Automated Moving Light Test System with Conveyor and Sensors
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Solution Overview
Problem
The existing methods for testing and inventorying automated lights upon return are inconsistent and prone to human error, leading to inefficiencies and inaccuracies in determining their readiness for re-rental and maintaining proper stock levels.
Innovation Solution
An automated moving light test system that uses a conveyor with multiple stations for testing, connected to a central computer, which performs a series of tests including barcode scanning, gobo recognition, color wheel analysis, movement testing, noise evaluation, and airflow assessment to determine the light's condition and maintain inventory records.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection methods are used to test lights upon return, then the testing process is simple and quick, but the accuracy and consistency of testing deteriorates due to human error
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated testing system that uses computers, sensors, and conveyor mechanisms to objectively measure and evaluate light conditions, thereby improving measurement precision while accepting increased system complexity
Solution Approach 2:
The testing system performs self-service through automated execution of test protocols without human intervention, where the system independently conducts inspections, records data, and determines light readiness for re-rental, eliminating human error in the process
2Reliability
If automated testing systems are implemented, then testing accuracy and consistency improve, but the complexity of the testing system increases
Solution Approach 1:
The testing system is divided into multiple functional modules including barcode scanning, gobo recognition, color wheel analysis, movement testing, noise evaluation, and airflow assessment. Each module performs a specific test function independently, which improves reliability through specialized functionality while managing overall system complexity through modular architecture
3Manufacturing precision
If comprehensive testing is performed on all light components, then the completeness of inspection improves, but the time required for testing increases
Solution Approach 1:
The testing process operates continuously as lights move through the conveyor system, with multiple tests conducted in sequence without interruption. The system maintains continuous monitoring and testing from barcode scanning through airflow assessment, ensuring comprehensive inspection while minimizing idle time between tests
Solution Approach 2:
The system performs preliminary actions by conducting quick barcode scanning and initial light-on checks immediately upon light arrival, before proceeding to more time-consuming tests. This staged approach ensures critical identification data is captured first, then allows subsequent comprehensive testing to proceed efficiently
Data Source
AI summary
A moving light tester includes plural sensors, each of which can test a function of the moving light. A conveyor can move the light between the sensors. Once tested, information about the test is used to characterize the light, to determine if it needs repair, or can be re rented. The information can also be used to create inventory lists, and bills for damage. The testing can include automated testing for gobos, colors, noise, heating and movement, or other tests.