Patent Description:
The subject matter of this application may have common inventorship with and/or may be related to the subject matter of the following:.

Various embodiments relate generally to indicators.

Manufacturing facilities produce useful articles by processing components into finished goods. The operations used to process the components may involve transformational steps that change the article from one state to another. Some of these transformational operations employ machinery, such as presses, cutting tools, conveyor systems, ovens, or chemical applicators, for example.

Some manufacturing facilities use machinery that can be dangerous to humans. For example, a worker who walks into a zone of operation of a large robotic arm is at risk of serious bodily harm if the arm's motion profile intersects the worker's body or clothing. In another example, a worker who places a workpiece in a press and reaches into the press while the press is activated could be severely injured.

To promote safety for operators and machines, many manufacturing machines are protected, either partially or entirely surrounded by light curtain systems. A light curtain safety system may cause a machine to be deactivated when an object interrupts any portion of the light curtain sensing zone. For example, a hand extending through the curtain of light may block one or more beams of the light curtain, which the light curtain may interpret as a potential danger condition. The light curtain may typically respond by causing the machine to be deactivated by, for example, engaging a braking system and/or interrupting electric power to motor drives that cause a press to move. A light curtain safety system may also prevent a machine from being activated when an object is present in any portion of the light curtain sensing zone. For example, prior to machine startup, an operator who is standing too close, or within hazardous proximity, to a machine may block one or more beams of the light curtain. The light curtain may interpret this as a danger condition and prevent machine startup.

A known light curtain safety system is described in <CIT>.

Apparatus and associated methods relate to a side-mounted field-installable indication module (SMFIIM) configured to reflect a status of a manufacturing area (e.g., a status a machine, status a light curtain). The invention provides for a light curtain status indicator according to claim <NUM>, and a safety system according to claim <NUM>.

Various embodiments may achieve one or more advantages. For example, some embodiments may advantageously allow the SMFIIMs to be slidingly adjustable at the housing of the light curtain to adjust a height of the visual indicium.

The invention does include a refractive cover (e.g., configured to provide a distributed 'glowing' effect over substantially an entire viewing portion of the cover) for the light emitting module to increase viewing angle of the visual indicium.

Some embodiments, for example, may advantageously include other functionality. For example, some embodiments may include input interfaces. Some embodiments may, for example, include sensors. Various such embodiments may, for example, provide customizable modular functionalities for interacting with a monitored area.

For example, some embodiments may advantageously provide cascade connectivity. Such embodiments may, for example, advantageously enable a length of the visual indicium to be extended. Some embodiments may, for example, advantageously enable multiple functionalities to be cascaded together.

Some embodiments may advantageously include, for example, a display array(s). The display array may, for example, provide icons, animations, texts, and/or other interpretation capabilities. For example, some embodiments provided with a sensor(s) and light(s) may advantageously warn an approaching user of an imminent risk of breaking a safety barrier (e.g., a light curtain) and interrupting a machine and/or process.

The details of various embodiments are set forth in the accompanying drawings and the description below.

To aid understanding, this document is organized as follows. First, to help introduce discussion of various embodiments, a side-mounted field-installable indication module (SMFIIM) is introduced with reference to <FIG>. Second, that introduction leads into a description with reference to <FIG> of some exemplary embodiments of cascaded side-mounted field-installable modules. Third, with reference to <FIG>, exemplary control systems for controlling the side mounted field installable modules are described in application to exemplary light curtain units. Finally, the document discusses further embodiments, exemplary applications and aspects relating to light curtain status indicators.

<FIG> depicts exemplary side-mounted field-installable indication modules (SMFIIM) depicted in an illustrative use-case scenario. In a depicted exemplary scenario <NUM>, a machine <NUM> (e.g., a hydraulic press) is deployed (e.g., on a shop floor). The machine <NUM> may, for example, require safeguarding. An optoelectronic safety guard (e.g., pair of light curtains) is being installed to safeguard the machine <NUM>. The optoelectronic safety guard includes two light curtain units <NUM>. The two light curtain units <NUM> are configured to generate a curtain of light <NUM>. Upon successful installation, the curtain of light <NUM> may, for example, be configured such that operation of the machine <NUM> is stopped upon interruption of the curtain of light <NUM>.

