Flexible Capacitive Sensor Film for Machine Safety Monitoring
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Solution Overview
Problem
Existing sensor systems struggle to reliably monitor complexly shaped surfaces and motion paths in automatic production or assembly machines, leading to potential collisions between humans and moving machine parts, which can result in safety hazards and operational disruptions.
Innovation Solution
A modular capacitive sensor system with a layered structure of flexible electrically conductive and insulating layers, allowing for the formation of measurable electrical field changes upon human approach or contact, enabling reliable detection and reporting of events, and featuring redundant sensor channels for enhanced safety and self-diagnosis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sensors (optical, ultrasound, capacitive) are used for collision detection, then simple shaped machine parts with defined motion paths can be monitored, but complexly shaped surfaces and complex motion paths cannot be reliably monitored
Solution Approach 1:
The patent applies a flexible capacitive sensor film that can be conformally mounted on complexly shaped surfaces of machine parts. The film contains conductive patterns that form capacitive sensors distributed across the surface, enabling monitoring of complex motion paths and surfaces that traditional rigid sensors cannot cover. This flexible film approach resolves the contradiction by providing both the adaptability to complex geometries and the reliability of capacitive sensing.
Solution Approach 2:
The patent replaces traditional mechanical contact sensors with capacitive sensing that detects changes in electrical field caused by approach or contact of objects. This substitution enables non-contact detection and provides more reliable monitoring for complex surfaces where mechanical sensors would require precise mechanical alignment and contact points.
2Reliability
If duplicate independent safety channels are employed for operator safety, then safety standards are fulfilled, but device complexity increases
Solution Approach 1:
The patent combines multiple capacitive sensor elements into a single integrated flexible sensor film that covers the machine part surface. This merging approach provides redundant monitoring capability across the entire surface while reducing the complexity of having multiple discrete sensor systems. The film itself acts as an integrated safety monitoring system that fulfills safety standards without requiring separate duplicate sensor installations.
Solution Approach 2:
The capacitive sensor film serves multiple functions simultaneously: it monitors approach of objects, detects contact, provides redundant safety channels, and can be mounted on various complexly shaped surfaces. This multi-functionality reduces overall system complexity while maintaining high reliability for safety applications.
3Reliability
If protective fences are used to separate humans from machines, then operator safety is ensured, but simultaneous presence of human and machine in the same workspace is prevented
Solution Approach 1:
The patent replaces physical protective fences with an electronic safety monitoring system based on capacitive sensing. This substitution allows the machine workspace to remain accessible to operators while providing continuous monitoring for approach and contact. The electronic safety system enables human-machine collaboration in the same workspace while maintaining operator safety through early detection and machine stoppage capability.
4Reliability
If two-handed operation with pushbuttons is used, then operator safety is improved, but simultaneous human-machine operation is limited
Solution Approach 1:
The patent replaces the two-handed operation pushbutton system with continuous capacitive sensing that monitors the workspace without requiring the operator to maintain specific hand positions on pushbuttons. This enables natural human-machine collaboration where the operator can perform tasks freely while the capacitive sensors continuously monitor for unsafe conditions, thereby improving both safety and productivity simultaneously.
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
Enables safe co-operation of humans and moving machine parts in the same workspace by providing full-surface two-channel monitoring, reducing the risk of collisions and ensuring prompt malfunction detection, thus preventing accidents and minimizing downtime.
Implementation Method 1
at least one capacitive sensor element which is mountable on the surface of machines or machine parts
Implementation Method 2
electrical field lines form between the conductive surfaces, which change measurably upon approach and/or contact with a body that changes the field
Implementation Method 3
or also using contact detection via the piezoelectric effect
Data Source
AI summary
A sensor system and an evaluation method for monitoring surroundings on a mechanical component, having at least one capacitive sensor element that is attachable on the surface of machines or machine parts, in which at least one sensor element is made up of a layered structure of flexible, electrically conductive and electrically insulating layers, electrically conductive surfaces of one layer being positioned with lateral spacing above insulating layers lying between them in such a way that electrical field lines form between the conductive surfaces, which change measurably upon approach to and/or contact with a body or object.