Adjustable Lens Illumination Device for Visual Sensors
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Solution Overview
Problem
Conventional illumination devices for visual sensors in factory automation require multiple variations to accommodate different illumination visual fields and work distances, leading to increased costs due to the need for customized chassis, LEDs, and optical components, and suffer from positional accuracy issues during mounting.
Innovation Solution
An illumination device with light emitting elements mounted perpendicular to a board, paired with adjustable lenses that have varying positional relationships, allowing for flexible alignment to achieve multiple illumination visual fields and work distances without the need for extensive customization, thereby reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple variations of illumination devices are produced to accommodate different illumination visual fields and work distances, then adaptability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies universality by designing a standardized illumination device platform where the same basic structure can serve multiple functions. By fixing LEDs perpendicular to the board and providing adjustable lens mounting positions, a single device design can accommodate different illumination visual fields and work distances, eliminating the need for multiple customized variations.
Solution Approach 2:
The patent implements dynamics by making the lens mounting position adjustable rather than fixed. The lens can be positioned at different locations relative to the LED depending on the required illumination parameters, allowing the device to adapt to different applications without requiring multiple fixed designs.
2Adaptability or versatility
If multiple variations with customized components are produced, then adaptability is improved, but manufacturing cost increases
Solution Approach 1:
The standardized platform design with universal LED mounting and adjustable lens positioning allows a single manufacturing process to produce devices suitable for multiple applications, reducing per-unit costs through economies of scale while maintaining adaptability.
Solution Approach 2:
The patent provides more lens mounting positions than strictly necessary, allowing selection of the most appropriate position for each application. This excessive provision of options simplifies the manufacturing decision-making process and reduces customization complexity.
3Manufacturing precision
If LEDs are mounted with non-perpendicular alignment to achieve specific illumination patterns, then illumination precision is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by providing different lens mounting positions with different optical characteristics. Each position is optimized for specific illumination requirements, allowing the system to achieve precise illumination patterns through position selection rather than complex angular alignment of the LEDs themselves.
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 solution enables the production of illumination devices that can handle various illumination requirements while maintaining cost efficiency and improving positional accuracy between LEDs and lenses, allowing for a wide range of illumination visual fields and work distances with minimal component variation.
Implementation Method 1
a plurality of light emitting elements that are mounted on the board, the plurality of light emitting elements being disposed such that a light irradiation direction of each light emitting element is substantially perpendicular to the board
Implementation Method 2
a plurality of lenses that are disposed such that each lens is paired with one of the plurality of light emitting elements
Data Source
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AI summary
An object of the invention is to provide an illumination device lineup having many variations that respond to various illumination visual fields and work distances while the cost is controlled. Another object of the invention is to provide a producing method for implementing the illumination device having the many variations. Each cell includes a light emitting element mounted on a board and a lens that is disposed so as to be paired with the light emitting element. A relative positional relationship between the light emitting element and the lens in each cell varies according to a position on the board. Therefore, light is emitted from the light emitting element to the outside with a non-zero angle that is determined in each cell with respect to a direction perpendicular to the board.