For safe and effective operation of humanoid robots in human-populated environments, the problem of commanding a large number of degrees of freedom (DoFs) while simultaneously considering dynamic obstacles and human proximity has still not been solved. In this article, we present a new reactive motion controller that commands two arms of a humanoid robot and three torso joints (17 DoF in total). We formulate a quadratic program that seeks joint velocity commands respecting multiple constraints while minimizing the magnitude of the velocities. We introduce a new unified treatment of obstacles that dynamically maps visual and proximity (precollision) and tactile (postcollision) obstacles as additional constraints to the motion controller, in a distributed fashion over the surface of the upper body of the iCub robot (with 2000 pressure-sensitive receptors). This results in a bioinspired controller that: first, gives rise to a robot with whole-body visuo-tactile awareness, resembling peripersonal space representations, and, second, produces human-like minimum jerk movement profiles. The controller was extensively experimentally validated, including a physical human–robot interaction scenario.

Two regimes permitting safe physical human-robot interaction, speed and separation monitoring and safety-rated monitored stop, depend on reliable perception of the space surrounding the robot. This can be accomplished by visual sensors (like cameras, RGB-D cameras, LIDARs), proximity sensors, or dedicated devices used in industrial settings like pads that are activated by the presence of the operator. The deployment of a particular solution is often ad hoc and no unified representation of the interaction space or its coverage by the different sensors exists. In this work, we make first steps in this direction by defining the spaces to be monitored, representing all sensor data as information about occupancy and using occupancy-based metrics to calculate how a particular sensor covers the workspace. We demonstrate our approach in two sensor-placement experiments in three static scenes and one experiment in a dynamic scene. The occupancy representation allow the comparison of the effectiveness of various sensor setups. Therefore, this approach can serve as a prototyping tool to establish the sensor setup that provides the most efficient coverage for the given metrics and sensor representations.

The need to guarantee safety of collaborative robots limits their performance, in particular, their speed and hence cycle time. The standard ISO/TS 15066 defines the Power and Force Limiting operation mode and prescribes force thresholds that a moving robot is allowed to exert on human body parts during impact, along with a simple formula to obtain maximum allowed speed of the robot in the whole workspace. In this work, we measure the forces exerted by two collaborative manipulators (UR10e and KUKA LBR iiwa) moving downward against an impact measuring device. First, we empirically show that the impact forces can vary by more than 100 percent within the robot workspace. The forces are negatively correlated with the distance from the robot base and the height in the workspace. Second, we present a data-driven model, 3D Collision-Force-Map, predicting impact forces from distance, height, and velocity and demonstrate that it can be trained on a limited number of data points. Third, we analyze the force evolution upon impact and find that clamping never occurs for the UR10e. We show that formulas relating robot mass, velocity, and impact forces from ISO/TS 15066 are insufficient—leading both to significant underestimation and overestimation and thus to unnecessarily long cycle times or even dangerous applications. We propose an empirical method that can be deployed to quickly determine the optimal speed and position where a task can be safely performed with maximum efficiency.