Integrated Contactless Sensor for Processing Machine Safety
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Solution Overview
Problem
Existing processing machines face limitations in achieving high productivity due to safety measures that require operators to leave defined areas for increased speed, as they rely on contact sensors that only initiate stopping upon contact, leading to reduced working speeds and inefficient use of space.
Innovation Solution
Integration of a contactless sensor with the contact sensor on a processing machine, allowing for enhanced detection range and speed adjustment, enabling proactive safety measures like speed reduction or warnings without the need for operators to leave protected areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact sensors are used for safety detection, then safety can be ensured, but the machine must reduce working speed to allow timely stopping upon contact
Solution Approach 1:
The contactless sensor performs preliminary detection of objects or persons in the danger zone before the processing unit reaches them. This early detection triggers preliminary safety actions (speed reduction or stopping) before contact occurs, eliminating the need to limit working speed while maintaining safety. The detection field extends beyond the contact point to provide advance warning.
Solution Approach 2:
The contactless sensor acts as an intermediary between the processing unit and the contact sensor. It provides early warning of approaching objects or persons, allowing the control system to take preventive action before the contact sensor is triggered. This intermediary detection layer enables higher working speeds while maintaining safety through proactive rather than reactive measures.
2Productivity
If upstream area protection is added to increase working speed, then productivity improves, but device complexity and space requirements increase due to additional light barriers or safety mats
Solution Approach 1:
The contactless sensor is integrated directly into the contact sensor housing, combining two safety functions into a single device. This eliminates the need for separate upstream protection systems like light barriers or safety mats, reducing device complexity and space requirements while maintaining the ability to achieve high working speeds through early detection.
Solution Approach 2:
The integrated sensor unit performs multiple functions: the contactless sensor detects objects or persons at a distance, while the contact sensor detects actual contact. This multi-functional design replaces multiple separate safety systems, simplifying the overall system while enabling high productivity through proactive safety monitoring.
3Loss of time
If the detection field of the contactless sensor is aligned in the direction of travel, then early detection is improved, but the detection area may not cover the operator area adequately
Solution Approach 1:
The safety monitoring is segmented into two functional zones: the contactless sensor detects objects or persons in the approach zone (upstream) in the direction of travel, while the contact sensor covers the contact zone at the processing unit. This segmentation allows optimized detection in each zone without compromising overall operator safety.
Solution Approach 2:
The contactless sensor serves as an intermediary detection layer that monitors the approach area, while the contact sensor provides backup coverage for the operator area. Together, they create a comprehensive safety net that maintains both early detection capability and adequate operator area coverage.
Data Source
Figure 1
Figure 2a~2b
AI summary
The present invention relates to a processing machine for machining workpieces, which, by way of example, may consist of wood, wood-like materials, plastic, or metal. The processing machine according to the invention comprises: a machine bed (1) and a processing unit (B) movably arranged along the machine bed, the processing unit (B) having a processing unit (3), as well as a contact sensor and a non-contact sensor provided on the processing unit (B). The processing machine is characterized in that the non-contact sensor is attached to the contact sensor.