Angle Measuring System With Integrated Switch For Mechanical Error Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing angle measuring systems in machines with movable elements face challenges in accurately diagnosing mechanical errors, leading to imprecise measurements and increased costs due to redundancy requirements in safety standards like European standard 13849-1, where deviations in sensor signals from tolerances result in poor workspace utilization and increased assembly work.
Innovation Solution
An angle measuring system with a switch mechanism that includes a lever connecting an actuator to a driver, featuring two switch elements to detect mechanical errors and misalignments, and an error detection system that infers faults based on changes in sensor signals, ensuring accurate alignment and fault detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If redundant angle measuring systems are provided to achieve safety performance levels, then machine safety is improved, but measurement precision deteriorates due to tolerance deviations of approximately 8°
Solution Approach 1:
A lever is introduced as an intermediary mechanical element that couples the actuator to the driver. The lever transmits rotational movement while maintaining a fixed geometric relationship, ensuring that the angle detection unit accurately reflects the actual angular displacement between legs. This mechanical intermediary eliminates the tolerance accumulation problem that occurs when using multiple independent angle measuring systems.
Solution Approach 2:
The angle detection unit serves multiple functions: it measures the angle between legs for workspace optimization and simultaneously provides fault diagnosis capability through the integrated switch mechanism. The switch monitors both electrical errors (short circuit, cable break) and mechanical errors (incorrect rotary position, lever misalignment) using the same sensor system, eliminating the need for separate redundant measurement systems.
2Reliability
If redundant angle measuring systems are provided to achieve safety performance levels, then machine safety is improved, but device complexity increases due to increased assembly work
Solution Approach 1:
Multiple diagnostic functions are merged into a single integrated system. The angle detection unit combines the angle measurement function with a switch mechanism that detects both electrical and mechanical errors. This unified approach replaces what would traditionally require multiple separate angle measuring systems, reducing assembly complexity while maintaining safety performance levels.
Solution Approach 2:
The single angle detection unit is designed to perform multiple safety-related functions: angle measurement for workspace optimization, electrical error detection through multiple channels, and mechanical error detection through the switch mechanism. This multi-functional design eliminates the need for multiple separate systems, thereby reducing assembly work and device complexity.
3Device complexity
If a single angle detection unit is used without redundancy, then device complexity is reduced, but reliability deteriorates due to inability to diagnose mechanical errors
Solution Approach 1:
A switch mechanism provides continuous feedback on the mechanical integrity of the angle measurement system. The switch monitors the alignment between the lever and the corresponding leg, detecting mechanical errors such as incorrect rotary position or lever misalignment. This feedback capability is integrated into the single angle detection unit, maintaining simplicity while enabling comprehensive fault diagnosis.
Solution Approach 2:
The switch acts as a mechanical intermediary that translates physical alignment conditions into electrical signals for error detection. By monitoring the positional relationship between the lever and leg through this intermediary switch, the system gains mechanical error diagnosis capability without adding complex redundant measurement systems.
Data Source
Figure 1
Figure 2
AI summary
The invention relates to an angle measuring system for measuring an angle between a first leg and a second leg, comprising at least one angle detection unit for determining an angular offset between an angle element fixed to rotation on the first leg and an actuator rotatably arranged therewith, a driver arranged on the second leg, and a lever connecting the actuator to the driver, wherein, upon rotation between the first leg and the second leg, the lever performs a corresponding rotational movement of the actuator with respect to the angle element, wherein a switch having two switch elements, wherein a first switch element is arranged on the lever connecting the actuator to the driver, a second switch element is attached to the first leg or the second leg, and the switch is designed toto assume a first switching state when the lever is correctly aligned with the corresponding leg and a second switching state when it deviates from this correct alignment.