Container Inlet Station With Optical Barrier Monitoring
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Solution Overview
Problem
Existing inlet stations for operating machines require the machine to be stopped for operator access, leading to inefficiencies due to unwanted downtime caused by the need to pause operations for maintenance or loading/unloading of products.
Innovation Solution
An inlet station design that includes a conveyor system, an inlet with movable barrier members, and an optical unit for detecting the position of the barrier members, allowing for safe operator access during machine operation by ensuring the barrier members are lifted only when products or containers pass through.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the machine is stopped to allow operator access to the inlet station, then operator safety is ensured, but machine productivity decreases due to unwanted downtime
Solution Approach 1:
The barrier members are made movable rather than fixed, allowing them to dynamically change position between a blocking position (when no product is present) and a retracted position (when product is present). This dynamic behavior enables the system to adapt to different operational states, allowing operator access when safe and preventing access when dangerous, thereby resolving the contradiction between safety and productivity
Solution Approach 2:
The optical detection unit provides real-time feedback about the presence of products or containers on the conveyor. This feedback is used by the control device to automatically control the barrier members' positions. The feedback mechanism ensures that the barrier members are only retracted when the detection unit confirms product presence, eliminating the need for manual safety assessments and allowing uninterrupted operation when safe
2Reliability
If barrier members are positioned to block the inlet passage, then operator safety is improved, but operator accessibility for maintenance and loading/unloading deteriorates
Solution Approach 1:
The barrier members transition from a static blocking structure to a dynamic controllable barrier. They can be automatically retracted when the optical detection unit confirms product presence, or when the control system determines it is safe to do so. This dynamic capability allows the barrier to provide safety when needed while eliminating obstacles to maintenance and loading operations when safe
Solution Approach 2:
The system uses automatic detection and control mechanisms rather than requiring manual intervention for safety management. The optical detection unit and control device work together to automatically adjust barrier positions based on detected conditions, eliminating the need for operators to manually assess safety conditions and making the system self-regulating for both safety and accessibility
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 continuous operation of the machine while allowing safe operator access to the inlet station, reducing downtime and improving overall efficiency by ensuring that the machine can operate without interruption for maintenance or loading/unloading tasks.
Implementation Method 1
a first optical unit (64A, 64B) for detecting a position of the barrier members; wherein the control device (60) comprises: a control unit (68) connected to the optical unit (64) and configured to generate an alarm signal and/or a stop signal for the operating machine (100), as a function of a signal coming from the optical unit (64)
Data Source
AI summary
A product or container inlet station for an operating machine is described and includes: a conveyor for advancing products or containers along a feed direction; an inlet intended to be traversed by the products or containers advancing on the conveyor along the feed direction; and a device for controlling the inlet including: at least one barrier member, which is movable as a result of the products or containers passing through the inlet; at least one optical unit for detecting the position of the at least one barrier member; and a control unit connected to the optical unit and configured to generate an alarm signal and/or a stop signal for the operating machine, as a function of a signal coming from the optical unit.