Optical Sensor Rotating Test Detector 360 Transparency
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Solution Overview
Problem
Existing optical sensors using the transit time principle face challenges in ensuring complete transparency and functionality of the separating disk, particularly in detecting contamination or damage, which can lead to inaccurate object detection due to incomplete monitoring of the disk's 360° peripheral range.
Innovation Solution
The optical sensor incorporates a rotating test detector and test light source aligned with the passage areas of the separating disk, utilizing a reflector element outside the housing to enable continuous and circumferential monitoring, allowing for comprehensive assessment of the disk's optical transparency across 360°, and positions the light source and detector rigidly on a rotor for simultaneous rotation, eliminating wobbling errors and enabling a 360° scanning range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a curved separating disk is used with test light radiated through it at several points, then some transparency monitoring is achieved, but complete check over the entire peripheral range of 360° is not possible
Solution Approach 1:
The patent applies the dynamics principle by making the test light source and test detector rotate together with the rotor at the same rotational speed. This dynamic configuration allows the test beam to continuously scan the entire peripheral range of the separating disk, achieving complete 360° coverage. The rotating test device transforms a static limited-point monitoring system into a dynamic comprehensive monitoring system, resolving the contradiction between monitoring coverage and device complexity.
2Ease of operation
If the light source and detector are positioned separately, then the beam direction can be rotated, but wobbling errors occur and blind spots are created
Solution Approach 1:
The patent merges the light source, detector, and mirror into a single integrated rotor assembly that rotates together as one unit. This combination eliminates the wobbling errors that occur when components are positioned separately and rotated independently. The unified rotor structure ensures that the beam direction rotates smoothly without deviation, eliminating blind spots and improving measurement reliability while maintaining the ease of beam direction rotation.
Solution Approach 2:
By positioning the light source and detector on the rotating rotor and having them rotate together with the beam direction, the system dynamically maintains proper alignment throughout the rotation cycle. This dynamic configuration eliminates the static alignment problems that cause wobbling errors, ensuring continuous accurate measurement without blind spots.
3Reliability
If the separating disk is monitored at multiple points, then more comprehensive checking is achieved, but complete circumferential monitoring is still not possible
Solution Approach 1:
The rotating test device transforms multiple discrete monitoring points into a continuous circumferential monitoring system. As the test light source and detector rotate with the rotor, the test beam sweeps across the entire perimeter of the separating disk, achieving complete 360° coverage. This dynamic approach significantly improves productivity by monitoring the entire disk circumference continuously rather than checking multiple fixed points intermittently.
Solution Approach 2:
The patent implements continuous monitoring of the separating disk by having the test beam continuously scan the entire peripheral range during rotor rotation. This continuous useful action ensures that no section of the disk goes unmonitored, achieving complete circumferential coverage and improving both reliability and productivity compared to discrete point checking.
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 configuration significantly enhances operational reliability by ensuring complete monitoring of the separating disk's transparency and allows for higher rotation frequencies, reducing mechanical and air turbulence, and eliminating blind spots, thereby improving measurement accuracy and efficiency across the entire scanning range.
Implementation Method 1
A light source for emitting transmitted light pulses (22) into a monitoring area (12)
Implementation Method 2
a detector (50) for detecting light pulses (26) that are reflected by objects (10) in the monitoring area (12)
Implementation Method 3
a test light source (54), which is also arranged on the rotor (40), to provide the test light (53)
Implementation Method 4
at least one reflector element (80) is arranged outside of the housing (60), at which the test light (53) is aligned, and that the test detector (52) is suitably positioned for detecting test light (55) reflected back from the reflector element (80)
Data Source
Figure 1
AI summary
The optical sensor (100) has test detector mounted on rotor (40) rotated along the rotation axis, which is arranged in inner surface of the sensor. The test detector is oriented towards regions of partitioning screen (66) through which the emergent light pulses and reflected light pulses pass. A test light source (54) supplying emergent light pulses, is mounted on the rotor. A reflector element (80) to which the test light is directed, is arranged outside housing (60). The test light reflected by reflector element is detected from the test detector.