Abstract: Apparatus and associated methods relate to detection systems with chatter-mitigated output indication. In an illustrative example, a sensor may generate a detection signal as a function of a physical relationship of a target to the sensor. A control circuit may, for example, generate a control signal in response to the detection signal and as a function of a predetermined indication response profile defining a transition threshold for each of multiple nominal transition points. A light-emitting indicator array may, for example, generate spatially distributed indication in response to the control signal. The indication may, for example, change from a first spatial distribution to a second spatial distribution in response to the detection signal crossing a first nominal transition point by at least a corresponding transition threshold (?1i). Various embodiments may, for example, advantageously prevent the visual indication from responding to perturbations in the detection signal.

Abstract: Apparatus and associated methods relate to a vibrational sensing system (VSS) including an accelerometer and a data processor, which determines an “operational state” of a mechanical drive unit, the processor further employing the “operational state” to gate learning of long-term vibrational data to exclude collection of non-operational data, the long-term data collected to calculate alarm thresholds. For example, vibrations from a target motor are sensed by a coupled accelerometer. Vibrational data from the accelerometer is fed into a data processor which determines the operational state of the motor. The operational state (e.g., on/off indication) may gate data collection such that data is only acquired during on-time, which may advantageously create accurate baselines from which alarm thresholds may be generated, and nuisance alarms may be avoided.

Abstract: Apparatus and associated methods relate to an alignment system including an alignment source module (ASM) and an alignment indicator module (AIM) configured to be releasably coupled to a first unit and a second unit, respectively, of a pair of optoelectronic arrays. In an illustrative example, the ASM may be oriented, when coupled, to emit an optical beam in substantial alignment with a first optical axis of the first unit. The AIM may, for example, be configured, when coupled, to provide a visible indication when the optical beam is within a predetermined near-alignment orientation range relative to a second optical axis of the second unit. Each of the AIM and the ASM may, for example, be configured to axially couple along respective longitudinal axes of the first unit and the second. Various embodiments may advantageously facilitate manipulation of the pair of optoelectronic arrays into near alignment with each other.

Abstract: Apparatus and associated methods relate to a method of non-contact motion detection. A one-dimensional optical sensor detects motion of a target or objects on a conveyor belt through a continuous measurement of targets or objects and a real-time comparison of the pixel images captured by the one-dimensional optical sensor. In an illustrative embodiment, a one-dimensional sensor may be configured to determine motion of objects based on changes to the captured intensities of pixel images over time. The sensor may continually capture photoelectric pixel images and compare a current pixel image with a previous pixel image to determine a frame differential image value. The frame differential image value is evaluated against a predetermined threshold over a predetermined time period. Based on the evaluation, a signal is output indicating whether the objects on the conveyor belt are moving or jammed.

Abstract: A sensor device has a metal sensor housing with a housing base coupled to a frame base of a metal optical frame. A device mounting plate is orthogonal to the frame base. A securing device secures an optical communication device to the device mounting plate. A barrel mounting channel has first and second sidewalls, each extending obliquely to the frame base and defining a linear translation pathway along the frame base for a metal lens barrel. A fastener secures the metal lens barrel to the first and second sidewalls. A glass lens is in contact with three protrusions extending outward from an inner annular surface of the lens barrel. The optical communication device is configured to be in optical communication with the lens and is secured in a particular position in a translation plane mutually defined by the device mounting plate and the optical communication device.

Abstract: Apparatus and associated methods relate to detecting jams when an intensity of a reflected signal exceeds a predetermined intensity threshold and an intensity window metric based on historic intensity value(s) fails to exceed an intensity window threshold for more than a predetermined time threshold. In an illustrative example, a jam detection unit (JDU) may emit a signal and detect a reflection of the signal. The JDU may, for example, compare intensity of the reflected signal to the intensity threshold. The JDU, for example, may compare the intensity threshold with at least one historic intensity value to determine the intensity window metric. If the intensity value exceeds the intensity threshold and the intensity window metric has not exceeded the intensity window threshold for longer than the time threshold, then the JDU may, for example, generate a jam signal. Various embodiments may advantageously detect jams based on intensity of a reflected signal.

