Optoelectronic sensor with collision protection and mounting bracket

Abstract

The application relates to the technical field of sensor protection, and discloses a photoelectric sensor with collision protection and a mounting bracket. The photoelectric sensor with collision protection comprises a connecting head, an encoder, a grating ruler and a photoelectric sensor, baffle plates are fixedly installed at the two ends of a guide rail, sliding shafts are fixedly and symmetrically installed between the baffle plates, bearing rollers are rotatably installed in sliding bodies, the bearing rollers are in rolling contact with the sliding shafts, driving elements for driving the bearing rollers to rotate are installed in the sliding bodies, and the sliding bodies are provided with the encoders on one side. The position feedback and the speed feedback are integrated in one body, a high-precision double-closed-loop feedback control system is constructed, the system can monitor the motion state of the sliding bodies in real time and accurately, the driver can quickly adjust the output accordingly, and excellent position and speed control precision can be realized under complex working conditions, so that the strict requirements of high-end manufacturing equipment on motion control are met.

Description

Technical Field

[0001] This invention relates to the field of sensor protection technology, and more specifically, to a photoelectric sensor with collision protection and a mounting bracket. Background Technology

[0002] In modern industrial manufacturing, precision measurement, and automation equipment, linear motion modules are the core components for achieving high-precision linear motion. They are widely used in CNC machine tools, 3C electronic manufacturing equipment, semiconductor processing equipment, precision testing instruments, and various automated production lines. Linear motion modules typically consist of guide rails, sliding bodies (such as sliders), and a drive system. Their motion accuracy directly determines the processing accuracy and product quality of the equipment.

[0003] To ensure the accuracy and stability of motion control, existing technologies generally employ closed-loop or semi-closed-loop feedback control systems. These systems collect motion parameters in real time and feed them back to the actuator by installing position sensors (such as encoders) and speed sensors (such as photoelectric sensors) on the sliding body, thereby achieving precise adjustment of the sliding body's thrust, speed, and position.

[0004] However, in practical applications, existing linear motion modules and their feedback systems still have the following technical problems and shortcomings: 1. During high-speed or high-load operation, if the control system malfunctions, parameters are set improperly, or there is a sudden external interference, the sliding body is very likely to collide violently with the baffle at the end of the guide rail. This collision will not only directly damage the precision photoelectric sensor, encoder and other sensing elements, but may also cause the guide rail to deform and the bearing to be damaged, resulting in huge economic losses and downtime.

[0005] 2. The fit between the sliding element and the guide rail, especially the contact pressure between the rolling element and the guide rail, has a decisive impact on the smoothness of motion, friction loss, and service life. Excessive pressure will lead to increased friction, severe heat generation, and accelerated wear; insufficient pressure may cause shaking and gaps during motion, affecting accuracy. In the existing technology, this pressure is often difficult to adjust and maintain precisely.

[0006] 3. In order to achieve accurate detection of both position and speed, it is necessary to integrate a variety of precision components such as encoders and grating rulers within a limited sliding space. Existing installation methods are often complex in structure and lack effective protection for these precision components, making them susceptible to damage during collisions or long-term operation. Summary of the Invention

[0007] This invention provides a photoelectric sensor with collision protection, solving the technical problem of how to achieve high-precision motion control feedback, effectively resist accidental collisions, and facilitate precise adjustment of contact pressure.

[0008] This invention provides a photoelectric sensor with collision protection, comprising a connector, an encoder, a grating ruler, and photoelectric sensors. Baffles are fixedly installed at both ends of the guide rail, and sliding shafts are symmetrically fixed between the baffles. Bearing rollers are rotatably installed in the sliding body, and the bearing rollers roll in contact with the sliding shafts. A driving component is installed in the sliding body to drive the bearing rollers to rotate. An encoder is installed on one side of the sliding body, and the encoder works synchronously with the driving component to collect position parameters. A grating ruler is installed on the other side of the sliding body. A plurality of photoelectric sensors are equidistantly installed on the guide rail. The grating ruler moves with the sliding body, passing through the photoelectric sensors sequentially to measure speed parameters. An external driver connector is provided on the sliding body, and the connector is electrically connected to both the encoder and the grating ruler.

