Multiple-optical-axis sensor muting sequence optimization
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Solution Overview
Problem
The existing multiple-optical-axis photoelectric sensor systems face challenges in reducing start-up time and minimizing 'muting errors' that lead to productivity losses, requiring extensive manual intervention and trial-and-error processes during facility start-up and workpiece changes.
Innovation Solution
The system provides statistical information to users for setting accurate muting sequences, eliminating the need for trial-and-error methods by analyzing and optimizing muting sequences based on actual operational data, ensuring proper alignment of productivity and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the muting function disables the whole detection area based on two independent muting signals with strict sequence checking, then the safety function is established, but the productivity is degraded due to frequent stopping of the production facility
Solution Approach 1:
The detection area is divided into multiple independent optical axes (first optical axis and second optical axis), allowing selective muting of specific axes rather than the entire detection area. This segmentation enables the system to maintain safety for specific dangerous zones while allowing production to continue in other areas.
Solution Approach 2:
The muting function transitions from a static whole-area disablement to a dynamic selective-axis muting capability. The control unit can independently mute or unmute specific optical axes based on real-time conditions, providing flexible control that adapts to different operational requirements and minimizes production disruption.
2Reliability
If the sequence of muting signals is strictly checked to prevent muting errors, then the safety is maintained, but the start-up time and adjustment time are increased due to trial-and-error processes
Solution Approach 1:
The system performs preliminary testing by detecting workpieces during the start-up phase to automatically determine the actual muting sequence. This preliminary data collection enables the control unit to establish accurate muting sequences before full production begins, eliminating the need for time-consuming trial-and-error adjustments later.
Solution Approach 2:
The system incorporates feedback mechanisms where the control unit monitors the actual muting sequence through workpiece detection and uses this information to automatically adjust and optimize the muting sequence. This feedback loop eliminates manual trial-and-error processes and reduces start-up time while maintaining safety.
3Productivity
If the muting sequence is defined based on sensor installation position, workpiece shape, and conveying speed, then the muting function can be optimized, but the complexity of setup and adjustment increases when workpieces are switched
Solution Approach 1:
The system performs self-adjustment by automatically detecting workpieces during operation and determining the actual muting sequence without requiring manual intervention. The control unit autonomously optimizes the muting sequence based on detected workpiece characteristics, eliminating the need for complex manual setup and adjustment when workpieces are switched.
Solution Approach 2:
The system dynamically adjusts muting sequence parameters based on detected workpiece characteristics such as shape, size, and conveying speed. By automatically adapting these parameters rather than requiring manual reconfiguration, the system maintains optimization across different workpiece types while reducing setup complexity.
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 approach reduces start-up time and man-hours, enhances productivity by minimizing errors and optimizing muting sequences, achieving a balance between productivity and safety.
Implementation Method 1
The light projecting unit causes the light projecting elements to sequentially emit the light beam. The light receiving unit takes out the amount of light that each light receiving element receives from a corresponding light projecting element
Data Source
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AI summary
A start-up time of a production facility is shortened while generation of a muting error is suppressed, whereby productivity is improved. A multiple-optical-axis photoelectric sensor system (100) includes a projector (1), an optical receiver (2), a light blocking determination unit configured to make a light blocking determination whether each of optical axes formed between the projector (1) and the optical receiver (2) is in a light blocking state, and a muting processor configured to temporarily disable the light blocking determination on condition that a detection signal input from an external muting instrument changes according to a predetermined sequence. The muting processor determines the sequence of the detection signal from the muting instrument during the muting by dividing the sequence into a plurality stages. The muting processor accumulates and analyzes measurement information acquired in each stage, and decides an optimum setting value for a muting operation condition based on an analysis result.