Modular Safety Mat with Segmented Sensor Cells
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Solution Overview
Problem
Existing safety mats for industrial production plants have limitations such as fixed size, non-homogeneous sensitivity, and inability to reliably detect unauthorized access in edge areas, making them unsuitable for large or complex systems and requiring improved sensor systems for targeted control.
Innovation Solution
A modular safety mat design featuring a rigid carrier body with a flexible, tactile active sensor surface and a separate evaluation unit, allowing for expandable coverage and reliable detection across the entire area, including edges, with the sensor system and housing structure separated to enhance sensitivity and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple step mat with two current-carrying plates is used, then the device complexity is low, but the measurement precision and reliability are insufficient, especially in edge areas
Solution Approach 1:
The sensor surface is divided into multiple independent sensor cells arranged in a matrix pattern, where each cell can independently detect pressure. This segmentation allows the system to achieve location-resolved detection and maintain high measurement precision across the entire surface including edge areas, while keeping individual sensor cells simple in structure
Solution Approach 2:
The patent replaces the simple mechanical deformation detection of traditional step mats with an electrical field-based detection system. Conductive plates are positioned at different heights, creating an electrical field that detects pressure through changes in electrical properties rather than relying solely on mechanical contact, thereby improving measurement precision
2Reliability
If the sensor active surface is completely separated from the housing structure, then the measurement precision and reliability are improved, but the device complexity increases due to separate mounting requirements
Solution Approach 1:
The sensor active surface is completely separated from the housing structure and divided into multiple independent sensor cells. This segmentation allows each sensor cell to be mounted independently on the housing, ensuring that detection reliability is not compromised by housing deformation while keeping the assembly process manageable through modular installation
Solution Approach 2:
The sensor active surface is extracted as a separate component from the housing structure, mounted independently on the housing surface. This extraction ensures that the sensor operates in a stable environment unaffected by housing deformation, improving detection reliability while the modular design keeps assembly complexity manageable
3Ease of manufacture
If traditional step mats are used, then the ease of manufacture is high, but the adaptability is limited, particularly for large areas and complex systems
Solution Approach 1:
The sensor surface is segmented into multiple identical sensor cells that can be arranged in various configurations. This segmentation allows the system to be manufactured using standardized components and then adapted to cover different areas and shapes by simply changing the arrangement pattern, thereby achieving both ease of manufacture and high adaptability
Solution Approach 2:
The sensor cells are designed as universal modular units that can be used in various configurations for different applications. Each sensor cell serves multiple purposes: detection, positioning, and signaling, allowing the same basic component to adapt to different area requirements and system complexities without requiring custom manufacturing
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 provides a modular, expandable, and reliable detection system with consistent sensitivity across the entire area, enabling effective monitoring of complex systems and ensuring safety by separating the sensor system from the housing structure, thus improving detection accuracy and durability.
Implementation Method 1
If a person steps on the safety mat, the panels and separators deform until there is a cross circuit between the panels
Data Source
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AI summary
A pressure-sensitive mat (10) for securing a technical installation (14), comprising a sensor (66), a rigid carrier body (48), and an evaluation unit (46). The sensor (66) has an active sensor surface (44) and a flexible connection area (70) for electrical contacting the sensor surface, which is formed at an edge of the active sensor surface (44). The carrier body (48) has a base (114) with a top surface (50) and an adjoining side surface (52), wherein the evaluation unit (46) is arranged inside the carrier body below the active sensor surface (44) and is configured to generate an output signal depending on the actuation of the active sensor surface (44). The active sensor surface (44) completely covers the top (50) of the base (114) of the carrier body (48) and the connection area (70) of the sensor (66) is folded over by 180° on the side surface (52) and led into the interior of the carrier body (48).