Field-selectable cable exit sensor housing

Abstract

Apparatus and associated methods relate to a sensor having a housing with multiple cable exit passageways extending from a recessed cable exit aperture. In various embodiments, the cable passageways may, for example, direct a cable to exit from a selected one of multiple housing faces, at least one the faces providing a sensor emitter or receiver interface associated with the sensor. For example, the passageways may extend from a cable exit aperture to different faces of the housing. The different faces may include, for example, an indicator face. A cable extending from the cable exit aperture may, for example, be configured to extend through the passageways to an aperture of one of the faces. Such implementations may, for example, mitigate cable stress by facilitating housing position with substantially reduced or eliminated cable interference, which may advantageously allow the housing to be positioned without the cable being interfered with.

Description

TPL Docket No.: 128-76-WOFIELD-SELECTABLE CABLE EXIT SENSOR HOUSING TECHNICAL FIELD

[0001] Various embodiments relate generally to a sensor housing.BACKGROUND

[0002] In some industries, positioning is a consideration. For example, various companies arrange their production layout with particular goals.

[0003] Some companies may, for example, prioritize the production flow so that goods are manufactured in a certain order. Some companies may, for example, prioritize the distance between different components of the production layout.SUMMARY

[0004] Apparatus and associated methods relate to a sensor having a housing with multiple cable exit passageways extending from a recessed cable exit aperture. In various embodiments, the cable passageways may, for example, direct a cable to exit from a selected one of multiple housing faces, at least one the faces providing a sensor emitter or receiver interface associated with the sensor. For example, the passageways may extend from a cable exit aperture to different faces of the housing. The different faces may include, for example, an indicator face. A cable extending from the cable exit aperture may, for example, be configured to extend through the passageways to an aperture of one of the faces. Such implementations may, for example, mitigate cable stress by facilitating housing position with substantially reduced or eliminated cable interference, which may advantageously allow the housing to be positioned without the cable being interfered with.

[0005] The passageways may, for example, extend to different adjacent faces of the sensor housing, defining apertures in these faces. For example, the apertures may be configured to removably receive the cable. The apertures may allow the cable to exit the sensor housing, for example. In some implementations, the passageways may, for example, be troughs.

[0006] In an illustrative embodiment, one of the apertures may be defined on the indicator face. The indicator face includes an indicator. For example, the indicator may include LED bars. In some embodiments, the LED bars may operate as a menu for the sensor housing. The LED bars may, for example, operate as a signal strength indicator.

[0007] Various embodiments may achieve one or more advantages. For example, the passageways may, advantageously be configured to removably receive the cable. The one or more indicators may, in some embodiments, advantageously provide performance data to the user. In some implementations, the indicator may advantageously enable the user to access a menu with different settings for the sensor in the sensor housing. The passageways may, for example, advantageouslyTPL Docket No.: 128-76-WO be configured to control the minimum bend radius of a cable. Advantageously, the configuration of the passageways may, for example, shield the elbow of the cable in a bend from impinging on other surfaces that could impair or degrade the cable, for example, due to abrasion. The configuration of the passageways may, in some embodiments, advantageously provide flexibility in field installation scenarios by providing, for example, user selectable direction of cable exit that is easily adapted and repeatably reconfigurable to in situ needs with a single sensor device.

[0008] Various examples may advantageously increase the longevity of the sensor housing. Some passageways may, for example, be configured to receive the cable. The placement of the cable in the passageway may, in some embodiments, advantageously enable the sensor housing to be mounted in a variety of positions. In some implementations, the apertures may advantageously be configured to removably receive the cable. The aperture defined on the indicator face may, for example, advantageously provides different mounting arrangements and possibilities. The configuration of the passageways may, in some implementations, allow strain relief from tangential forces that may tangentially act on the cable. The arrangement of the passageways may, in some embodiments, advantageously enable a user to interact with the indicator face while also managing the positioning of the cable extending from the aperture on the indicator face.

[0009] In various implementations, different features described herein, taken alone or in combination, may facilitate installation of sensor housings, for example, in various commercial, industrial, or residential applications that may, for example, be constrained and / or compromised by cable routing requirements. For example, the indicator may adjust the sensitivity of the sensor that may advantageously increase the accuracy of the sensor.

