Insulated Fiber Optic Paint Robot Tool for Safe Component Detection
Solution Overview
Problem
Automated paint processes in automotive manufacturing require detection of movable components without using high-voltage cameras or electronic tools to avoid shock hazards, necessitating a cost-effective and safe detection method.
Innovation Solution
An electrically insulated tool with an optical sensor system using first and second optical fiber cables and spaced-apart optic ports for light communication, where an interruption in the light beam indicates the presence of a workpiece component, triggering painting operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If high-voltage cameras or electronic detection tools are used to detect movable components, then detection capability is improved, but shock hazard increases
Solution Approach 1:
The patent replaces electronic detection systems with a mechanical optical detection system using fiber optic cables and light sources. The system uses a light source positioned on one side of the workpiece and a fiber optic cable with light sensor positioned on the other side, detecting the presence of movable components through interruption or modification of light transmission rather than using electronic cameras or sensors that would pose shock hazards in the high-voltage paint spray environment.
Solution Approach 2:
The patent introduces light as an intermediary medium to transfer detection information across the workpiece. Instead of directly using electronic sensors in the hazardous high-voltage zone, the system uses light transmission through the workpiece as an intermediary mechanism, with fiber optic cables carrying light signals from a safe external light source through the workpiece to external sensors, thereby eliminating direct electronic component exposure to shock hazards.
2Object-affected harmful factors
If electronic detection components are minimized for safety, then shock hazard is reduced, but detection precision may worsen
Solution Approach 1:
The patent substitutes electronic detection components with an optical detection system using fiber optic cables and light sources. This mechanical/optical system achieves detection precision without relying on electronic components that could be affected by high-voltage shock hazards. The system can detect the presence, position, and movement of movable components through precise measurement of light transmission characteristics.
Solution Approach 2:
The patent creates an optical copy or representation of the workpiece state by measuring light transmission through the workpiece. The fiber optic system captures optical information about the movable components' position and presence, creating a non-electronic replica of the detection data that maintains precision while eliminating shock hazard risks associated with direct electronic sensing in the high-voltage environment.
3Object-affected harmful factors
If optical fiber cables are used for detection, then shock hazard is minimized, but device complexity increases
Solution Approach 1:
The patent employs fiber optic cables that serve multiple functions: they act as both the light transmission medium and the detection sensor. The same fiber optic cable that carries light from the source also collects and transmits the modified light back to the detection system, eliminating the need for separate illumination and sensing components and thereby reducing overall device complexity despite the introduction of fiber optic technology.
Solution Approach 2:
The fiber optic cable serves as an intermediary that combines multiple functions in a single component. It transmits light from the source, carries the light through the detection region where it interacts with the workpiece, and returns the modified light signal to the detection system. This multi-functional intermediary approach simplifies the overall system architecture compared to using separate electronic sensors, light sources, and wiring in the high-voltage environment.
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 and cost-effective detection of movable components in a paint booth, minimizing electronic components and preventing shock hazards while ensuring accurate timing for painting processes.
Implementation Method 1
The tool has an optical sensor system including first and second optical fiber cables, and first and second spaced-apart optic ports coupled to the respective first and second optical fiber cables
Data Source
AI summary
An electrically insulated tool is provided for a paint robot of a robotic painting system. The insulated tool includes an insulated main body having a mounting bracket disposed at a first end of the main body, configured for removably coupling the insulated tool to a paint robot. The tool has an optical sensor system including first and second optical fiber cables, and first and second spaced-apart optic ports coupled to the respective first and second optical fiber cables. The optic ports are configured to provide light communication as a light emitter and a light receiver. An interruption in the light communication between the light emitter and the light receiver indicates a presence of a workpiece component adjacent a detection region of the insulated tool.