Timestamped Binary Sensor for Throughput Machine Object Detection
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Solution Overview
Problem
Existing processing machines face inefficiencies in determining the precise position and length of moving objects due to limitations in throughput speed and precision, primarily caused by the use of simple binary sensors that require frequent querying, leading to slowed response times and reduced accuracy.
Innovation Solution
A sensor system with a control unit and timer that outputs a binary object detection signal with a time stamp, allowing for precise timing synchronization and enabling more accurate processing times, thereby improving precision and efficiency without reducing throughput speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If simple binary sensors are used for object detection, then device complexity is reduced and cost is lowered, but response time increases and measurement precision deteriorates due to the need for frequent querying
Solution Approach 1:
The patent combines the binary sensor with an integrated timer that automatically timestamps object detection events. This merging eliminates the need for separate querying mechanisms while providing both simple detection capability and precise timing information, resolving the contradiction between device simplicity and measurement precision.
Solution Approach 2:
The timer in the sensor performs preliminary timing action by automatically recording the detection time as soon as an object is detected, rather than waiting for external queries. This preliminary timestamping action ensures precise measurement without requiring continuous polling, thus maintaining both simplicity and precision.
2Device complexity
If simple binary sensors are used for object detection, then device complexity is reduced, but productivity decreases due to slowed response time from frequent querying
Solution Approach 1:
By merging the timer function into the binary sensor, the system eliminates the need for frequent external queries while maintaining simple sensor operation. The integrated timer automatically records detection times, enabling high throughput processing without the productivity loss associated with repeated polling of simple sensors.
Solution Approach 2:
The sensor performs self-service by internally timing its own detection events without requiring external control system intervention. This self-timestamping capability allows the sensor to operate simply while simultaneously providing precise timing data that enables high productivity in the overall system.
3Productivity
If throughput speed is increased to improve productivity, then output increases, but measurement precision deteriorates due to greater disturbance influences on workpiece position
Solution Approach 1:
The timer records the detection time at the exact moment of detection, creating a preliminary timestamp before any disturbances can affect the workpiece position. This preliminary timing action captures precise position information even at high throughput speeds where disturbances are more significant.
Solution Approach 2:
The patent replaces mechanical position measurement methods with time-based measurement. By substituting direct mechanical position sensing with timing-based calculation (using the timestamp and known conveyor speed), the system achieves high precision at high speeds without being subject to mechanical disturbance influences.
4Measurement precision
If multiple simple binary sensors are used for processing devices, then device complexity increases, but response time decreases and measurement precision improves
Solution Approach 1:
Instead of using multiple separate sensors, the patent merges the timing function into each sensor, creating a unified sensor unit that provides both detection and precise timing. This approach achieves the measurement precision of multiple sensors while maintaining lower overall system complexity compared to coordinating multiple independent sensors.
Data Source
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AI summary
The processing device (100) has a control unit (C) with a timer (ZG) for displaying a system time, and two machine units (S11,A11) which are connected with the control unit for receiving the system time. The former machine unit has a sensor element (SE11) for detecting an occurrence and for displaying an occurrence time based on the system time. The latter machine unit has an actuator element (AE11) for executing an operation according to an operating time based on the system time and the occurrence time. An independent claim is included for a processing method, particularly for a throughput machine.