[0010] The details of various embodiments are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 depicts an illustrative perspective view of an example sensor housing.

[0012] FIG. 2 depicts an illustrative bottom view of an example sensor housing.

[0013] FIG. 3 depicts an illustrative front view of an example sensor housing.

[0014] FIG. 4 depicts an illustrative right side view of an example sensor housing.

[0015] FIG. 5 depicts an illustrative left side view of an example sensor housing.

[0016] FIG. 6 depicts an illustrative back view of an example sensor housing.

[0017] FIG. 7 depicts an illustrative top view of an example sensor housing.

[0018] FIG. 8 depicts an illustrative exploded left side view of an example sensor device.

[0019] FIG. 9 depicts an illustrative LED panel of an embodiment of an example sensor housing.TPL Docket No.: 128-76-WO |0020| FIG. 10 is a flowchart illustrating an illustrative use-case method of placing a cable in a passageway of an example housing.

[0021] Like reference symbols in the various drawings indicate like elements.DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0022] To aid understanding, this document is organized as follows. First, to help introduce discussion of various embodiments, a sensor housing is introduced with reference to FIGS. 1-7. Second, that introduction leads into a description with reference to FIGS. 8-9 of some exemplary embodiments of a sensor housing and an LED panel. Third, with reference to FIG. 10, an illustrative use-case method of placing the cable in the passageway is described.

[0023] FIG. 1 depicts an illustrative perspective view of an example sensor housing. A sensor housing 100 includes a passageway face 105 with embedded passageways 110. In the depicted figure, the passageways 110 provide fluid communication through intersecting concave passageways recessed from the surface of the passageway face 105. The passageways 110 are configured to receive a cable 115. The cable 115 extends through the intersection of the passageways 110. The cable 115 may, for example, be bent to extend through one of the passageways 110. In some implementations, the cable 115 may be selectively placed in one of the passageways 110. The selective placement of the cable 115 may advantageously enable the sensor housing 100 to be mounted in a variety of positions. This placement may advantageously prevent damage to the cable 115 by allowing the sensor housing 100 to be positioned in multiple positions without the cable 115 receiving damaging forces from its surroundings. Such placement may advantageously increase the longevity of the sensor housing 100.

[0024] The sensor housing 100 includes multiple faces. The passageways 110 extend to different faces of the sensor housing 100. The passageways 110 define face apertures 120 in the different faces. In some implementations, the face apertures 120 may be configured to receive the cable 115. For example, the face apertures 120 may allow the cable 115 to exit the sensor housing 100. One of the face apertures 120 is defined on the indicator face 125. In some examples, the indicator face 125 may advantageously be configured to provide indicia to a user. The indicator face 125 includes an indicator 130. The indicator 130 includes LED bars 135. Various embodiments include LED bars 135 that operate as a menu for the sensor housing 100. In some embodiments, the LED bars 135 may operate as a signal strength indicator.

[0025] The indicator face 125 includes button 140. In some embodiments, the button 140 may enable a user to control the sensor in the sensor housing 100. For example, the button 140 may enable the user to operate the LED bars 135 as a menu. The button 140 is located in a portion of the indicator face 125 tapering inwards towards the sensor housing 100. This location may, forTPL Docket No.: 128-76-WO example, advantageously enable the user to engage the button 140 with the tip of a pen and / or screwdriver. This location may, in some embodiments, advantageously prevent the user from pressing the button 140 accidentally. In various embodiments, the menu of the sensor in the sensor housing 100 may be configured to display through the LED bars 135.

[0026] The indicator face 125 includes windows 145. In some embodiments, the windows 145 may be transparent. For example, the windows 145 may enable viewing of a power LED and / or a signal LED. In some implementations, the windows 145 are configured to display the power LED and / or the signal LED.

[0027] FIG. 2 depicts an illustrative bottom view of an example sensor housing. The passageways 110 extend to different faces of the sensor housing 100. The passageways 110 extending to different faces form the face apertures 120. The passageways 110 intersect with each other. In the depicted embodiment of FIG. 2, the passageways 110 form a tee-shape intersection. The passageways 110 form the face apertures 120 in each of the adjacent faces. In some examples, the passageways 110 may be isolated from one another.

