Reel Changer Safety Area with Segmented Sensor System
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Solution Overview
Problem
Existing roll changers face challenges in providing comprehensive safety area protection, particularly during automatic roll loading, as they struggle to distinguish between authorized and unauthorized objects and ensure safety across varying roll diameters and structural limitations, leading to potential accidents.
Innovation Solution
The implementation of a non-contact sensor system with a light grid and evaluation unit that differentiates between permitted and unauthorized passages, featuring a muting function to temporarily deactivate parts of the protective device for known objects, and a second, permanently active sensor subsystem for enhanced security, allowing for expanded safety areas and varied roll sizes handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a safety area is established with sensor-monitored entrances to prevent unauthorized entry, then safety is improved, but the complexity of the protective device increases due to the need for sensor systems and evaluation units
Solution Approach 1:
The protective device is segmented into multiple independent sensor subsystems: a first sensor subsystem that can be deactivated for authorized objects and a second sensor subsystem that remains permanently active. This segmentation allows the system to maintain high safety while reducing the operational complexity by dividing the monitoring function into manageable, independent parts.
Solution Approach 2:
The first sensor subsystem is designed to be dynamically deactivatable when authorized objects are detected, while the second sensor subsystem remains permanently active. This dynamic configuration allows the system to adapt its protective level based on the situation, improving ease of operation for authorized users while maintaining safety through the permanently active second subsystem.
2Reliability
If the safety area is expanded to include the transfer point for automatic roll loading, then safety is improved, but the passage width is restricted due to structural limitations such as neighboring units and building walls
Solution Approach 1:
The patent replaces mechanical physical barriers with a non-contact sensor-based protective system. Light beams or electromagnetic fields are used to define the safety area boundaries instead of physical walls or gates, allowing the safety area to be expanded to include the transfer point without being constrained by structural limitations that would restrict passage width.
3Reliability
If a sensor system is used to distinguish between permitted and unauthorized objects, then safety is improved, but the difficulty of detecting and measuring unauthorized passages increases
Solution Approach 1:
The sensor system is segmented into two distinct subsystems with different functions: the first sensor subsystem detects and identifies authorized objects, allowing temporary deactivation, while the second sensor subsystem continuously monitors for unauthorized passages. This segmentation simplifies the detection logic by separating authorized object recognition from unauthorized intrusion detection.
Solution Approach 2:
The evaluation unit serves as an intermediary that processes signals from both sensor subsystems and determines whether a passage is authorized or unauthorized. It mediates between the detection data and the protective response, using predetermined criteria to distinguish between permitted objects and unauthorized intrusions, thereby reducing the complexity of the detection and measurement process.
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 significantly enhances safety by allowing for wider access and handling of various roll sizes without restrictions, reducing the risk of accidents by accurately distinguishing between authorized and unauthorized entries and maintaining permanent protection across different roll diameters.
Implementation Method 1
The protective device has a non-contact sensor system which is connected to an evaluation unit. The protective device or the sensor system is z. B. formed with a light grid, which has a plurality of mutually parallel light beams.
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
The invention relates to a reel changer having a securing means for a safety area, which safety area extends on a receiving and/or dispensing side at least over the entire width to the end-face side frames, which comprise vertically supporting frame parts and optionally switch boxes and/or side boxes arranged directly on said frame parts, wherein the safety area is substantially completely enclosed by the reel changer and by one or more connected units and/or mechanical blocking devices and by one or more sensor-monitored access means in such a way that operators can enter during operation only by means of the one or more monitored access means. A control element for functions of the reel changer is physically separated from the reel changer and arranged at a distance from the side frame at a location that can be reached by an operator located outside the safety area.