Coaxial Photoelectric Sensor Using Virtual Source Alignment
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Solution Overview
Problem
Coaxial photoelectric sensors face challenges due to their complex and expensive optical designs, requiring specialized mechanical parts and assembly, which increases production costs and complexity, and often suffer from power loss and spot deformation due to misalignment issues.
Innovation Solution
A coaxial photoelectric sensor configuration is developed with a virtual source positioned 90° relative to the receiver axis, using an additional optical element like a curved mirror or lens for total internal reflection, aligning both emitting and receiving signals on the same axis, reducing the number of optical components and manufacturing steps while maintaining functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coaxial photoelectric sensors use traditional optical designs with beam splitters and multiple optical axes, then the sensor can achieve coaxial emission and receiving, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent combines the emission and reception optical paths into a single integrated optical element that performs both functions. Instead of using separate beam splitters and multiple optical axes, the invention merges these functions into one optical component that guides both the emitted light to the target and the reflected light back to the receiver, thereby reducing device complexity while maintaining coaxial alignment.
Solution Approach 2:
The optical element in the patent serves multiple functions simultaneously: it acts as both the emission optical path and the reception optical path. This multi-functional design eliminates the need for separate optical components for transmission and reception, reducing the overall number of parts and simplifying the device structure while achieving coaxial operation.
2Reliability
If coaxial photoelectric sensors use traditional optical designs with multiple optical axes and beam splitters, then the sensor can achieve coaxial emission and receiving, but the manufacturing cost increases
Solution Approach 1:
The patent combines the emission and reception optical paths into a single integrated optical element that performs both functions. Instead of using separate beam splitters and multiple optical axes, the invention merges these functions into one optical component that guides both the emitted light to the target and the reflected light back to the receiver, thereby reducing device complexity while maintaining coaxial alignment.
Solution Approach 2:
The patent uses a virtual image approach where the optical element creates a virtual copy of the LED light source that appears to be positioned at the receiver location. This virtual copying allows the system to achieve coaxial alignment without requiring physical duplication of optical components, thereby reducing manufacturing cost while maintaining the desired optical geometry.
3Reliability
If coaxial photoelectric sensors use traditional optical designs with beam splitters, then the sensor can achieve coaxial emission and receiving, but power loss and spot deformation occur due to misalignment
Solution Approach 1:
The patent combines the emission and reception optical paths into a single integrated optical element that performs both functions. Instead of using separate beam splitters and multiple optical axes, the invention merges these functions into one optical component that guides both the emitted light to the target and the reflected light back to the receiver, thereby reducing device complexity while maintaining coaxial alignment.
Solution Approach 2:
The patent introduces an optical element that acts as an intermediary between the LED light source and the receiver. This intermediary optical component efficiently couples the light from the LED, directs it to the target, and captures the reflected light, minimizing losses that would occur with traditional beam splitter configurations and misalignment issues.
4Manufacturing precision
If coaxial photoelectric sensors use specialized mechanical parts and assembly, then the sensor can achieve precise coaxial alignment, but the production complexity and resource requirements increase
Solution Approach 1:
The patent combines the emission and reception optical paths into a single integrated optical element that performs both functions. Instead of using separate beam splitters and multiple optical axes, the invention merges these functions into one optical component that guides both the emitted light to the target and the reflected light back to the receiver, thereby reducing device complexity while maintaining coaxial alignment.
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 configuration results in a cost-effective solution with reduced mechanical complexity, improved alignment, and minimized optical losses, enabling efficient and affordable production of coaxial photoelectric sensors without sacrificing performance.
Implementation Method 1
using an additional optical element like a curved mirror or lens for total internal reflection
Implementation Method 2
A reflective optical component is optically aligned with the reflection optical component so as to reflect the first reflected illumination signal
Implementation Method 3
A target reflector component is optically aligned with the reflective optical component to coaxially reflect the second reflected illumination signal
Implementation Method 4
an optical emitter disposed on a printed circuit board (PCB), and configured to generate an illumination signal
Implementation Method 5
An optical detector is disposed on the PCB, and is configured to generate an electrical signal in response to receiving the illumination signal
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A coaxial photoelectric sensor may include both an optical emitter and optical receiver disposed on a printed circuit board. A total internal reflection optical component may be optically aligned with the optical emitter so as to reflect an illumination signal generated by the emitter. A reflective optical component may be optically aligned with the total internal reflection optical component so as reflect the illumination signal received from the total internal reflection optical component. A target reflector component may be optically aligned with the reflective optical component to coaxially reflect the illumination signal received from the reflective optical component. An optical detector may be configured to generate an electrical signal in response to receiving the illumination signal.