Light Curtain Calibration for Misalignment Compensation
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Solution Overview
Problem
Light curtain arrangements experience a decrease in operating range due to misalignment of deflection elements with respect to light emitter and receiver elements, leading to a reduced monitored area size, and existing solutions do not effectively address the alignment issue.
Innovation Solution
A method and system that involves sequentially activating light emitter elements, determining the intensity of the light signals received by a light receiver element, and selecting the most effective emitter elements to maximize signal intensity, thereby increasing the operating range without physical repositioning of elements, and optionally includes periodic recalibration to maintain high signal intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If deflection elements are used to direct light from multiple emitter elements to a single receiver element, then the operating range can be increased, but misalignment between deflection elements and emitter/receiver elements causes the operating range to decrease
Solution Approach 1:
The system performs a preliminary calibration process before normal operation. During calibration, each emitter element is activated sequentially while measuring the intensity of light received by the receiver element. The control unit stores these intensity values and uses them to automatically determine the optimal emitter elements for operation, compensating for any misalignment issues before the system begins monitoring.
Solution Approach 2:
The system continuously monitors the intensity of light signals received by the receiver element and uses this feedback information to identify which emitter elements produce the strongest signals. The control unit adjusts the operation mode based on this feedback, selecting only the most effective emitter elements to maintain optimal performance despite potential misalignment.
2Area of stationary object
If all light emitter elements are activated simultaneously, then the monitored area coverage is maximized, but the signal intensity at the receiver element decreases due to light path interference and misalignment
Solution Approach 1:
The system divides the emitter elements into separate groups and activates them sequentially rather than simultaneously. The control unit manages the activation of individual emitter elements or small groups, measuring the received signal intensity for each configuration. This segmentation allows the system to identify which emitter elements provide the strongest signals without interference from simultaneously activated elements.
Solution Approach 2:
The system activates only the necessary subset of emitter elements based on calibration results, rather than all emitter elements simultaneously. The control unit selects and activates only those emitter elements that demonstrate sufficient signal intensity during calibration, reducing the total light load on the receiver element while maintaining adequate monitored area coverage.
3Area of stationary object
If the light curtain arrangement is reconfigured physically to correct misalignment, then the operating range can be maintained, but the complexity and time required for installation and maintenance increase
Solution Approach 1:
The system performs self-diagnosis and self-adjustment through the calibration process. The control unit automatically measures the intensity of light signals from each emitter element, compares these values, and determines the optimal emitter elements without requiring external intervention or physical reconfiguration. This self-service capability eliminates the need for complex manual alignment procedures.
Solution Approach 2:
The patent replaces mechanical adjustment mechanisms with an optical and electronic solution. Instead of physically moving or repositioning emitter elements and receiver elements to correct misalignment, the system uses the calibration process to identify and select the most effective emitter elements electronically, substituting mechanical reconfiguration with software-based optimization.
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 method enhances the operating range of the light curtain arrangement by selecting the most effective light emitter elements, allowing for a larger monitored safety area without physical reconfiguration and providing a simplified calibration process, with optional automatic recalibration and warning mechanisms for malfunction detection.
Implementation Method 1
the light emitter elements are configured to emit light along respective light paths
Implementation Method 2
the at least one deflection element is configured to deflect the light emitted along the light paths such as to direct it towards the light receiver element
Implementation Method 3
determining an intensity of a light signal received from the sequentially activated light emitter element by the light receiver element
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
A method for operating a light curtain arrangement for monitoring a safety area is provided. The light curtain arrangement comprises a light receiver element, a plurality of light emitter elements and a deflection element placed between the light emitter elements and the light receiver element. The method comprises the steps of: sequentially activating the light emitter elements of the plurality of light emitter elements; for each of the sequentially activated light emitter elements, determining an intensity of a light signal received from the sequentially activated light emitter element by the light receiver element; and selecting at least one selected light emitter element from the plurality of light emitter elements in accordance with the determined intensities of the light signals.