Optical Sensor Pane Contamination Detection via Rotating Test Unit
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Solution Overview
Problem
Optical sensors used in safety technology face reliability issues due to external environmental influences, such as dirt and damage on the pane, which impede light beam transmission and hinder accurate object detection.
Innovation Solution
An optical sensor design with a test unit that includes stationary test transmitters and detectors, along with a rotating body with guide means, allows for comprehensive pane monitoring by emitting test light beams through different areas and evaluating their reflection to assess pane permeability and component functionality, generating warnings for maintenance if impairments are detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a test unit is used to check pane contamination, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The test unit is divided into multiple independent test transmitters, each responsible for illuminating a specific sector of the pane. This segmentation allows comprehensive pane coverage while keeping each transmitter relatively simple in structure.
Solution Approach 2:
The rotating body serves multiple functions: it positions the test transmitters, guides the test light beams through the pane, and directs reflected beams to the detector. This multi-functionality reduces the need for separate components, thereby reducing overall device complexity.
2Reliability
If multiple test transmitters are used to cover different pane areas, then reliability is improved, but device complexity increases
Solution Approach 1:
Multiple test transmitters are integrated into a single rotating body structure, which is driven by one motor. The transmitters, guide means, and detector are all mounted on this common rotating platform, merging what would otherwise be separate assemblies into one unified mechanism.
Solution Approach 2:
The test unit employs rotational movement to dynamically position the test transmitters and guide means relative to the pane and detector. This dynamic approach allows a limited number of physical components to achieve comprehensive coverage of the entire pane surface over time.
3Measurement precision
If a rotating body with guide means is used to direct test beams, then measurement precision is improved, but ease of operation worsens
Solution Approach 1:
The rotating body is designed with through-bores and guide means that pre-establish precise optical paths for the test light beams. This preliminary structural arrangement ensures accurate beam positioning without requiring complex active control or adjustment mechanisms during operation.
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 design significantly enhances the functional reliability of optical sensors by ensuring thorough pane inspection and component checks, enabling timely maintenance and preventing system malfunctions, especially in safety-critical applications.
Implementation Method 1
test light beams emitted by a test transmitter pass through the pane, hit the reflector unit and are guided from there through the pane to the test detector
Implementation Method 2
test light beams emitted by a test transmitter pass through the pane, hit the reflector unit and are guided from there through the pane to the test detector
Data Source
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AI summary
The invention relates to an optical sensor (1) for detecting objects in a monitoring area, comprising a housing (3) and a transmitter/receiver unit (6) arranged within the housing (3). Light beams (8) emitted by a transmitter (9) of the transmitter/receiver unit (6) are periodically guided within the monitoring area and pass through a disk. Light beams (8) reflected back from an object are guided through the disk to a receiver (10) of the transmitter/receiver unit (6). In an evaluation unit, received signals from the receiver (10) are evaluated to generate an object detection signal. A test unit is provided for checking the transmittance of the disk. The test unit has several test transmitters (13) arranged stationary within the housing (3), the test light beams (15) of which are directed at different areas of the disk.The test unit has a reflector unit arranged outside the housing (3), onto which the test light beams (15) from the test transmitters (13) are directed. Each test transmitter (13) is assigned a test detector (18) as a further component of the test unit in a detection position, such that the test light beams (15) emitted by this test transmitter (13) pass through the disk, strike the reflector unit, and are guided from there through the disk to the test detector (16). A reference measurement is performed with the test detector (16) or another test detector (18), whereby the test light beams (15) emitted by a test transmitter (13) are guided via a reference path to this test detector (16, 18).