Cutting Device Sensor Failure Compensation
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Solution Overview
Problem
The existing tape printing devices face operational issues when one of the two sensors used in the cutting mechanism fails to function properly, leading to improper cutting operations.
Innovation Solution
A cutting device and printing device are designed with a movable blade, moving mechanism, driver, detecting portions, and a controller that allows normal operation even if one sensor fails by setting and storing updated positions for the moving mechanism based on detection results from the functioning sensor, enabling the cutting mechanism to operate accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two sensors are used to detect the angular position of the cam plate, then the cutting mechanism can operate accurately under normal conditions, but the system becomes vulnerable to failure when one sensor malfunctions
Solution Approach 1:
The system dynamically changes operational parameters by switching from dual-sensor mode to single-sensor mode when a malfunction is detected. The controller adjusts the detection methodology by relying solely on the functioning sensor's output and compensates for the lost detection capability through alternative control strategies, thereby maintaining cutting operation reliability without adding redundant hardware
Solution Approach 2:
The sensor system is segmented into independent detectable states that can be individually evaluated for normality. The controller divides the detection task by identifying which sensor is malfunctioning and isolating that sensor's output, allowing the remaining functional sensor to handle the full detection burden without requiring a complete system redesign
2Manufacturing precision
If the system continues to use original detection positions when a sensor malfunctions, then the device structure remains simple, but the cutting operation becomes inaccurate
Solution Approach 1:
The controller performs preliminary evaluation of sensor output signals to detect malfunctions before they cause cutting inaccuracies. By continuously monitoring sensor readings and identifying abnormal patterns in advance, the system can switch to alternative detection methodologies proactively, ensuring cutting position accuracy is maintained without requiring complex real-time corrections during operation
Solution Approach 2:
The system implements feedback control by continuously comparing sensor outputs against expected ranges and adjusting the cutting control parameters accordingly. When a sensor malfunction is detected, the feedback mechanism enables the controller to compensate for the lost detection accuracy by relying on the remaining functional sensor's data, thereby maintaining cutting precision through adaptive control rather than hardware redundancy
Data Source
AI summary
A cutting device includes: a movable blade; a moving mechanism moving the movable blade and having a first mechanism portion movable between a first operating position and a first non-operating position and a second mechanism portion movable between a second operating position and a second non-operating position; a first detecting portion and a second detecting portion detecting positions of the first mechanism portion and the second mechanism portion; and a controller configured to perform: setting, when one of the first detecting portion and the second detecting portion detects abnormally, updated positions of the first operating position and the second operating position or the first non-operating position and the second non-operating position. The updated positions are set based on detection result of another of the first detecting portion and the second detecting portion and are new start points of movement of the first mechanism portion and the second mechanism portion.