Adaptive Sensor Protection for Contaminated Machine Enclosures
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Solution Overview
Problem
Measurement devices in machine tool environments face contamination issues from coolant, debris, and other substances, leading to inaccurate readings or device failure, as existing protection methods are not adaptive to varying contamination levels and may provide unnecessary protection when the environment is clear.
Innovation Solution
A measurement apparatus with a switchable protection system and contaminant sensor that adjusts protection modes based on sensed contamination levels, allowing for reduced protection when the environment is clear to enhance measurement accuracy and prevent contamination, while maintaining higher protection when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective stream of air is continuously provided to protect the measurement device from contaminants, then the device is protected from contamination, but measurement accuracy deteriorates due to air interference and the device cannot operate in clear environments
Solution Approach 1:
The protection system dynamically adjusts its state based on real-time contamination detection. The controller switches between first mode (protective air stream active) and second mode (protective air stream inactive) according to the contamination level detected by the sensor, allowing optimal balance between protection and measurement accuracy at different times
Solution Approach 2:
A feedback loop is established where the contaminant sensor continuously monitors the environment and provides information to the controller. The controller uses this feedback to automatically adjust the protection mode, creating a closed-loop system that adapts to changing contamination conditions without manual intervention
2Measurement precision
If the protective air stream is turned off to improve measurement accuracy in clear environments, then measurement accuracy improves, but the device becomes vulnerable to contamination
Solution Approach 1:
The contaminant sensor performs preliminary detection of the environment before measurement operations commence. The controller uses this advance information to pre-position the protection system in the appropriate mode, preventing contamination before it can affect measurements while avoiding unnecessary air streams that would degrade accuracy
3Reliability
If a mechanical shutter is used to protect the imaging sensor, then protection is provided when closed, but the system complexity increases and the shutter may fail or require maintenance
Solution Approach 1:
The patent replaces the mechanical shutter system with a pneumatic protection system using streams of air or gas. This substitution eliminates moving mechanical parts that can fail, reducing maintenance requirements and improving reliability while maintaining effective protection through fluid-based contaminant removal
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus effectively reduces the risk of contamination-related inaccuracies or device failure by adaptively adjusting protection levels based on real-time contamination data, ensuring accurate measurements and prolonged device functionality.
Implementation Method 1
A contaminant sensor is provided for sensing contamination within the machine enclosure
Implementation Method 2
a protective flow of air is bled out of the optical apertures to reduce the risk of contaminants etc entering the device
Data Source
Figure 1~2c
Figure 3~4
Figure 5~6
AI summary
A measurement apparatus for mounting within an enclosure of a machine is described. The apparatus comprises a measurement device(2;300;400;500)and a protection means (40,42;70;100;230) for protecting the measurement device (2;300;400;500) from contaminants (420) present within the machine enclosure. The protection means (40,42;70;100;230) is switchable between at least a first mode that protects the measurement device (2;300;400;500) from contaminants and a second mode that provides less protection of the measurement device (2) from contaminants than the first mode. A contaminant sensor (14;242;302;360; 410) is used for sensing contamination within the machine enclosure and thereby determining when the protection means(40,42;70;100;230)can adopt the second mode. A corresponding method is also described.