Sensor Illuminant Carrier Layout for All-Round Status Visibility
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Solution Overview
Problem
Existing sensors face challenges in achieving all-round visibility of operating and switching states due to the placement of illuminants on the same module carrier as sensor electronics, limiting the illumination of the signal lighting surface and making it difficult to see displays from various installation positions, especially in industrial settings.
Innovation Solution
A separate plate-like illuminant carrier is positioned transversely to the module carrier, allowing for improved positioning of illuminants directly behind the signal lighting surface, and the transducer receptacle is made partially transparent to enhance light transmission, enabling effective illumination and visibility from multiple angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If illuminants are placed on the same module carrier as sensor electronics, then device complexity is reduced, but illumination quality and all-round visibility deteriorate
Solution Approach 1:
The patent divides the sensor into separate functional modules: the module carrier with electronics is separated from the illuminant carrier with lighting elements. This segmentation allows each component to be optimized independently - the illuminants can be positioned on the illuminant carrier directly behind the signal lighting surface to achieve optimal illumination and all-round visibility, while the electronics remain on the module carrier. The two carriers are connected via a coupling mechanism, enabling independent positioning for best performance.
2Volume of moving object
If sensor diameter is minimized, then compactness is improved, but available surface area for illumination deteriorates
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement to a three-dimensional spatial configuration by positioning the illuminant carrier transversely to the module carrier. The illuminants are arranged on the illuminant carrier in a manner that provides three-dimensional illumination coverage, with light directed at the signal lighting surface from multiple angles. This spatial arrangement maximizes the effective illumination area while maintaining a compact sensor diameter.
3Ease of manufacture
If illuminant positioning is constrained to module carrier, then manufacturing simplicity is improved, but positioning flexibility for optimal illumination deteriorates
Solution Approach 1:
The patent segments the sensor into a module carrier and an illuminant carrier that can be independently manufactured and then coupled together. The illuminant carrier is designed as a separate component with pre-positioned illuminants optimized for illumination performance. This segmentation allows the illuminant carrier to be manufactured with precise positioning of lighting elements, while the module carrier can be manufactured separately with electronics. The coupling mechanism enables assembly of the two independently optimized components.
4Length of moving object
If transducer unit length is reduced, then compactness is improved, but light transmission distance deteriorates
Solution Approach 1:
The patent introduces a transparent or translucent coupling mechanism between the illuminant carrier and the transducer receptacle that acts as an optical intermediary. This coupling allows light to pass through from the illuminants positioned on the illuminant carrier to the transducer element in the transducer receptacle. The transparent material maintains mechanical connection while enabling effective light transmission over the reduced distance, solving the conflict between compactness and light transmission.
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 design achieves up to 50% shorter sensor designs, improved EMC characteristics, and all-round visibility of operating and switching states, facilitating easier installation and fault diagnosis, even in inaccessible locations, with enhanced illumination and reduced construction lengths.
Implementation Method 1
The light of the illuminants can then be passed to the outside through the transducer receptacle
Data Source
AI summary
The invention relates to a sensor with a transducer unit, which is located at a measurement end in a housing sleeve, with connection means at a connection end of the housing sleeve opposite to the measurement end, with a module carrier received in the housing sleeve and on which is placed a sensor electronics and which extends along an axis of the housing sleeve, with illuminants for the optical signaling to the outside of operating and/or switching states of the sensor. The sensor is characterized in that there is a separate, plate-like illuminant carrier, that a plurality of illuminants are placed on the illuminant carrier and that the illuminant carrier is positioned transversely to the module carrier in the vicinity of the transducer unit. The invention also relates to a method for the manufacture of a sensor.