Photoelectric Sensor Light Spot Overlap via Depth Dimensionality
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Solution Overview
Problem
Photoelectric sensors with RGB LED light sources face issues due to non-overlapping light spots, leading to decreased performance and accuracy, as well as aesthetic problems, and existing solutions either reduce brightness or are costly.
Innovation Solution
A photoelectric sensor design that includes an emitter emitting multiple light beams, with an optically powered surface and two bodies positioned to ensure overlap of light spots on the target, while maintaining brightness, using a method that involves passing fractions of light beams through transparent and opaque portions to focus them effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an RGB LED light source is used in a photoelectric sensor, then the sensor can detect marks with varying reflectivity and color, but the light spots from the three different diodes do not overlap, resulting in decreased performance and accuracy
Solution Approach 1:
The patent introduces a new spatial dimension by positioning the red, green, and blue diodes at different depths along the optical axis rather than simply arranging them side-by-side. This depth dimensionality allows the light spots to overlap on the target surface while maintaining color differentiation, thereby resolving the contradiction between versatility and measurement precision
Solution Approach 2:
The patent changes the spatial parameter of diode positioning by adjusting the distance of each diode from the optically powered surface. By varying these distances, the light spots from different colored diodes are focused to overlap at the same location on the target, enabling both color differentiation and precise measurement
2Measurement precision
If the light spots from different diodes are made to overlap, then sensor accuracy improves, but the brightness of the collective light spot is reduced
Solution Approach 1:
The patent applies local quality by allowing different regions of the optical path to have different properties. Specifically, the optically powered surface is positioned at different distances from each diode, creating localized optical conditions that focus each color's light spot to the same location while maintaining individual brightness, thus achieving both accuracy and illumination intensity
3Measurement precision
If known solutions are used to address light spot overlap, then overlap is achieved, but the solutions are either costly or reduce brightness significantly
Solution Approach 1:
The patent employs self-service by using the optically powered surface itself to focus the light spots rather than requiring separate external lenses for each diode. This integrated approach achieves light spot overlap without adding costly components, and the natural focusing action maintains brightness while enabling precise overlap
Solution Approach 2:
The optically powered surface serves multiple functions simultaneously: it acts as the detection surface for the photoelectric sensor and also functions as the focusing element for all three colored diodes. This multi-functionality eliminates the need for separate lenses, reducing cost while achieving the desired light spot overlap
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 solution achieves a sharp and bright collective light spot on the target, improving sensor performance and accuracy by ensuring overlap of light spots without reducing brightness, and can be implemented using affordable technologies.
Implementation Method 1
The photoelectric sensor focuses the collective light spot on the target such that respective light spots of each of the multiple light beams overlap on the target
Data Source
AI summary
A photoelectric sensor includes an emitter that emits a plurality of light beams. Fractions thereof pass through transparent portions of a first body and a second body in series before intersecting an optically powered surface, which directs the fractions to a target focusing an image that passes through a perimeter of the first body in one direction and focusing an image that passes through a perimeter of the second body in a perpendicular direction. The emitter, first and second bodies, and the optically powered surface are positioned so as to form a light spot on the target within which the fractions of the plurality of light beams substantially overlap. The fractions of the plurality of light beams reflect off of the target and are received by a receiver, which detects changes in the light to determine whether a mark is present on the target.