Fiber-Optic I/O Module Illumination via Segmented Housing
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Solution Overview
Problem
Existing input/output modules in industrial automation systems suffer from reduced luminosity in optical displays due to light loss at the interface between fiber-optic conductors and housing materials, leading to inefficient light transmission.
Innovation Solution
The input/output module employs a fiber-optic conductor with a first illuminated panel and a light inlet, where the fiber-optic conductor is embedded in the housing using a dual-component injection molding process, allowing only a partial peripheral surface to adhere to the side wall, creating a cavity to decouple the materials and improve light transmission, and includes a second illuminated panel aligned with connection points for enhanced diagnostics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the fiber-optic conductor is permanently connected to the housing material through injection molding, then the structural stability is improved, but the light transmission is worsened due to light loss at the interface
Solution Approach 1:
The fiber-optic conductor is segmented in its connection to the housing: only a partial peripheral surface (first portion) is permanently connected to the housing material, while the remaining peripheral surface (second portion) is decoupled and extends into the housing interior without contact. This segmentation allows the connection region to provide structural stability while the decoupled region maintains optimal light transmission by eliminating interface losses.
2Strength
If the fiber-optic conductor is fully embedded in the housing material, then the mechanical strength is improved, but the luminosity is worsened due to increased light loss at the interface
Solution Approach 1:
Different regions of the fiber-optic conductor's peripheral surface have different connection qualities: the first portion (near the end face) is permanently connected to the housing material for mechanical strength, while the second portion (extending into the housing) is decoupled to minimize light loss. This local differentiation of connection quality optimizes both mechanical strength and luminosity.
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
This configuration significantly enhances the luminosity and diagnostic capabilities by minimizing light loss and ensuring clear status signaling at connection points, facilitating easier module diagnosis and operation.
Implementation Method 1
If light beams from a light source hit a barrier layer between two media of different optical density, they are not simply reflected, but they pass from the optically denser medium, e.g., the fiber-optic conductor plastic, into an optically thinner medium, such as air, at the barrier layers between the two different media. Thus, in this case, the fiber-optic conductor plastic and the opaque housing plastic; a light wave is no longer totally reflected and thus the light loses intensity.
Data Source
AI summary
An input/output module includes a connection element having a plurality of connection points for connecting input or output lines, a housing that accommodates the connection element such that the connection points are accessible and visible, display elements each including a plurality of status displays, each with a fiber-optic conductor associated with a status display, where a fiber-optic conductor includes a first illuminated panel and a light inlet, where a light source is arranged in the interior of the housing such that light is fed into the fiber-optic conductor via the light inlet and exits via the first illuminated panel to display a status, where the first illuminated panel is arranged in an end face of a side wall, and where the fiber-optic conductor is held in the side wall via a receptacle in the end face of the side wall.