Collaborative robots (cobots) become more and more important in industrial manufacturing as flexible companions, working side by side with humans without safety fences. A key challenge of such workplaces is to guarantee the safety of the human co-workers. The safeguarding Power and Force Limiting, as specified by ISO 10218-2 and ISO/TS 15066, has the objective to protect humans against robot collisions by preventing the robot from exceeding biomechanical limits. Unintended contact such as collisions can occur under unconstrained spatial conditions (a human body part can move freely) or constrained spatial conditions (a human body part is pinched). In particular, collisions under constrained conditions involve a high risk of injury and thus require the robot to stop immediately after detecting the collision. The robot’s speed has a significant influence on its stopping behavior, though, and thus on the maximum collision forces that the robot can exert on the human body. Consequently, a safe velocity is required that avoids the robot from exerting forces and pressures beyond the biomechanical limits. Today, such velocities can only be ascertained in costly robot experiments. In this article, we describe a model that enables us to determine the contact forces of a cobot as they occur in constrained collisions. Through simulations, it becomes possible to iteratively determine the maximum safe velocity for a specific contact hazard that occurs under constrained spatial conditions. Experimental tests with different cobots confirm the results of our model, albeit not for all robots. Despite the mixed test results, we strongly believe that our model can significantly improve the reliability of assumptions made today during the planning of cobots.

The Emschergenossenschaft based in Germany is currently planning the Emscher sewer system, arguably the largest residential water management project in Europe in years to come. The Emschergenossenschaft engaged the Fraunhofer Institute for Factory Operation and Automation (IFF) in Magdeburg, Germany, as the general contractor to develop automatic inspection and cleaning systems to meet the requirements imposed by legal guidelines. The systems must operate continuously in a sewer line that has diameters ranging from 1400 to 2800 mm and is partially filled, 25% at minimum, all the time. To construct the Emscher sewer system, the Emschergenossenschaft favors a one-pipe line in long sections. A walk-through or inspection by personnel would be impossible in these sections. The Fraunhofer Institute IFF has developed prototypes of all systems for motion through the sewer and all sensor systems, thus achieving a new quality of inspection above and below the water line under these difficult conditions. This article describes significant project results and important components of inspection such as the inspection systems, pipe axis measurement, system positioning, and sensor systems for damage detection. Fundamental for the development of the inspection systems is the detail of the inspection, which goes far beyond the video inspection common today, and the ability to take comparative measurements throughout the sewer system's period of operation in order to track the development of damage.