Photo Receiver Laser Beam Alignment Monitoring
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Solution Overview
Problem
Existing laser-based systems for detecting double parts during transport and machine loading face challenges in process reliability due to misalignment, vibration, and potential measurement errors, which can lead to incorrect detection of material presence and thickness, especially when the laser beam is interrupted.
Innovation Solution
Incorporating a photo receiver to monitor the laser beam and detect any misalignment or absence of material between the laser sensors, ensuring that measurements are only taken when the laser beam is correctly received and aligned, and using optical shielding to prevent erroneous interpretations from scattered light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two laser sensors are used to measure thickness by calculating the difference between distances, then measurement capability is improved, but measurement precision deteriorates due to alignment errors and vibrations
Solution Approach 1:
A laser beam intermediary is introduced between the two laser sensors to monitor alignment. The beam acts as a mediator that detects misalignment conditions and triggers a fault signal, preventing inaccurate measurements without requiring complex real-time alignment correction mechanisms
Solution Approach 2:
The system implements feedback by continuously monitoring the laser beam alignment status and using this information to control measurement execution. When misalignment is detected through the laser beam monitor, the system generates a fault signal that prevents thickness measurement, ensuring only valid measurements are performed
2Reliability
If continuous monitoring of laser beam alignment is implemented, then reliability is improved, but device complexity increases
Solution Approach 1:
The laser beam serves as a simple intermediary monitor that provides alignment information without requiring complex sensors or additional hardware. The beam itself indicates misalignment when deviated, offering a low-complexity solution for continuous monitoring
Solution Approach 2:
The laser beam self-monitors its own alignment status through its propagation characteristics. When the beam is misaligned, it naturally deviates or fails to reach the expected position, providing self-diagnostic information without requiring external monitoring equipment
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 approach significantly enhances process reliability by unambiguously determining the presence or absence of material and maintaining accurate alignment, reducing measurement errors and ensuring continuous fault detection, thereby improving the reliability of double part detection.
Implementation Method 1
each having a laser source and a detector between which the parts pass
Implementation Method 2
the relevant laser beam is detected by means of a photo receiver situated opposite one of the two laser sources
Data Source
AI summary
The invention relates to the positioning of an additional photo receiver in addition to the known laser sensors for detecting double parts during transport and during the loading of machines, which are situated opposite each other. The additional photo receiver receives the laser beam from a laser sensor located opposite, exactly when there is no material in the measuring gap and the two laser sensors are precisely aligned. This arrangement makes it possible to improve the measuring process and the analysis of the measurement, and thereby increases process reliability during the monitoring of transport and the loading of machines.