SMFIIMs <NUM> are mounted, as depicted, on the light curtain units <NUM>. In the depicted example, the SMFIIMs <NUM> are operated to emit indications <NUM>. The indications <NUM> may, for example, indicate an operation state of the light curtain units <NUM>. The indications <NUM> may, for example, indicate a state of the curtain of light <NUM> (e.g., muted, armed, check alignment, cleaning needed, weak signal). The indications <NUM> may, for example, indicate a state of the machine <NUM> (e.g., error state, operating state, dangerous, safe to load material, lockout). The indications <NUM> may, for example, indicate a state of the factory (e.g., in operation, in maintenance). In some implementations, the indications <NUM> may display a diagnostic of the light curtain units <NUM> (by turn up intensity, changing colors). For example, the indications <NUM> may change from red to yellow to green to indicate levels of optical alignment of the light curtain units <NUM>.

The SMFIIMs <NUM> may, for example, be controlled by the two light curtain units <NUM>. The SMFIIMs <NUM> may, for example, be controlled by an external controller (e.g., the machine <NUM>, a PLC, a control unit). A more detailed discussion of controlling the light curtain units <NUM> and the SMFIIMs <NUM> is described with reference to <FIG>.

In some implementations, the SMFIIMs <NUM> may be slidingly adjustable along a longitudinal axis of a housing of the light curtain unit <NUM>. For example, the SMFIIMs <NUM> may be installed at a height close to eye level for workers in a production floor to advantageously improve visibility of the indications <NUM>. As shown in <FIG>, one or more of the SMFIIMs <NUM> may be mounted. Accordingly, for example, a length of the indication <NUM> may be extended to be one unit long, two unit long, or extending through the housing of the light curtain unit <NUM> entirely. For example, the total light output of the SMFIIMs <NUM> at a side of the light curtain unit <NUM> may be increased. In some implementations, multiple SMFIIMs <NUM> may be configured to emit an indication with different animations to represent various status of the machine <NUM> or the light curtain units <NUM>. For example, the SMFIIMs <NUM> may display different colors (e.g., in multiple independently addressable segments) at the same time that may represent a color coded message. In some examples, when the SMFIIMs <NUM> are mounted to an entire length of the light curtain unit <NUM>, different colors of the indications <NUM> may represent areas where the light curtain unit <NUM> are currently being muted, and areas where the light curtain unit <NUM> are currently being activated.

The SMFIIMs <NUM> include a 'glowing' refractive cover (e.g., a plastic light permissible cover) over the indications <NUM>. The glowing cover refracts an emitted light from the SMFIIMs <NUM> so that a wide angle of at least <NUM>° (e.g. at least <NUM>°, <NUM>°) of the indications is visible around the mounted light curtain unit <NUM>.

In some implementations, the indications <NUM> may include a display grid. For example, the display grid may be configured to display icons, text, and interpretations of status. In some examples, the display grid may assist in troubleshooting help (e.g., aid in alignment of the light curtain unit <NUM>). For example, the display grid may display a bar graph that increase in height as an alignment of the light curtain units <NUM> improves.

In the depicted example, the SMFIIMs <NUM> are operated at each side of the light curtain unit <NUM>. In some examples, having SMFIIMs <NUM> mounted on both sides of the light curtain unit <NUM> may advantageously provide a <NUM>° viewing of the indications <NUM> around the housing of the light curtain unit <NUM>.

<FIG> and <FIG> depict exemplary SMFIIMs mounted on an exemplary light curtain housing. A longitudinal light curtain housing and indicator assembly <NUM> is depicted. An SMFIIM <NUM> is mounted on each side of a light curtain housing <NUM> along a longitudinal axis <NUM>. The light curtain housing <NUM> may, for example, be constructed as an extrusion. The light curtain housing <NUM> may, for example, include plastic. The light curtain housing <NUM> may, for example, include aluminum.

The light curtain housing <NUM> is provided with a longitudinally extending aperture <NUM> (having a width as shown). The longitudinally extending aperture <NUM> defines an opening into a cavity <NUM> defined by the light curtain housing <NUM>. Light curtain circuitry may, for example, be disposed in the cavity240 and/or the longitudinally extending aperture <NUM>.

