Side-Mounted Light Curtain Status Module
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Solution Overview
Problem
Existing light curtain safety systems in manufacturing facilities lack effective and customizable solutions for indicating the status of light curtains and machines, which can lead to safety risks and operational inefficiencies.
Innovation Solution
The development of a side-mounted field-installable indication module (SMFIIM) that is slidingly adjustable, provides a wide viewing angle through a refractive cover, and includes customizable modular functionalities such as input interfaces and sensors, enabling enhanced visibility and interaction with the monitored area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a light curtain safety system is installed to protect workers from dangerous machinery, then worker safety is improved, but the system lacks effective visual indication of light curtain and machine status
Solution Approach 1:
The patent introduces a status indicator module as an intermediary device that receives status information from the light curtain safety system and machine controller, then displays this information through visual indicators. This mediator translates complex system status into simple, understandable visual signals that provide immediate feedback to operators about safety conditions.
Solution Approach 2:
The patent employs color-coded visual indicators (such as green, yellow, red lights) to represent different operational states of the light curtain and machine. This color change system provides intuitive status information where different colors correspond to different safety conditions, enabling rapid comprehension of system state without requiring complex displays or interpretation.
2Loss of information
If fixed status indication is provided at the light curtain housing, then basic status information is available, but the indication is not visible from all necessary viewing angles
Solution Approach 1:
The patent utilizes a refractive cover with curved or angled surfaces that refract and distribute light from the status indicators in multiple directions. This curved optical element expands the viewing angle significantly, allowing operators to see the status indicators from various positions around the light curtain housing, ensuring visibility regardless of operator location.
3Ease of manufacture
If the status indicator module is built into the light curtain housing during manufacturing, then integration is achieved, but field installation and customization become difficult
Solution Approach 1:
The patent divides the status indication functionality into a separate, modular status indicator module that can be independently installed on the light curtain housing. This segmentation allows the indication system to be added or modified in the field without requiring complete manufacturing integration, enabling customization and adaptation to different installation scenarios while maintaining functional integration.
Solution Approach 2:
The patent creates a dynamic installation system where the status indicator module can be easily attached, detached, or repositioned on the light curtain housing. This dynamic mounting capability allows the system to adapt to different field installation requirements and enables future modifications or upgrades without permanent fixed installation constraints.
4Adaptability or versatility
If multiple functionalities are integrated into the light curtain system, then system capability is improved, but device complexity increases
Solution Approach 1:
The patent implements a universal status indicator module that can display multiple types of status information through a unified interface. The same physical device provides visual indication for light curtain status, machine operational state, and safety conditions, consolidating multiple functions into a single component rather than requiring separate indicators for each function.
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 SMFIIM effectively enhances safety by providing clear and customizable visual indications of light curtain and machine status, improving operator awareness and reducing the risk of accidents and operational downtime.
Implementation Method 1
The invention does include a refractive cover (e.g., configured to provide a distributed 'glowing' effect over substantially an entire viewing portion of the cover) for the light emitting module to increase viewing angle of the visual indicium.
Data Source
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AI summary
Apparatus and associated methods relate to a side-mounted field-installable indication module (SMFIIM) configured to reflect a status of a manufacturing area (e.g., a status a machine, status a light curtain). In an illustrative example, the SMFIIM may include a light emitting module configured to emit a visual indicium corresponding to the status of the manufacturing area, and a coupling member configured to be releasably captured within a longitudinally extending channel of a housing of a light curtain. After installation, for example, the SMFIIM may be disposed on a side of and substantially parallel to the housing. The light emitting module may emit the visual indicium in an emitting plane oriented at an angle less than 90° to a plane tangential to a mounting surface of the light curtain housing. Various embodiments may advantageously provide a wide viewing angle of the light emitting module around the lighting curtain.