The Department of Defense, specifically the United States Air Force, is seeking innovative solutions through the SBIR program for a project titled "Shop Floor Human Detection Using Low-Cost Equipment." The objective is to develop a system utilizing time-of-flight (ToF) sensor technologies and custom control systems to enable industrial robots to safely operate in environments populated by humans, eliminating the need for traditional static safety measures. This initiative is crucial as it addresses the growing need for automation in dynamic industrial settings while ensuring safety and operational efficiency. Interested parties should note that the solicitation is currently in pre-release, with an open date of May 28, 2025, and a close date of June 25, 2025, for applications. For more information, please visit the official source link at https://www.dodsbirsttr.mil/topics-app/.

## Description

The industrial landscape is evolving, with increasing demands for automation in environments that are inherently dynamic and populated by human workers. Traditional safety measures, such as static fencing and interlocks, are inadequate in these settings, particularly when mobile robots are involved. These environments pose significant challenges to ensuring safety while maintaining operational efficiency.In many industrial applications, robotic systems must adapt to varying conditions without compromising safety. The challenge is to create a system that can accurately detect and respond to human presence and other unexpected obstacles in real-time, ensuring that robots can function effectively without the need for external safety systems. Such a system must function for industrial robots mounted on mobile robots as well as for industrial robots mounted on rails, gantries, or pedestals.This project seeks to develop a system using ToF sensor technologies combined with a custom control system that can map the three-dimensional environment in real-time as well as be integrated into an existing industrial mobile robot at an Air Logistics Complex in order to enable them to operate collaboratively and safely. The goal is to create a solution that not only addresses safety concerns but also enhances the operational capabilities of these robots in human-populated environments.

## Objective

to develop a system that can achieve a third party safety rating comprised of software controls and three dimensional time-of-flight (ToF) sensors for data capture. This system will enable existing non-collaborative mobile heavy industrial robots to operate safely in human-populated settings, eliminating the need for static safety measures such as fencing, door interlocks, and light/laser curtains. To ensure a comprehensive field of view, the system will identify and process implied presence zones to account for blind spots in real time. The system must be compliant with international robotic safety standards, and be certified by a third party as PLd, Cat. 3 or SIL 2. This certification is the key here, systems that cannot obtain this certification would be considered unsuccessful.

## Phase I

this is a Direct-to-Phase II initiative and companies must demonstrate, from the outset, a prototype system with the capability to interface with ToF sensors and robotic control hardware. They must demonstrate practical experience detecting unforeseen obstacles and humans using point cloud technology and accurately recognize the position of objects within a global coordinate system. Additionally, companies need to identify regions that are obscured or not visible to each camera in real-time and have an established methodology for incorporating blind spot information into the robotic control system to ensure comprehensive environmental awareness.

## Phase II

Create a functional prototype which communicates with an existing robotic system at an Air Logistics Complex via an application programming interface. This system would send safety signals to the robotic system, similar to traditional safety devices (e.g., pressure mats, light curtains). The system must communicate the detection of unexpected obstacles and humans inside the environment and within different zones (e.g., warning/slow, hazard/stop) in order to trigger appropriate responses from the robot. The prototype should allow for safe operation without the need for additional external safety measures.Furthermore, implement real-time mapping of the dynamic environment to improve the robot's operational flexibility, minimize false positives, and enhance overall system efficiency. Optimize the hardware and software to maximize performance, leading to a robust, reliable solution suitable for integration into an Air Logistics Center's robotic systems. The system will be compliant with international robotic safety standards and be certified by a third party as PLd, Cat. 3 or SIL 2.

## Phase III: Dual Use Applications

If the Phase II is successful in developing the technology, the government would like to pursue a phase III to further develop autonomous decision-making algorithms that allow the robotic system to predict and adapt to environmental changes proactively by integrating advanced artificial intelligence-driven predictive analytics, enabling the robot to anticipate potential hazards before they arise. Moreover, Phase III&rsquo;s would be leveraged to coordinate the technology between multiple robotic systems, allowing them to communicate and collaborate in real-time. Other Phase III activities would include scaling the solution to other robotic systems in a multitude of facilities and refine the prototype into a market-ready product that meets the requirements of federal agencies, such as the Air Force, while also being suitable for private industry applications. This solution should be customizable for deployment across various sectors, providing a scalable, reliable enhancement to robotic systems operating in diverse environments.

Topic

Agency

Program

Topic Link

Additional Information