Pneumatic Stop and Magnetic Sensing for Rack Positioning
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Solution Overview
Problem
Existing multi-chamber washer systems face challenges in accurately positioning racks due to premature wear of mechanical stops and the need for magnets on each rack, which can lead to faulty readings and sensor failure in damp environments.
Innovation Solution
A conveyor system with a rocker device and sensing element that uses a magnet on a rotatable arm to signal a controller for precise rack positioning, and a pneumatic stop assembly that applies axial force, reducing wear and eliminating the need for magnets on the racks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mechanical stop with a barrier attached to a cylinder is used to stop racks at predetermined positions, then the racks can be positioned accurately within chambers, but the cylinder rod experiences premature wear due to forces causing it to be pushed out of axial alignment
Solution Approach 1:
Instead of having the cylinder push the barrier perpendicular to its axis (which causes misalignment forces), the invention inverts the arrangement by having the cylinder push axially along its own axis. The barrier is now oriented parallel to the cylinder axis, and the rack engages the barrier from behind, converting the problematic perpendicular force into a beneficial axial force that maintains proper alignment and reduces wear.
Solution Approach 2:
The invention changes the dimensional orientation of the barrier from being perpendicular to the cylinder axis (original arrangement) to being parallel to the cylinder axis (new arrangement). This dimensional change transforms the force vector from causing lateral misalignment to being applied axially, fundamentally resolving the wear problem while maintaining positioning accuracy.
2Measurement precision
If magnetic switches with magnets on each rack are used to monitor rack position, then rack position can be tracked, but the system becomes complex and magnets on racks can lead to faulty readings and sensor failure in damp environments
Solution Approach 1:
The invention extracts the magnet from the rack and relocates it to the stationary barrier component within the washer. This eliminates the need to attach magnets to each rack, simplifying the system by removing magnets entirely from the moving baskets while maintaining the magnetic sensing function for accurate rack position monitoring.
Solution Approach 2:
The invention introduces a stationary barrier with an embedded magnet as an intermediary element between the rack and the sensor. Instead of directly sensing the rack (which requires magnets on each rack), the system senses the position of the barrier, which is in direct contact with the rack. This intermediary approach simplifies the system by eliminating the need for magnets on racks while maintaining measurement precision.
3Measurement precision
If sensors are placed within the washer unit to detect rack position, then real-time monitoring is achieved, but the sensors are exposed to damp and wet environments where they are more likely to fail
Solution Approach 1:
The stationary barrier with embedded magnet serves as an intermediary that allows the sensor to be positioned outside the damp chamber environment. The barrier transmits positional information to the sensor without requiring the sensor to be physically exposed to the harsh wet environment, thus maintaining real-time monitoring capability while improving sensor reliability.
Solution Approach 2:
The invention replaces the need for direct mechanical contact between the sensor and rack with a magnetic field-based sensing system. The magnet embedded in the stationary barrier creates a magnetic field that can be detected by the sensor from a distance, eliminating the need for the sensor to be in direct contact with or exposed to the damp environment inside the washer chamber.
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 solution provides accurate and durable rack positioning within multi-chamber washers, reducing wear on mechanical components and protecting sensors from moisture, ensuring reliable operation.
Implementation Method 1
A magnet is disposed on the lower arm of the rocker device. A sensing element is aligned with the magnet when the rocker device is in the first normal position.
Implementation Method 2
a pneumatic stop assembly that applies axial force, reducing wear and eliminating the need for magnets on the racks
Data Source
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AI summary
A conveyor system for conveying a basket or rack (40) through a chamber having a system for stopping a rack (40) at a predetermined location along the conveyor (30). The system is comprised of a rocker device (114) mounted relative to the chamber. The rocker device(114) has a first normal position wherein the rocker device (114) is movable from the first normal position when the rack(40) engages the rocker device (114). The rocker device (114) has an upper arm (116) and a lower arm (118). The rocker device (114) is rotatable about an axis (122) disposed between the upper arm (116) and the lower arm (118). A magnet (132) is disposed on the lower arm (118) of the rocker device (114). A sensing element (100) is aligned with the magnet (132) when the rocker device (114) is in the first normal position. The sensing element (100) is operable to provide a signal to a system controller. A stop 200 is mounted relative to the chamber and is rotatable from a first position to a second position.