Optical Sensor Reading Gate Sleep Control for Overheat Prevention

Solution Overview

Problem

Optical sensors used in conveyor systems face high thermal stress and potential failure due to prolonged activation of the reading gate when the conveyor system stops, leading to increased downtime and design complexity when temperature sensors are used for protection.

Innovation Solution

Implement a reading gate control system with a time- or event-controlled mechanism that activates a sleep mode when camera parameters reach a limit, reducing power consumption and thermal load by switching electronic components to an energy-saving mode.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a temperature sensor and switch-off mechanism are used to protect the camera from overheating, then the camera is protected from damage, but the optical sensor experiences long periods of downtime which significantly limits its availability

Engineering Contradiction:

Improvecamera protection from damageVSAvoiddowntime of optical sensor

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent implements dynamic operation modes for the camera: normal mode for active code detection and sleep mode for energy-saving and thermal management. The camera dynamically transitions between these modes based on operational conditions, allowing it to reduce power consumption and cooling requirements during sleep mode, thereby minimizing downtime while protected from overheating damage

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent employs periodic activation of the reading gate and corresponding periodic switching between normal and sleep modes. The camera operates in normal mode only during active reading gates when code detection is required, then transitions to sleep mode periodically, creating a rhythm of operation that prevents continuous thermal buildup while maintaining operational availability

Inventive Principle:

Principle #19Periodic action

2Loss of time

If heat sinks and fans are attached to the optical sensor to reduce downtime, then the availability is improved, but the design complexity of the sensor arrangement increases undesirably

Engineering Contradiction:

Improvedowntime of optical sensorVSAvoiddesign complexity of sensor arrangement

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The patent replaces mechanical thermal management systems (heat sinks and fans) with an electronic control system that manages thermal loads through software-controlled mode switching. The control unit monitors operational states and dynamically switches the camera between normal and sleep modes, eliminating the need for additional mechanical cooling components and their associated complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes operational parameters of the camera by switching between different power consumption states. During sleep mode, the camera reduces its power consumption and thermal output through parameter changes in its operation, allowing thermal management without additional hardware. This parameter-based approach simplifies the overall design by avoiding mechanical cooling systems

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the reading gate remains permanently open when the conveyor stops, then the optical sensor can detect objects, but the electronic components operate at full power leading to increased thermal stress and potential failure

Engineering Contradiction:

Improvedetection capabilityVSAvoidthermal stress on electronic components

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent implements dynamic operation modes for the camera: normal mode for active code detection and sleep mode for energy-saving and thermal management. The camera dynamically transitions between these modes based on operational conditions, allowing it to reduce power consumption and cooling requirements during sleep mode, thereby minimizing downtime while protected from overheating damage

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent employs periodic activation of the reading gate and corresponding periodic switching between normal and sleep modes. The camera operates in normal mode only during active reading gates when code detection is required, then transitions to sleep mode periodically, creating a rhythm of operation that prevents continuous thermal buildup while maintaining operational availability

Inventive Principle:

Principle #23Feedback

Data Source

PatentEP4675314A1Sensor assembly

Publication Date: 2026.01.07 LEUZE ELECTRONIC GMBH & CO KG

Figure 1~2
Figure 3~4

AI summary

The invention relates to a sensor arrangement (10) with an optical sensor (1) including electronic components, comprising a receiver unit in the form of a camera (2) and a control and evaluation unit (4) designed for evaluating image signals from the camera (2). A reading gate defined by a time interval can be activated. When the reading gate is activated, the electronic components operate in normal mode, in which features of or on objects (12) are detected and recorded. When the reading gate is activated, a sleep mode is activated if at least one camera parameter of the camera (2) reaches a limit value, in which the electronic components are switched from normal operation to an energy-saving mode.