Mail-Feeder Double Detection Using Proximity Sensor Phase Shift
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Solution Overview
Problem
Conventional mail-piece inserter systems face issues with detecting doubles, which can lead to jamming and potential damage, especially in space-constrained rotary feeders, due to limited detection accuracy and efficiency.
Innovation Solution
A double detection apparatus using a detectable flag affixed to a rotating mail-piece gripper and a stationary proximity sensor generates a voltage output, with a decision unit triggering alerts based on phase shifts above predetermined thresholds to accurately detect doubles in a geometrically efficient manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional double detection method is used in a rotary feeder, then the system can detect doubles, but the detection accuracy and efficiency are insufficient leading to jams and potential damage
Solution Approach 1:
The patent replaces mechanical double detection methods with an optical sensing system. A reflector is mounted on the rotary feeder drum, and an optical sensor detects the reflector's position to determine if a double feed has occurred. This optical substitution provides more accurate and reliable detection compared to conventional mechanical methods, preventing jams and damage while maintaining feeder operation.
Solution Approach 2:
The patent introduces a reflector as an intermediary element between the rotary feeder drum and the optical sensor. The reflector serves as a mediator that reflects light to the sensor, enabling indirect detection of the drum's rotational position and mailpiece presence. This intermediary approach allows for non-contact, high-precision detection that improves reliability without adding mechanical complexity to the feeder mechanism.
2Volume of moving object
If the rotary feeder space is limited, then the feeder can be compact, but the ability to implement effective double detection is constrained
Solution Approach 1:
The patent moves the detection mechanism from the radial space of the rotary feeder to the optical dimension. Instead of requiring additional radial space for mechanical detection components, the solution uses optical fields that can extend beyond the physical boundaries of the compact feeder. The reflector and optical sensor are positioned to utilize light paths that do not consume valuable radial space within the rotary feeder, enabling effective double detection in a compact configuration.
Solution Approach 2:
By replacing mechanical detection components with an optical sensing system, the patent eliminates the need for additional mechanical space within the rotary feeder. The optical sensor and reflector configuration requires minimal space compared to mechanical detectors, allowing the feeder to maintain a compact form factor while achieving reliable double detection capability.
3Measurement precision
If a detectable flag and stationary proximity sensor are used, then double detection accuracy is improved, but the system complexity increases
Solution Approach 1:
The patent uses an optical sensor and reflector system that, while providing high measurement precision, maintains relatively simple device architecture. The optical components are non-contact and require no mechanical adjustment or calibration mechanisms, reducing overall system complexity despite the enhanced detection accuracy achieved through precise optical positioning.
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 solution enables quick and accurate detection of doubles, preventing system jams and damage by integrating over the cycle position region and comparing voltage outputs to established thresholds, ensuring reliable operation even in limited spaces.
Implementation Method 1
A stationary proximity sensor may generate a voltage output based on a presence of the detectable flag in a direction along a first axis normal to the rotation of the mail-piece gripper
Data Source
AI summary
According to some embodiments, a double detection apparatus for a mail-piece inserter includes a detectable flag affixed to a rotating mail-piece gripper of a mail-piece rotary feeder. A stationary proximity sensor may generate a voltage output based on a presence of the detectable flag in a direction along a first axis normal to the rotation of the mail-piece gripper. A decision unit may then generate a double detect alert signal when a phase shift above a pre-determined threshold value is detected in the voltage output generated by the stationary proximity sensor. According to some embodiments, the decision unit may also generate a thin detect alert signal when a phase shift past another pre-determined threshold value is detected in the voltage output generated by the stationary proximity sensor.