Deforming Machine Light Barrier Layout for Working Gap Safety
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Solution Overview
Problem
Deforming machines lack simplified operation and effective safety measures to prevent accidents, particularly during the approach movement of tools and when operators intervene in the working gap or interact with moving parts.
Innovation Solution
The implementation of a deforming machine with multiple optical safety light barriers that monitor distinct safety spaces to detect operator intervention and automatically control the movement of tools, preventing accidents by switching off the driving mechanism when safety thresholds are breached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple optical safety light barriers are implemented to monitor different safety spaces, then operational safety is improved, but device complexity increases
Solution Approach 1:
The second optical safety light barrier is designed with multi-functionality to monitor both the second safety space (in front of the upper tool) and the third safety space (below the upper tool) using the same beam source and light receiver components. This allows a single device to perform multiple safety monitoring functions, improving operational safety while avoiding the need for additional separate safety light barriers that would increase device complexity
Solution Approach 2:
The safety monitoring system is segmented into multiple specialized light barriers: the first optical safety light barrier monitors the first safety space adjacent to the working gap, while the second optical safety light barrier monitors the second and third safety spaces. This segmentation allows each barrier to be optimized for specific monitoring tasks, improving overall safety coverage without requiring a single overly complex system
2Reliability
If automated safety monitoring systems are implemented to detect operator intervention, then accident prevention is improved, but ease of operation deteriorates
Solution Approach 1:
The safety monitoring system operates autonomously without requiring operator intervention. The optical safety light barriers automatically detect when objects or operators enter monitored safety spaces and trigger appropriate responses (stopping tool movement, activating alarms) through integrated control systems. This self-service capability ensures continuous safety monitoring while minimizing the operational burden on workers
Solution Approach 2:
The safety monitoring system implements continuous feedback loops where optical sensors detect the presence of objects or operators in safety spaces and immediately communicate this information to the control system. The control system then provides real-time feedback by adjusting tool movement or activating safety protocols, creating a closed-loop system that automatically responds to safety conditions without requiring manual intervention
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
Enhances operational safety by automatically controlling tool movement and preventing accidents during tool approach and operator interaction, allowing for safer operation and reduced risk of injury.
Implementation Method 1
a first optical safety light barrier which comprises a first beam source for providing first safety light beams and a first light receiver for receiving the first safety light beams
Data Source
AI summary
A deforming machine (1) with a machine frame (2), on which an upper tool (4) and a lower tool (5) are arranged, which form a working gap (8) of variable size, with a first optical safety light barrier (20) for securing a first safety space (28) adjacent to the working gap (8) and with a second optical safety light barrier (30) for securing a second safety space (31), which is located in front of a largest surface (18) of the upper tool (4). The second optical safety light barrier (30) is designed for monitoring a third safety space (51) which extends downwards beyond the end face (6) of the upper tool (4) facing the lower tool (5) along the movement path (14) in the direction of the lower tool (5), so that a projection of the third safety space (51) onto the working gap (8) covers at least a section of the working gap (8).