Optical Sensor Triangulation Evaluation Zones
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Solution Overview
Problem
Existing optical sensors require multiple units for parallel detection of objects, leading to increased costs and time-consuming reconfiguration when application changes occur, and they often struggle with reliable and efficient detection of objects amidst background structures and interference.
Innovation Solution
An optical sensor with a matrix-shaped receiver and a transmitter that emits a constant line of light, using the triangulation principle for distance profiling and binary status information generation within evaluation windows, allowing for simultaneous detection of multiple objects without moving parts and enabling adaptable parameterization for different applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple individual optical sensors are used for parallel detection of objects on conveyor belt tracks, then each object can be detected locally on a track, but the costs increase very quickly and all sensors have to be reset and parameterized when changes are made to the application
Solution Approach 1:
The patent divides the monitoring area into multiple evaluation zones (first, second, third evaluation zones) along the light line, allowing a single sensor to detect objects in different positions simultaneously. This segmentation of the detection space replaces the need for multiple physical sensors with one sensor that processes spatially separated evaluation zones
Solution Approach 2:
The single optical sensor is designed to perform multiple detection functions across different evaluation zones and object types. By configuring multiple evaluation zones with different parameters (window sizes, sensitivity thresholds) within one sensor, it can detect various objects (containers, pallets, boxes) in different positions, replacing what would otherwise require multiple dedicated sensors
2Productivity
If multiple individual optical sensors are used for parallel detection, then simultaneous detection of objects is achieved, but the expenditure of time for resetting and parameterizing all sensors increases considerably
Solution Approach 1:
The patent combines multiple sensor functions into a single optical sensor by implementing multiple evaluation zones within one device. This merging allows all evaluation zones to be configured and parameterized simultaneously through a single interface, eliminating the time required to individually reset and parameterize multiple separate sensors while maintaining simultaneous detection capability across all zones
3Measurement precision
If a line of light is generated on an object structure for distance profiling, then distance information can be obtained, but it is difficult to reliably detect objects amidst background structures and interference
Solution Approach 1:
The patent applies different evaluation criteria and parameters to different evaluation zones along the light line. Each zone can have customized window sizes, sensitivity thresholds, and evaluation algorithms tailored to the specific object types and background conditions in that region. This local optimization of detection parameters improves reliability by adapting to local characteristics rather than using uniform settings across the entire detection area
Solution Approach 2:
The evaluation windows and detection parameters can be dynamically adjusted based on the detected signal characteristics and background conditions. The system can adaptively modify window sizes, sensitivity levels, and evaluation thresholds in real-time to maintain reliable object detection despite variations in lighting, object positions, and background interference
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 reliable, precise, and efficient detection of objects with reduced computing time, improved sensitivity against interference, and easy adaptation to changing conditions, while minimizing costs by eliminating the need for multiple sensors and simplifying parameter adjustments.
Implementation Method 1
a transmission unit which emits light beams (2) and forms a line of light (5) on an object structure to be detected
Implementation Method 2
a receiver (8) having a matrix-shaped arrangement of reception elements... Distance values and thus height profiles of objects are determined
Implementation Method 3
Distance values and thus height profiles of objects are determined by means of a triangulation method
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The sensor (1) has a transmission unit for emitting light beams (2) that form a light line on an object structure to be detected, where the light line is represented on a receiver. An evaluation unit determines a distance profile of the structure by evaluating receiving signals of receiving elements of the receiver based on a triangulation principle. Evaluation windows (12.1-12.8) are generated in the evaluation unit, and are comprised of local- and remote areas in two directions, respectively, where binary state information is generated by evaluation of object points falling in the windows.