Camera Sensor Job Selection via I/O Signals
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Solution Overview
Problem
Industrial control systems face inefficiencies in vision sensor setup and operation, particularly in transitioning between job setups without requiring downtime for reprogramming, as conventional methods lack efficient signaling mechanisms for job selection changes.
Innovation Solution
The system allows for job selection changes in camera sensors via simple signals broadcast over existing I/O lines, utilizing signal combinations or Morse Code to switch between pre-programmed job setups without interrupting sensor operation or necessitating reprogramming, enabling rapid integration and configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional reprogramming methods are used to change job setups in camera sensors, then job setup changes can be made, but sensor operation must be interrupted and reprogramming time is required
Solution Approach 1:
Multiple job setups are pre-programmed into the camera sensor's memory before operation begins. This allows the sensor to store multiple configurations (different I/O line assignments, exposure settings, gain settings, etc.) in advance, so that during operation, the system can simply switch between pre-loaded setups without requiring reprogramming. The preliminary programming of multiple jobs resolves the contradiction by eliminating runtime reprogramming needs while maintaining full job setup change capability.
Solution Approach 2:
The patent replaces the mechanical/manual reprogramming process with an electronic signal-based job selection mechanism. Instead of physically reprogramming the sensor through complex setup procedures, the system uses simple electrical signals transmitted over existing I/O lines to trigger pre-programmed job setups. This substitution of manual reprogramming mechanics with electronic signaling eliminates downtime while preserving adaptability.
2Device complexity
If simple signals are used for job selection, then system complexity is reduced and existing I/O lines can be utilized, but the signaling mechanism must be efficient enough to enable rapid job switching
Solution Approach 1:
The patent makes existing I/O lines multi-functional by using them for both their original sensing/actuation purposes and for job selection signaling. The same I/O lines that connect sensors and actuators to the PLC are also used to transmit job setup selection signals to the camera sensor. This universal use of existing infrastructure reduces system complexity by eliminating dedicated signaling wires while maintaining fast job switching capability through efficient reuse of available communication pathways.
Solution Approach 2:
The system encodes job selection information by changing the state parameters of existing I/O lines (on/off states, signal levels) rather than introducing new complex signaling protocols. By utilizing different combinations of I/O line states to represent different job setups, the system achieves rapid job switching through simple parameter changes on existing lines, balancing low complexity with high switching speed.
Data Source
AI summary
Systems and methods are disclosed that facilitate permitting a user to select one of a plurality of job setups stored in a camera sensor. The plurality of job setups can be pre-programmed into the sensor utilizing conventional methods. During sensor operation, a user can select a particular application, and a simple signal can be generated for transmission over existing input/output lines to the camera sensor, upon receipt of which the camera sensor can initiate the particular job setup associated with the signal. Job setup signals can be formatted in binary utilizing HIGH and LOW voltages or can be transmitted as a simple Morse Code message and/or integer value.