Fail-to-Safe Sensor System for Allergen Detection
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Solution Overview
Problem
Manufacturing facilities face challenges in preventing cross-contamination of allergens in food products, leading to potential health risks and costly recalls due to the inability to effectively differentiate between correct and incorrect packaging on conveyor systems.
Innovation Solution
A fail-to-safe system with redundant sensors and a controller that detects three operating states (pass, fail, and inoperative) to ensure accurate identification of food products, preventing allergenic items from mixing with non-allergenic ones by shutting down the conveyor or diverting items to a reject path when discrepancies are detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional binary sensor systems (pass/fail only) are used, then the control system is simple, but the system cannot differentiate between correct packaging and sensor malfunctions leading to false rejects
Solution Approach 1:
The sensor system is segmented into multiple independent sensors (first sensor and second sensor) that each perform the same detection function. This segmentation allows the system to cross-validate readings and differentiate between actual packaging defects and sensor malfunctions, improving reliability without requiring each individual sensor to be more complex
Solution Approach 2:
The system implements feedback by comparing outputs from multiple sensors and using the controller to analyze discrepancies. When sensor readings conflict, the system generates appropriate signals (pass, fail, or maintenance alert) based on the comparison, enabling the system to self-correct and maintain high classification accuracy
2Object-affected harmful factors
If separate manufacturing lines are constructed to avoid cross-contamination, then allergen contamination is prevented, but production efficiency decreases and recall costs increase
Solution Approach 1:
The patent replaces the mechanical separation approach (physical separate manufacturing lines) with an electronic/detection-based system. Multiple sensors and a controller work together to identify and reject potentially contaminated products in real-time, allowing a single production line to maintain safety without sacrificing the efficiency benefits of consolidated production
Solution Approach 2:
The system performs preliminary detection and rejection of potentially contaminated products before they can cause cross-contamination. By detecting allergen presence early in the process and immediately diverting or rejecting affected items, the system prevents contamination spread without requiring separate production lines
3Object-affected harmful factors
If the conveyor system shuts down immediately upon detecting a potential allergen, then cross-contamination is prevented, but production downtime increases
Solution Approach 1:
Instead of shutting down the entire conveyor system upon detecting a potential issue, the patent applies local action by diverting or rejecting only the specific contaminated item while allowing the rest of the production line to continue operating. This localized response prevents cross-contamination of the affected product while minimizing production downtime
Data Source
AI summary
Some embodiments for a fault detection apparatus may include one or more monitors to detect at least three operating states of a sensor, such as pass, fail, and inoperative so as to enable a manufacturing facility to differentiate between situations in which a container does not have the appropriate machine readable label and situations wherein the sensor is actually inoperative. The fail state may be indicative of an object on a conveyor system not matching a predetermined description, identity or characteristic. The pass state may be indicative of an object on a conveyor system matching the predetermined description, identity or characteristic. The inoperative state may be indicative of a sensor output associated with a malfunction in the sensor itself. The fault detection apparatus may also include a fail-to-safe controller configured to detect these operating states.