Flame Detector Distance Sensor for Obstruction Monitoring
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Solution Overview
Problem
Existing flame detectors in machine tools are unreliable due to contamination and obstruction issues, as they fail to accurately detect electromagnetic radiation emitted by flames when the window is soiled or obstructed by objects within the field of view.
Innovation Solution
A detector system that includes a distance sensor using pulsed signals and a receiver to determine the distance and position of obstructing objects, with a transmitter and receiver separated to prevent direct electromagnetic interference, and an evaluation unit to issue warnings when obstructions are within a critical range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the detector window is monitored for contamination using existing methods, then the window soiling can be detected, but obstacles in the detector's field of view that shadow the detector are not detected
Solution Approach 1:
The distance sensor is integrated into the detector housing to perform dual functions: monitoring window contamination and detecting obstacles in the field of view. This multi-functional approach resolves the contradiction by enabling obstacle detection without adding a separate monitoring system, thereby improving reliability while maintaining measurement capability.
Solution Approach 2:
A light source is introduced as an intermediary element that emits light toward the window and obstacle areas. The light reflects off the window surface and obstacles, allowing the distance sensor to detect both window soiling conditions and obstacles in the field of view through the reflected light patterns.
2Device complexity
If the transmitter and receiver are placed close together for compact design, then device size is reduced, but direct electromagnetic coupling between transmitter and receiver occurs
Solution Approach 1:
A reflective surface is positioned between the transmitter and receiver to mediate the electromagnetic interaction. The transmitter emits electromagnetic waves that reflect off the intermediate surface before reaching the receiver, preventing direct coupling while enabling the sensing function. This resolves the contradiction by maintaining compact dimensions without allowing harmful direct electromagnetic interference.
Solution Approach 2:
The transmitter and receiver are arranged in a spatial configuration where they are separated along one dimension while maintaining proximity in other dimensions. This dimensional arrangement allows compact overall device size while preventing direct electromagnetic coupling by positioning components such that their electromagnetic fields do not directly intersect.
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 reliably detects and determines the distance and position of obstructing objects, ensuring accurate monitoring of electromagnetic radiation and preventing false alarms or missed detections caused by window contamination or obstructions.
Implementation Method 1
a receiver that receives the pulsed signals reflected by an object in the field of view of the detector
Implementation Method 2
the evaluation unit (28) is connected to the transmitter (29) and the receiver (30) and performs a runtime measurement to determine the distance of the object
Implementation Method 3
the transmitter is a diode which emits electromagnetic radiation in a defined frequency range that differs from the frequency range emitted by the electromagnetic radiation of the flames
Implementation Method 4
at least one optical receiver device for the electromagnetic radiation emitted by flames
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The detector (20) has an optical receiving unit (26) for an electromagnetic radiation that is emitted from flames, where the receiving unit is arranged in a detector housing (21) with a window (23). A distance sensor (27) is arranged in or at the detector housing for visual field monitoring of the detector. The distance sensor has a transmitter and a receiver.