[0009] As a further aspect of the present invention: the drive unit, encoder, and grating ruler are connected to an external driver via a connector to form a detection feedback system. In the detection feedback system, the position parameters collected by the encoder and the speed parameters collected by the grating ruler are fed back to the driver, and the driver adjusts the current intensity and phase output to the drive unit in real time.

[0010] As a further aspect of the present invention: the sliding body is provided with a pressure adjustment mechanism that cooperates with the sliding shaft. The pressure adjustment mechanism includes a cover, a sliding plate, a screw hole and an adjusting screw. The cover is fixedly installed on the sliding body. The sliding plate is slidably installed in the cover. The sliding plate is in pressure contact with the sliding shaft. The cover has a screw hole. The adjusting screw is fitted in the screw hole and abuts against the sliding plate.

[0011] An installation bracket includes a base, a bracket body, and a limiting mechanism. The base is fixedly installed on the bottom of a guide rail, the bracket body is fixedly installed on the side of the guide rail, the photoelectric sensor is fixed in the bracket body, and the limiting mechanism includes a limiting collar, which is in the shape of a circular tube and extends from the inner wall of the baffle towards the sliding body.

[0012] The bracket body is U-shaped, with side blocks protruding outward on both sides. A mounting position for the body is provided at the center of one of the side blocks, and a fixing screw is fitted in the mounting position. The bracket body can be detachably installed and removed from the guide rail by fixing screws. A photoelectric mounting position for installing a photoelectric sensor is provided on the inner side of the bracket body.

[0013] The beneficial effects of this invention are as follows: This invention provides primary energy absorption protection by setting up an elastic buffer pad, and then combines it with a limiting collar for secondary mechanical limiting. This effectively prevents the sliding body from directly colliding with precision sensing elements (such as grating rulers and encoders) when it is out of control. This multi-level protection mechanism minimizes the risk of damage to expensive precision components from accidental collisions, improves the reliability and service life of the equipment, and reduces maintenance costs and downtime.

[0014] The pressure adjustment mechanism proposed in this invention achieves online, stepless adjustment of the contact pressure between the sliding body and the sliding shaft through the ingenious cooperation of the adjusting screw and the sliding plate. Operators can easily adjust to the optimal pressure value according to the actual working conditions, thereby ensuring smooth and gapless movement while minimizing friction and wear, and optimizing the dynamic performance and long service life of the module.

[0015] This invention integrates an encoder (position feedback) and a grating sensor (speed feedback) into one unit to construct a high-precision dual closed-loop feedback control system. This system can monitor the motion state of the sliding body in real time and accurately, and the driver adjusts the output quickly accordingly, ensuring excellent position and speed control accuracy even under complex working conditions, and meeting the stringent motion control requirements of high-end manufacturing equipment.

[0016] This invention rationally arranges components such as encoders, photoelectric sensors, and pressure adjustment mechanisms on both sides of the sliding body, resulting in a compact structure without increasing the module volume. The base and limiting collar design of the mounting bracket provide a stable installation foundation and also serve as cable protection, making the installation, debugging, and maintenance of the entire system more convenient and efficient. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the actual installation structure of a photoelectric sensor with collision protection proposed in this invention. Figure 2 This is a preliminary exploded view of the actual installation structure of a photoelectric sensor with collision protection proposed in this invention. Figure 3 This is a schematic diagram showing the actual disassembled structure of a photoelectric sensor with collision protection proposed in this invention. Figure 4 This is a schematic diagram of the actual installation side cross-section of a photoelectric sensor with collision protection proposed in this invention; Figure 5 yes Figure 3 Enlarged structural diagram at point A in the middle; Figure 6 This is a schematic diagram of a first alternative configuration of a mounting bracket proposed in this invention; Figure 7 This is a schematic diagram of a second alternative configuration of a mounting bracket proposed in this invention; Figure 8 This is a schematic diagram of a third alternative configuration of a mounting bracket proposed in this invention; Figure 9 This is a schematic diagram of a fourth alternative configuration of a mounting bracket proposed in this invention.

