Modular Light Curtain Status Module for Sealed Field Installation
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Solution Overview
Problem
Existing light curtain systems lack efficient and user-friendly methods for field installation and replacement of status indicators, leading to prolonged downtime and increased risk of contaminating the optical and electrical components during maintenance.
Innovation Solution
A modular, plug-in accessory with an omni-directional light indicator that can be easily connected to the end cap of a light curtain, providing visual status indication without breaking the seal, allowing for rapid identification and isolation of faults or lockout conditions without the need for complex tools or control station access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional status indicators are installed in light curtain systems, then status information can be provided, but installation and replacement require breaking the seal on the chamber containing optical elements, which risks contaminating the components
Solution Approach 1:
The device separates the status indicator module from the sealed chamber containing optical elements. The indicator module is a standalone component that connects to the light curtain system through a sealed interface, allowing status indication functionality to be added without compromising the integrity of the sealed chamber.
Solution Approach 2:
A sealed connector or interface module serves as an intermediary between the status indicator and the light curtain system. This intermediary allows electrical and optical signals to pass through while maintaining the seal, enabling status indication without direct access to the sealed chamber.
2Difficulty of detecting and measuring
If status indicators are integrated into the light curtain system, then fault identification can be achieved, but the system complexity increases and requires access to control station for diagnosis
Solution Approach 1:
The status indicator module provides self-service fault identification by displaying system status and fault conditions through visual indicators that are directly observable without requiring access to control station interfaces or programming knowledge. The module autonomously monitors and communicates system state.
Solution Approach 2:
The device uses color-changing LEDs or similar visual indicators to communicate different system states and fault conditions. Different colors represent different statuses (e.g., green for normal, yellow for warning, red for fault), enabling rapid visual diagnosis without complex interfaces.
3Loss of time
If field replacement of status indicators is performed, then downtime can be reduced, but the risk of introducing contaminants increases
Solution Approach 1:
The status indicator is designed as a modular, field-replaceable component that connects to the light curtain system through a sealed interface. This segmentation allows the indicator to be replaced without opening or breaking the seal on the chamber containing optical elements, enabling quick field replacement without contamination risk.
Solution Approach 2:
The status indicator module is designed as a relatively simple, potentially disposable component that can be quickly replaced in the field. The low cost and simplicity of the indicator module justify its replacement without complex procedures, while the sealed interface ensures no contamination occurs during replacement.
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 solution enables rapid field installation and replacement of light curtain status indicators, reducing downtime, minimizing the risk of contaminating the light curtain components, and improving production uptime by allowing low-skilled operators to quickly identify and address issues visually, thus enhancing overall productivity.
Implementation Method 1
an omni-directional light indicator to illuminate a light signal indicative of a status of the light curtain
Data Source
AI summary
Apparatus and associated methods relate to a modular plug-in accessory including a connector for making pluggable electrical connection to a cascading electrical output port for providing cascading connection from an elongate light curtain, the accessory comprising an omni-directional light indicator to illuminate a light signal indicative of a status of the light curtain, wherein the accessory is configured to releasably make or break operative connection to the end cap containing the output port while the end cap is sealably connected to an end of the light curtain. In an illustrative example, the accessory may plug in directly to the terminal end of a light curtain. The receiving light curtain may be connected at the distal end of a string of light curtains. In some examples, the accessory may provide high visibility status indication information about any of the light curtain segments in the string of light curtains.