Self-Cleaning Optical Sensor Shielding for Debris and Static

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Solution Overview

Problem

Photo eye sensors in gypsum manufacturing are impaired by debris and static charge, leading to performance issues and requiring labor-intensive manual cleaning, which disrupts the manufacturing process.

Innovation Solution

A shielding apparatus with a housing assembly and fan system is used to deflect debris and ionize air to prevent accumulation on the lens, maintaining sensor effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual cleaning of photo eye sensors is performed, then sensor performance is maintained, but manufacturing time is lost and labor requirements increase

Engineering Contradiction:
Improvesensor performanceVSAvoidmanufacturing time
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The system uses automated air blowers and ionization devices to self-clean the sensor lens, eliminating the need for manual intervention. The sensor assembly performs its own maintenance by using powered air to deflect debris and ionized air to prevent static charge accumulation, thereby maintaining sensor performance without stopping the manufacturing line.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The air blower and ionization device perform preliminary cleaning actions continuously or periodically before debris accumulates to problematic levels. By proactively removing debris and preventing static charge buildup in advance, the system avoids sensor occlusion and maintains continuous operation without requiring reactive manual cleaning.

Inventive Principle:
Principle #10Preliminary action

2Reliability

If manual cleaning of photo eye sensors is performed, then sensor performance is maintained, but labor requirements increase

Engineering Contradiction:
Improvesensor performanceVSAvoidlabor requirements
Core Design Contradiction:
ReliabilityVSEase of operation

Solution Approach 1:

The system uses automated air blowers and ionization devices to self-clean the sensor lens, eliminating the need for manual intervention. The sensor assembly performs its own maintenance by using powered air to deflect debris and ionized air to prevent static charge accumulation, thereby maintaining sensor performance without stopping the manufacturing line.

Inventive Principle:
Principle #25Self-service

3Productivity

If photo eye sensors are exposed to debris environment, then manufacturing operations can continue, but sensor effectiveness is impaired

Engineering Contradiction:
Improvemanufacturing operationsVSAvoidsensor effectiveness
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The air blower and ionization device act as intermediary protective elements between the sensor lens and the debris-containing manufacturing environment. These intermediaries continuously remove debris and neutralize static charge, creating a protective barrier that allows the sensor to operate effectively despite being exposed to a harsh environment with constant debris generation.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The air blower and ionization device operate continuously or at regular intervals to maintain constant protection of the sensor lens. This continuous action ensures that debris is constantly deflected and static charge is continuously neutralized, maintaining sensor effectiveness throughout the manufacturing process without interruption.

Inventive Principle:
Principle #20Continuity of useful action

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 apparatus effectively prevents debris and static charge from affecting photo eye sensors, reducing manual cleaning needs and ensuring continuous manufacturing operations.

Implementation Method 1

a fan assembly. In further embodiments, the fan assembly may include a fan having an airflow opening and a fan housing

Methodology Applied
Scientific EffectAirflow:

Implementation Method 2

one or more ionizer units configured to ionize air passing through the at least one airflow passage

Methodology Applied
Scientific EffectIonization: Ionisation

Data Source

PatentUS20250370249A1Apparatuses and systems for shielding an optical sensor, self-cleaning optical sensor assembly, and methods of using the same
Publication Date: 2025.12.04 GEORGIA PACIFIC GYPSUM LLC
  • US20250370249A1 patent drawing
  • US20250370249A1 patent drawing
  • US20250370249A1 patent drawing

AI summary

Methods, apparatuses, assemblies, and/or the like are provided. An example apparatus may include a housing assembly including a first component and a second component configured for selective attachment to the first component, the first component having a first annular portion and the second component having a second annular portion opposite the first annular portion, the first and second annular portions collectively defining a central opening of the housing assembly, the central opening defining a longitudinal axis of the housing assembly. An example apparatus may also include a fan assembly, which may include a fan having an airflow opening and a fan housing, wherein: the second component has a curved portion extending from the second annular portion and along the longitudinal axis, the curved portion having an opening formed therethrough, the opening defining at least one airflow passage extending from an exterior surface of the curved portion to an interior surface.