Non-contact Sensor Workpiece Dimension Detection
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Solution Overview
Problem
Existing methods for detecting the overall dimensions of plate-shaped workpieces on processing machines are either contact-based, leading to wear and inefficiency, or lack precision in determining the workpiece's position, which can result in incorrect processing and potential tool damage.
Innovation Solution
A contactless sensor system connected to an evaluation device that detects the presence and absence of a workpiece by relative motion, allowing for precise determination of overall dimensions and position without wear, using a light barrier or alternative sensors like capacitive or inductive proximity switches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If contact-based detection methods (adjustable grippers, tactile stoppers) are used to detect workpiece dimensions, then the detection can be performed, but wear occurs and efficiency is reduced
Solution Approach 1:
The patent replaces contact-based mechanical detection systems (grippers, tactile stoppers) with a non-contact optical sensor system. The sensor detects workpiece edges by monitoring changes in the reflected light beam as the workpiece moves through the processing machine, eliminating mechanical contact and associated wear while maintaining detection accuracy.
Solution Approach 2:
The patent introduces an optical beam as an intermediary between the detection system and the workpiece. The light beam serves as a mediator that interacts with the workpiece surface without physical contact, allowing dimension detection through optical reflection changes rather than direct mechanical measurement.
2Reliability
If non-contact sensors are used to detect workpiece presence, then wear-free detection is achieved, but precise position determination and dead zone violation prevention may be compromised
Solution Approach 1:
The patent implements a feedback mechanism where the sensor continuously monitors workpiece position by detecting edge presence, and this information is fed back to the control system. The control system uses this feedback to determine precise workpiece positioning, calculate dimensions, and prevent dead zone violations by adjusting machine operations based on real-time detection data.
Solution Approach 2:
The patent performs preliminary detection of workpiece edges and position before processing operations begin. By detecting workpiece dimensions and position in advance using the non-contact sensor, the system can validate suitability for processing and prevent dead zone violations before they occur, ensuring safe and accurate operations.
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 reliable, wear-free detection of workpiece dimensions and position, ensuring correct material usage and preventing tool damage by accurately identifying suitable workpieces and avoiding dead zones, thus ensuring efficient and safe processing.
Implementation Method 1
The sensor (2) is connected to an evaluation device (15) and configured to detect a presence of the workpiece (12) and an absence of the workpiece as well as a change of state from the presence to the absence or from the absence to the presence
Data Source
AI summary
A method of detecting an overall dimension of a plate-shaped workpiece to be processed on a processing machine by a contactless-acting sensor includes moving the workpiece by a motion device of the processing machine in a predetermined direction until the sensor detects a first workpiece edge by a first change of state, detecting a first position of the workpiece where the first change of state happens by an evaluation device connected to the sensor, moving the workpiece by the motion device in a direction toward a second workpiece edge until the sensor detects the second workpiece edge by a second change of state, detecting a second position of the workpiece where the second change of state happens by the evaluation device, and determining an overall dimension of the workpiece by a determination of a distance between the first position and the second position of the workpiece.