Dual-Source Optical Safety Scanner for Obstruction Detection
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Solution Overview
Problem
Triangulation-based optical scanners used in industrial safety systems fail to reliably detect people or prohibited objects within hazardous industrial areas due to limitations in accuracy and depth of field, and physical conditions can obstruct detection, leading to unreliable results.
Innovation Solution
An optical safety scanner system that employs two illumination sources – a primary light source for triangulation and a supplemental illumination source – alternating between emission to generate two image frames, allowing for accurate detection of objects and verification of triangulation reliability, with a hazard analysis and decision component generating fault messages if detection is obstructed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If triangulation-based optical scanning is used to detect objects in hazardous areas, then distance measurement capability is provided, but detection reliability deteriorates due to obstructions and limited depth of field
Solution Approach 1:
The patent combines two different detection methods (triangulation-based distance measurement and supplemental illumination-based object detection) into a single safety scanner system. The triangulation component provides distance measurement capability while the supplemental illumination component ensures reliable object detection by illuminating areas that may be obscured, thereby merging the advantages of both approaches to achieve both precision and reliability
Solution Approach 2:
The supplemental illumination component acts as an intermediary that facilitates reliable detection by providing additional light paths. When the primary triangulation beam is obstructed or when objects are in areas with limited depth of field, the supplemental illumination serves as a mediator to ensure these objects are still detected, thus improving overall detection reliability without compromising the triangulation measurement capability
2Device complexity
If a single light source is used for triangulation scanning, then device complexity is reduced, but detection accuracy deteriorates due to obstructions and limited depth of field
Solution Approach 1:
The illumination system is segmented into two distinct components: a primary light source for triangulation and a supplemental illumination source. This segmentation allows each component to perform its specific function optimally - the primary source maintains triangulation accuracy while the supplemental source ensures complete area coverage, thereby improving detection accuracy without requiring a completely complex unified system
Solution Approach 2:
The safety scanner system is designed with multi-functionality where the primary light source performs triangulation measurements and the supplemental illumination source provides additional detection coverage. This universal design allows the system to handle various detection scenarios (clear line-of-sight, obstructed views, different depth ranges) using appropriate illumination modes, improving overall detection accuracy while managing complexity through functional differentiation
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
The system enhances detection reliability and accuracy by verifying the presence of objects through alternating light sources, ensuring safe operation of industrial machines by preventing false negatives and generating fault messages for obstructed detection scenarios.
Implementation Method 1
a distance determination component configured to generate distance information based on triangulation analysis performed on the first image data
Implementation Method 2
a supplemental illumination component configured to emit a second beam of light during a second stage of the scan cycle
Data Source
AI summary
An optical safety scanner system comprises a first illumination source for detecting presence and distances of people or other objects within a hazardous industrial area based on triangulation, and a second illumination source that verifies accurate and reliable detection by the first illumination source. The first illumination source can project LED or laser light for triangulation of objects, and the second illumination source can project a wide beam of light for detection of other intrusive objects that may be blocking the scanner system's camera and preventing accurate triangulation of people or vehicles. If the image frame generated based on the second light identifies presence of an object that is not detected by the triangulation analysis of the laser light, the safety scanner system assumes that an object is obstructing the safety scanner system's camera, and performs a suitable safety action.