Real-Time Safety Evaluation of Human Arm Operations Using a Wrist-Mounted IMU with PSM System

Humanoid robots are emerging as co-workers in smart manufacturing, yet their dynamic, human-like movements introduce safety risks that differ fundamentally from those of fixed or wheeled robots. Conventional safety paradigms based on reactive force or distance limits fail to capture the sequential, uncertain nature of humanoid failures. This study proposes a precursor-driven, trust-calibrated framework to enable proactive humanoid risk perception. Accident evolution is modeled through sequential precursor cues using a Logistic-Exponential (LE) formulation that couples logistic escalation from diverse precursors with exponential decay for temporal dissipation. Trust is defined as the inverse of the estimated accident probability, allowing humanoids to adapt behavior in real time, reducing aggressiveness when risk intensifies, and restoring confidence as stability returns. A multi-source dataset of 126 documented events and 241 precursors revealed twelve dominant accident modes, most evolving through overlapping cues within one second. A simulated case study ("fall-onto-human") demonstrated how the LE-Trust coupling can trigger early intervention and prevent collapse. The results advance humanoid safety from static thresholds toward dynamic, evidence-based inference, establishing a foundation for risk-aware and trustworthy human-robot collaboration in Industry 5.0 environments.

Ensuring human safety is of paramount importance in warehouse environments that feature mixed traffic of human workers and autonomous mobile robots (AMRs). Current approaches often treat humans as generic dynamic obstacles, leading to conservative AMR behaviors like slowing down or detouring, even when workers are fully aware and capable of safely sharing space. This paper presents a real-time vision-based method to estimate human awareness of an AMR using a single RGB camera. We integrate state-of-the-art 3D human pose lifting with head orientation estimation to ascertain a human's position relative to the AMR and their viewing cone, thereby determining if the human is aware of the AMR. The entire pipeline is validated using synthetically generated data within NVIDIA Isaac Sim, a robust physics-accurate robotics simulation environment. Experimental results confirm that our system reliably detects human positions and their attention in real time, enabling AMRs to safely adapt their motion based on human awareness. This enhancement is crucial for improving both safety and operational efficiency in industrial and factory automation settings.

What is considered safe for a robot operator during physical human-robot collaboration (HRC) is specified in corresponding HRC standards (e.g., ISO 10218-2:2025). The regime that allows collisions between the moving robot and the operator, called Power and Force Limiting (PFL), restricts the permissible contact forces. Using the same fixed contact thresholds on the entire robot surface results unnecessary productivity losses, as the robot needs to stop even when impact forces are within limits. Here we present a framework that decides whether the robot should interrupt motion based on estimated collision force computed individually for different parts of the robot body and dynamically on the fly, based on the Effective Mass (EM) of each robot link. We performed experiments on a simulated and real collaborative robot arm (UR10e) with sensitive skin (AIRSKIN) for collision detection and isolation. To demonstrate the generality of our method, we added experiments on simulated KUKA LBR iiwa robot, where collision sensing draws on joint torque sensing. On a mock pick-and-place scenario with both transient and quasi-static collisions, we show an increase in productivity over 45% from using the standard approach. The method is applicable to any robot for which the EF can be calculated.