Manipulation Unit Rebound Detection at End Stop Impact
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Solution Overview
Problem
Existing handling units with damping elements and limit switches may not always ensure that components move against stops with low enough speed or energy, leading to potential damage or destruction due to inadequate absorption of braking energy, especially under varying loads or non-linear movement paths.
Innovation Solution
A method where a limit switch generates an impact signal when the component bounces off the stop and returns to hit it again, allowing for detection of excessive rebounds, with adjustable sensitivity and polling intervals to identify potential damage risks, and a microprocessor evaluates signals to output end and impact signals through separate outputs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the damping element is designed to absorb braking energy, then the component should move against the stop with low speed or energy, but under varying loads or non-linear movement paths the damping element cannot always ensure sufficient energy absorption
Solution Approach 1:
The patent implements a feedback mechanism by using a limit switch with a sensor to detect the position of the movable component and generate impact signals when rebound is detected. The system continuously monitors the component's position and provides feedback about excessive impact, enabling the control system to respond and adjust operations to prevent damage under varying load conditions.
Solution Approach 2:
The patent replaces reliance on purely mechanical damping elements with an electronic detection and control system. Instead of depending solely on the damping element's mechanical properties to handle all varying loads, the system uses sensors and electronic signal processing to detect rebound conditions and can trigger appropriate responses, effectively substituting mechanical passivity with electronic activity.
2Measurement precision
If the limit switch generates an end position signal when the component is detected at the stop, then the positioning function is achieved, but it cannot distinguish between normal stopping and damaging rebound
Solution Approach 1:
The patent segments the limit switch's signaling function into two distinct outputs: one for normal end position detection and another for impact/rebound detection. This segmentation allows the system to differentiate between permissible stopping and damaging rebound by using separate evaluation criteria for each function, with the impact signal requiring specific temporal patterns (exit signal followed by entry signal within a short time window).
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
This method reliably detects rebounds and allows for timely intervention to prevent damage by distinguishing between permissible and damaging rebounds, ensuring the handling unit's safety and longevity.
Implementation Method 1
The movable component preferably has a magnet that is detected by the sensor. The sensor can be designed in particular as a magnetic sensor.
Implementation Method 2
the handling unit having a damping element for damping the movement of the component before the stop is reached
Data Source
Figure 1~2
AI summary
The invention relates to a method for determining the recoil of a movable component (14) against a stop (20) of a manipulation unit (10), the manipulation unit (10) having a damping element (18) for damping the movement of the component (14) before it reaches the stop (20), and an end position switch (22) with a sensor (24), the end position switch (22) generating an end position signal (A1=1) when the sensor (24) detects the component (14) at the stop (20), characterised in that the end position switch (22) then generates a bounce signal (A2=1) when, after an initial impact (EA) of the component (14) against the stop (20), the sensor (24) detects a return movement (a) and then a second impact (ZA) of the component (14) against the stop (20) owing to recoil of the component (14).