Capacitive Sensor System for Complex Machine Surfaces
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Solution Overview
Problem
Existing sensor systems struggle to effectively monitor complexly shaped machine surfaces and trajectories, often requiring extensive setup or failing to provide uninterrupted proximity detection due to issues like shadowing and limited installation space, which can compromise safety standards.
Innovation Solution
A sensor system with a layered structure of flexible electrically conductive and insulating plies, featuring laterally spaced conductive potential surfaces that form measurable electric field lines, allowing for separate operation of multiple measuring elements to ensure reliable detection and adaptation to complex surfaces, with chronological control and evaluation to prevent mutual interference and ensure safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical sensors are used for proximity detection, then detection capability is improved, but shadowing at edges and undercuts of the machine surface impedes sensing
Solution Approach 1:
The patent replaces optical sensing systems with capacitive sensing technology. The capacitive sensor system uses electric field lines that extend into the surrounding space and are not blocked by shadows, allowing detection on complexly shaped surfaces including edges and undercuts where optical sensors fail.
Solution Approach 2:
The patent changes the physical parameter used for detection from optical properties to electrical capacitance. By measuring changes in capacitance caused by proximity of objects or persons, the system achieves reliable detection independent of surface geometry, lighting conditions, and shadowing effects.
2Reliability
If dual sensor-based monitoring with two independent safety channels is implemented, then safety reliability is improved, but device complexity increases
Solution Approach 1:
The patent divides the sensor system into two independent safety channels, each with its own sensor elements and evaluation circuits. This segmentation ensures that a failure in one channel does not affect the other, meeting safety standards while maintaining manageable system architecture through modular design.
Solution Approach 2:
The patent designs the sensor elements to serve multiple functions: they operate as both safety monitoring devices and provide diagnostic capabilities. The same capacitive sensor elements detect proximity for safety purposes while also enabling self-diagnosis of the system status, reducing the need for separate diagnostic hardware.
3Area of stationary object
If sensors are integrated onto complexly shaped surfaces with limited installation space, then coverage is improved, but integration becomes impossible due to lack of space
Solution Approach 1:
The patent employs flexible sensor elements that can be conformally attached to complexly shaped surfaces. These thin-film capacitive sensors can wrap around contours and fit into tight spaces, enabling comprehensive coverage of machine surfaces regardless of geometric complexity or installation space constraints.
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
Enables reliable and adaptable sensor systems that meet safety standards by allowing independent operation of multiple measuring elements, reducing the risk of system failure and ensuring safe machine operation, even on complexly shaped surfaces, with efficient detection of impending collisions and self-diagnosis capabilities.
Implementation Method 1
electric field lines form between the conductive potential surfaces and change measurably upon proximity and/or contact of a body or an object
Implementation Method 2
layered structure of flexible electrically conductive and electrically insulating plies
Implementation Method 3
electric field lines form between the conductive potential surfaces
Data Source
AI summary
A sensor system for monitoring surroundings on a mechanical component, includes at least one capacitive sensor element that is attachable to the surface of machines or machine parts, the at least one sensor element being constructed from a layered structure of flexible electrically conductive and electrically insulating plies, electrically conductive potential surfaces of one ply being disposed, laterally spaced apart via insulating plies located therebetween, in such a way that electric field lines form between the conductive potential surfaces and change measurably upon proximity and/or contact of a body or an object. The layered structure of a sensor element has at least two measuring elements operating separately from one another.