Light Beam Imaging System for Industrial Machine Safety
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Solution Overview
Problem
Existing light beam safety systems for industrial machines are limited in accuracy and productivity due to their reliance on manual intervention and complex mechanisms, particularly when determining the bending angle of sheet materials, and they often switch to slower speeds prematurely, reducing efficiency.
Innovation Solution
A light beam imaging system that uses a collimated beam transmitted to a receiver with a pixel matrix to determine the extent of work on a work piece, allowing for automatic determination of the bending angle and switching from safety mode to imaging mode at a mute point to maintain productivity and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a light beam safety system uses manual intervention and complex mechanisms to determine bending angle, then measurement capability is provided, but accuracy and productivity deteriorate
Solution Approach 1:
The patent replaces manual measurement mechanisms with an automated optical measurement system. A light source projects a light beam that passes through or reflects off the workpiece, and a detector automatically tracks the beam position to calculate bending angle, eliminating manual intervention and improving both accuracy and productivity.
Solution Approach 2:
The patent introduces a light beam as an intermediary between the workpiece and the measurement system. The light beam serves as a reference that interacts with the workpiece geometry, allowing the detector to indirectly measure bending angle through optical path changes, achieving high precision without mechanical contact.
2Reliability
If the safety system switches to slower speeds to ensure safety, then safety is improved, but productivity deteriorates due to premature switching
Solution Approach 1:
The patent implements a feedback mechanism where the optical measurement system continuously monitors workpiece position and bending progress in real-time. Based on this feedback, the control system dynamically adjusts machine speed, maintaining high speed when safe and only reducing speed when necessary, thereby preserving both safety and productivity.
Solution Approach 2:
The patent makes the system speed dynamic rather than static. The machine operates at high speed during safe zones and automatically transitions to lower speed only when the workpiece enters the danger zone or bending completes, optimizing productivity while maintaining safety through real-time condition-based speed adjustment.
3Reliability
If a single continuous planar laser beam is used for safety monitoring, then safety coverage is provided, but measurement accuracy deteriorates due to beam width
Solution Approach 1:
The patent segments the continuous planar laser beam into multiple discrete measurement points or uses a focused narrow beam for measurement purposes while maintaining separate safety beams. This segmentation allows precise position detection at specific points while maintaining comprehensive safety coverage through the overall beam array.
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 enables continuous monitoring and precise determination of the work progress without manual intervention, maintaining high productivity by switching to imaging mode after the mute point, thus avoiding premature slowdowns and improving accuracy in bending angle measurement.
Implementation Method 1
at least one light transmitter for mounting to a first portion of the industrial machine, said at least one transmitter including means to transmit a substantially collimated beam of light to a receiver, said receiver including at least one pixel matrix arranged to receive at least a portion of said beam
Data Source
AI summary
An imaging system, safety system or combined imaging and safety system includes a light transmitter and a corresponding receiver. Image data relating to a machine tool and/or workpiece is derived and processed to determine information regarding the tool and/or tool position and/or extent of work carried out on the workpiece. A screen, such as a shadow screen, can be used to form an image of a profile of the tool tip and end of the workpiece. Tool tip position and extent of work on the workpiece can be derived from the image. Certain aspects are directed to a safety system application for halting a machine or tool when a light beam is interrupted, and can provide progressive muting of beam interruption detection, such as by systematically disregarding or muting signals from rows of receiver array elements as the beam passes through a mute point ahead of a tool.