Adjustable Media Width Sensor for Mailing Machines
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Solution Overview
Problem
Existing mailing machines lack cost-effective and accurate media width sensors with adjustable capabilities to meet varying postal rating requirements, as they often rely on expensive fixed linear arrays of optical sensors with large pitch and fixed sensor locations, leading to inaccurate measurements.
Innovation Solution
An adjustable media width sensor subsystem with a narrow linear sensor window and a sensor carriage mount, allowing for precise placement and adjustment of sensor carriages with small measurement increments, using a locking mechanism to secure the sensor carriage during operation, enabling reconfiguration for different postal rating requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a linear array of optical sensors is used to measure media width, then measurement capability is provided, but cost increases and measurement accuracy decreases due to fixed sensor locations and large pitch
Solution Approach 1:
The patent makes the sensor system dynamic by allowing the sensor carriage to be positioned at different locations along the media path. Instead of fixed sensor arrays, the sensor can be moved to optimal positions to measure different media widths, enabling accurate measurement without requiring multiple fixed sensors across the entire width range.
Solution Approach 2:
The patent introduces a sensor carriage as an intermediary component that carries the optical sensor along the media path. This carriage system allows the sensor to be positioned at various locations to measure different width breakpoints, replacing the need for multiple fixed sensor pairs and reducing overall system complexity.
2Measurement precision
If fixed sensor locations are used in the media width sensor, then device simplicity is maintained, but measurement accuracy deteriorates due to large pitch between sensors
Solution Approach 1:
The sensor system transitions from static fixed positions to dynamic adjustable positions. The sensor carriage can be moved along the media path and locked at different locations, allowing the system to adapt to different measurement requirements and achieve accurate width measurements without being constrained by fixed sensor spacing.
Solution Approach 2:
The patent enables change in the sensor's positional parameter along the media path. By adjusting the sensor carriage location, the system can optimize measurement accuracy for different media widths and applications, transforming a fixed-parameter system into a variable-parameter system.
3Adaptability or versatility
If multiple sensor pairs are arranged in a linear array to cover different width breakpoints, then measurement coverage is improved, but cost and device complexity increase significantly
Solution Approach 1:
Instead of deploying multiple sensor pairs simultaneously across different positions, the patent uses a single sensor pair mounted on a movable carriage. The carriage can be positioned at different locations to measure different width breakpoints sequentially, providing the same adaptability with fewer sensors and reduced system complexity.
Solution Approach 2:
The sensor carriage serves multiple functions: it holds the optical sensor, provides positioning along the media path, and enables measurement at various width breakpoints. This universal component replaces the need for multiple dedicated sensor pairs, each designed for specific width measurements, thereby reducing overall device complexity while maintaining versatility.
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 provides a cost-effective and accurate width measurement system with adjustable sensor pairs that can be set to as small as 1 mm increments, improving measurement accuracy and adaptability to various postal standards without the need for expensive fixed sensor arrays, reducing crosstalk and enhancing operational stability.
Implementation Method 1
a media width sensor that may include a linear array of optical sensors positioned perpendicular to the path of travel of the mail piece
Data Source
AI summary
An illustrative mailing machine is provided including at least one adjustable optical media width sensor that may be reconfigured for differing postal rating requirements. The media width sensor subassembly has a narrow linear sensor window that is positioned perpendicular to the path of travel of the mail piece. The media width sensor subassembly includes a sensor carriage mount and width measurement scale for facilitating the accurate placement of the adjustable, but secure when placed, sensor carriage. The sensor carriage slidably engages a mount and is spring biased into a locking mechanism in the underside of the media width sensor locating scale.