Light Grid With Diverging Cones For Alignment Tolerance
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Solution Overview
Problem
Existing light grid systems for measuring objects and securing dangerous zones around machines are limited by the need for precise alignment of narrow, focused rays, which are costly to control and prone to malfunction if misaligned, and are not adaptable to varying environments with reflecting surfaces.
Innovation Solution
A light grid system with a light emitting unit and a receiving unit using multiple optical arrangements to form diverging light cones with a larger dimension in the plane and circular cross-section, allowing for adjustable and tolerant alignment, reducing interference from reflecting surfaces, and enabling precise object measurement and zone security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If narrow, focused rays are used for sensing, then measurement precision is improved, but alignment difficulty increases and system reliability deteriorates
Solution Approach 1:
The light beam is segmented into multiple sub-beams or rays that collectively form a measurement plane. Each ray can be independently detected, maintaining measurement precision while the overall distributed structure reduces alignment sensitivity compared to a single focused beam.
Solution Approach 2:
The system transitions from one-dimensional focused rays to two-dimensional light planes with distributed rays. This dimensional expansion allows the measurement function to be distributed across multiple rays, reducing the criticality of individual ray alignment while maintaining overall measurement precision.
2Measurement precision
If narrow, focused rays are used for sensing, then measurement precision is improved, but device complexity increases due to costly controls
Solution Approach 1:
Multiple light emitters and receivers are merged into coordinated arrays that operate together. The control system manages these elements collectively rather than individually, reducing overall device complexity while maintaining the precision benefits of multiple focused rays through coordinated operation.
3Measurement precision
If light emitters and receivers are alternatingly arranged, then measurement capability is improved, but device complexity increases due to costly controls for operating emitters and receivers
Solution Approach 1:
The alternating arrangement of emitters and receivers creates a periodic spatial pattern that simplifies control logic. Elements can be activated in periodic sequences or groups rather than individually, reducing control complexity while maintaining measurement capability through the periodic spatial distribution.
4Adaptability or versatility
If light rays are expanded in the direction of the lit plane, then adaptability and alignment tolerance are improved, but interference from reflecting surfaces increases
Solution Approach 1:
Different regions of the light plane have different expansion characteristics. The light distribution is optimized locally - expanded in directions where adaptability is needed while maintained in directions where reflection interference is a concern, creating spatially varying light properties that balance these competing requirements.
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 system provides enhanced adaptability and usability by allowing easy adjustment and alignment, minimizing interference from reflecting surfaces, and enabling precise object measurement and secure zone protection with reduced operational costs.
Implementation Method 1
a light emitting unit with a plurality of individual light emitters that emit individual light beams in a lit plane and form emitted light cones having diverging boundaries
Implementation Method 2
The emitting unit and/or the receiving unit are provided with at least two different optical arrangements (optics) for forming the emitted and received light cones
Implementation Method 3
a receiving unit that is spaced apart from the emitting unit and has a number of individual light receivers that receive the light from the receiving light cones
Data Source
AI summary
A light grid for measuring an object and securing a dangerous zone of a machine has an emitting unit with individual light emitters for directing a plurality of light beams in the form of emitted light cones approximately along a lit plane. A receiving unit is spaced apart from the emitting unit and has individual light receivers for receiving light from the emitted light cones. The emitting unit and the receiving unit define a protected zone between them. The emitting unit and/or the receiving unit has at least two differently formed first and second optics. The first optics generate the emitted and/or the received first light cones. The first light cones have a greater dimension in a direction parallel to the plane than in a direction transverse to the lit plane. The second optics generate a second emitted and/or received light cone. The second light cones have an approximately circular cross-section, and the first and second optics are alternatingly arranged with a spacing between them so that optical axes of the emitting and receiving units lie approximately in the lit plane.