Side-Mounted Light Curtain Status Module for Wide-Angle Visibility
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manufacturing facilities face safety challenges due to machinery hazards, and existing light curtain safety systems lack effective visual indicators for status and alignment, which can lead to accidents and production downtime.
Innovation Solution
A side-mounted field-installable indication module (SMFIIM) with a light emitting module and refractive cover, providing a wide viewing angle and customizable functionalities, including sensors and input interfaces, to visually indicate the status of light curtains and machines, enhancing safety and visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional light curtain safety systems are used without visual indicators, then the safety function is maintained, but the visibility of status and alignment is insufficient leading to accidents and production downtime
Solution Approach 1:
The patent employs color-changing visual indicators (LEDs or other light sources) that display different colors to indicate various operational states of the light curtain system. This provides clear, intuitive status information to operators, improving visibility and reducing misinterpretation of system state.
Solution Approach 2:
The patent introduces visual indicator modules as intermediary elements between the light curtain sensing system and the operators. These indicators serve as mediators that translate invisible infrared or laser beam status into visible visual signals, making system state observable without requiring direct observation of the light beams themselves.
2Loss of information
If fixed status indicators are integrated into the light curtain housing, then status visibility is improved, but the adaptability to different installation locations and viewing angles is reduced
Solution Approach 1:
The patent divides the visual indication system into separate, modular indicator units that can be independently positioned and oriented. This segmentation allows each indicator to be placed at optimal locations for visibility while maintaining the overall system's adaptability to different installation configurations.
Solution Approach 2:
The patent incorporates adjustable and repositionable visual indicator modules that can be dynamically repositioned along the light curtain housing or adjusted in orientation. This dynamic positioning capability allows the system to adapt to different installation locations, viewing angles, and operational requirements.
3Device complexity
If narrow viewing angle indicators are used, then the device complexity is reduced, but the viewing angle and visibility around the light curtain is limited
Solution Approach 1:
The patent employs optical elements such as diffusers, reflectors, or prisms that redirect light in multiple dimensions, transforming a narrow viewing angle into a wide omnidirectional or multi-directional viewing capability. This dimensional expansion of light distribution achieves broad visibility without requiring multiple separate indicator sources.
Solution Approach 2:
The patent utilizes optical parameters such as refraction, reflection, or diffusion angles to expand the viewing cone of the visual indicators. By changing the optical path and distribution parameters through specialized optical elements, the system achieves wide viewing angles while maintaining relatively simple indicator structures.
4Adaptability or versatility
If multiple customizable functionalities (sensors, input interfaces) are integrated into the side-mounted module, then the versatility and safety monitoring capability are enhanced, but the device complexity increases
Solution Approach 1:
The patent designs the side-mounted module as a universal platform that can perform multiple functions including visual indication, sensing, and user input. This multi-functional integration allows a single modular component to replace what would otherwise require multiple separate devices, achieving versatility while managing complexity through functional consolidation.
Solution Approach 2:
The patent implements a nested modular architecture where sensors, input interfaces, and visual indicators are integrated within the side-mounted module housing. This nesting approach allows multiple functionalities to be contained within a compact, organized structure, reducing overall system complexity while maintaining adaptability.
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 SMFIIM enhances safety by providing clear visual warnings and status indicators, reducing the risk of accidents and minimizing production downtime through improved visibility and customizable functionalities.
Implementation Method 1
Some embodiments, for example, may advantageously include a refractive cover (e.g., configured to provide a distributed 'glowing' effect over substantially an entire viewing portion of the cover) for the light emitting module to increase viewing angle of the visual indicium.
Data Source
AI summary
Apparatus and associated methods relate to a side-mounted field-installable indication module (SMFIIM) configured to reflect a status of a manufacturing area (e.g., a status of a machine, status of a light curtain). In an illustrative example, the SMFIIM may include a light emitting module configured to emit a visual indicium corresponding to the status of the manufacturing area, and a coupling member configured to be releasably captured within a longitudinally extending channel of a housing of a light curtain. After installation, for example, the SMFIIM may be disposed on a side of and substantially parallel to the housing. The light emitting module may emit the visual indicium in an emitting plane oriented at an angle less than 90° to a plane tangential to a mounting surface of the light curtain housing. Various embodiments may advantageously provide a wide viewing angle of the light emitting module around the lighting curtain.