[0018] In the picture: 1. Base; 2. Guide rail; 3. Slider; 4. Connector; 5. Encoder; 6. Grating ruler; 7. Photoelectric sensor; 8. Baffle; 9. Limiting collar; 10. Drive component; 11. Bearing roller; 12. Sliding shaft; 13. Cover; 14. Slide plate; 15. Screw hole; 16. Adjusting screw; 17. Bracket body; 171. Side guard; 172. Body mounting position; 173. Fixing screw; 174. Photoelectric mounting position. Detailed Implementation

[0019] The subject matter described herein will now be discussed with reference to exemplary embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and implement the subject matter described herein, and changes may be made to the function and arrangement of the elements discussed without departing from the scope of this specification. Various processes or components may be omitted, substituted, or added as needed in the examples. Furthermore, features described in some examples may be combined in other examples.

[0020] At least one embodiment of the present invention discloses a photoelectric sensor with collision protection, which is disposed on a linear motion module formed by sliding cooperation between a guide rail 2 and a slider 3, such as... Figure 1 — Figure 4 As shown, the system includes a connector 4, an encoder 5, a grating ruler 6, and photoelectric sensors 7. Baffles 8 are fixedly installed at both ends of the guide rail 2. Sliding shafts 12 are symmetrically fixed between the baffles 8. Bearing rollers 11 are rotatably installed in the sliding body 3, and the bearing rollers 11 roll in contact with the sliding shafts 12. A driving component 10 is installed in the sliding body 3 to drive the bearing rollers 11 to rotate. An encoder 5 is installed on one side of the sliding body 3, and the encoder 5 and the driving component 10 work synchronously to collect position parameters. A grating ruler 6 is installed on the other side of the sliding body 3. Several photoelectric sensors 7 are equidistantly installed on the guide rail 2. The grating ruler 6 moves with the sliding body 3, passing sequentially through the photoelectric sensors 7 to measure speed parameters. An external driver connector 4 is provided on the sliding body 3, and the connector 4 is electrically connected to both the encoder 5 and the grating ruler 6.

[0021] The drive unit 10, encoder 5, and grating ruler 6 are connected to an external driver via connector 4 to form a detection feedback system. In the detection feedback system, the position parameters collected by encoder 5 and the speed parameters collected by grating ruler 6 are fed back to the driver. The driver adjusts the current intensity and phase output to drive unit 10 in real time, thereby accurately controlling the thrust, speed, and position of sliding body 3 and ensuring motion accuracy. This dual feedback mechanism (position loop and speed loop) effectively improves the dynamic response capability and steady-state accuracy of the system.

[0022] In order to protect the precision components in the event of a collision, an elastic buffer pad is also installed on the inner side of the baffle 8. When the sliding body 3 accidentally loses control and rushes towards the baffle 8, the elastic buffer pad will first contact the sliding body 3 and absorb most of the impact energy, thus playing a primary collision protection role.

[0023] More importantly, the sliding body 3 is provided with a pressure adjustment mechanism that cooperates with the sliding shaft 12. The pressure adjustment mechanism includes a cover 13, a sliding plate 14, a screw hole 15, and an adjusting screw 16. The cover 13 is fixedly installed on the sliding body 3, and the sliding plate 14 is slidably installed in the cover 13. The sliding plate 14 is in pressure contact with the sliding shaft 12. The cover 13 has a screw hole 15, and the adjusting screw 16 is fitted in the screw hole 15. The adjusting screw 16 abuts against the sliding plate 14.

