Optical Position Sensor for Plastic Container Machine
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Solution Overview
Problem
Current methods for controlling the displacement of movable elements in plastic container manufacturing machines are inefficient, relying on operator expertise for noise-based detection, vibration sensors that are costly and complex, and on/off sensors that only allow for remedial maintenance, leading to increased downtime and maintenance costs.
Innovation Solution
A device with a distance sensor that continuously measures the displacement of a movable element relative to a fixed reference point, using either inductive or optical sensors, to detect deviations and send warnings for predictive maintenance, reducing the risk of machine failure and downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vibration sensors are used to detect machine deviations, then predictive maintenance capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex vibration sensors with a simple optical sensor system that uses a light source and photodetector to monitor the position of the movable element. This substitution of mechanical sensing with optical sensing achieves predictive maintenance capability while dramatically reducing device complexity and cost.
Solution Approach 2:
The patent employs inexpensive optical components (LED light source, photodetector, and transparent scale) instead of expensive vibration sensors. These simple optical elements can be easily replaced if needed, providing a cost-effective solution for continuous position monitoring that enables predictive maintenance without high investment.
2Loss of time
If vibration sensors are used for predictive maintenance, then machine downtime is reduced, but signal processing complexity and cost increase
Solution Approach 1:
The patent replaces vibration-based sensing requiring complex signal processing with direct optical position measurement. The transparent scale with markings provides immediate positional information that is easily detected by the photodetector, eliminating the need for complex vibratory analysis and signal filtering algorithms.
Solution Approach 2:
The patent creates a visual copy of the position information through the transparent scale with optical markings. This physical/optical copy of position data can be directly read by the photodetector without requiring complex processing, simplifying the system while enabling continuous monitoring for predictive maintenance.
3Ease of manufacture
If on/off sensors are used to detect positioning, then device cost is reduced, but maintenance capability becomes remedial rather than predictive
Solution Approach 1:
The patent enables preliminary detection of position deviations before they cause machine failure. By continuously monitoring the position of the movable element against the transparent scale, the system detects wear and misalignment trends early, allowing maintenance to be scheduled proactively rather than reactively after breakdown occurs.
Solution Approach 2:
The patent implements continuous feedback monitoring of the movable element's position through the optical sensor system. This ongoing feedback allows the system to track position deviations over time, identifying trends that indicate wear or misalignment, thereby transforming maintenance from remedial to predictive while keeping sensor costs low.
4Reliability
If continuous position monitoring is implemented, then predictive maintenance is enabled, but device complexity increases
Solution Approach 1:
The patent segments the monitoring function into simple, discrete components: a transparent scale with position markings, an optical light source, and a photodetector. This segmentation of the monitoring system into basic optical elements reduces overall complexity while enabling continuous position tracking for predictive maintenance.
Solution Approach 2:
The patent substitutes complex mechanical position sensing mechanisms with a simple optical system. The transparent scale with optical markings replaces complex encoders or potentiometers, and the photodetector replaces complex position sensors, achieving continuous monitoring with minimal complexity.
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 predictive maintenance, reduces downtime and maintenance costs, and provides a more precise and cost-effective method for monitoring and adjusting the machine's operation, avoiding excessive damage and allowing for planned maintenance.
Implementation Method 1
The sensor is of the inductive type
Implementation Method 2
the sensor is of the optical type
Data Source
AI summary
A plastic container manufacturing machine, comprising a chassis having a camway with a cam and a countercam and an element which is movable relative to the chassis, bearing a roller interacting with the camway so as to ensure the displacement of the movable element, wherein the machine also comprises a device for controlling the displacement of the movable element, wherein the countercam has at least one portion which is movable relative to the chassis, and wherein the control device incorporates a distance sensor that continuously measures the distance of a movable portion of the countercam relative to a fixed reference point on the chassis.