Preform Heating Enclosure with Near-Infrared Radiation Leak Detection
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Solution Overview
Problem
The use of monochromatic or pseudo-monochromatic electromagnetic radiation emitting elements in heat treatment units poses a risk of invisible infrared radiation exposure to operators, which is difficult to detect and prevent due to the lack of visible cues, leading to potential injuries.
Innovation Solution
A safety system incorporating near-infrared imaging and image processing devices is used to detect and alert for radiation leaks outside the enclosure, ensuring removable panels are correctly positioned before operation, and preventing unit activation if leaks are detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser emitters are used for heating preforms, then heating efficiency and speed are improved, but radiation leakage risk increases
Solution Approach 1:
A near-infrared camera acts as an intermediary detection device between the laser radiation source and the external environment. The camera captures infrared radiation that leaks from the enclosure, converting invisible harmful radiation into visible image signals that can be monitored and analyzed by the control system.
Solution Approach 2:
The system establishes a feedback loop where the near-infrared camera continuously monitors for radiation leakage, the image processing device analyzes the captured images to detect leaks, and the control device receives alerts and can respond by stopping the laser emitters or alerting operators, creating a closed-loop safety mechanism.
2Object-affected harmful factors
If the enclosure is closed to prevent radiation leakage, then operator safety is improved, but detection of leaks becomes more difficult
Solution Approach 1:
The manual visual inspection mechanism is replaced with an automated optical detection system. Instead of operators visually checking for radiation leaks (which is ineffective against invisible infrared radiation), the near-infrared camera automatically detects and images radiation leakage, enabling reliable detection while maintaining enclosure closure.
Solution Approach 2:
The detection system changes the parameter of observation from the visible spectrum to the near-infrared spectrum. Since laser radiation leaks are in the infrared range and invisible to the naked eye, using a near-infrared camera allows the system to detect radiation leaks by capturing them in the infrared spectrum where they are visible to the detector.
3Ease of operation
If removable panels are used for maintenance access, then ease of operation is improved, but radiation leakage risk increases
Solution Approach 1:
The system performs preliminary detection of radiation leaks at removable panel locations before the heat treatment unit is activated. The near-infrared camera captures images during the setup phase when panels are being installed, allowing operators to verify proper panel placement and seal integrity before laser emitters are activated, preventing radiation leakage from improperly installed panels.
Solution Approach 2:
The control device receives image data from the near-infrared camera and provides feedback to operators about the presence or absence of removable panels and potential radiation leaks at panel locations, enabling verification of proper panel installation before operation begins.
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
Ensures safe operation by detecting and preventing radiation leaks, verifying panel placement, and alerting operators to potential hazards, thereby safeguarding against invisible infrared radiation exposure.
Implementation Method 1
said image acquisition device acquiring images at least in the near-infrared range, the images acquired by said image acquisition device being capable of showing radiation emitted outside the fairing
Implementation Method 2
at least one emitting wall comprising at least one emitting element of monochromatic or pseudo-monochromatic electromagnetic radiation arranged to emit said radiation towards the preforms circulating in the enclosure
Data Source
Figure 1
Figure 2
AI summary
The heat treatment unit (1) comprises an enclosure (4) within which the preforms (2) pass along a predefined path (T) and at least one emitting wall (6) comprising at least one electromagnetic radiation-emitting element, said enclosure (4) being at least partially closed by a shroud (16). The heat treatment unit comprises at least one safety system including an image acquisition device (24) disposed outside the shroud (16) and an image processing device (26), the acquired images being capable of showing radiation emitted outside the shroud (16), the processing device (26) being configured to identify the presence of radiation leakage outside the enclosure (4) if an image acquired by said image acquisition device (24) shows radiation.