected.

In the evaluation unit 10, a binary switching signal is generated in response to the evaluation of the output signals of the receiving elements and output via the switching output 13, by means of which the working fluid can be activated or deactivated. In the detection of an object intervention in the detection area 2, a switching state of the switching signal is generated, which leads to deactivation, that is to the decommissioning of the working medium. Furthermore, in the evaluation unit 10, if necessary, a warning signal is generated, which can be output via the warning output 14.

According to a first variant, the distance measurement is performed with the sensor unit according to a phase measurement method. To carry out the phase measurement, the light beams 6 of the transmitter 5 are impressed with an amplitude modulation having a predetermined modulation frequency. To increase the uniqueness range of the phase measurement and thus of the detectable distance range, the light beams can also be impressed with a plurality of amplitude modulations with different modulation frequencies. In the phase measurement, the phase difference of the light beams 6 reflected there from the detection area 2 is ascertained with respect to the light beams 6 emitted by the transmitter 5 for each receiving element of the CMOS chip 8. Distance values ​​are calculated in the evaluation unit 10 from these phase differences. From the totality of the distance values ​​determined for the reception elements, three-dimensional images of the objects in the surveillance area are obtained.

According to a second variant, the distance measurement with the sensor unit takes place according to a pulse transit time method. In this case, the transmitter 5 emits light beams 6 in the form of light pulses. For distance determination, the transit time of each light pulse from the transmitter 5 to the detection area 2 and back to the camera 4 is evaluated for each receiving element. From the totality of all distance values ​​for the individual receiving elements, three-dimensional images of objects within the detection area 2 are then obtained again.

FIG. 3 shows schematically the principle of distance measurement according to a pulse transit time method. The first diagram in FIG. 3 shows the sequence of the light pulses emitted by the transmitter 5, referred to as transmitted light pulses in FIG. The transmitted light pulses each have the same pulse duration T. The pulse pauses between two transmitted light pulses are also constant. The third diagram in FIG. 3 shows the light pulses emitted by the transmitter 5 and reflected back from an object at a distance d from the device 1 to a receiving element, referred to as received light pulses in FIG. In accordance with the light propagation time of a light pulse from the transmitter 5 to the object and back to the receiving element, each received light pulse is delayed by the time duration ΔT = 2d / c with respect to the associated transmitted light pulse. Where d is the distance of the object to the device 1 and c is the speed of light. For determining the distance, the duration ΔT can in principle be determined by a counting method. In this case, a counter controlled by an oscillator is started with the emission of a transmitted light pulse, preferably with its rising edge. With the receipt of the associated received light pulse, preferably with its rising edge, the counter is stopped.

In the present case, the time period ΔT is determined by means of an integration method. The second diagram in FIG. 3 shows sequences of integration intervals during which this is determined by the respective reception intervals output signal generated pulse at the receiving element is integrated. As can be seen from FIG. 3, the individual integration intervals each extend over the duration of a transmitted light pulse, that is to say the output signal at the receiving element is integrated in each case only during the emission of a transmitted light pulse. Since each received light pulse with respect to the associated transmitted light pulse is delayed by .DELTA.T, only a portion of the received light pulse falls in the corresponding integration interval. Accordingly, for example, for the first received light pulse, the output signal is only during the time interval between t_a and t_b integrated.

The integrated output signal U thus obtained is shown in the fourth diagram of FIG.

For the determination of ΔT, two measurement points of the integrated output signal are selected within each integration interval. The position of the measuring points is chosen so that they lie in a time interval within which just the received light pulse impinges on the receiving element.

For the first integration interval, the measuring points U₁, U₂ at the times t₁, t₂ selected. From these measuring points ΔT is determined according to the following relationship:<maths id="math0001" num=""><math display="block"><mrow><msub><mrow><mtext>.DELTA.T = (U</mtext></mrow><mrow><mtext>2</mtext></mrow></msub><msub><mrow><mtext>t</mtext></mrow><mrow><mtext>1</mtext></mrow></msub><msub><mrow><mtext>-U</mtext></mrow><mrow><mtext>1</mtext></mrow></msub><msub><mrow><mtext>t</mtext></mrow><mrow><mtext>2</mtext></mrow></msub><msub><mrow><mtext>) / (U</mtext></mrow><mrow><mtext>2</mtext></mrow></msub><msub><mrow><mtext>-U</mtext></mrow><mrow><mtext>1</mtext></mrow></msub><mtext>)</mtext></mrow></math><img file="EP1548351A2_D0001.tif" /></maths>

Based on the distance measurements carried out for the individual receiving elements of the camera 4, two-dimensional images of objects are obtained, by means of which, in particular, objects can also be detected against background surfaces of any desired surface finish.

For the use of the device 1 in the field of personal protection, this must meet the requirements of the appropriate level of security. For this purpose, the evaluation unit 10 has a redundant, two-channel structure with two mutually monitoring computer units 11, 11 '.

The sensor unit, in particular the camera 4, has a single-channel structure. To achieve the required level of security, a self-fault control is performed for the sensor unit, so that it is self-confident.

In the event that the distance measurement in the device 1 is carried out according to a pulse-transit time method, the transmission of a transmission light pulse is delayed to carry out the inherent error control at predetermined time intervals and controls the resulting change in the distance measurement for the individual receiving elements in the evaluation unit 10.

Accordingly, in the event that the distance measurement takes place according to a phase measuring method, the phase of the amplitude modulation impressed on the light beams 6 is shifted and the change in the distance measurement caused thereby for the individual receiving elements is controlled.

