Wireless Sensor Control Device for Machine Tool Safety
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing machine control systems for bending or press brake operations restrict operator freedom and increase the risk of injury by requiring attention diversion for complex operations and lack the ability to transmit variable control commands efficiently, leading to potential incorrect operation or injury.
Innovation Solution
A machine control system with a sensor module integrated into clothing, such as shoes, that uses a wireless evaluation module to generate control signals based on physical variables like pressure and acceleration, allowing for multiple control commands without diverting attention from the work area, and includes a wireless connection for flexible operation and safety features like tactile feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a foot switch is used to control the bending process, then the operator can trigger the bending process, but the operator's freedom of movement is restricted and attention must be diverted from the work area
Solution Approach 1:
The patent replaces the mechanical foot switch system with a wireless sensor system. The sensor module detects physical variables (pressure, acceleration, position) and transmits signals wirelessly to the control module, eliminating the need for physical contact with control devices and allowing the operator to maintain freedom of movement while controlling the bending process safely
Solution Approach 2:
The patent introduces a wireless communication system as an intermediary between the operator and the machine control. The sensor module acts as a mediator that captures operator intent through physical gestures and transmits control commands wirelessly, allowing the operator to control the machine without direct physical interaction with control elements
2Reliability
If additional emergency actuation elements are added to the machine tool, then emergency stop functionality is provided, but circuitry complexity and equipment costs increase
Solution Approach 1:
The patent makes the sensor module multi-functional by programming it to recognize different gesture patterns for different functions (normal operation, emergency stop, etc.). A single sensor module replaces multiple dedicated control elements, reducing circuitry complexity while maintaining comprehensive safety functionality through software-based differentiation of commands
3Productivity
If the operator must divert attention to operate control elements, then control commands can be executed, but the risk of incorrect operation or injury increases
Solution Approach 1:
The sensor module operates passively by detecting natural physical gestures without requiring active operator intervention. The system automatically captures control intent through physical variables and transmits commands wirelessly, allowing the operator to maintain focus on the work area while the system serves itself by interpreting and executing control commands from natural movements
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
Enables operators to perform complex machine tool operations safely and efficiently by allowing multiple control commands without attention diversion, reducing the risk of injury and improving usability with integrated safety features like tactile feedback and precise position determination.
Implementation Method 1
the sensor module (4) has a converter which detects the effect of a physical variable and generates an electrical parameter
Implementation Method 2
a sensor module integrated into clothing, such as shoes, that uses a wireless evaluation module to generate control signals based on physical variables like pressure and acceleration
Data Source
Figure 1
Figure 2~3
Figure 4a~4b
AI summary
The invention relates to a machine controller, comprising a sensor module (4), an evaluating module (9), and a control module (5), wherein the sensor module (4) has a converter, which converts a mechanical quantity acting on the sensor module (4) into a proportional electrical parameter and wherein the evaluating module (9) is connected to the sensor module (4) by means of a first signal connection (8) and to the control module (5) by means of a second signal connection (11). The evaluating module (9) forms a signal profile from the detected electrical signal by means of a potential analysis and/or a change analysis. The signal profile is compared with at least one reference signal profile stored in a storage element of the evaluating module (9) by a comparison module of the evaluating module (9), and the control signal is generated therefrom. Furthermore, at least one of the two signal connections (8, 11) is designed to be wireless.