Each of the SMFIIM <NUM> is mounted substantially parallel to the longitudinal axis of the light curtain housing <NUM>. The SMFIIM <NUM> includes a base <NUM>. To the base <NUM> is coupled a cover <NUM>. The cover <NUM> may, for example, be at least partially optically translucent. The cover <NUM> may, for example, be glowing and refracting light into a wide angle.

The SMFIIM <NUM> is provided with a longitudinally extending mounting member <NUM>. The mounting member <NUM> extends substantially perpendicularly away from a surface of the SMFIIM <NUM> configured to face the light curtain housing <NUM>. The longitudinally extending mounting member <NUM> releasably couples within a longitudinally extending channel <NUM> in the light curtain housing <NUM>. Accordingly, the SMFIIM <NUM> is releasably coupled to the light curtain housing <NUM>.

As depicted in <FIG>, the SMFIIM <NUM> includes a circuit board <NUM>. The circuit board <NUM> may, for example, include at least one light-emitting element. In some embodiments the circuit board <NUM> may, for example, include at least one array of light-emitting elements. The light-emitting elements may, for example, include light-emitting diodes (LEDs). The array(s) of light-emitting elements may, for example, include linear arrays. The arrays may, for example, extend longitudinally along the circuit board such that, when the SMFIIM <NUM> is coupled to the <NUM>, the arrays are oriented substantially parallel to the longitudinal axis of the light curtain housing <NUM>.

In the depicted example, the cover <NUM> is a unitary housing. The unitary housing may, for example, be formed as a linear extrusion. The cover <NUM> includes mounting features <NUM>. The mounting features may, for example, releasably couple to the circuit board <NUM>. In the depicted example, the mounting features are arranged such that an optical axis <NUM> of the light-emitting elements of the circuit board <NUM> is oriented at an angle α relative to a plane <NUM> tangential to a mounting surface of the light curtain housing <NUM>. The α, as depicted, may be less than <NUM> degrees. Accordingly, the SMFIIM <NUM> may, by way of example and not limitation, be advantageously mounted on a side of the light curtain housing <NUM> while still being visible from a front of the light curtain housing <NUM>. (e.g., from an optical axis along an emission plane of the light curtain, extending from a center of the light curtain housing <NUM> through a center of the width of the longitudinally extending aperture <NUM> and substantially parallel to the longitudinal axis.

The longitudinally extending mounting member <NUM> includes a rib <NUM> extending longitudinally. The rib <NUM> extends distally away from a mounting surface of the cover <NUM>. The longitudinally extending mounting member <NUM> may, for example, be a retention member configured to be inserted into the longitudinally extending channel <NUM>. The longitudinally extending mounting member <NUM> may, for example, be configured to assemble to the light curtain housing <NUM> in response to application of a force perpendicular to a tangential of a surface of the light curtain housing <NUM>. In the depicted example, a distal coupling member <NUM> is provided, extending longitudinally along a distal end of the rib <NUM>.

The longitudinally extending mounting member <NUM> is configured to releasably couple to the longitudinally extending channel <NUM>. The longitudinally extending channel <NUM> includes an opening <NUM>. The opening <NUM> may, for example, have a width W (e.g., <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, wider). The opening <NUM> may transition to a restriction <NUM> having a width W1 < W. The restriction <NUM> may open into a channel <NUM> having a width (e.g., diameter) W2 > W > W1. The distal coupling member <NUM> may, for example, be configured to be releasably captured within the <NUM>. The distal coupling member <NUM> may, for example, be configured to be (substantially elastically) compressed to pass through the <NUM> when inserted radially thereinto and then expand (e.g., substantially elastically) once within the channel <NUM>. Accordingly, the SMFIIM <NUM> may be advantageously coupled to the light curtain housing <NUM> by the longitudinally extending mounting member <NUM> engaging the longitudinally extending channel <NUM>.

The longitudinally extending mounting member <NUM> may, for example, prevent rotation of the SMFIIM <NUM> relative to the light curtain housing <NUM>. Accordingly, for example, a user may advantageously position the lights freely up or down along a longitudinal axis of the light curtain housing <NUM>.