Abstract: Apparatus and associated methods relate to a field-adjustable distance sensor configured to translate a transfer function of the sensor by a substantially constant value in a position domain by calibration at one or more known distances. In an illustrative example, the transfer function may correlate multiple distances to corresponding position vectors describing a position of a light signal on a receiver. The receiver may, for example, generate a detection signal corresponding to a position on the receiver of a light signal reflected off a target. A control circuit may, for example, generate a position vector in response to the detection signal. A calibration constant (C) may be generated, for example, as a function of a known distance of the target and position vector. C may be applied, for example, to translate the transfer function in the position domain. Various embodiments may advantageously reduce non-linear error in a distance sensor.

Abstract: Apparatus and associated methods relate to an array of individually readable distance sensors disposed along a first axis on a platform and configurable to detect penetration of a first plane containing the first axis, and an array of individually controllable light emitting indicators disposed on the platform along at least a second axis and configurable to emit visual indicia to a user out of the first plane. The visual indicia may, for example, be associated with the detected penetration. A reconfigurable predetermined detection window may, for example, be generated by associating adjacent sensors detecting input during a teaching operation. The detection window may, for example, be further generated by determining at least one distance threshold profile as a function of input received from the adjacent sensors during the teaching operation. Various embodiments may advantageously enable efficient configuration of generic sensing and indication units.

Abstract: Apparatus and associated methods relate to a safety control system having a processor that (1) automatically interrogates a portable data storage device, (2) determines whether a configuration profile of the safety control system matches a stored configuration profile in the portable data storage device, (3) obtains network settings of the safety control system, and (4) stores network settings into the portable data storage device. In an illustrative example, a safety control system may include a processor designed to perform operations to configure the safety control system with a configuration profile stored in the portable data storage device or download network settings of the safety control system to the portable data storage device under some predetermined conditions. By using the above method, the safety control system may be quickly configured, and network settings may be easily obtained and backed up.

Abstract: Apparatus and associated methods relate to generating a wiring schema with more than one safety device sharing at least one test signal through one or more external terminal blocks when the number of terminals required by safety devices exceeds the number of available terminals of a safety controller. In an illustrative example, the method may include determining a total number of terminals A of safety devices to be connected to a safety evaluation device having a number of terminals B. If A is greater than B, the method may then include generating a wiring schema that one or more external terminal blocks may show indicia of electrical connections between an identified set of safety devices and a shared terminal of the safety evaluation device associated with that set. By using the method, the number of devices that can be connected to the safety evaluation device may be expanded.

Abstract: Apparatus and associated methods relate to pairing a receiver with an emitter based on a presence of an amplitude of a spectral profile at at least one predetermined frequency. In an illustrative example, a receiver may receive, from the emitter, an emitted optical signal modulated by the at least one predetermined frequency. A receiver may, for example, generate a digital signal corresponding to the optical signal received. A controller may, for example, generate the spectral profile from the digital signal. The controller may, for example, apply a predetermined threshold to the spectral profile. The controller may, for example, generate an output signal based on the presence of the amplitude of the spectral profile above the first predetermined threshold at the at least one predetermined frequency. Various embodiments may advantageously discriminate a corresponding emitter to establish an optical source-to-detector-link, for example, in the presence of other emitters and/or optically noisy environments.

Abstract: Apparatus and associated methods relate to generating a wiring schema with more than one safety device sharing at least one test signal through one or more external terminal blocks when the number of terminals required by safety devices exceeds the number of available terminals of a safety controller. In an illustrative example, the method may include determining a total number of terminals A of safety devices to be connected to a safety evaluation device having a number of terminals B. If A is greater than B, the method may then include generating a wiring schema that one or more external terminal blocks may show indicia of electrical connections between an identified set of safety devices and a shared terminal of the safety evaluation device associated with that set. By using the method, the number of devices that can be connected to the safety evaluation device may be expanded.

Abstract: Apparatus and associated methods relate to an open-loop control circuit (OLCC) configured to determine a photodiode element (PDE) drive voltage as a function of a commanded photodiode gain level and a measured temperature signal. In an illustrative example the OLCC may receive a current temperature of an APD element. The OLCC may, for example, receive a commanded gain for the APD relative to a predetermined reference gain. The OLCC may, for example, retrieve a predetermined efficiency characteristic (PEC) of the APD based on the current temperature. If the temperature corresponds to a substantially non-linear portion of the PEC, the OLCC may, for example, determine the drive voltage as a function of the temperature and the commanded gain based on the PEC. Various embodiments may advantageously provide direct control of output gain of photodiodes over a wide dynamic range of temperature associated with the photodiode.

