Stack Light Module Identification via Sensor-Target Detection
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Solution Overview
Problem
The modularity of stack lights, while allowing for flexible configurations, can lead to errors in assembly due to interchangeable modules, resulting in incorrect wiring and improper indication of operating conditions, such as a green beacon illuminated when the access gate is open and a red beacon illuminated when it is closed.
Innovation Solution
A system is implemented where sensors and targets are used within each module to generate unique signals upon detection, allowing the circuit board or a programmable logic controller to verify the identity of each module, ensuring correct configuration and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If modules are made interchangeable with identical connectors, then ease of assembly and flexibility increase, but assembly accuracy and reliability decrease
Solution Approach 1:
The patent applies local quality by introducing unique identifying features (such as colored rings, patterns, or shapes) at specific locations on each module housing. These localized features allow modules to be easily distinguished during assembly while maintaining the overall interchangeability of the modular components. The identifying features are placed strategically to be detectable by sensors without compromising the mechanical compatibility of the modules.
Solution Approach 2:
The patent implements feedback by using sensors (optical, magnetic, or capacitive) to detect the unique identifying features on module housings during assembly. The sensors provide feedback signals to a control system that verifies the correct placement and configuration of modules. This feedback mechanism ensures assembly accuracy while maintaining the ease of modular assembly, as the system automatically verifies correctness without requiring complex manual procedures.
2Adaptability or versatility
If multiple interchangeable modules are used, then adaptability and configuration flexibility increase, but error rates in assembly increase
Solution Approach 1:
The patent applies local quality by introducing unique identifying features (such as colored rings, patterns, or shapes) at specific locations on each module housing. These localized features allow modules to be easily distinguished during assembly while maintaining the overall interchangeability of the modular components. The identifying features are placed strategically to be detectable by sensors without compromising the mechanical compatibility of the modules.
Solution Approach 2:
The patent implements feedback by using sensors (optical, magnetic, or capacitive) to detect the unique identifying features on module housings during assembly. The sensors provide feedback signals to a control system that verifies the correct placement and configuration of modules. This feedback mechanism ensures assembly accuracy while maintaining the ease of modular assembly, as the system automatically verifies correctness without requiring complex manual procedures.
3Measurement precision
If sensors and identification systems are added to modules, then assembly verification accuracy improves, but device complexity increases
Solution Approach 1:
The patent applies the extraction principle by separating the identification function from the main module functionality. Instead of integrating complex identification electronics into each module, the patent extracts the identification features as simple visual or magnetic markers on the module housings. The sensing and processing functions are extracted to a separate control system, reducing the complexity within individual modules while maintaining high identification accuracy.
Solution Approach 2:
The patent uses an intermediary approach by introducing simple passive identifying features (such as colored rings, patterns, or magnetic markers) as mediators between the modules and the detection system. These intermediaries carry the identification information without requiring active electronics, reducing complexity. The control system with sensors acts as an intermediary that processes this information to verify module placement, achieving accurate identification with minimal added complexity to the overall system.
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
This system effectively prevents assembly errors by confirming the correct placement and function of each module, ensuring accurate visual and audible indications of operating conditions, thereby reducing maintenance and ensuring safe operation.
Implementation Method 1
A sensor is mounted to a circuit board inserted within a housing of the module. A target is mounted to or integrally formed in the housing. When the circuit board is inserted into the housing, the sensor detects the target and generates a signal corresponding to the detected target.
Data Source
AI summary
A system to verify the identity of modules within a stack light is disclosed. A sensor is mounted to a circuit board inserted within a housing of the module, and a target is mounted to or integrally formed in the housing. The sensor detects and generates a signal corresponding to the detected target. Different targets or locations for the target are provided for each housing. The module, a base for the stack light, or a remote controller in communication with the stack light identifies the housing in which the circuit board is mounted based on the feedback signal generated by detecting the target. At power-up, a routine may initiate a verification routine by which each module in the stack light determines the type of housing in which the circuit board for that module is located.