<FIG> shows an exemplary SMFIIM mounted on an exemplary light curtain housing. An exemplary side-indicator light curtain system <NUM> includes an SMFIIM <NUM> mounted on a light curtain <NUM>. The light curtain <NUM> includes a longitudinally extending channel <NUM>. The SMFIIM <NUM> is releasably coupled to the light curtain <NUM> by insertion of a retaining member (not shown) (e.g., such as the rib <NUM>) into the longitudinally extending channel <NUM>.

The SMFIIM <NUM> includes a unitary linear extrusion body <NUM> coupled to a base <NUM>. Light-emitting elements (not shown) of the SMFIIM <NUM> are provided power and/or command signals by a cable <NUM> (e.g., coupled to the light curtain <NUM>, coupled to a separate power and/or command source). As depicted, a fastening member (e.g., screw) may be inserted through the base <NUM> to engage the longitudinally extending channel <NUM>. The fastening member may, for example, prevent movement of the SMFIIM <NUM> along the longitudinal axis relative to the light curtain <NUM>.

<FIG> and <FIG> depict an exemplary SMFIIM deployed in an exemplary use-case scenario. As shown in <FIG>, two SMFIIMs <NUM> are mounted on the light curtain unit <NUM>. In this example, the SMFIIMs <NUM> are connected to a central hub <NUM> for control. In this scenario <NUM>, a first indication <NUM> (e.g., the light curtain is not armed, and workers can pass through) is displayed at the SMFIIMs <NUM>. As shown in <FIG>, a scenario <NUM> indicates that a second indication <NUM> is displayed at the SMFIIMs <NUM>. For example, the second indication <NUM> may indicate that a machine behind the light curtain is armed. For example, it may be hazardous to pass through the light curtain <NUM> at this time.

<FIG> depicts exemplary different types of cascaded side-mounted field-installable modules (CSMFIMs) depicted in an illustrative use-case scenario <NUM>. In this example, the light curtain unit <NUM> is mounted with the SMFIIM <NUM>, a side mounted input module (SMIM <NUM>), and a side mounted sensing module (SMSM <NUM>). As shown, the SMFIIM <NUM>, the SMIM <NUM>, and the SMSM <NUM> are serially connected to the light curtain unit <NUM>. For example, the SMFIIM <NUM>, the SMIM <NUM>, and the SMSM <NUM> may receive power from the light curtain unit <NUM> cascadingly. In some implementations, the SMFIIM <NUM>, the SMIM <NUM>, and the SMSM <NUM> may be parallelly connected to a hub (for electrical power, control).

The SMIM <NUM> includes an input interface <NUM>. For example, the input interface <NUM> may be a touch input (e.g., a capacitive touch input). For example, the input interface <NUM> may include push buttons. The input interface <NUM> may, for example, include sliding inputs. In some implementations, a user may use the input interface <NUM> to, for example, control the light curtain unit <NUM>, the SMFIIM <NUM>, the machine <NUM>, or a combination thereof.

The SMSM <NUM> includes sensors <NUM>. The sensors <NUM> may, for example, include light sensors. The sensors <NUM> may, for example, include temperature sensors. The sensors <NUM> may, for example, include distance sensors (e.g., a very low range time-of-flight sensor). In some implementations, the distance sensors may detect whether an object (e.g., a person, vehicles, other moving objects) is getting too close to possibly break the curtain of light <NUM>. For example, the sensors <NUM> may transmit a signal to trigger the SMFIIM <NUM> to display (e.g., in changing the indication from green to amber) to advantageously provide an early warning before the curtain of light <NUM> is broken. For example, the early warning may advantageously prevent unnecessarily shutting down of the machine <NUM>, causing production delays. In various implementations, the CSMFIM may advantageously provide a cost effective way to provide customizable functionality to the light curtain unit <NUM>.

<FIG>, <FIG> are block diagrams showing exemplary control circuits of exemplary side mounted modules. As shown in <FIG>, a control system <NUM> includes the light curtain unit <NUM> and a side mounted module <NUM>. The light curtain unit <NUM> is mechanically coupled to the side mounted module <NUM>. The side mounted module <NUM> includes an indicator <NUM> (e.g., the SMFIIM <NUM>), a touch input <NUM> (e.g., the SMIM <NUM>), and sensors <NUM> (e.g., the SMSM <NUM>). For example, the side mounted module <NUM> may be mounted to the light curtain unit <NUM> using mechanisms as described with reference to <FIG>.