[0024] By rotating the adjusting screw 16, the slide plate 14 can be precisely pushed, thereby changing the degree of compression of the slide plate 14 on the slide shaft 12. This achieves the purpose of precisely controlling the contact pressure between the slide shaft 12 and the bearing roller 11. This allows the operator to find the best balance point between friction and stability according to the load, speed and other working conditions, so as to ensure motion stability and reduce friction loss.

[0025] Furthermore, the present invention also provides a mounting bracket for mounting the aforementioned components such as the grating ruler 6 and the photoelectric sensor 7. The mounting bracket includes a base 1, a bracket body 17, and a limiting mechanism. The base 1 is fixedly mounted on the bottom of the guide rail 2, the bracket body 17 is fixedly mounted on the side of the guide rail 2, the photoelectric sensor 7 is fixed in the bracket body 17, and the limiting mechanism includes a limiting collar 9. The limiting collar 9 is in the shape of a cylindrical tube and extends from the inner wall of the baffle 8 toward the sliding body 3. This structural design serves two purposes: firstly, it acts as a physical limit to prevent the sliding body 3 from moving excessively and directly impacting the sensing element; secondly, its tubular structure provides a wiring channel for the internal circuitry, protecting the cables and making the overall layout neater and safer.

[0026] The bracket body 17 is U-shaped, with side blocks 171 protruding outward on both sides. A body mounting position 172 is provided at the center of one side block 171. A fixing screw 173 is fitted in the body mounting position 172. The bracket body 17 is detachably installed on the guide rail 2 by fixing screw 173. A photoelectric mounting position 174 for installing the photoelectric sensor 7 is provided on the inner side of the bracket body 17.

[0027] Slotted photoelectric sensors are widely used in the automation industry. They come in different shapes and installation sizes and are fixed with screws. Traditionally, installation involves using L-shaped sheet metal parts with threaded holes for mounting. This has two problems: First, the off-state sensor is exposed on the outside and easily touched, causing damage. Second, the mounting holes for the off-state sensor are not compatible with various types.

[0028] In response, the above implementation uses a two-color injection molding process to create the sensor protective shell, which has excellent impact resistance and temperature resistance. It is made of ABS material and is injection molded in one piece, eliminating the need for post-assembly and avoiding the sealing risks at the joint between the slot and the shell. The shell is designed with a U-shaped groove structure to reduce the refraction loss of the detection beam and ensure detection accuracy. The injection-molded protective structure shell is integrally injection molded, avoiding the problems of easy detachment and sealing failure in traditional assembled structures. The sensor outlet uses an injection molding and encapsulation process to tightly connect the cable to the shell without affecting the overall structure of the sensor.

[0029] And by adopting, for example Figures 5-9 The various bracket bodies 17 shown can accommodate different types of photoelectric sensors (674 type / 951 type), domestic and imported brands, as well as mainstream transmission modules such as aluminum profile modules, steel base modules, and embedded modules.

[0030] By adopting the above implementation, durability and environmental adaptability are improved, waterproof and dustproof performance is significantly enhanced, the shell is free from cracks and deformation, the detection performance is stable, it is suitable for industrial environments, the surface is free from obvious scratches, the universal injection molding adaptability reduces costs and improves efficiency, ensures high precision and stability, reduces risks and operational difficulty, the injection molding design of the overpressure protection chamber and the anti-accidental touch button, the injection molding process markings are clear and durable, no need for later stickers, operators can reduce identification time and improve operational efficiency.