[0028] In the depicted embodiment of FIG. 2, the cable 115 extends from the sensor housing 100 through a cable exit aperture 205. The cable exit aperture 205 is arranged at the intersection of the passageways 110. The cable exit aperture 205 is recessed. For example, the cable exit aperture 205 may define a lumen between an interior cavity of the sensor housing 100 and the passageways 110.

[0029] In some implementations, the passageways 110 include means for routing the cable 115 to extend from the face aperture 120 on the indicator face 125, examples of which are shown in further detail with reference to FIGS. 1 and 2. In some examples, the passageways 110 include a selectable means for routing the cable 115 to extend from different face apertures 120 on the different faces. The passageways 110 includes field configurable means for routing the cable 115 to the internal electronics of the sensor housing 100.

[0030] FIG. 3 depicts an illustrative front view of an example sensor housing. The indicator face 125 includes one of the face apertures 120. In some implementations, the cable 115 extending through the face apertures 120 may advantageously enable the cable 115 to extend from the indicator face 125 of the sensor housing 100. For example, the cable 115 extending through the face apertures 120 may advantageously enable the cable 115 to be mounted in additional positions.

[0031] In some embodiments, the LED bars 135 include multiple LEDs. The LED bars 135 may, for example, function as a signal strength indicator, which indicates the performance of the sensor in the sensor housing 100.

[0032] Various implementations of the LED bars 135 may operate as a menu for the sensor in the sensor housing 100. For example, each of the LED bars 135 may correspond to a specific menuTPL Docket No.: 128-76-WO option and a user may navigate the menu by pressing the button 140. Each press of the button 140 may, for example, move the selected menu option to the next menu option. In some implementations, the movement may be indicated by one LED bar 135 switching to a different LED bar 135 upon the button 140 being clicked.

[0033] In some embodiments, the sensor housing 100 may have labels adjacent to the LED bars 135. In some implementations, the labels may correspond to what each LED bar 135 represents in the menu. The labels may, for example, advantageously assist the user in identifying the function of each menu item.

[0034] In some embodiments, the LED bars 135 may include only one LED bar. In different embodiments, the LED bars 135 may include multiple LED bars.

[0035] In various implementations, the LED bars 135 visible through the windows 145 may be configured to operate together. In some implementations, the LED bars may be configured to operate separately. The LED bars 135 may, for example, be set to different states of illuminations. For example, the LED bars 135 may be set to an on mode. This may, for example, advantageously enable the indicator functionality of the LED bars 135 to occur, allowing a user to operate the sensor. The LED bars 135 may, for example, be set to different states of illumination such as off, steady, flashing, strobe, warble, pulsing and / or different colors, at least in part depending on the operation of the sensor. Each individual LED bar may, for example, advantageously illuminate multiple colors along its length simultaneously. For example, the multiple colors may provide additional options for the user to control a sensor in the sensor housing 100.

[0036] FIG. 4 depicts an illustrative right side view of an example sensor housing. In the depicted embodiment of FIG. 4, the sensor housing 100 may include side faces 405, 505. The side face 405 includes one of the face apertures 120. In some implementations, the configuration of the face apertures 120 may advantageously enable the sensor housing 100 to be mounted in additional positions. For example, the configuration of the face apertures 120 may prevent the cable 115 from being damaged when the sensor housing 100 is placed in certain positions.

[0037] FIG. 5 depicts an illustrative left side view of an example sensor housing. The sensor housing 100 may, for example, include side faces 405, 505. The side face 505 includes one of the face apertures 120. In some implementations, the configuration of the face apertures 120 may advantageously enable the sensor housing 100 to be mounted in additional positions. For example, the configuration of the face apertures 120 may prevent the cable 115 from being damaged when the sensor housing 100 is placed in certain positions.

[0038] FIG. 8 depicts an illustrative exploded left side view of an example sensor housing. In the depicted figure, the sensor housing 100 includes an LED panel 805. In some implementations, the LED panel 805 may be formed integrally with the indicator face 125. In some embodiments, theTPL Docket No.: 128-76-WO LED panel 805 may be attached to the indicator face 125. The LED panel 805 may, for example, include the LED bars 135.

