Light Curtain Self-Alignment via LCD Transmissive Apertures
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Solution Overview
Problem
Conventional light curtain systems require precise alignment of emitters and receivers, leading to costly maintenance and machine downtime due to false alarms caused by misalignment, which can be time-consuming and reduce productivity.
Innovation Solution
A system utilizing liquid crystal display (LCD) screens with transmissive apertures that allow light beams to pass through, allowing for misalignment tolerance and correction without requiring precise emitter-receiver alignment, using analysis and feedback mechanisms to adjust aperture positions and beam angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional light curtain systems use precise emitter-receiver alignment, then detection accuracy is improved, but maintenance complexity and time investment increase
Solution Approach 1:
The patent introduces an intermediary alignment mechanism that mediates between the emitter and receiver. This mechanism includes adjustable components and feedback systems that automatically adjust the alignment, eliminating the need for manual precise alignment while maintaining detection accuracy.
Solution Approach 2:
The patent implements feedback mechanisms that continuously monitor the light beam alignment and provide real-time adjustments. The system detects misalignment conditions and automatically corrects them, ensuring sustained detection accuracy without requiring manual intervention during operation.
2Reliability
If conventional light curtain systems require critical alignment of each emitter-receiver pair, then detection reliability is improved, but machine downtime during maintenance increases
Solution Approach 1:
The patent enables the light curtain system to self-align and self-correct misalignment conditions. The automatic alignment mechanisms allow the system to maintain reliability without requiring external intervention or manual realignment during maintenance, thereby reducing machine downtime.
Solution Approach 2:
The patent incorporates preliminary alignment adjustments and preventive maintenance features that ensure the system remains reliable before failures occur. The system includes monitoring and adjustment capabilities that can be activated during maintenance windows to prevent detection reliability issues.
3Manufacturing precision
If conventional light curtain systems use manual alignment procedures, then initial setup precision is improved, but maintenance time and cost increase
Solution Approach 1:
The patent replaces manual mechanical alignment procedures with automated electronic and optical alignment systems. The system uses sensors, actuators, and control algorithms to automatically achieve and maintain precise alignment, eliminating time-consuming manual adjustment during maintenance while preserving initial setup precision.
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 approach simplifies the alignment process, reduces maintenance costs, and minimizes downtime by allowing the light curtain to function correctly even with misalignment, ensuring accurate detection and preventing false alarms.
Implementation Method 1
Liquid crystal display (LCD) screens with transmissive apertures that allow light beams to pass through
Implementation Method 2
Light that is permitted to pass through the transmissive apertures can then be focused by a lens before traversing the monitored area. At the receiver side of the system, light can be re-focused (e.g., diffracted, . . . ) by a second lens
Data Source
AI summary
Systems and methods are disclosed that facilitate tolerating and/or correcting light beam misalignment in a light-emitting device, such as a light curtain. Attributes of the light beam can be assessed and compared to predetermined threshold values to evaluate whether the light beam is misaligned, and corrective feedback can be generated to adjust the position of one or more transmissive apertures generated on an LCD, through which light is permitted to pass, in order to re-align the light beam.