Collaborative robots (cobots) are reshaping modern production floors, not by replacing human workers but by working alongside them. They blend human judgment with robotic precision to tackle tasks that demand both adaptability and unerring accuracy. Critical to this is the development of high-performance time of flight sensors (ToF). These ensure that collaborative robots, once limited to niche applications, are now central to industries ranging from electronics assembly to healthcare.
Moreover, their ability to safely share spaces with humans in the same open, fenceless factory floor unlocks new opportunities for efficiency and customisation, redefining what is possible in manufacturing and beyond.
One of the pivotal innovations enabling cobots to share workspaces with humans is the development of sophisticated sensing technologies. Ensuring that cobots can detect objects and humans with high precision is critical for maintaining safety and efficiency. Among the available technologies, Time of Flight sensors are emerging as a standout solution. They offer superior performance and cost-effectiveness compared to traditional methods.
The Role of Object Detection in Collaborative Safety
Safety is the cornerstone of any successful human-robot collaboration. Cobots use a combination of proximity sensors, force/torque detectors, and object detection systems to ensure they remain non-threatening to humans. Object detection plays a dual role: it helps cobots accurately position their effectors while handling materials and ensures that their movements are dynamically adjusted to avoid collisions with human workers.
Historically, optical and ultrasonic sensors have been the primary methods for object detection, yet these systems have limitations. Ultrasonics for instance, struggle with range and precision, especially when dealing with soft materials. On the other hand, traditional optical systems like 2D LiDAR are unable to detect objects outside their scanning plane. This risks blind spots that could pose risks in dynamic environments.
Time of flight sensors are a game changer for cobots
ToF sensors are a modern solution that addresses many of these shortcomings. Unlike scanning systems that rely on moving parts, or stereo vision requiring complex algorithms, ToF sensors measure distances by calculating the time it takes for light to travel to an object and back. This straightforward yet powerful principle enables ToF sensors to capture highly accurate 3D images of a scene in real time.
The advantages of ToF sensors are noticeable in collaborative robotics:
- Precision and Speed: ToF sensors generate 3D images at speeds of up to twenty frames per second. This makes them ideal for tracking fast-moving objects and adapting to real-time changes in the environment.
- Ambient Light Immunity: Unlike conventional cameras, which struggle with poor lighting or monochromatic scenes, ToF sensors perform reliably even in challenging conditions such as bright sunlight or low illumination.
- Compact and Durable Design: ToF systems lack mechanical moving parts, reducing maintenance requirements and increasing longevity. Their compact design also makes integration with cobots seamless.
Omron’s B5L raises the bar for ToF sensors
Omron’s B5L ToF sensor exemplifies how this technology is reaching new heights. With its 320×240-pixel resolution, the B5L provides real-time 3D sensing over distances ranging from 0.5 to 4 meters. Furthermore, it delivers an impressive accuracy of ±2%. Additionally, its immunity to ambient light—up to 100,000 lux—ensures stable performance in diverse environments.
Designed with practical applications in mind, the B5L minimises computational demands on the cobot’s processing systems by outputting pre-compensated signals. Its interference prevention features allow multiple units to operate simultaneously, supporting scenarios where several cobots share a workspace.
The inclusion of skeleton detection software further enhances its capabilities. It enables cobots to interpret human body poses and optimise their interactions for greater efficiency.
Shaping the Future of Collaborative Robotics
The rapid adoption of cobots highlights the growing demand for intelligent, safe, and versatile automation solutions.
With advancements like Omron’s B5L Time of flight sensor, cobots are becoming even more integral to industries seeking to balance human ingenuity with robotic precision.
As engineers continue to refine collaborative technologies, the synergy between humans and cobots will redefine production possibilities, transforming not only how we work but also how we innovate.
