Light Curtain End Cap Flat Adapter Design
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Solution Overview
Problem
Conventional light curtains have dead zones at the ends of their housings due to end caps, which are not used for object detection, leading to reduced monitoring efficiency and increased structural complexity.
Innovation Solution
The design incorporates flat adapters on end caps that accommodate electronic components, allowing the optoelectronic elements to occupy the entire housing length, minimizing dead zones and enabling efficient object detection across the entire surveillance area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If end caps are used to close the hollow profiles, then the housing structure is complete and protected, but dead zones are created at the ends where optoelectronic elements cannot be integrated
Solution Approach 1:
The end cap is divided into two functional parts: a cap body for structural closure and protection, and a flat adapter for mounting optoelectronic elements. This segmentation allows each part to fulfill its specific function while eliminating the dead zone problem.
Solution Approach 2:
The flat adapter extends the functional surface of the end cap laterally beyond the hollow profile boundaries, creating a new mounting dimension. This allows optoelectronic elements to be positioned at the extreme ends of the housing, maximizing the monitoring area coverage.
2Adaptability or versatility
If electronic components are integrated into the end caps, then functionality is enhanced, but the dead zones increase due to larger end cap dimensions
Solution Approach 1:
The end cap is segmented into a cap body for electronic components and a flat adapter for optoelectronic elements. This separation allows electronic components to be housed without increasing the lateral footprint that would create dead zones.
Solution Approach 2:
The flat adapter serves multiple functions: it closes the opening of the hollow profile, provides a mounting surface for optoelectronic elements, and extends the functional area without creating dead zones. This multi-functionality resolves the contradiction between electronic component integration and monitoring area coverage.
3Area of stationary object
If the entire length of the hollow profile is used for optoelectronic elements, then the measurement field is maximized, but the end caps become protruding and create dead zones
Solution Approach 1:
The flat adapter extends laterally beyond the hollow profile in a direction perpendicular to the longitudinal axis, allowing optoelectronic elements to be mounted at the extreme ends without the end cap protruding axially. This dimensional change eliminates dead zones while maximizing measurement field coverage.
Solution Approach 2:
The end cap is segmented into a cap body that fits within the hollow profile and a flat adapter that extends laterally. This segmentation allows the optoelectronic elements to be positioned at the maximum possible distance from the center, maximizing the measurement field while maintaining a compact axial profile.
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
This configuration ensures nearly complete object detection without dead zones, allowing for effective monitoring in cramped spaces and enabling cascading of multiple light curtains for larger areas without significant dead zones.
Implementation Method 1
The light barrier arrangement comprises optoelectronic elements integrated into two housings, consisting of light-emitting transmitters and light-receiving receivers
Data Source
Figure 1
Figure 2~3
AI summary
The curtain (1) has emitters (6) for emitting light beams (5), and receivers (7) for receiving the light beams. A housing comprises a hollow housing body (11), where optoelectronic elements are arranged one behind the other in the housing body at a distance towards a longitudinal axis of the housing body. An aperture is formed at a longitudinal end of the housing body. An end cap (14) comprises a planar adapter (15) that closes the aperture. A cap body (16) lies close to the housing body and receives electronic components (18), where a side of the cap body is attached on the adapter.