Through-beam Sensor Lamp Panel Positioning
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Solution Overview
Problem
Existing through-beam photoelectric sensors face challenges in aligning the emission lamp with the emitter lens during assembly, leading to position deviations and increased manufacturing costs due to the complexity of precise alignment and potential defects in the assembly process.
Innovation Solution
The design separates the lamp panel and the first PCB, allowing for independent mounting and alignment, with a limit block and positioning grooves to stabilize the lamp panel and ensure precise positioning of the emission lamp relative to the emitter lens, reducing assembly complexity and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the emission lamp is welded directly on the PCB main board, then the assembly process is simple, but the alignment precision between the emission lamp and emitter lens deteriorates
Solution Approach 1:
The patent divides the assembly into separate functional modules: the emission lamp is mounted on a lamp panel, which is then mounted on the PCB main board. This segmentation allows the emission lamp to be precisely positioned on the lamp panel independently, improving alignment precision while keeping the overall assembly process manageable through modular construction.
2Device complexity
If the emission lamp is welded on the PCB main board, then the device structure is compact, but the adjustability of the emission lamp position deteriorates
Solution Approach 1:
By separating the emission lamp mounting (lamp panel) from the PCB main board, the patent enables independent positioning and adjustment of the emission lamp on the lamp panel, which is then mounted at the appropriate location on the PCB. This maintains structural compactness while providing necessary adjustability.
3Manufacturing precision
If precise alignment is required during welding, then the alignment precision improves, but the assembly complexity and reject ratio increase
Solution Approach 1:
The patent implements preliminary positioning of the emission lamp on the lamp panel before final assembly. The lamp panel is designed with pre-positioned mounting features that guide the emission lamp into correct alignment with the emitter lens, eliminating the need for complex real-time alignment adjustments during welding and reducing reject ratio.
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 simplifies the assembly process, reduces reject ratios, and improves the manufacturability of through-beam photoelectric sensors by ensuring accurate alignment of the emission lamp with the emitter lens, thereby enhancing the product's quality and reducing production costs.
Implementation Method 1
an emission lamp 6 welded on the lamp panel 5 and clamped in the light hole 53
Implementation Method 2
an emitter lens 31 mounted on an emitter housing 3
Implementation Method 3
a photoelectric sensor is a device for converting an optical signal into an electrical signal
Data Source
AI summary
A through-beam photoelectric sensor includes an emitter and a receiver, the emitter is opposite the receiver, the receiver is configured to receive an optical signal from the emitter, the emitter comprises a first housing, an emitter lens, a first PCB, a lamp panel and an emission lamp, the emitter lens is embedded in the first housing, a light hole is formed in the lamp panel, the emission lamp is welded on the lamp panel and clamped in the light hole, a limit block is provided in the first housing, the lamp panel is detachably mounted on the limit block, and the first PCB is sleeved over the limit block and engaged with the lamp panel, such that a wick of the emission lamp is aligned with an optical center of the emitter lens. An assembly method is applied to the through-beam photoelectric sensor.