In object detection by means of the device 1, a switching signal for deactivating the working means can generally be generated in the evaluation unit 10 when any object in the detection area 2 is registered.

Alternatively, it is possible to differentiate safety-critical objects and non-safety-critical objects with the device 1, with only the penetration of safety-critical objects into the detection area 2 leading to deactivation of the working medium.

Such non-safety-critical objects can be formed, for example, by machine parts, in particular parts of the working medium, workpieces which are machined by means of the working means, or else by stationary parts such as building parts. In general, an intervention of such non-safety-critical objects in the detection area 2 does not pose a risk, especially of persons.

In order to avoid an unnecessary shutdown of the working fluid upon penetration of a non-safety-critical object in the detection area 2, the contours and, where appropriate, the tracks of non-safety-critical objects, if they always move along such trajectories are detected and stored in the evaluation unit 10 during a learning process ,

During the subsequent operation of the device 1, detected objects in the detection area 2 are compared with the stored non-safety-critical objects or, if appropriate, their paths in the evaluation unit 10. If no match of a detected object with a non-safety-critical object is detected, the detected object is classified as a safety-critical object and a switching signal for decommissioning of the work equipment is generated.

The device 1 may in particular be arranged on machines in which a first machine part carries out working movements against a second machine part.

FIGS. 4a-c show an exemplary embodiment with a machine designed as a press brake 15. The press brake 15 has, as the first machine part, an upper tool 16, which can be moved in the vertical direction against a sub-tool 17 forming the second machine part for performing bending processes. With the press brake 15 workpieces are folded, wherein in Figure 4c designed as a sheet metal part 18 workpiece is shown. In this case, the sheet metal part 18 is bent or bent along a bending line by guiding the lower edge of the upper tool 16 extending in the horizontal direction onto the upper edge of the lower tool 17 which also extends in the horizontal direction.

For processing the workpieces, these are usually introduced by operators in predetermined positions between the upper tool 16 and the lower tool 17. As a result, there is the risk of injuries to the respective operator due to the introduction of the hands or fingers into the area between the upper tool 16 and lower tool 17.

To protect the operator, the device 1 is attached to the press brake 15, is monitored by means of the danger area between the upper tool 16 and lower tool 17.

In this case, the device 1 is mounted in the area of ​​the upper tool 16 such that the detection area 2 covers the entire area which excludes the upper side of the lower tool 17. In the present case, the device 1 is attached to the upper tool 16 receiving frame of the press brake 15. Alternatively, the device 1 may also be attached to the upper tool 16, so that the device 1 is moved with the upper tool 16.

As can be seen from FIG. 4 b, the detection area 2 is delimited by the upper edge of the lower tool 17. Since two-dimensional images of objects in the detection area 2 are formed with the device 1 as a result of the distance measurements carried out there, objects in the detection area 2 can be reliably distinguished from the background formed by the upper edge of the lower tool 17.

FIG. 4c shows the press brake 15 with a sheet metal part 18 lying between the upper tool 16 and lower tool 17, this having laterally in the vertical direction protruding wall segments from a base part to be machined by previously performed bending processes. When monitoring with light barriers arranged laterally on the press brake 15, the transmitting light beams of the light barriers extending in the horizontal direction would be blocked by these wall segments, so that monitoring of the danger zone between the upper tool 16 and lower tool 17 would no longer be possible.

In contrast, monitoring of the danger zone is also possible in this case with the device 1 according to the invention, since it is arranged in the region of the upper tool 16 such that the field of view of the camera 4 of the device 1 is directed from above onto the lower tool 17.

Since the lying in the danger area sheet metal part 18 may not lead to a response of the device 1 and thereby to a decommissioning of the press brake 15, the contour of the sheet metal part 18 is taught as non-safety-critical object and expediently also its trajectory during the bending operation and in the evaluation unit 10th stored.

During the subsequent operation of the device 1, a shutdown command for the press brake 15 is generated by this when a safety-critical object is detected, that is, when an object is detected, which does not match the non-safety-critical object or its trained path.

LIST OF REFERENCE NUMBERS

<dl id="dl0002" compact="compact"><dt>(1)</dt><dd>device</dd><dt>(2)</dt><dd>detection range</dd><dt>(3)</dt><dd>lighting unit</dd><dt>(4)</dt><dd>camera</dd><dt>(5)</dt><dd>transmitter</dd><dt>(6)</dt><dd>light rays</dd><dt>(7)</dt><dd>transmission optics</dd><dt>(8th)</dt><dd>CMOS chip</dd><dt>(9)</dt><dd>receiving optics</dd><dt>(10)</dt><dd>evaluation</dd><dt>(11, 11 ')</dt><dd>computer unit</dd><dt>(12)</dt><dd>output circuit</dd><dt>(13)</dt><dd>switching output</dd><dt>(14)</dt><dd>warning output</dd><dt>(15)</dt><dd>press brake</dd><dt>(16)</dt><dd>upper tool</dd><dt>(17)</dt><dd>lower tool</dd><dt>(18)</dt><dd>sheet metal part</dd></dl><dl id="dl0003" compact="compact"><dt>c</dt><dd>Speed ​​of Light</dd><dt>d</dt><dd>Distance of the object to the device</dd><dt>t₁, t₂, t_a, t_b</dt><dd>timings</dd><dt>T</dt><dd>pulse duration</dd><dt>U</dt><dd>output</dd><dt>U₁, U₂</dt><dd>measuring points</dd><dt>.DELTA.T</dt><dd>time</dd></dl>