Movable Optical Sensor for Sheet Metal Plate Counting
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Solution Overview
Problem
Existing methods for conveying sheet metal plates into forming or working plants lack reliability and safety, particularly due to issues like plate adhesion and potential damage to tools when double or multiple plates are conveyed, which existing double plate control methods do not adequately address.
Innovation Solution
A method and device utilizing a signal-based arrangement of two sensor elements, one on a movable feeder and one fixed, to accurately determine the number of plates, ensuring high reliability and safety by preventing collisions and detecting double or multiple plates, with options for acoustic, capacitive, inductive, or optical sensors for plate number determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If weight-based double plate control is used to detect multiple plates, then plate adhesion can be detected, but the system lacks reliability and safety when plates change shape or size
Solution Approach 1:
The patent replaces mechanical/weight-based detection systems with optical sensor systems. Instead of using weight measurement to detect double plates, the invention uses optical sensors to directly measure plate presence and count, providing reliable detection that is not affected by plate shape or size variations.
Solution Approach 2:
The patent introduces optical sensor elements as intermediary devices between the plates and the detection system. These sensors act as mediators that convert physical plate presence into detectable optical signals, enabling accurate plate counting without direct mechanical contact or weight measurement.
2Device complexity
If fixed sensor elements are used for plate detection, then the structure is simple, but the feeder may collide with sensor elements when plate shape changes require feeder path modification
Solution Approach 1:
The patent applies dynamics by making the first sensor element movable, attached to the feeder rather than fixed. This allows the sensor to move with the feeder when plate shape changes require path modifications, preventing collisions while maintaining detection capability. The sensor system transitions from static to dynamic configuration.
Solution Approach 2:
The movable sensor element serves multiple functions: it detects plates during normal operation and simultaneously adapts to feeder path changes without requiring separate collision avoidance mechanisms. This multi-functionality reduces overall system complexity while improving reliability.
3Object-affected harmful factors
If double plate detection is implemented to prevent tool damage, then tool safety is improved, but the system lacks automatic stopping capability
Solution Approach 1:
The patent implements feedback by connecting the optical sensors to the feeder control system. When sensors detect an incorrect number of plates, the system automatically provides feedback to stop the feeder, creating a closed-loop control system that prevents tool damage and enables automatic operation.
Solution Approach 2:
The system performs preliminary detection of plate count before the feeder operates. By detecting the number of plates in advance using optical sensors and comparing it to the required number, the system prevents harmful actions (tool damage from multiple plates) before they can occur.
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 ensures high measuring accuracy and reliability, allowing for automatic stopping of plate conveying if an incorrect number of plates is detected, thereby preventing tool damage and ensuring safe operation.
Implementation Method 1
the sensor elements are acoustic sensor elements, particularly ultrasonic sensor elements
Implementation Method 2
a transmission signal passing through the plate is used
Data Source
AI summary
The invention relates to a method for the monitored conveying of sheet metal plates, particularly into a working or forming plant, in which a plate is taken up by a feeder from a first position and the plate and feeder are moved to a second position. According to the invention, during feeder movement to the second position a first sensor element located at the feeder, as well as a second sensor element located in the second position, are brought into a signal-based arrangement, and that on the basis of a measurement signal transmitted between the sensor elements the number of plates at the feeder and/or the second position is determined. The invention also relates to a device for the monitored conveying of plates, particularly into a forming plant.