Integrated Sensor Substrate in Proximity Lanyard
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Solution Overview
Problem
Conventional lanyard systems with magnets adhesively attached to clips face issues such as magnet detachment, exposure to environmental elements, and obstruction of clip operation due to the small surface area, leading to unreliable proximity sensing in bucket truck applications.
Innovation Solution
Integrating sensor substrates, such as magnets, within the lanyard material or fabric, allowing for internal detection by sensors, which eliminates adhesion issues and protects the magnets from environmental factors, while enabling reliable proximity sensing through a magnetic field or alternative sensing mechanisms like RFID, pressure, inductive, or photoelectric sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnets are adhesively attached to the lanyard clip, then proximity sensing can be achieved, but the magnets can easily be removed or fall off due to adhesive weakening over time
Solution Approach 1:
The patent merges the magnet with the lanyard structure by integrating it into the fabric or webbing material. The magnet is sewn, bonded, or embedded within the lanyard body itself, creating a unified structure where the magnet becomes an inherent part of the lanyard rather than a separate attached component. This eliminates the adhesive attachment problem while maintaining proximity sensing functionality.
Solution Approach 2:
The patent uses composite construction by combining magnetic material with lanyard fabric or webbing material. The magnet is integrated within layers of fabric, webbing, or other lanyard materials, creating a composite structure that provides both structural integrity and magnetic sensing capability without relying on adhesive bonds.
2Reliability
If magnets are adhesively attached to the lanyard clip, then proximity sensing can be achieved, but the magnets are exposed to deleterious environmental elements
Solution Approach 1:
The patent applies nesting by placing the magnet inside the lanyard structure, surrounded by fabric or webbing layers. The magnet is nested within the lanyard body, protected by multiple layers of material that shield it from environmental elements such as moisture, UV radiation, and physical damage, while still allowing magnetic field transmission for sensing.
Solution Approach 2:
The patent uses fabric or webbing material as a flexible protective shell around the magnet. These thin film-like structures envelop the magnet, providing protection from environmental degradation while maintaining flexibility and allowing the magnetic field to pass through for proximity detection functionality.
3Reliability
If magnets are placed on the relatively small metal clip, then proximity sensing can be achieved, but it may obstruct operation of the clip and impart a weaker seal
Solution Approach 1:
The patent extracts the magnet from the clip component and relocates it to the lanyard body. By removing the magnet from the clip, the clip's operational functionality is restored without obstruction, while the magnet remains positioned on the lanyard where it can still be detected by sensors for proximity sensing purposes.
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
Ensures consistent and reliable proximity detection, preventing potential harm by alerting users to unsafe conditions, and allowing for integration into various lanyard configurations, meeting safety standards like ANSI Z359.13 and ASTM F887.
Implementation Method 1
a magnet, as a sensor substrate, is configured to emit a magnetic field that is designed to be used and operate in conjunction with a preinstalled sensor
Data Source
AI summary
A system and method for detecting securement of a proximity lanyard system to a bucket anchor in a bucket having a proximity sensor positioned therein. The proximity lanyard system can include an elongated body portion having a first end and a second end; a harness attachment positioned at the first end of the body portion; an anchor attachment positioned at the second end of the body portion; and a sensor substrate section comprising a sensor substrate and being integrated with the second end of the flexible body portion. The proximity sensor can detect the sensor substrate when the anchor attachment is connected to the bucket anchor.