Recessed Sensor Module for AGV Optical Safety
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Solution Overview
Problem
Automatic Guided Vehicles (AGVs) face challenges in using optical beam safety sensors due to dirt, high-pressure water contamination, and physical abuse in factory environments, which leads to maintenance and replacement costs for physical contact type safety stop bumpers and renders optical sensors ineffective.
Innovation Solution
A sensor module with a housing and cover that encloses an optical sensor unit, featuring a recessed design to protect the sensor from water and dirt, and drain holes to prevent water accumulation, along with a sloping cover to prevent objects from resting on it, and a strong mounting system to withstand impacts, allowing commercially available optical sensors to be used in harsh environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If optical beam safety sensors are used on AGVs, then maintenance costs can be reduced compared to physical contact bumpers, but the sensors become ineffective due to dirt, water contamination, and physical abuse in factory environments
Solution Approach 1:
A protective housing acts as an intermediary barrier between the optical sensor and the harsh factory environment. The housing encloses the sensor while allowing the optical beam to pass through, protecting against dirt, water, and physical damage without interfering with sensor operation
Solution Approach 2:
The housing uses a transparent or translucent protective shell that allows optical transmission while providing environmental protection. The shell acts as a barrier against contaminants while maintaining optical functionality
2Measurement precision
If the sensor unit is exposed on the housing, then the sensor can detect objects effectively, but the sensor becomes vulnerable to water contact, dirt accumulation, and physical damage
Solution Approach 1:
The transparent housing serves as an intermediary protective layer that allows optical detection to function while blocking harmful environmental factors such as water, dirt, and physical impact from reaching the sensor
Solution Approach 2:
The housing provides beforehand protection by enclosing the sensor before exposure to harsh conditions. The recessed mounting and protective cover create a buffer zone that cushions the sensor against physical abuse and contamination
3Ease of manufacture
If the housing is designed with a flat top surface, then it is simple to manufacture, but objects and people may rest on it causing damage or false readings
Solution Approach 1:
The top surface of the housing is designed with a slope or curvature instead of being flat, preventing objects and people from resting on it. This curved geometry maintains ease of manufacture while eliminating the risk of damage or false sensor readings
4Ease of operation
If the sensor unit is mounted flush with the housing exterior, then installation is simple, but the sensor cannot be protected from high-pressure water washdown and direct contamination
Solution Approach 1:
The sensor unit is nested within the housing structure, specifically recessed into the housing body. This nested configuration protects the sensor from direct exposure to water and dirt while maintaining a compact, simple installation design
Solution Approach 2:
The sensor is positioned in a recessed dimension within the housing rather than being flush with the exterior surface. This dimensional change creates a protective depth that shields the sensor from environmental contaminants
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 sensor module effectively protects optical sensors from contamination and physical damage, enabling their use in harsh factory environments while maintaining functionality and reducing maintenance costs.
Implementation Method 1
The sensor unit emits or receives a radiation beam which is directed along a surface of the frame
Data Source
AI summary
A sensor module for a vehicle includes a sensor unit enclosed in a housing. The sensor unit has an active end which emits or receives said radiation beam. The housing has a removable cover, a back wall for mounting to the vehicle, a bottom wall, a first end wall and a second end wall spaced apart from the first end wall. The radiation beam is directed through an opening in the first end wall. The active end is internal to the housing and spaced apart internally from the first end wall. A hollow sleeve is received by the opening, and a portion of the sleeve receives at least a portion of the sensor unit. The active end of the sensor unit is inside the sleeve and spaced apart from an end of the sleeve.