Sensor Unit Abnormality Source Identification via Multi-Channel Light Analysis
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Solution Overview
Problem
Safety sensors in factory automation struggle to determine the cause of abnormal light reflections, leading to unnecessary shutdowns, as they cannot differentiate between changes on the object side or the window side, causing inefficiencies and delays in identifying and addressing issues.
Innovation Solution
A sensor unit with a light emitting unit, light receiving unit, window, emitter, reflector, and optical receiver, which acquires and compares different light amounts to determine whether abnormalities occur on the object side or the window side by analyzing changes in received light amounts, allowing for precise identification of the cause of abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a safety sensor monitors reference points by detecting reflected light, then it can detect intrusion and ensure safety, but it cannot identify whether abnormality occurs on the object side or window side, leading to unnecessary shutdowns and work delays
Solution Approach 1:
The patent segments the light detection process into multiple independent measurement channels: (1) light reflected from the object measured by the light receiving unit, (2) light reflected from the window measured by the light receiving unit, and (3) light reflected from the reflector measured by the optical receiver. By dividing the monitoring function into these separate measurement paths, the system can independently evaluate each component's contribution to the total received light amount, thereby identifying which specific component is causing abnormality without compromising safety monitoring reliability
Solution Approach 2:
The patent introduces an intermediary measurement system using the emitter and optical receiver to measure the light amount reflected from the reflector. This intermediary measurement acts as a reference baseline that helps distinguish whether abnormalities in the main detection path are caused by window issues or object issues. The intermediary channel provides additional information that mediates between the safety monitoring function and the diagnostic function
2Reliability
If the safety sensor turns off control output when received light amount falls outside allowable range, then it maintains safety by detecting abnormalities, but it causes work stoppage until the cause is identified and dealt with
Solution Approach 1:
The patent performs preliminary diagnostic measurements by continuously monitoring light amounts from multiple sources (object, window, and reflector) before making safety control decisions. The system pre-identifies the location and nature of abnormalities through comparative analysis of received light amounts from different paths, so that when an abnormality is detected, the control output can be maintained or restored more quickly without requiring extended troubleshooting downtime
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
Enables rapid identification of the cause of light reflection changes, reducing downtime by accurately determining if issues are on the object or window side, thus facilitating quicker resolution and improving operational efficiency.
Implementation Method 1
a light emitting unit (22) configured to emit light
Implementation Method 2
a second received light amount that is a light amount of light obtained when light emitted from the light emitting unit and reflected by the window is received by the light receiving unit
Implementation Method 3
a third received light amount that is a light amount of light obtained when light that is emitted from the emitter, passes through the window, and is reflected by the reflector
Data Source
AI summary
A sensor unit includes a first unit to acquire a first light amount that is a light amount of light obtained when light reflected by an object is received by a light receiving unit, a second unit to acquire at least one of a second light amount that is a light amount of light obtained when light emitted from a light emitting unit and reflected by the window is received by the light receiving unit and a third light amount that is a light amount of light obtained when light that is emitted from the emitter, passes through the window, and is reflected by the reflector and light that is emitted from the emitter and reflected by the window are received by the optical receiver, and a determination unit to determine whether abnormality occurs on a side of the object or a side of the window.