Bale Opener Laser Scanning for Dynamic Safety Zone Monitoring
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Solution Overview
Problem
Existing safety systems for textile machines, such as bale openers, face challenges with cumbersome light beam barriers, sensor malfunctions due to vibrations, and limited lateral coverage, leading to unreliable protection of personnel from moving parts.
Innovation Solution
A method utilizing a two-dimensional laser scanner with adjustable and time-variable monitoring areas, allowing for redundant coverage of different protective fields, which can be switched dynamically to ensure safety and robustness, even when the removal element is rotated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a light beam barrier is used to protect dangerous areas, then personnel safety is improved, but the device complexity and operational cumbersome nature increase
Solution Approach 1:
The protective device is divided into multiple independent sensor units arranged in a matrix pattern, where each sensor monitors a specific sector. This segmentation allows the complex monitoring task to be distributed across multiple simple units, reducing overall system complexity while maintaining comprehensive safety coverage.
Solution Approach 2:
The sensor matrix serves multiple functions simultaneously: it monitors for personnel intrusion, detects fiber bales, identifies foreign objects, and provides collision monitoring. This multi-functionality eliminates the need for separate detection systems, reducing device complexity while maintaining high reliability through redundant monitoring capabilities.
2Adaptability or versatility
If sensors are attached to moving parts to create mobile protection areas, then adaptability is improved, but reliability deteriorates due to vibrations causing malfunctions
Solution Approach 1:
The sensor matrix is extracted from the moving removal element and repositioned on the stationary support structure. This extraction removes the sensors from the source of vibrations, eliminating the reliability problem while the sensors continue to monitor the moving removal element and create mobile protection areas through electronic control.
Solution Approach 2:
The stationary sensor matrix acts as an intermediary between the control system and the moving removal element. Instead of attaching sensors to the moving part, the stationary sensors optically monitor the moving element's position and status, providing adaptability without vibration-induced reliability issues.
3Measurement precision
If ultrasonic sensors are used for protection, then detection capability is improved, but cost and susceptibility to air influences increase
Solution Approach 1:
The patent employs inexpensive optical sensors instead of expensive ultrasonic sensors. These simple optical sensors are sufficient for the detection task and are not susceptible to air influences like wind or air layers, reducing both cost and environmental susceptibility while maintaining adequate detection precision.
4Reliability
If the monitoring area is reduced to avoid detecting fiber bales, then false alarms are reduced, but lateral coverage and protection effectiveness decrease
Solution Approach 1:
The sensor matrix dynamically adjusts its monitoring behavior based on the detected object. When a fiber bale is detected, the system recognizes the characteristic pattern and temporarily excludes that area from alarm generation. When a person is detected, full monitoring is maintained. This dynamic adaptation allows comprehensive lateral coverage without false alarms from fiber bales.
Solution Approach 2:
The system continuously analyzes sensor signals to identify whether detected objects are fiber bales or persons based on their distinct reflection patterns. This feedback mechanism allows the monitoring area to be effectively expanded to cover lateral areas while maintaining reliability by using intelligent discrimination to prevent false alarms from fiber bales.
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
This approach provides a more reliable, fault-resistant, and cost-effective safety system that effectively monitors the area around the bale opener, reducing the risk of accidents by detecting intrusions and ensuring the machine stops in case of anomalies, while allowing for reduced lateral distance and improved lateral coverage.
Implementation Method 1
the protective device is at least a two-dimensional laser scanner with which at least one adjustable and time-variable monitoring area is monitored
Implementation Method 2
a two-dimensional laser scanner 12 is present on the face of the removal element. The laser scanner 12 scans their surroundings by emitting a laser pulse. If the laser pulse hits an object, it is reflected to the receiver of the laser scanner 12
Data Source
Figure 1
Figure 2~3c
AI summary
The invention relates to a method for operating a bale opener (1) with a take-off element (3) and a protective device for protecting people if they enter a danger zone of the take-off element (3), which protective device consists of sensory protective means, with a monitoring area (13 , 131, 132, 133) is detected at the end under the removal element (3), and wherein the removal element (3) is fastened to a removal tower (2). According to the invention, the protective device is at least a two-dimensional laser scanner (12) on which at least one adjustable and time-variable monitoring area (13, 131, 132, 133) is monitored. The invention also relates to a corresponding bale opener (1).