[0039] FIG. 9 depicts an illustrative LED panel of an embodiment of an example sensor housing. The LED panel 805 includes a power LED 905. In the depicted embodiment of FIG. 9, the power LED 905 may be visible through the windows 145. In some implementations, the power LED 905 may indicate that the sensor in the sensor housing 100 is electrically powered. For example, the power LED 905 indicates that the sensor in the sensor housing 100 is activated.

[0040] The LED panel 805 includes a signal LED 910. In some implementations, the signal LED 910 may be visible through the windows 145. For example, the signal LED 910 may indicate the signal status of the sensor. The signal LED 910 may, for example, be configured to detect a discrete contact and / or discrete non-contact.

[0041] FIG. 10 is a flowchart illustrating an illustrative use-case method of placing a cable in a passageway of an example housing. The method 1000 starts with positioning the sensor housing in step 1005. For example, the sensor housing 100 may be mounted flat against a structure.

[0042] The method 1000 continues with determining which passageway to place the cable into in step 1010. In some implementations, the placement of the sensor housing 100 may influence which passageway 110 is selected. The indicator face passageway is selected as in step 1015 or one of the side face passageways is selected in step 1020. The cable is placed in the appropriate passageway in step 1025. In some implementations, a cable is placed in a passageway to extend through to a selected face.

[0043] Although various embodiments have been described with reference to the figures, other embodiments are possible.

[0044] Although an exemplary system has been described with reference to FIGS. 1-10, other implementations may be deployed in other industrial, scientific, medical, commercial, and / or residential applications.

[0045] In some embodiments, the sensor housing 100 may be mounted in tight positions. The tight positions may include corners of the wall. In some implementations, tight positioning ensure optimal placement of the sensor housing 100.

[0046] In some embodiments, the cable exit aperture 205 may be arranged in the center of the intersection of the passageways 110.

[0047] In some implementations, the sensor housing 100 may include a photoelectric sensor. For example, the photoelectric sensor may include a retroreflective arrangement. The retroreflective arrangement may place a transmitter and a receiver in the same location. In some embodiments, the retroreflective arrangement may use a reflector to bounce the inverted light beam back fromTPL Docket No.: 128-76-WO the transmitter to the receiver. The photoelectric sensor in the retroreflective arrangement may, for example, sense when the beam is interrupted and fails to reach the receiver.

[0048] In some embodiments, a user may select numerous options in the menu. For example, the options may include the type of object to be detected. This option may advantageously enable the sensor to detect only certain shapes. For example, if an undesired item were to pass through the sensor, it would not be detected by the sensor.

[0049] Various embodiments include an option to enable the sensor to detect objects that should not pass through the sensor. For example, the sensor may alert users that an undesired object passed through the sensor’s detection.

[0050] In some implementations, the options may include the detection range. The detection range may, for example, be wide enough to detect multiple objects at once or narrow enough to only detect one object at a time.

[0051] In some embodiments, the options may include the sensitivity of the sensor. For example, the sensitivity of the sensor may be adjusted to where it only detects objects that take up a certain percentage of the frame. The percentage of the frame may, for example, advantageously be adjusted between zero percent and up to one-hundred percent.

[0052] In some implementations, an envelope represents an effective volume occupied by various embodiments of the sensor housing 100. For example, an envelope may include the maximum volumetric space within which a component or assembly must fit. In some examples, the envelope defined by the sensor housing 100 may include the outermost boundaries of the sensor housing 100, including the outermost boundaries of the passageways 110.

[0053] In some embodiments, the envelope may be rectangular. The rectangular envelope may advantageously provide the sensor housing with selectively larger and smaller faces for different purposes.

[0054] In some implementations, the envelope may be rhomboidal. A substantially rhomboidal shaped sensor housing may, for example, facilitate insertion into a correspondingly shaped recess.

[0055] In some embodiments, the envelope may be parallelepiped. For example, the parallelepiped sensor housing may facilitate insertion into non-standard recesses.

[0056] In various examples, the envelope may advantageously be shaped in a variety of ways to provide the same desirable sensor housing to numerous environments that may require different embodiments of the sensor housing 100. For example, the envelope may be defined as planar surface sides that intersect and contain the outer dimensions of the housing.

