Sensor Test Mode for Reliability Assessment
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Solution Overview
Problem
Existing sensors, particularly optical sensors, face reliability issues due to component aging and pollution, leading to potential failure in object detection, which can result in dangerous situations.
Innovation Solution
A sensor system that can be transferred to a test mode independently of its working mode, allowing for automatic checking and optimization of sensor parameters, such as radiation intensity and signal processing, to assess and improve functional reliability, with a display unit indicating the status through different light colors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor operates continuously in working mode, then productivity is maintained, but functional reliability deteriorates due to component aging and contamination
Solution Approach 1:
The sensor system implements periodic test modes at defined intervals during continuous operation. The control unit automatically switches between working mode and test mode, performing functional checks at regular intervals to detect aging and contamination effects before they cause complete failure, thereby maintaining reliability over extended operational periods
Solution Approach 2:
The system performs preliminary functional checks and parameter optimizations during test modes before the sensor reaches critical failure points. By detecting reduced functional reliability early and automatically adjusting parameters or alerting users, the system prevents complete sensor failure and extends the operational period between maintenance interventions
2Reliability
If test mode is implemented to check functional reliability, then reliability assessment is improved, but productivity is reduced due to mode switching
Solution Approach 1:
The test mode implements partial functionality by focusing on specific critical parameters (signal strength, noise levels, key component responses) rather than comprehensive testing. This selective approach provides sufficient reliability assessment while minimizing the time spent in test mode, thus reducing the impact on overall productivity
Solution Approach 2:
Test modes are executed at defined intervals during continuous operation rather than requiring complete shutdowns. The control unit automatically manages transitions between working and test modes, ensuring that reliability checks are performed periodically without significantly interrupting the overall object detection throughput
3Reliability
If sensor parameters are varied to optimize output variable, then functional reliability is improved, but device complexity increases
Solution Approach 1:
The control unit automatically varies sensor parameters and optimizes output variables without requiring external intervention. The system self-diagnoses parameter deviations and autonomously adjusts transmission power, reception sensitivity, and evaluation thresholds to restore optimal functionality, thereby improving reliability while avoiding the complexity of manual parameter management systems
Solution Approach 2:
The system implements feedback loops where the control unit continuously monitors sensor output variables and parameter states. Based on this feedback, the control unit automatically adjusts parameters to optimize performance and compensate for aging or contamination effects, improving reliability through a relatively simple feedback mechanism rather than complex predictive control
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 system enhances the functional reliability of sensors by automatically detecting and addressing impairments, extending the sensor's operational period without significant functional degradation, and providing users with timely information for maintenance.
Implementation Method 1
at least one transmitter (4) which emits light beams (3) and one receiver (5) which receives light beams (3)
Implementation Method 2
one receiver (5) which receives light beams (3)... sensor components that generate sensor signals
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a sensor for detecting objects (14) in a detection area (13), comprising sensor components and an evaluation unit (6). In an operating mode, sensor signals generated by the sensor components are evaluated in the evaluation unit (6), and an object detection signal is generated based on the evaluation. The sensor can be switched to a test mode. In test mode, an object (14) placed in the detection area (13) is detected. Depending on the detection of this object (14), parameters of the sensor components and/or the evaluation unit (6) are checked and/or varied in the evaluation unit (6), and an output value is generated based on these changes and displayed by a display unit (10).