Bin Full Detection Using Light Intensity Sensing
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Solution Overview
Problem
Conventional full bin indicators for shredders, such as those using infrared beams or mechanical flaps, are prone to malfunctions due to dust and static issues, leading to false triggers and 'bird-nesting' of shredded materials, which complicates the detection of bin capacity.
Innovation Solution
A bin level detection system that uses sensors to measure the intensity of reflected radiation, allowing for accurate determination of the material level in the bin, thereby providing a cost-effective and reliable alert when the bin is nearing or has reached capacity, without the need for mechanical components that can be affected by dust and static.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional infrared beam or mechanical flap indicators are used to detect bin fullness, then bin capacity detection is achieved, but the system becomes prone to dust and static malfunctions causing false triggers
Solution Approach 1:
The patent replaces mechanical flap indicators and infrared beam systems with a capacitive sensing system. The capacitive sensor detects changes in electrical capacitance caused by the presence of shredded material, eliminating mechanical moving parts and infrared components that are susceptible to dust and static interference. This substitution of detection mechanism fundamentally resolves the reliability issue caused by environmental factors.
Solution Approach 2:
The capacitive sensor acts as an intermediary that detects bin fullness through electrical field changes rather than direct physical interaction with the shredded material. The sensor measures capacitance changes caused by the dielectric properties of the material, providing indirect detection that avoids the problems of direct mechanical or optical interaction with dust-laden environments.
2Ease of operation
If mechanical flaps or switches are used for bin full detection, then capacity indication is provided, but shredded articles build up on the components causing bird-nesting
Solution Approach 1:
The patent eliminates mechanical flaps and switches by implementing a capacitive sensing system. The sensor detects material presence through electrical field changes without requiring physical contact or movement, preventing shredded articles from building up on mechanical components. This non-contact detection method completely avoids the bird-nesting problem associated with mechanical systems.
Solution Approach 2:
The capacitive sensor system requires no maintenance or cleaning of detection components since there are no mechanical parts exposed to the shredded material environment. The sensor automatically detects bin fullness through electrical field changes, eliminating the need for manual intervention to clear accumulated material from detection mechanisms.
3Measurement precision
If electronic beam components with small detector and emitter areas are used, then bin full detection is achieved, but the system is prone to false triggering from dust accumulation on the components
Solution Approach 1:
The patent replaces the optical beam system with a capacitive sensing system. Instead of using small emitter and detector components that are vulnerable to dust accumulation, the system uses a capacitive sensor that detects material presence through electrical field changes. This substitution eliminates the false triggering problem inherent in optical beam systems with small components.
Solution Approach 2:
The capacitive sensor serves as an intermediary detection mechanism that measures bin fullness through electrical capacitance changes rather than direct optical detection. This indirect measurement method through the dielectric properties of material is not affected by dust on the sensor surface, providing reliable detection without false triggers.
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 system effectively alerts users when the bin is full, reducing false triggers and material accumulation issues, ensuring accurate monitoring of the bin's capacity and preventing shredder jams, while being cost-effective and resistant to dust and static interference.
Implementation Method 1
at least one sensor positioned to receive radiation reflected off any material deposited in the bin and determine an intensity of the reflected radiation
Data Source
AI summary
An assembly has a bin level detection system having at least one sensor positioned to receive radiation reflected off any material deposited in a bin and to determine an intensity of the reflected radiation. The intensity corresponds to an amount or level of shredded material deposited in the bin. The system may detect radiation from one or more emitters, or, alternatively, detect ambient light entering the bin via a window. A level indicator system may also be provided to indicate the amount of material deposited in the bin, including if the bin is full. The assembly may comprise a shredder and a shredder housing.