Hinged Transition Plate Position Sensor for Conveyor Safety
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Solution Overview
Problem
Conventional transition plates for conveyor systems at retail check-out counters are prone to being improperly secured or lost, leading to hazards as they can create pinch points or fail to prevent articles from being drawn into gaps between the conveyor and run-out ramp, potentially causing damage or injury.
Innovation Solution
A transition plate assembly with a hinged design, a fin plate, and a light emitter/detector system that ensures the conveyor only operates when the transition plate is securely seated, using a signal generator to enable or disable the motor based on the plate's position, preventing accidental operation when the plate is unseated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the transition plate is made removable to enable removal of articles or debris, then ease of operation is improved, but reliability deteriorates because the plate may not be promptly and safely restored to its seated position
Solution Approach 1:
The patent replaces mechanical sensing methods with an optical system using a light source, light sensor, and interrupter mechanism. The interrupter is mechanically coupled to the transition plate, so when the plate moves from its seated position, it interrupts the light beam, triggering a safety response that stops the conveyor. This optical-mechanical coupling provides reliable detection of the plate's position without requiring complex mechanical switches or sensors.
Solution Approach 2:
The system implements feedback by continuously monitoring the position of the transition plate through the light interrupter mechanism. When the plate is properly seated, the light beam is blocked, and the system knows the plate is in place. If the plate is removed or dislodged, the light beam is interrupted, and the control system receives feedback to stop the conveyor, ensuring safety while allowing easy removal of articles.
2Device complexity
If conventional mechanical switches or sensors are used to detect transition plate position, then device complexity is reduced, but reliability deteriorates because these components can fail or be overridden
Solution Approach 1:
The patent replaces conventional mechanical switches and sensors with an optical detection system consisting of a light source, light sensor, and interrupter. This optical system is more reliable because it has fewer moving parts, is not susceptible to electrical interference, and cannot be easily overridden. The interrupter is mechanically coupled to the transition plate, providing a direct physical connection that ensures accurate position detection.
Solution Approach 2:
The light interrupter serves as an intermediary between the transition plate and the light sensor. Instead of directly sensing the plate's position or using complex mechanical linkages, the system uses the interrupter to translate the plate's movement into a light beam interruption signal. This intermediary mechanism simplifies the detection system while improving reliability.
3Reliability
If the transition plate is secured with fasteners to prevent unseating, then reliability is improved, but ease of operation deteriorates because fasteners are time-consuming to remove and may be lost
Solution Approach 1:
The patent makes the transition plate dynamic by allowing it to move between a seated position (where it blocks the light beam and enables conveyor operation) and a removed position (where it interrupts the light beam and stops the conveyor). The plate is retained in the seated position during normal operation but can be easily removed when needed. The hinge mechanism provides controlled movement while maintaining reliability during operation.
Solution Approach 2:
The system provides self-service safety by automatically detecting when the transition plate is removed or dislodged through the light interrupter mechanism and automatically stopping the conveyor without requiring human intervention or complex locking mechanisms. The plate's own movement triggers the safety response.
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
Enhances safety by ensuring the conveyor is only activated when the transition plate is correctly positioned, preventing articles from being drawn into hazardous gaps and automatically disabling the conveyor if the plate is removed or dislodged, thus reducing the risk of damage or injury.
Implementation Method 1
a light emitter and a light detector positioned in a stationary spaced-apart relationship on opposing sides of the fin plate and aligned to emit and detect light through the fin plate aperture only when the transition plate is in its seated position
Implementation Method 2
the fin plate blocks the path between the light emitter and the light detector throughout the range of hinged motion of the transition plate
Data Source
AI summary
A transition plate assembly and a position sensor assembly are used to detect a dislodged or removed transition plate from a gap between the discharge end of a conveyor and the first end of a run-out ramp. The position sensor assembly may detect a safe seated position of a hinged transition plate protecting the gap and generate a motor-enabling signal to a drive motor that drives the conveyor. An interrupted motor-enabling signal, corresponding to an unsafe condition, may turn off the drive motor to prevent damage to articles or persons until an enabling signal is restored. In one embodiment, the termination of the power to the drive motor continues until a delay period has elapsed following the detection of an enabling signal.