Photoelectric Sensor with Reference Area for Mispositioning Detection
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Solution Overview
Problem
Conventional photoelectric sensors fail to detect objects within a predetermined detection area if the scanning area is incorrectly set or positioned, leading to potential accidents due to undetected objects in uncovered areas.
Innovation Solution
A photoelectric sensor system that defines both a detection area and a reference area within a scanning plane, using optical scanners and photoelectric transducers to emit and receive light, and provides enable or disable signals based on object presence in these areas, ensuring accurate detection and preventing accidental operation of hazardous apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single detection area is used for safety monitoring, then the system is simple to operate, but the system fails to detect objects when the scanning area is mispositioned or incorrectly set
Solution Approach 1:
The patent divides the scanning area into multiple distinct regions: a first detection area for monitoring object approach, a second detection area for confirming object presence, and a reference area for verifying sensor positioning. This segmentation allows the system to reliably detect objects even when partially mispositioned, as long as some portion of the scanning area correctly covers the hazardous zone.
Solution Approach 2:
The system performs preliminary detection in the reference area to verify correct sensor positioning before enabling full operation. By checking for reference objects in advance, the system prevents false negatives caused by mispositioning, ensuring detection reliability before the apparatus begins hazardous operations.
2Reliability
If the scanning area is expanded to cover all possible object locations, then detection coverage is improved, but the system cannot distinguish between intended and unintended objects
Solution Approach 1:
The patent segments the scanning area into functionally distinct zones with different detection criteria. The first and second detection areas monitor for objects in the hazardous zone, while the reference area monitors for known reference objects. This segmentation enables the system to differentiate between intended objects (reference objects in the reference area) and unintended objects (objects in detection areas), maintaining detection accuracy without losing object identification information.
Solution Approach 2:
Different regions of the scanning area are assigned different detection qualities and purposes. The reference area has the quality of containing known, expected objects used for positioning verification, while the detection areas monitor for unknown, potentially hazardous objects. This local quality differentiation allows the system to distinguish between intended and unintended objects based on their spatial location and expected presence.
3Ease of operation
If the sensor operates without position verification, then the system is easier to operate, but accidental mispositioning leads to undetected objects in uncovered areas
Solution Approach 1:
The system performs preliminary verification by detecting reference objects in the reference area before enabling normal operation. This preliminary action automatically confirms correct sensor positioning without requiring manual intervention or complex alignment procedures, maintaining ease of operation while ensuring detection coverage reliability.
Solution Approach 2:
The sensor system performs self-verification by automatically detecting reference objects and confirming its own correct positioning. This self-service capability eliminates the need for external alignment tools or manual positioning verification, making the system easy to install and operate while ensuring reliable detection coverage through automatic position confirmation.
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 system reliably secures safety by preventing undesirable objects from accessing hazardous areas, even when the sensor is mispositioned, by differentiating between intended and unintended objects, thus enhancing operational safety.
Implementation Method 1
receive a scanning light beam reflected by an object located in the measurement area
Implementation Method 2
receive a scanning light beam reflected by an object located in the measurement area, thereby detecting the presence or the absence of an object within the object detection area based on a signal representing an intensity of the reflected scanning light beam
Data Source
AI summary
A photoelectric sensor according to the present invention, performs a determination as to whether or not an object is present in a predetermined detection area and provides (1) a enable signal to enable operation related to a hazardous source and (2) a disable signal to disable the operation based on a result of the determination. The photoelectric sensor determines whether or not the object is present within the predetermined detection area and whether or not the object is present at a reference point which is a different location within a measurement area from the predetermined detection area, based on a position information; and provides the enable signal when the object is absent from the predetermined detection area but the object is present at the reference point, and provides the disable signal when the object is present within the predetermined detection area and the object is absent at the reference point.