Sensor Mount for Conveyor Side Guards
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Solution Overview
Problem
Current sensor mounts for package transport conveyors require extensive time and cost for preparation and installation, as they need to be cut and shaped to fit properly without obstructing the package path, which is not efficiently addressed by existing technologies.
Innovation Solution
A device that utilizes a tapered mounting surface created by deforming the substrate to securely attach sensing devices without additional bracketry, allowing the sensing beam to pass through, reducing the need for metal-cutting and enabling easy installation and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional metal brackets are used for sensor mounting, then structural support is provided, but extensive time and cost are required for cutting, preparation, and installation
Solution Approach 1:
The mounting device is divided into separate modular components: a base element that attaches to the conveyor structure, a sensor mounting element that holds the sensor, and a beam passage element. This segmentation allows each component to be manufactured independently and assembled quickly without extensive on-site preparation work.
Solution Approach 2:
The mounting device is pre-assembled with all necessary structural elements, mounting surfaces, and alignment features before installation. The base element includes pre-formed attachment means and pre-positioned sensor mounting surfaces, eliminating the need for on-site cutting, welding, or surface preparation.
2Strength
If traditional mounting methods are used, then sensors can be securely attached, but additional bracketry creates obstructions in the package path
Solution Approach 1:
The sensor mounting element positions the sensor in three-dimensional space relative to the conveyor, allowing the sensing beam to pass through openings in the side guard at optimal angles. This spatial arrangement provides structural support while eliminating obstructions in the horizontal package path.
Solution Approach 2:
The mounting device uses curved or contoured surfaces that follow the geometry of the conveyor side guard, allowing it to integrate smoothly with the existing structure without creating sharp edges or protrusions that could obstruct packages.
3Strength
If machined tapered surfaces are used for mounting, then secure attachment is achieved, but material removal processes are required
Solution Approach 1:
The tapered mounting surfaces and attachment features are pre-formed during the manufacturing of the base element, rather than requiring on-site material removal. This allows secure attachment to be achieved through simple insertion and fastening operations.
Solution Approach 2:
The mounting device uses geometric parameters such as tapered angles and friction-fit dimensions that are optimized during design to provide secure attachment without requiring material removal. The interference fit and friction-based retention mechanisms achieve strong attachment through carefully controlled dimensional parameters.
4Adaptability or versatility
If universal sensor mounts are used, then compatibility with various conveyors is improved, but specific application needs and constraints are not addressed
Solution Approach 1:
The base element is designed with universal attachment features that can be mounted on various conveyor side guard configurations. The modular design allows the same base element to accommodate different sensor types and mounting configurations, providing both universality and adaptability to specific application requirements.
Data Source
AI summary
The present invention pertains to the art of sensing articles typically moving on a conveyor. An apparatus is disclosed, for the purpose of securely attaching a sensing device to a sub-structure such as a sidepan metal sheet that contains a hole through which the sensing/detection device passes its sensing beam. A primary novelty of the apparatus is that it enables secure mounting of various ‘through-hole’ devices without the need for attaching any additional bracketry and without creating obstructions to package movement. It is unique in that it utilizes the “through-hole” which is necessary to allow passage of the sensing beam through the side guards of the conveyor, with the below-surface attachment being made possible by means of a tapered, or ‘sloping’ surface that is created when the hole is made.