Safe Stopping Distances and Times in Industrial Robotics

This study presents a procedure for the estimation of stopping behavior of industrial robots with a trained neural network. This trained network is presented as a single channel in a redundant architecture for safety control applications, where its potential for future integration with an analytical model of robot stopping is discussed. Basic physical relations for simplified articulated manipulators are derived, which motivate a choice of quantities to predict robot stopping behavior and inform the training and testing of a network for prediction of stopping distances and times.

Robot stopping behavior is considered in the context of relevant standards ISO 10218-1, ISO/TS 15066 and IS0 13849-1, which inform the definitions for safety related stopping distances and times used in this study. Prior work on the estimation of robot stopping behavior is discussed alongside applications of machine learning to the broader field of industrial robotics, and particularly to the cases of prediction of forward and inverse kinematics with trained networks.

A state-driven data collection program is developed to perform repeated stopping experiments for a controlled stop on path within a specified sampling domain. This program is used to collect data for a simulated and real robot system. Special attention is given to the identification of meaningful stopping times, which includes the separation of stopping into pre-deceleration and post-deceleration phases. A definition is provided for stopping of a robot in a safety context, based on the observation that residual motion over short distances (less than 1 mm) and at very low velocities (less than 1 mm/s) is not relevant to robot safety.

A network architecture and hyperparameters are developed for the prediction of stopping distances and times for the first three joints of the manipulator without the inclusion of payloads. The result is a dual-network structure, where stopping distance predictions from the distance prediction network serve as inputs to the stopping time prediction network. The networks are validated on their capacity to interpolate and extrapolate predictions of robot stopping behavior in the presence of initial conditions not included in the training and testing data.

A method is devised for the calculation of prediction errors for training training, testing and validation data. This method is applied both to interpolation and extrapolation to new initial velocity and positional conditions of the manipulator. In prediction of stopping distances and times, the network is highly successful at interpolation, resulting in comparable or nominally higher errors for the validation data set when compared to the errors for training and testing data. In extrapolation to new initial velocity and positional conditions, notably higher errors in the validation data predictions are observed for the networks considered.

Future work in the areas of predictions of stopping behavior with payloads and tooling, further applications to collaborative robotics, analytical models of stopping behavior, inclusion of additional stopping functions, use of explainable AI methods and physics-informed networks are discussed.