Optical Sensor Device for Yarn Foreign Material Detection
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Solution Overview
Problem
Existing optical sensor devices for detecting foreign material in elongate textile bodies, such as yarn, face challenges in reliability and ease of assembly, particularly in compensating for positional deviations of the yarn within the measurement chamber.
Innovation Solution
The sensor device features a measurement chamber with light sources and detectors arranged alternately on opposite sides, ensuring that the signal is less dependent on the yarn's position, with at least one detector between two light sources on one side and one light source between two detectors on the opposite side, allowing for partial compensation of positional effects and facilitating easy assembly using carrier plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If light sources and detectors are arranged in a conventional configuration, then the device structure is simple, but the measurement signal is highly dependent on yarn position causing reliability issues
Solution Approach 1:
The device divides light sources and detectors into multiple groups arranged at different angular positions around the measurement chamber. Each light source-detector pair forms an independent measurement channel, segmenting the overall measurement system into multiple redundant channels that collectively improve reliability while managing complexity through modular arrangement.
Solution Approach 2:
The patent transitions from a linear arrangement of light sources and detectors to a radial/angular arrangement around the measurement chamber. By distributing components in multiple angular dimensions rather than a single line, the system compensates for yarn position variations from any direction, improving measurement reliability without proportionally increasing structural complexity.
2Reliability
If multiple light sources and detectors are arranged around the measurement chamber, then positional deviation effects are compensated, but assembly difficulty increases
Solution Approach 1:
Multiple light sources are integrated into a single light source unit or housing, and multiple detectors are combined into a detector unit or array. This merging approach maintains the angular distribution needed for positional compensation while reducing the number of separate components that need to be individually assembled, thereby improving assembly ease while preserving signal stability.
Solution Approach 2:
The measurement chamber design incorporates universal mounting features and standardized interfaces that allow the same structural components to accommodate multiple light sources and detectors at different angular positions. This multi-functional design enables easy assembly by using repeated modular elements rather than custom configurations for each component.
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 enhances the reliability and ease of assembly of the sensor device by minimizing the impact of yarn position deviations on measurement signals, ensuring accurate detection of foreign materials in elongate textile bodies.
Implementation Method 1
at least one of the detectors is used for measuring transmitted light
Implementation Method 2
at least one other detector is used to detect light reflected from the yarn
Data Source
Figure 1~2
Figure 3~4
AI summary
The sensor device comprises a support body (14) forming a measurement chamber (10) for receiving an elongate body (16), such as a yarn. Six light channels (26a - 26f) extend through the support body (14) to opposite peripheral sides (20a, 20b), where light sources (30a - 30c) and light detectors (32a - 32c) are arranged in alternating fashion on two carrier plates (34a, 34b). The sensor device can be used for detecting foreign material in the elongate body (16).