[0057] In some implementations, the passageways 110 may be concave. For example, the concavity of the passageways 110 may define areas of increased distance between a surface of theTPL Docket No.: 128-76-WO sensor housing 100 and the envelope formed of planar surface sides that are defined to contain the sensor housing 100.

[0058] In some embodiments, the passageways 110 may, for example, form troughs. The troughs are arranged in the passageway face 105.

[0059] In some implementations, the sensor housing 100 may include a clearance volume. In such an implementation, the clearance volume may include additional space around the sensor housing 100. The clearance volume may be advantageously used to provide space for the cable 115 to fit. The clearance volume may provide additional space for the cable 115 to pass through each of the passageways 110. The additional space may advantageously provide the user the ability to change the cable 115 position depending on the arrangement of the sensor housing 100.

[0060] In some embodiments, the passageways 110 may, for example, be configured to receive a cable that extends through a cable exit aperture and a selected one of the indicator face and at least one other face of the multiple faces of the sensor housing 100.

[0061] In various embodiments, the sensor housing 100 may include a multimodal LED display. The multimodal LED display may, for example, include the LED bars 135. The LED bars 135 may, for example, be configured to operatively control the sensor. In some implementations, the LED bars 135 may include a green LED. The green LED may, for example, indicate power. In various embodiments, the LED bars 135 may include an amber LED. The amber LED may, for example, indicate a discrete contact. The amber LED may, for example, indicate a non-discrete contact.

[0062] In some implementations, the indicator face 125 includes the windows 145 that may be arranged at the edge of the sensor housing 100. This arrangement may, for example, advantageously enable the LEDS bars 135 to be visible from various angles. For example, this visibility may advantageously enhance user interaction and feedback.

[0063] In various implementations, the windows 145 may be a single, integral piece. The windows 145 may, for example, be completely overmolded with a material. For example, the material may be black to achieve the desired appearance and functionality. This may, for example, advantageously enable the LED bars 135 to be visible from the edge, providing better visibility from different angles. The overmolding process may, for example, prevent cracking.

[0064] In an illustrative aspect, a sensor may include a housing having a plurality of faces including a passageway face and an indicator face; the passageway face may have intersecting concave passageways recessed from a planar surface of the passageway face; and, a cable exit aperture may define a lumen between an interior cavity of the housing and the plurality of concave passageways; the concave passageways may be configured to receive a cable that extends through the cable exit aperture and a selected one of the indicator face and at least one of the other facesTPL Docket No.: 128-76-WO of the plurality of faces; and, one of the concave passageways may extend through to an aperture on an indicator face.

[0065] In some implementations, the concave passageways may form a tee-shape.

[0066] In various implementations, the concave passageways may form troughs.

[0067] In some embodiments, the cable may extend from an intersection of the concave passageways. The cable may, for example, extend from a center of the intersection of the concave passageways. For example, the cable exit aperture may be recessed.

[0068] In various embodiments, the indicator face may include an indicator. The indicator may, for example, be configured to indicate a signal strength. In some implementations, the indicator face may be configured to navigate a menu.

[0069] In an illustrative aspect, a sensor may include a housing that may have a plurality of faces including a passageway face and an indicator face; the passageway face may have intersecting concave passageways recessed from a planar surface of the passageway face; and, a cable exit aperture that may define a lumen between an interior cavity of the housing and the concave passageways; the concave passageways may be configured to receive a cable that extends through the cable exit aperture and a selected one of the indicator face and at least one of the other faces of the plurality of faces.

[0070] In some implementations, the concave passageways may include a means for routing the cable to extend from a face aperture on the indicator face.

[0071] In various implementations, one of the concave passageways may extend through to a face aperture on the indicator face; and, the indicator face may, for example, include a button configured to control a menu. For example, the menu may be configured to display through a plurality of indicators. In some embodiments, the button is located in a portion of the indicator face tapering inwards.

[0072] In various embodiments, the indicator face may include at least one window. A signal LED may, for example, be visible through the at least one window. For example, the signal LED may be configured to detect a discrete contact.

