Dynamic update of a virtual cell for programming and safe monitoring of an industrial robot

A hardware/software architecture for robot motion planning and on-line safe monitoring has been developed with the objective to assure high flexibility in production control, safety for workers and machinery, with user-friendly interface. The architecture, developed using Microsoft Robotics Developers Studio and implemented for a six-dof COMAU NS 12 robot, established a bidirectional communication between the robot controller and a virtual replica of the real robotic cell. The working space of the real robot can then be easily limited for safety reasons by inserting virtual objects (or sensors) in such a virtual environment. This paper investigates the possibility to achieve an automatic, dynamic update of the virtual cell by using a low cost depth sensor (i.e., a commercial Microsoft Kinect) to detect the presence of completely unknown objects, moving inside the real cell. The experimental tests show that the developed architecture is able to recognize variously shaped mobile objects inside the monitored area and let the robot stop before colliding with them, if the objects are not too small.