[0031] Overall, the above implementation results in improved core performance, significantly reduced size, elimination of paired linear guide pairs, and adaptation to the installation requirements of equipment in confined spaces through an integrated base and integrated guide structure. The use of contactless electromagnetic drive and rolling guide design reduces mechanical friction and vibration, meeting precision manufacturing needs. The closed-loop feedback system further enhances positioning stability, outperforming traditional guide rail modules in accuracy. Costs are significantly reduced by eliminating expensive imported linear guide pairs, and the integrated structure reduces the number of parts, significantly lowering material procurement costs. Modular design enables standardized production, simplifies the assembly process, eliminates complex guide rail debugging procedures, and further reduces processing costs through large-scale production. The absence of mechanical contact transmission minimizes rolling element wear, reducing downtime for maintenance and component replacement costs, thus lowering the total lifecycle cost. While maintaining higher motion performance, the cost is lower than traditional modules, resulting in significant market price competitiveness. It eliminates dependence on imported linear guide pairs, allows for domestic production of core components, reduces supply chain risks, and aligns with the trend of industrial self-reliance.

[0032] The embodiments of the present invention have been described above. However, the embodiments are not limited to the specific implementation methods described above. The specific implementation methods described above are merely illustrative and not restrictive. Those skilled in the art can make more equivalent embodiments under the guidance of the present embodiments, and all of them are within the protection scope of the present embodiments.

Claims

1. A photoelectric sensor with collision protection, characterized in that, The system includes a connector (4), an encoder (5), a grating ruler (6), and a photoelectric sensor (7). Both ends of the guide rail (2) are fixedly mounted with baffles (8). Sliding shafts (12) are symmetrically fixed between the baffles (8). Bearing rollers (11) are rotatably mounted in the sliding body (3), and the bearing rollers (11) roll in contact with the sliding shafts (12). A driving component (10) for rotating the bearing rollers (11) is installed in the sliding body (3). An encoder is mounted on one side of the sliding body (3). The encoder (5) works synchronously with the drive unit (10) to collect position parameters. A grating ruler (6) is installed on the other side of the sliding body (3). Several photoelectric sensors (7) are installed at equal intervals on the guide rail (2). The grating ruler (6) moves with the sliding body (3) and passes through the photoelectric sensors (7) in sequence to measure speed parameters. An external driver connector (4) is provided on the sliding body (3). The connector (4) is electrically connected to the encoder (5) and the grating ruler (6).

2. The photoelectric sensor with collision protection according to claim 1, characterized in that, The drive unit (10), encoder (5) and grating ruler (6) are connected to an external driver via connector (4) to form a detection feedback system. In the detection feedback system, the position parameters collected by the encoder (5) and the speed parameters collected by the grating ruler (6) are fed back to the driver. The driver adjusts the current intensity and phase output to the drive unit (10) in real time.

3. A photoelectric sensor with collision protection according to claim 2, characterized in that, The sliding body (3) is provided with a pressure adjustment mechanism that cooperates with the sliding shaft (12). The pressure adjustment mechanism includes a cover (13), a sliding plate (14), a screw hole (15), and an adjusting screw (16). The cover (13) is fixedly installed on the sliding body (3). The sliding plate (14) is slidably installed in the cover (13). The sliding plate (14) is in contact with the sliding shaft (12). The cover (13) is provided with a screw hole (15). The adjusting screw (16) is fitted in the screw hole (15). The adjusting screw (16) abuts against the sliding plate (14).

4. A mounting bracket, applied to a photoelectric sensor with collision protection as described in any one of claims 1-3, characterized in that, The device includes a base (1), a bracket body (17), and a limiting mechanism. The base (1) is fixedly installed at the bottom of the guide rail (2), the bracket body (17) is fixedly installed on the side of the guide rail (2), the photoelectric sensor (7) is fixed in the bracket body (17), and the limiting mechanism includes a limiting collar (9). The limiting collar (9) is in the shape of a round tube and extends from the inner wall of the baffle (8) toward the sliding body (3).

5. A mounting bracket according to claim 4, characterized in that, The bracket body (17) is U-shaped, with side blocks (171) protruding outward on both sides. A body mounting position (172) is provided at the center of one side block (171). A fixing screw (173) is fitted in the body mounting position (172). The bracket body (17) can be detachably installed with the guide rail (2) by fixing screw (173). A photoelectric mounting position (174) for installing the photoelectric sensor (7) is provided on the inner side of the bracket body (17).

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