Precision lasers boost safety and efficiency in smart factories

The drive toward greater accuracy, efficiency, and automation in manufacturing environments and smart factories is accelerating at an unprecedented pace. This includes the deployment of advanced robotic systems, including autonomous mobile robots (AMRs) and collaborative robots working alongside humans, known as cobots.

The future of manufacturing depends on safe and seamless human-robot collaboration, requiring robots to dynamically adapt to the presence and movements of human workers. Maximizing the potential of these collaborative environments demands a critical capability: fast, accurate, and reliable 3D spatial sensing.

Traditional sensing methods often fall short in dynamic industrial settings that require reliable performance and high resolution. So, precision laser technologies, particularly time-of-flight (ToF) and frequency modulated continuous wave (FMCW) lidar, are emerging as key technologies, providing the detailed environmental sensing technology necessary for robots to navigate safely around personnel and to optimize workflows without compromising human safety.

Advanced lidar systems enable highly precise obstacle detection, distance measurement and real-time mapping, facilitating safer interaction between humans and robots. Design engineers are integrating the technology into automated factory systems to address the challenges of modern manufacturing while boosting accuracy, operational safety, and overall production efficiency.

How ToF lidar uses light to measure distance in smart factories

ToF lidar delivers highly accurate distance measurements by timing the round-trip travel of laser pulses, creating precise 3D point clouds of all objects in the surrounding environment—giving AMRs and cobots a detailed, real-time picture of their workspace. A ToF lidar system emits a pulse of invisible laser light onto an object and receives the reflected pulse back.

The system then calculates the distance between the transmitter/receiver and the object based on how long that round trip takes. Figure 1 shows a high-level diagram of a single-point optical ToF lidar system.

Figure 1 Distance measurement is shown between the object and the ToF lidar. Source: Texas Instruments

Cameras and ultrasonic sensors fall short in dynamic applications

Camera-based systems and ultrasonic sensing cannot match the speed and precision that ToF lidar delivers for distance measurement. While cameras excel at extracting texture and color information from their environment, they struggle with depth perception, especially in challenging lighting conditions.

Cameras often require illumination of the entire area of interest to function accurately, while ToF lidar systems, such as the module on top of the robot in Figure 2, supply their own illumination in the form of laser pulses. Most ToF lidar systems use laser light with a 905-nm wavelength invisible to humans and can sense objects over 100 m away while remaining eye-safe. Some scanning ToF lidar systems can provide 360-degree distance measurements, making them particularly useful in AMR applications where spatial awareness in all directions matters.

Figure 2 AMR is equipped with a ToF lidar module on top to supply illumination in the form of laser pulses. Source: Texas Instruments

Obtaining accurate 3D distance information from cameras requires complex and computationally expensive image processing algorithms that can introduce latency and potential inaccuracies. Camera-based systems also require good lighting conditions to operate properly.

Due to light dispersion, most camera-based systems deliver accurate distance measurements only for objects a few meters away and lose accuracy at greater distances unless design engineers use large, costly lenses.

Ultrasonic sensors offer a low-cost solution for proximity detection, but suffer from limited range, poor accuracy, and susceptibility to interference from noise and surface characteristics. Accuracy for distance measurement typically falls within a range of several centimeters, and environmental factors such as temperature, humidity, and the object surface texture heavily influence results. Additionally, a wide field of view makes it difficult to pinpoint the exact location of an obstacle, increasing the risk of false positives.

FMCW lidar adds velocity measurement for safer human-robot collaboration

FMCW lidar is quickly emerging as a superior sensing solution for smart factories, particularly in collaborative robotic applications.

Unlike ToF, which measures distance based on the time it takes a laser pulse to return, FMCW lidar transmits a continuous wave laser that varies in frequency. By analyzing the frequency difference between the transmitted and received signals, the system applies the Doppler principle to directly measure both distance and velocity with extremely high precision.

This velocity measurement provides critical advantage in environments where robots work alongside humans and other robots, enabling a proactive response to movement and significantly reducing collision and injury risks. FMCW lidar also achieves longer distance measurement range at the same laser power as ToF-based systems. Figure 3 shows a high-level diagram of an FMCW lidar system.

Figure 3 The high-level diagram shows how an FMCW lidar system works. Source: Texas Instruments

In high-throughput manufacturing environments utilizing conveyor belts, FMCW lidar offers significant advantages over traditional camera-based vision systems for object detection and tracking.

Camera-based systems rely on image processing and pattern recognition, which can be computationally intensive and sensitive to object orientation. Conversely, FMCW lidar directly measures distance and velocity regardless of these factors, enabling quicker and more reliable detection even with fast-moving objects.

FMCW lidar’s ability to create a dense 3D point cloud allows engineers to determine accurate size and shape without complex image analysis, significantly increasing overall manufacturing line throughput and system accuracy.

Driving what’s next in smart factory automation

The increasing demand for automation, efficiency, and safety in modern manufacturing is driving the rapid adoption of advanced sensing technologies such as ToF and FMCW lidar. Both technologies offer substantial advantages over camera-based vision systems and ultrasonic sensors in dynamic environments where human-robot collaboration takes priority.

ToF lidar provides accurate 3D spatial data for reliable obstacle detection and precise distance measurements. FMCW lidar further elevates performance through the direct measurement of both distance and velocity, crucial for proactive collision avoidance and enhanced safety.

Companies such as Texas Instruments provide essential semiconductor building blocks such as transimpedance amplifiers, laser drivers, analog-to-digital converters (ADCs), digital-to-analog converters (DACs), and a comprehensive range of power products that are vital for designing and building high-performance ToF and FMCW lidar systems.

Ongoing innovation in laser technology and signal processing promises continued advancements in lidar capabilities, positioning it as a cornerstone technology in the evolution of smart factories and industrial automation.

Anthony Vaughan is marketing manager for high-speed amplifiers at Texas Instruments.

 

 

Special Section: Smart Factory

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