Light Curtain Array for 3D Product Characterization on Transport Paths
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Solution Overview
Problem
Existing light grid systems for monitoring and controlling automated manufacturing systems lack the capability to efficiently detect and characterize objects with varying shapes and sizes, particularly in high-density product environments.
Innovation Solution
A system comprising a support frame with vertical light-emitting and detector arrays arranged on either side of a transport path, capable of measuring product height, edge locations, and contour, using wide-angle light sources and detectors with adjustable transmission and acceptance angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional light grid systems are used for monitoring, then the system structure is simple, but the capability to detect and characterize objects with varying shapes and sizes is insufficient
Solution Approach 1:
The system divides the monitoring function into multiple vertical light source arrays and corresponding detector arrays, with each segment capable of independently characterizing specific portions of passing objects. This segmentation enables detailed spatial mapping of object features while maintaining modular system architecture.
Solution Approach 2:
The patent transitions from traditional 2D light grid planes to 3D vertical light source arrays that emit light at multiple heights and angles. This dimensional expansion enables comprehensive characterization of objects with varying shapes and sizes by capturing spatial information across multiple vertical levels and angular perspectives.
2Adaptability or versatility
If parallel light curtains are used to detect hazards, then safety detection is achieved, but the system cannot efficiently characterize objects with varying shapes and sizes
Solution Approach 1:
The system performs preliminary characterization of objects by analyzing light blockage patterns across multiple vertical levels and angles as objects pass through the monitoring zone. This preliminary spatial mapping enables efficient identification and classification of objects before they reach critical positions, improving both characterization capability and detection efficiency.
Solution Approach 2:
The patent replaces traditional mechanical safety sensors with optical detection using vertical light source arrays and photodetector arrays. This substitution enables non-contact, high-speed optical characterization of objects based on light absorption and reflection patterns, significantly improving detection efficiency while maintaining safety functionality.
3Measurement precision
If multiple light sources are used to improve detection accuracy, then measurement precision increases, but the device complexity increases
Solution Approach 1:
Each vertical light source array and detector array is designed to perform multiple functions: hazard detection, object characterization, spatial mapping, and classification. This multi-functionality allows the system to achieve high measurement precision across various object types and conditions without proportionally increasing device complexity, as the same hardware infrastructure serves multiple detection 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
Enables accurate detection and measurement of product characteristics, allowing for real-time monitoring and validation of products, as well as the deactivation of hazardous machinery when unexpected objects are detected, thereby enhancing safety and efficiency in manufacturing processes.
Implementation Method 1
a light-emitting array including multiple light sources arranged along the support frame
Implementation Method 2
a detector array including multiple light detectors, where each detector of the multiple light detectors is arranged on the support frame opposite the transport path from a light source
Data Source
AI summary
Methods, systems, and apparatus, including medium-encoded computer program products, for a light curtain system including a support frame arranged around a transport path including a product support, a light-emitting array including multiple light sources arranged along the support frame, each light source of the multiple light sources arranged along the support frame at a respective distance above the product support, a detector array including multiple light detectors, where each detector of the multiple light detectors is arranged on the support frame opposite the transport path from a light source of the multiple light sources and at a respective distance above the product support, and a data processing apparatus in data communication with the light-emitting array and the detector array.