Light Sensor Picker Jaw Thickness Detection

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Solution Overview

Problem

Existing methods for detecting the thickness of materials, particularly in mailing insert sheets, are prone to errors due to uncorrected signal generation and analysis issues, leading to inaccuracies in thickness measurement and increased downtime from manual setup procedures.

Innovation Solution

A light sensor-based system that uses a picker jaw assembly with a fulcrum and target plate to measure the thickness of inserts, emitting and receiving a light beam to correlate the target plate position with the thickness determination, and a controller with programming to compare measurements to a standard, generating alarms for missed or double inserts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If capacitance techniques are used to measure material thickness, then measurement capability is provided, but measurement accuracy deteriorates due to temperature variations, machine vibrations, and electronic drift

Engineering Contradiction:

Improvethickness measurement accuracyVSAvoidmeasurement stability under environmental variations

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent replaces capacitance-based electrical measurement systems with a mechanical lever system coupled to a light sensor. The pick jaw assembly acts as a mechanical lever that translates thickness variations into positional changes of a target plate, which are then detected by an optical sensor. This substitution eliminates the sensitivity to temperature, vibration, and electronic drift that plagues capacitance-based systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a mechanical lever (pick jaw assembly) as an intermediary between the material being measured and the detection system. This mechanical intermediary converts direct thickness measurements into lever arm displacement, which is then optically detected. The lever mechanism provides mechanical amplification and isolation from environmental disturbances.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If manual setup procedures are used for thickness detection calibration, then device complexity is reduced, but productivity deteriorates due to increased downtime

Engineering Contradiction:

Improvemachine operational efficiencyVSAvoiddowntime for manual calibration

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system performs automatic self-calibration by measuring the position of the target plate when the pick jaw is in known reference positions (open and closed). The controller automatically calculates the thickness measurements based on these reference positions without requiring manual intervention or setup procedures, thereby eliminating calibration downtime.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system establishes reference measurements for the pick jaw assembly at predetermined positions before actual thickness measurement begins. These preliminary reference measurements enable subsequent automatic calculations without requiring manual calibration during operation.

Inventive Principle:

Principle #10Preliminary action

3Extent of automation

If light sensor-based automatic measurement is implemented, then productivity is improved through automation, but device complexity increases due to additional components

Engineering Contradiction:

Improveautomatic thickness detectionVSAvoidpicker jaw assembly structure

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The pick jaw assembly serves multiple functions: it acts as both the material gripping mechanism and the measurement lever. The same mechanical components that pick and hold the material also translate thickness variations into detectable positional changes, eliminating the need for separate measurement mechanisms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the material handling function (pick jaw) with the measurement function (lever mechanism) into a single integrated assembly. The target plate is attached to the pick jaw assembly, combining the gripping mechanism and measurement indicator into one unified structure.

Inventive Principle:

Principle #5Merging (Combining)

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 accurate and reliable thickness measurements, reducing operator errors and downtime by automating the detection of missing or double inserts, and allowing programmable variance settings for improved control and data collection.

Implementation Method 1

a light sensor that emits a light beam and receives a reflected light beam that is reflected back from the light reflective surface

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS9157729B1Light sensor facilitated insert thickness detection system

Publication Date: 2015.10.13 DST OUTPUT WEST LLC

AI summary

A light sensor-containing apparatus for detecting the thickness of inserts placed within a mailer including a picker arm, movable picker jaw that pivots during an insert gripping process, a target plate having a light reflective surface and secured to the picker arm end that moves when gripping an insert, and a light sensor mounted to the picker arm that emits a light beam and receives a reflected light beam that is reflected back from the light reflective surface to establish the thickness of the insert as controlled by associated computer programming is presented.