Shredder Sensor Calibration for False Positive Reduction
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Solution Overview
Problem
Existing shredders face issues with false positive signals due to varying electrical characteristics and sensitivities of optical sensors, leading to unreliable detection of articles and bin fullness, causing unnecessary shredder activation or deactivation, and increased wear on the mechanism.
Innovation Solution
A shredder system with sensors that emit and detect radiation, featuring automatic calibration to adjust the intensity of the radiation beam to ensure reliable detection of articles and shredded particles, preventing false positives and optimizing shredder operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the drive signal intensity is increased to detect single sheet paper, then paper detection sensitivity is improved, but false positive signals increase causing unnecessary shredder activation
Solution Approach 1:
The system performs preliminary calibration before normal operation to establish the baseline radiation intensity and detection threshold. The controller stores calibration data and uses it to adjust subsequent detection operations, preventing false positives while maintaining sensitivity to single sheets of paper.
Solution Approach 2:
The system dynamically adjusts the radiation intensity parameter based on calibration data. By changing the drive signal intensity from a fixed value to a calibrated value, the system optimizes detection sensitivity while eliminating false positives caused by inappropriate intensity levels.
2Reliability
If the drive signal intensity is decreased to reduce false positives, then reliability is improved, but paper detection sensitivity deteriorates
Solution Approach 1:
The system performs preliminary calibration before normal operation to establish the baseline radiation intensity and detection threshold. The controller stores calibration data and uses it to adjust subsequent detection operations, preventing false positives while maintaining sensitivity to single sheets of paper.
Solution Approach 2:
The system dynamically adjusts the radiation intensity parameter based on calibration data. By changing the drive signal intensity from a fixed value to a calibrated value, the system optimizes detection sensitivity while eliminating false positives caused by inappropriate intensity levels.
3Measurement precision
If radiation intensity is increased to detect shredded particles, then bin full detection sensitivity is improved, but false positive signals from dust and oil residues increase
Solution Approach 1:
The system performs preliminary calibration when the bin is empty to establish the baseline radiation intensity. This calibration accounts for dust and oil residues present during normal operation, creating a reference point that distinguishes actual bin fullness from contamination.
Solution Approach 2:
The controller continuously compares current radiation intensity readings against the calibrated baseline and adjusts detection decisions accordingly. This feedback mechanism allows the system to maintain high sensitivity while compensating for dust and oil residues that would otherwise cause false positives.
4Reliability
If radiation intensity is decreased to reduce false positives from dust and oil, then reliability is improved, but bin full detection sensitivity deteriorates
Solution Approach 1:
The system performs preliminary calibration when the bin is empty to establish the baseline radiation intensity. This calibration accounts for dust and oil residues present during normal operation, creating a reference point that distinguishes actual bin fullness from contamination.
Solution Approach 2:
The controller continuously compares current radiation intensity readings against the calibrated baseline and adjusts detection decisions accordingly. This feedback mechanism allows the system to maintain high sensitivity while compensating for dust and oil residues that would otherwise cause false positives.
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 effectively reduces false positive signals, ensuring accurate detection of articles and bin fullness, thereby preventing unnecessary shredder operation and extending the mechanism's lifespan by maintaining optimal sensor performance.
Implementation Method 1
a sensor for emitting and detecting radiation. The sensor consists of either (a) a throat sensor operable to detect insertion of the at least one article into the throat based on interruption of the radiation by the at least one article, or (b) a waste level sensor operable to detect an accumulation of shredded particles discharged by the shredder mechanism based on an interruption of the radiation on the accumulated shredded particles
Data Source
AI summary
Disclosed herein is a shredder having a throat for receiving at least one article to be shredded therethrough and a shredder mechanism received in a shredder housing which is driven to shred the at least one article fed therein. At least one sensor emits and detects radiation to detect the presence of the at least one article or shredded particles. The sensor communicates with a controller to operate the shredder mechanism. The controller also calibrates an intensity of the radiation of the sensor(s) to or within a predetermined amount above a minimum level in order to reduce wear and run-on conditions.