Machining Unit Safety via Contactless Pre-Detection
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Solution Overview
Problem
Existing processing machines in the furniture and construction supply industry face limitations in allowing operators to monitor operations safely and efficiently while maintaining high working speeds, as current safety systems either restrict speed or lead to unintended machine stoppages due to contact sensors and light barriers.
Innovation Solution
A two-stage safety concept utilizing contactless sensors for pre-detection and contact sensors for final stopping, combined with a control device to reduce movement speed upon detection, and a protective hood to ensure safe monitoring, allowing continuous and rapid operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact sensors are used to stop machine units when contact is detected, then safety is improved, but working speed is reduced to comparatively low speeds
Solution Approach 1:
The patent applies preliminary action by using contactless sensors to detect objects before they reach the machine units. The system performs pre-detection in advance, allowing the control device to prepare for potential stopping actions before actual contact occurs, thereby maintaining higher working speeds while ensuring safety.
Solution Approach 2:
The safety system is segmented into two distinct sensor types: contactless sensors for early detection and contact sensors for final stopping. This segmentation allows each sensor type to operate in its optimal performance range, with contactless sensors enabling high-speed operation through pre-detection and contact sensors providing reliable safety stopping when needed.
2Reliability
If light barriers are used to stop machine units when objects enter the monitoring area, then safety is improved, but the machine cannot operate at high speed and unintended stoppages occur
Solution Approach 1:
The patent applies local quality by assigning different detection zones and functions to different sensors. Contactless sensors monitor a first area at a distance from the machine units for early detection, while contact sensors monitor a second area closer to the machine units for final stopping. This localized differentiation allows high-speed operation in the first area while maintaining safety in the second area.
Solution Approach 2:
The system performs preliminary detection using contactless sensors before objects enter the critical monitoring area of contact sensors. This early warning allows the control device to prepare for potential stopping actions without immediately halting the machine, thereby maintaining operation continuity while ensuring safety.
3Speed
If contactless sensors are used for early detection, then working speed is maintained, but additional sensors and control complexity are required
Solution Approach 1:
The control device is designed with multi-functionality to handle both contactless sensor signals for speed adjustment and contact sensor signals for stopping. This universal control approach consolidates the complexity into a single control unit that manages multiple sensor types, rather than requiring separate control systems for each sensor type.
Solution Approach 2:
The control device acts as an intermediary that processes signals from both contactless and contact sensors. It mediates between the early detection signals (which trigger speed reduction) and the final contact signals (which trigger stopping), coordinating the responses to manage system complexity centrally.
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 high-speed operation with uninterrupted monitoring, maintaining safety by reducing speed upon object detection and only stopping the machine upon contact, thus balancing speed and safety.
Implementation Method 1
at least one contactless sensor which is set up to detect objects penetrating a predetermined area
Implementation Method 2
at least one contactless sensor to be selected from a laser sensor, infrared sensor, ultrasonic sensor, laser triangulation sensor and image detection sensor
Implementation Method 3
at least one contactless sensor to be selected from a laser sensor, infrared sensor, ultrasonic sensor, laser triangulation sensor and image detection sensor
Implementation Method 4
at least one contactless sensor to be selected from a laser sensor, infrared sensor, ultrasonic sensor, laser triangulation sensor and image detection sensor
Data Source
Figure 1
Figure 2
AI summary
The machine (1) for cutting pieces (2) such as of wood, wood materials, has several machine units, including a processing unit (4) and a holding unit (6). A contact sensor (8) is provided on the machine unit. The machine also has contactless sensor (10) which, is set up, in a predetermined area (12) to sense intruding objects. The sensor is provided in a moveable part of the machinery unit. The sensor is a laser sensor, infrared sensor, ultrasonic sensor, imaging sensor. An independent claim is included for a method for safe operation of a processing machine.