Ultrasonic and Optical Sensor Arrangement for Label Detection
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Solution Overview
Problem
Existing sensor arrangements with integrated ultrasonic and optical sensors face challenges in flexibility and cost due to rigid designs and expensive manufacturing, limiting their applicability and efficiency in label detection on carrier materials.
Innovation Solution
A sensor arrangement where the ultrasonic and optical sensors are connected via coupling means, forming separate but signal-exchange-capable units, allowing for flexible use and standard component manufacturing, with a compact fork-shaped design ensuring coaxial beam paths for enhanced detection sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the optical sensor and ultrasonic sensor are integrated in one housing, then reliable label detection is achieved for a wide range of label and carrier materials, but the design becomes relatively large, rigid and inflexible
Solution Approach 1:
The sensor system is divided into separate optical sensor and ultrasonic sensor units that can be independently positioned and adjusted. Each sensor type maintains its own housing and mounting structure, allowing flexible placement while achieving reliable detection across diverse label materials through selective activation.
2Volume of moving object
If the optical sensor is integrated within the ultrasonic sensor, then a compact sensor arrangement with small construction volume is achieved, but special designs are required that are relatively expensive to manufacture
Solution Approach 1:
The optical sensor housing is positioned within the fork structure of the ultrasonic sensor housing, creating a nested arrangement where the optical sensor components are located in the space between the ultrasonic fork arms. This nesting achieves compact volume while allowing each sensor to be manufactured as a separate standard component.
Solution Approach 2:
The fork-shaped ultrasonic sensor housing serves dual purposes: it provides the structural framework for the ultrasonic sensor and simultaneously accommodates the optical sensor housing within its fork arms. This multi-functional design eliminates the need for separate specialized housings, reducing manufacturing costs.
3Ease of manufacture
If standard optical sensor and ultrasonic sensor components are used with coupling means, then the sensor arrangement can be produced with little structural effort and used flexibly, but additional coupling components are required
Solution Approach 1:
The mechanical coupling means integrate the optical and ultrasonic sensors into a unified functional unit while maintaining the ability to separate them. The coupling structure combines mounting, positioning, and signal connection functions into a single integrated assembly, reducing the number of separate components needed.
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 solution provides a flexible, cost-effective sensor arrangement with increased detection reliability and sensitivity, enabling independent or combined use of sensors for enhanced functionality and fail-safety in detecting labels on carrier materials.
Implementation Method 1
the ultrasonic transmitter and the ultrasonic receiver of the ultrasonic sensor on the other hand are each on both sides of a detection level in which the carrier material with the labels is guided relative to the device
Implementation Method 2
the beam axis of the ultrasonic waves emitted by the ultrasonic transmitter and the optical axis of the transmission light beams emitted by the transmitter intersect in the detection plane
Data Source
Figure 1
Figure 2~4
AI summary
The arrangement (1) has an ultrasonic sensor (2) and an optical sensor (3) that are connected by a coupling element i.e. patch cord, to form a functional unit. The optical sensor is integrated into an optics sensor housing and the ultrasonic sensor is integrated into an ultrasonic sensor housing (5). The optics sensor housing and the ultrasonic sensor housing are connected to a component by a mechanical coupling element i.e. connecting rail. Parts of the optics sensor housing form screens for ultrasonic waves (6) that are emitted by an ultrasonic transmitter (7) of the ultrasonic sensor.