Line-of-Sight Sensor Mounting with Alignment Jig for Obstructed Access
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Solution Overview
Problem
Installation of line-of-sight sensor systems on agricultural or industrial equipment is challenging due to limited physical access and obstructed geometries, making accurate alignment and mounting difficult.
Innovation Solution
A line-of-sight sensor mounting system and method that uses a mounting plate with an alignment jig to form aligned apertures in external walls and secure the transmitter and receiver in place using a cooperative twist-lock mechanism, allowing for effective alignment even in obstructed environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom brackets are riveted or welded to the side of a clean grain elevator, then the LoS sensors can be mounted, but accurate alignment becomes extremely difficult due to limited space and obstructed access
Solution Approach 1:
The patent introduces a mounting plate as an intermediary component that is first secured to the accessible side of the grain elevator, providing a stable base for subsequent alignment operations. The alignment jig then acts as a mediator tool that transfers the aperture position through the wall to the opposite side, enabling precise alignment without direct access to both sides simultaneously.
Solution Approach 2:
The mounting plate is secured to the grain elevator wall in advance, creating a preliminary fixed reference point. The alignment jig is then attached to this pre-mounted plate, and the aperture is formed through preliminary alignment actions before the final sensor installation, ensuring precision despite access constraints.
2Ease of operation
If a right angle drill is used to drill through the grain elevator wall, then apertures can be formed in obstructed locations, but installation time and complexity increase significantly
Solution Approach 1:
The alignment jig serves as a mediator that simplifies the complex task of drilling through the grain elevator wall at right angles. By providing a guided aperture-forming tool that attaches to the pre-mounted plate, the system enables straightforward drilling operations without requiring complex positioning maneuvers, thereby reducing installation time despite the need for right-angle drilling.
3Adaptability or versatility
If belts or tensioner rods are present in the available mounting space, then mounting brackets can be positioned, but accurate positioning and mounting of sensors becomes extremely frustrating
Solution Approach 1:
The mounting plate acts as an intermediary that is secured to the grain elevator wall in a location that can accommodate the equipment geometry (belts or tensioner rods). This pre-mounted plate provides a stable reference surface that is not obstructed by these components, allowing the alignment jig to be attached and the aperture to be formed with high precision despite the presence of belts or tensioner rods in the surrounding area.
Data Source
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AI summary
Described are various embodiments of a line-of-sight (LoS) sensor mounting system and method. In one such embodiment, a LoS sensor mounting system is described for operatively mounting a LoS receiver and LoS transmitter on a structure having opposed external walls, comprising a mounting plate and an alignment jig comprising a mounting plate engagement structure and an alignment barrel dimensioned. The alignment barrel is dimensioned to receive an aperture-forming tool operable therethrough along a LoS axis so to form a counterpart external wall LoS aperture within an opposed external wall.