Abstract: Apparatus and associated methods relate to a safety control system having a processor that (1) automatically interrogates a portable data storage device, (2) determines whether a configuration profile of the safety control system matches a stored configuration profile in the portable data storage device, (3) obtains network settings of the safety control system, and (4) stores network settings into the portable data storage device. In an illustrative example, a safety control system may include a processor designed to perform operations to configure the safety control system with a configuration profile stored in the portable data storage device or download network settings of the safety control system to the portable data storage device under some predetermined conditions. By using the above method, the safety control system may be quickly configured, and network settings may be easily obtained and backed up.

Abstract: Apparatus and associated methods relate to dual safety touch button systems for generating machine operation commands, according to predetermined safety guidelines, from status information received via an intercommunications link (ICL) operably connecting the dual safety touch buttons (STBs). In an illustrative example, each of a pair of STBs includes a processor configured to receive, via an intercommunications link port, status information from the other STB. In response to the received information and predetermined safety guidelines, the STBs may generate machine operation commands that operate a pair of relay switches. In some embodiments, each STB may be activated within a substantially simultaneous period (e.g., less than 0.5 seconds) to actuate corresponding relay switches for operating a potentially dangerous machine.

Abstract: Apparatus and associated methods relate to a vibrational sensing system (VSS) including an accelerometer and a data processor, which determines an “operational state” of a mechanical drive unit, the processor further employing the “operational state” to gate learning of long-term vibrational data to exclude collection of non-operational data, the long-term data collected to calculate alarm thresholds. For example, vibrations from a target motor are sensed by a coupled accelerometer. Vibrational data from the accelerometer is fed into a data processor which determines the operational state of the motor. The operational state (e.g., on/off indication) may gate data collection such that data is only acquired during on-time, which may advantageously create accurate baselines from which alarm thresholds may be generated, and nuisance alarms may be avoided.

Abstract: Apparatus and associated methods relate to a photoelectric sensor system having a transmitter and a receiver, and at least one aperture module configured to modify a nominal field of view (FOV) of the transmitter and/or receiver, such that an overlap between the transmitter and receiver FOVs is controlled. In an illustrative example, the aperture module may be a plate having respective receiver and transmitter apertures. The transmitter and/or receiver apertures may be aligned or slightly offset from respective transmitter and receiver optical axes. The transmitter and/or receiver apertures may have a specific size/shape/position that produces a custom predetermined FOV overlap. At least one registration/alignment pin may extend through the aperture plate, a baffle, and a lens module to control orientation. The photoelectric sensor system may advantageously (1) be more resistant to the “white card effect,” (2) increase maximum sensor range, and (3) control the shape/size/overlap of the FOVs.

Abstract: Apparatus and associated methods relate to a vibrational sensing system (VSS) including an accelerometer and a data processor, which determines an “operational state” of a mechanical drive unit, the processor further employing the “operational state” to gate learning of long-term vibrational data to exclude collection of non-operational data, the long-term data collected to calculate alarm thresholds. For example, vibrations from a target motor are sensed by a coupled accelerometer. Vibrational data from the accelerometer is fed into a data processor which determines the operational state of the motor. The operational state (e.g., on/off indication) may gate data collection such that data is only acquired during on-time, which may advantageously create accurate baselines from which alarm thresholds may be generated, and nuisance alarms may be avoided.

Abstract: Apparatus and associated methods relate to a method of non-contact motion detection. A one-dimensional optical sensor detects motion of a target or objects on a conveyor belt through a continuous measurement of targets or objects and a real-time comparison of the pixel images captured by the one-dimensional optical sensor. In an illustrative embodiment, a one-dimensional sensor may be configured to determine motion of objects based on changes to the captured intensities of pixel images over time. The sensor may continually capture photoelectric pixel images and compare a current pixel image with a previous pixel image to determine a frame differential image value. The frame differential image value is evaluated against a predetermined threshold over a predetermined time period. Based on the evaluation, a signal is output indicating whether the objects on the conveyor belt are moving or jammed.