In this example, the light curtain unit <NUM> and the side mounted module <NUM> are operably coupled to a controller <NUM>. For example, the controller <NUM> may be a safety control network. For example, the controller <NUM> may be a network controlled by a safety PLC. In this example, the controller <NUM> may control both the light curtain unit <NUM> and the side mounted module <NUM>. For example, the controller <NUM> may control the color of the indicator <NUM> based on a status of the light curtain unit <NUM>. In some implementations, the controller <NUM> may also receive input (e.g., sensor input) from the side mounted module <NUM> and operate the light curtain unit <NUM> based on the received input (e.g., mute or arm the light curtain unit <NUM>).

As shown in <FIG>, the side mounted module <NUM> is connected to the light curtain unit <NUM> mechanically and operably. For example, the indicator <NUM> may be operated with an output signal switching device (OSSD) signal wire of the light curtain unit <NUM>.

As shown in <FIG>, a control system <NUM> includes two independent controllers 1005a, 1005b. The light curtain unit <NUM> is connected to the controller 1005a. The side mounted module <NUM> is connected to the controller 1005b. As such, the light curtain unit <NUM> and the side mounted module <NUM> are coupled mechanically. For example, the light curtain unit <NUM> and the side mounted module <NUM> are controlled independently. In this example, the controllers 1005a, 1005b are optionally connected via a network <NUM>. For example, the network <NUM> may coordinate smart customer applications with the controllers 1005a, 1005b.

Although various embodiments have been described with reference to the figures, other embodiments are possible. Although an exemplary system has been described with reference to the figures, other implementations may be deployed in other industrial, scientific, medical, commercial, and/or residential applications.

In some embodiments a system for a lighting bar may be designed for a wide-viewing angle. The system may, for example, include a lighting bar configurable to be removably attached by a user to a light curtain at a user-defined location.

Some embodiments may, for example, provide a method of providing illumination to a light curtain by releasably attaching a SMFIIM to it by applying an insertion force to the SMFIIM substantially perpendicular to a channel of the light curtain.

In some embodiments, a retention member of the SMFIIM may, for example, be replaceable (e.g., interchangeable for different sizes). In some embodiments a retention member of the SMFIIM may, for example, include a channel. The channel may, for example, releasably engage a rib. The rib may, for example, be releasably coupled to the light curtain. The rib may, for example, be integrally formed with the light curtain.

In some embodiments the SMFIIM may, for example, be configured to couple to a linear measuring device (e.g., measuring light curtain). In some embodiments the SMFIIM may, for example, be configured to releasably couple to linear extrusion (e.g., standard aluminum extrusions).

In various safety light curtain applications, highly visible indication of the light curtain status may be desirable. The highly visible indicators can be used to quickly and/or easily determine a status of the light curtain and/or minimize downtime of the guarded machine. In some cases, the indicators may be used to display information other than (e.g., in additional to, instead of) the light curtain status, such as a status of a warehouse floor. In various examples, the indicators need to be visible to personnel from a variety of angles and positions.

Various embodiments may include field-installable strip lights mounted to one or more sides of a safety light curtain sensor to provide bright illumination of an indication. The indication may, for example, correspond to a light curtain, warehouse, and/or machine status. The lights may be controlled directly by the light curtain. The lights may be controlled externally by a separate controller.

In some embodiments, internal printed circuit boards (PCBs) may, for example, be angled at approximately <NUM>° to provide viewing from a variety of angles (e.g., α may be substantially <NUM>°). In some embodiments an entire, molded plastic extrusion may be illuminated. Such embodiments may, for example, provide excellent viewing from multiple angles. For example, in some such embodiments, an emitted indication may be visible even from behind the light curtain.

In various embodiments, some bypass circuits implementations may be controlled in response to signals from analog or digital components, which may be discrete, integrated, or a combination of each. Some embodiments may include programmed, programmable devices, or some combination thereof (e.g., PLAs, PLDs, ASICs, microcontroller, microprocessor), and may include one or more data stores (e.g., cell, register, block, page) that provide single or multi-level digital data storage capability, and which may be volatile, non-volatile, or some combination thereof. Some control functions may be implemented in hardware, software, firmware, or a combination of any of them.

