Photoelectric Sensor Welded Optical Module for Vibration Sealing
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Solution Overview
Problem
Existing photoelectric sensors face challenges in connecting optical modules to the housing with a simple, cost-effective method that provides increased vibration and shock resistance while ensuring effective sealing and minimal mechanical stress.
Innovation Solution
The photoelectric sensor employs a laser penetration welding process to create a welded connection between a plastic housing and optical module, using compatible thermoplastics with infrared-absorbing additives at contact points, allowing for a non-contact energy application that forms a strong, stable bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive bonding or ultrasonic welding is used to connect the protective screen to the aluminum profile, then the connection strength is improved, but the device complexity and manufacturing cost increase due to additional sealing requirements and multiple production steps
Solution Approach 1:
The patent combines the protective screen and housing into a single integrated plastic component, eliminating the need for separate connection and sealing steps. The protective screen is formed as an integral part of the housing during molding, which simplifies the production process while maintaining connection strength through the unified structure.
Solution Approach 2:
The plastic housing serves multiple functions simultaneously: it provides structural support, acts as the protective screen, and creates the sealing environment for the optical module. This multi-functionality eliminates the need for separate protective screens and sealing components, reducing device complexity while maintaining strength.
2Ease of operation
If mechanical fastening methods are used to attach the optical module to the housing, then the assembly ease is improved, but the vibration and shock resistance deteriorates due to the mechanical weak points created
Solution Approach 1:
The patent replaces mechanical fastening methods with ultrasonic welding to attach the optical module to the housing. This substitution eliminates mechanical weak points and provides a more reliable connection that better resists vibration and shock, while still maintaining ease of assembly through the efficient ultrasonic welding process.
3Strength
If the housing is made of aluminum with openings, then the structural strength is improved, but the sealing effectiveness deteriorates requiring additional protective measures
Solution Approach 1:
The patent changes the material parameter from aluminum to plastic, which enables the housing to be molded as a seamless, splash-proof structure. This material parameter change allows the housing to provide both structural strength and effective sealing without requiring additional protective measures.
Solution Approach 2:
The plastic housing integrates multiple functions including structural support, protection, and sealing in a single component. The seamless molded structure provides splash protection inherently, eliminating the need for separate sealing measures while maintaining structural integrity.
4Reliability
If multiple connection points are used to attach the optical module, then the vibration and shock resistance is improved, but the manufacturing cost increases due to additional sealing requirements at each connection point
Solution Approach 1:
The patent uses ultrasonic welding to create strong, reliable connections between the optical module and housing without requiring multiple sealed connection points. The ultrasonic welding process provides vibration and shock resistance through a unified welded structure, eliminating the need for separate sealing components and reducing manufacturing costs.
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 method simplifies assembly, reduces manufacturing costs, enhances vibration and shock resistance, and ensures effective sealing without mechanical stress, while maintaining precise alignment of optical elements.
Implementation Method 1
the contact points are designed as welded connections, in particular as laser welded connections
Implementation Method 2
The optical module and the housing are made of plastic, in particular of compatible thermoplastics, even more preferably of polycarbonate, wherein at least in the region of the contact points, either the housing is transparent to infrared rays and the optical module absorbs infrared rays
Implementation Method 3
an increase in temperature of one of the two components will cause the other component to heat up as well. In this process, the temperature of the material at the irradiated points is increased up to its melting temperature. As a result, the material of both components melts at the irradiated contact point, and after cooling, a permanent bond is formed
Data Source
AI summary
A photoelectric sensor, in particular a light curtain, is shown, including an elongated housing and an optical module arranged in the housing. Transmitting and/or receiving elements are arranged at a distance from one another on the optical module, and the optical module is connected to the housing via contact points, wherein the contact points are flat. The optical module and the housing are made of plastic. At least some of the contact points are designed as welded connections, with the housing and the optical module being welded together.