With the development of robot technology, robot utilization is expanding in industrial fields and everyday life. To employ robots in various fields wherein humans and robots share the same space, human safety must be guaranteed in the event of a human–robot collision. Therefore, criteria and limitations of safety need to be defined and well clarified. In this study, we induced mechanical pain in humans through quasi-static contact by an algometric device (at 29 parts of the human body). A manual apparatus was developed to induce and monitor a force and pressure. Forty healthy men participated voluntarily in the study. Physical quantities were classified based on pain onset and maximum bearable pain. The overall results derived from the trials pertained to the subjective concept of pain, which led to considerable inter-individual variation in the onset and threshold of pain. Based on the results, a quasi-static contact pain evaluation method was established, and biomechanical safety limitations on forces and pressures were formulated. The pain threshold attributed to quasi-static contact can serve as a safety standard for the robots employed.
Recent developments in robotics have resulted in implementations that have drastically increased collaborative interactions between robots and humans. As robots have the potential to collide intentionally and/or unexpectedly with a human during the collaboration, effective measures to ensure human safety must be devised. In order to estimate the collision safety of a robot, this study proposes a virtual sensor based on an analytical contact model that accurately estimates the peak collision force and pressure as the robot moves along a pre-defined path, even before the occurrence of a collision event, with a short computation time. The estimated physical interaction values that would be caused by the (hypothetical) collision were compared to the collision safety thresholds provided within ISO/TS 15066 to evaluate the safety of the operation. In this virtual collision sensor model, the nonlinear physical characteristics and the effect of the contact surface shape were included to assure the reliability of the prediction. To verify the effectiveness of the virtual sensor model, the force and pressure estimated by the model were compared with various experimental results and the numerical results obtained from a finite element simulation.
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