Although an example of a system, which may be portable, has been described with reference to the above figures, other implementations may be deployed in other processing applications, such as desktop and networked environments.

Temporary auxiliary energy inputs may be received, for example, from chargeable or single use batteries, which may enable use in portable or remote applications. Some embodiments may operate with other DC voltage sources, such as batteries, for example. Alternating current (AC) inputs, which may be provided, for example from a <NUM>/<NUM> power port, or from a portable electric generator, may be received via a rectifier and appropriate scaling. Provision for AC (e.g., sine wave, square wave, triangular wave) inputs may include a line frequency transformer to provide voltage step-up, voltage step-down, and/or isolation.

In various implementations, the system may communicate using suitable communication methods, equipment, and techniques. For example, the system may communicate with compatible devices (e.g., devices capable of transferring data to and/or from the system) using point-to-point communication in which a message is transported directly from the source to the receiver over a dedicated physical link (e.g., fiber optic link, point-to-point wiring, daisy-chain). The components of the system may exchange information by any form or medium of analog or digital data communication, including packet-based messages on a communication network. Examples of communication networks include, e.g., a LAN (local area network), a WAN (wide area network), MAN (metropolitan area network), wireless and/or optical networks, the computers and networks forming the Internet, or some combination thereof. Other implementations may transport messages by broadcasting to all or substantially all devices that are coupled together by a communication network, for example, by using omni-directional radio frequency (RF) signals. Still other implementations may transport messages characterized by high directivity, such as RF signals transmitted using directional (i.e., narrow beam) antennas or infrared signals that may optionally be used with focusing optics. Still other implementations are possible using appropriate interfaces and protocols such as, by way of example and not intended to be limiting, USB <NUM>, Firewire, ATA/IDE, RS-<NUM>, RS-<NUM>, RS-<NUM>, <NUM> a/b/g, Wi-Fi, Ethernet, IrDA, FDDI (fiber distributed data interface), token-ring networks, multiplexing techniques based on frequency, time, or code division, or some combination thereof. Some implementations may optionally incorporate features such as error checking and correction (ECC) for data integrity, or security measures, such as encryption (e.g., WEP) and password protection.

In various embodiments, the computer system may include Internet of Things (IoT) devices. IoT devices may include objects embedded with electronics, software, sensors, actuators, and network connectivity which enable these objects to collect and exchange data. IoT devices may be in-use with wired or wireless devices by sending data through an interface to another device. IoT devices may collect useful data and then autonomously flow the data between other devices.

Various examples of modules may be implemented using circuitry, including various electronic hardware. By way of example and not limitation, the hardware may include transistors, resistors, capacitors, switches, integrated circuits, other modules, or some combination thereof. In various examples, the modules may include analog logic, digital logic, discrete components, traces and/or memory circuits fabricated on a silicon substrate including various integrated circuits (e.g., FPGAs, ASICs), or some combination thereof. In some embodiments, the module(s) may involve execution of preprogrammed instructions, software executed by a processor, or some combination thereof. For example, various modules may involve both hardware and software.

Claim 1:
A light curtain status indicator (<NUM>), comprising:
a light emitting module (<NUM>) comprising a refractive cover (<NUM>) and configured to emit a visual indicium (<NUM>) at a wide angle corresponding to a status of at least one predetermined signal, wherein the wide angle comprises a viewing angle of at least <NUM>°; characterized by
a coupling member (<NUM>) configured to be releasably captured within a longitudinally extending channel (<NUM>) of a housing of a light curtain (<NUM>), such that the light curtain status indicator is coupled to the housing to be disposed on a side of and substantially parallel to the housing,
wherein the light emitting module is configured to emit the visual indicium in an emitting plane (<NUM>) intersecting an optical axis (<NUM>) of the light curtain, and,
when the light curtain status indicator is releasably coupled to the housing, the emitting plane is oriented at an angle α relative to a plane tangential to a mounting surface of the light curtain housing, and α < <NUM>°, such that the light emitting module is viewable from the wide angle.