[0073] In an illustrative aspect, a method may include providing a sensor housing which includes a plurality of faces, each of the faces may define a rectangular envelope, the plurality of faces that may include an indicator face that may be configured to provide indicia to a user, and a passageway face that may include intersecting concave passageways recessed from a planar surface of the passageway face; and, a cable exit aperture that may define a lumen between an interior cavity of the housing and the plurality of concave passageways, the concave passageways may be configured to receive a cable that extends through the cable exit aperture and a selected one of the indicator face and at least one of the other faces of the plurality of faces; positioning the sensorTPL Docket No.: 128-76-WO housing; selecting from among the indicator face and the at least one of the other faces of the plurality of faces; and, placing the cable in the concave passageway to extend through the selected face.

[0074] In some embodiments, the concave passageways may extend to a side face of the plurality of faces, the side face may be adjacent to the indicator face. For example, the concave passageway may extend to the indicator face, forming a face aperture.

[0075] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made. For example, advantageous results may be achieved if the steps of the disclosed techniques were performed in a different sequence, or if components of the disclosed systems were combined in a different manner, or if the components were supplemented with other components. Accordingly, other implementations are contemplated within the scope of the following claims.

Claims

TPL Docket No.: 128-76-WOCLAIMSWhat is claimed is:

1. A sensor comprising:a housing having a plurality of faces including a passageway face and an indicator face; the passageway face having intersecting concave passageways recessed from a planar surface of the passageway face; and,a cable exit aperture defining a lumen between an interior cavity of the housing and the plurality of concave passageways;wherein the concave passageways are configured to receive a cable that extends through the cable exit aperture and a selected one of the indicator face and at least one of the other faces of the plurality of faces; and,wherein one of the concave passageways extends through to an aperture on an indicator face.

2. The sensor of claim 1 , wherein the concave passageways form a tee-shape.

3. The sensor of claim 1 , wherein the concave passageways form troughs.

4. The sensor of claim 1, wherein the cable extends from an intersection of the concave passageways.

5. The sensor of claim 4, wherein the cable extends from a center of the intersection of the concave passageways.

6. The sensor of claim 5, wherein the cable exit aperture is recessed.

7. The sensor of claim 1 , wherein the indicator face comprises an indicator.

8. The sensor of claim 7, wherein the indicator is configured to indicate a signal strength.TPL Docket No.: 128-76-WO 9. The sensor of claim 7, wherein the indicator is configured to navigate a menu.TPL Docket No.: 128-76-WO 10. A sensor comprising:a housing having a plurality of faces including a passageway face and an indicator face; the passageway face having intersecting concave passageways recessed from a planar surface of the passageway face; and,a cable exit aperture defining a lumen between an interior cavity of the housing and the concave passageways;wherein the concave passageways are configured to receive a cable that extends through the cable exit aperture and a selected one of the indicator face and at least one of the other faces of the plurality of faces.

11. The sensor of claim 10, the concave passageways further comprise means for routing the cable to extend from a face aperture on the indicator face.

12. The sensor of claim 10, wherein one of the concave passageways extends through to a face aperture on the indicator face; and, wherein the indicator face comprises a button configured to control a menu.

13. The sensor of claim 12, wherein the menu is configured to display through a plurality of indicators.

14. The sensor of claim 12, wherein the button is located in a portion of the indicator face tapering inwards.

15. The sensor of claim 12, wherein the indicator face comprises at least one window.

16. The sensor of claim 15, wherein a signal LED is visible through the at least one window.

17. The sensor of claim 16, wherein the signal LED is configured to detect a discrete contact.TPL Docket No.: 128-76-WO 18. A method comprising:providing a sensor housing comprising:a plurality of faces, each of the faces defining a rectangular envelope, wherein the plurality of faces comprising an indicator face configured to provide indicia to a user, and a passageway face comprising intersecting concave passageways recessed from a planar surface of the passageway face; and,a cable exit aperture defining a lumen between an interior cavity of the housing and the plurality of concave passageways, wherein the concave passageways are configured to receive a cable that extends through the cable exit aperture and a selected one of the indicator face and at least one of the other faces of the plurality of faces; positioning the sensor housing;selecting from among the indicator face and the at least one of the other faces of the plurality of faces; and,placing the cable in the concave passageway to extend through the selected face.

19. The method of claim 18, wherein the concave passageways extends to a side face of the plurality of faces, wherein the side face is adjacent to the indicator face.

20. The method of claim 18, wherein the concave passageway extends to the indicator face, forming a face aperture.

Images