Tool Carrier Position Detection with Spring-Loaded Distance Sensing
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Solution Overview
Problem
Existing position detection systems for tool carriers on production lines require multiple detectors per fixing device to ensure precise positioning and error-free fixation, increasing complexity and susceptibility to failures.
Innovation Solution
A position detector system with at least one sensor and one spring, aligned along a central infeed axis, applies a defined spring force to detect incorrect positioning or fixation, generating a signal for error messages, thereby simplifying the setup and enhancing reliability with self-centering fixing devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple detectors are used per fixing device to ensure precise positioning and secure fixation, then measurement precision and reliability are improved, but device complexity and susceptibility to malfunctions increase
Solution Approach 1:
The patent combines multiple detection functions into a single detector by integrating a multi-axis sensor (capable of detecting position in X, Y, and Z directions) with a spring mechanism. This single integrated detector replaces what would traditionally require multiple separate detectors, thereby reducing device complexity while maintaining the ability to detect positioning accuracy across all degrees of freedom
Solution Approach 2:
The single detector is designed with multi-functionality to detect positioning status in multiple directions (X, Y, Z axes) simultaneously. The sensor can measure displacement along different axes and the spring mechanism provides force in multiple directions, allowing one detector to perform the work of multiple detectors while monitoring positioning and fixation across all degrees of freedom
2Reliability
If multiple detectors are deployed to monitor positioning and fixation in all degrees of freedom, then reliability of detection is improved, but the susceptibility to malfunctions in the control and safety system increases
Solution Approach 1:
The patent merges multiple detection capabilities into a single integrated detector unit. By combining multi-axis sensing with a spring-based force application mechanism, the system achieves comprehensive monitoring of positioning and fixation status across all degrees of freedom using one detector, thereby reducing the overall number of detectors in the system and lowering susceptibility to malfunctions while maintaining high detection reliability
3Device complexity
If a single sensor and spring arrangement is used to simplify the system, then device complexity is reduced, but measurement precision and positioning accuracy may be compromised
Solution Approach 1:
The patent employs parameter changes by utilizing a multi-axis sensor that can detect displacement along multiple axes (X, Y, Z) and by adjusting the spring constant and pre-load force to optimize detection sensitivity. The spring mechanism is designed with specific mechanical properties to amplify small positioning errors, allowing a single sensor to achieve measurement precision comparable to multiple detectors through optimized physical parameters
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
Ensures reliable detection of positioning and fixation status with reduced apparatus complexity and increased accuracy, using a single sensor and spring arrangement to address the limitations of multiple detectors, while maintaining stability and precision across all degrees of freedom.
Implementation Method 1
the sensor system comprises the at least one sensor and at least one spring, which, upon successful positioning of the tool carrier along a central positioning axis defined as orthogonal to a centroid of the second surface, is designed to exert a defined spring force against the first surface and the second surface of the production line
Implementation Method 2
the at least one sensor is a distance sensor and is designed such that if the first surface is pressed off the second surface beyond a predetermined distance between sensor and detection object, a signal can be generated to output an error message about incorrect positioning or incorrect fixation
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
The invention relates to a position detector for detecting the positioning of a first surface (A) of a movable tool carrier (1) relative to a second surface (B) of a production line (2).The position detector comprises at least three self-centering fixing devices (3) on the production line (2), by which the first surface (A) can be positioned and fixed in a defined manner on the second surface (B) during a feed along a central feed axis (Z), and a sensor system (4) with at least one sensor (41) for detecting the position of a detection object (5) and at least one spring (42) for generating a defined spring force (FF) between the first surface (A) and the second surface (B) when the tool carrier (1) has been fed, whereby the first surface (A) can be pressed off the second surface (B) in the event of incorrect positioning or fixing, and the at least one sensor (41) is designed as a distance sensor to output an error message when the first surface (A) is pressed off beyond a predetermined distance.