Patent Description:
<CIT> describes a locomotion safety and health assistant comprising a quad cane with an integrated suite of sensors, microcontrollers, power sources, external communication devices, lights, tactile communication devices, alerts and activation sensors. A plurality of environment sensors can monitor the terrain ahead, watching for obstacles or changes in elevation. The assistant can provide communication with the user to warn of any obstacles or dangers.

<CIT> describes a virtual walking stick for assisting blind or visually impaired people.

<CIT> describes an apparatus for measuring the heights and/or determining the configuration of overhead electric cables used for supplying power to electric trains which includes an elongate frame locatable by feet in a predetermined position across a pair of parallel rails. A pair of upwardly facing electro-acoustic transducers are mounted at opposite ends of the frame. A circuit is adapted to energise a selected one of the transducers to transmit a burst of sound directed upwardly at overhead cables and to discriminate between multiple echoes received by a selected one of the transducers after reflection of a burst from said cables. From the measurement of a plurality of round trip delays the circuit can determine the heights and/or configuration of the overhead cables.

A sensor device is provided according to the claims. An elongate sleeve has a first end and a second end and extends along a longitudinal axis. A plurality of sensors are fixed relative to the sleeve. A first endcap is coupled to the first end, where the first endcap has an endcap body. An intermediate component is coupled to the first axle, and the intermediate component is selectively rotatable about the longitudinal axis. A second endcap (<NUM>, <NUM>) is coupled to the second end (<NUM>) of the sleeve', wherein the second endcap (<NUM>, <NUM>) has a rail coupler (<NUM>, <NUM>) that is freely rotatable relative to the sleeve.

In some such embodiments, the intermediate component is linearly translatable relative to the endcap body along the first axle, is freely rotatable about the longitudinal axis when the intermediate component is in a first linear position relative to the endcap body and has a fixed orientation about the longitudinal axis when the intermediate component is in a second linear position relative to the endcap body. Additionally or alternatively, the endcap body has the first axle, where the intermediate component is rotatably disposed about the first axle between the endcap body and the retaining feature, and the intermediate component is linearly translatable between the endcap body and the retaining feature.

Additionally or alternatively, the intermediate component has the first axle, where the endcap body is rotatably disposed about the first axle between the intermediate component and the retaining feature and the endcap body is linearly translatable between the intermediate component and the retaining feature. Additionally or alternatively, the retaining feature extends radially outward from a distal end of the first axle. Additionally or alternatively, the intermediate component and the first endcap mutually define the orientation locking structure that selectively engages when the intermediate component is in the second linear position. Additionally or alternatively, the orientation locking structure selectively engages in a plurality of fixed orientations about the first axle when the intermediate component is in the second linear position relative to the endcap body.

Additionally or alternatively, the orientation locking structure has a first protrusion extending outward from the endcap body and a series of protrusion receptacles defined by the intermediate component, where the first protrusion has a radial position relative to the longitudinal axis, and each of the protrusion receptacles in the series of protrusion receptacles are in circumferential alignment with the first protrusion to selectively receive the first protrusion. Additionally or alternatively, the first protrusion extends longitudinally outward from a distal end of the endcap body. Additionally or alternatively, the series of protrusion receptacles are defined by an inner region of the intermediate component.

Additionally or alternatively, the orientation locking structure has a first protrusion extending outward from the intermediate component and a series of protrusion receptacles defined by the endcap body, where the first protrusion has a radial position relative to the longitudinal axis, and each of the protrusion receptacles in the series of protrusion receptacles are each in circumferential alignment with the first protrusion to selectively receive the first protrusion. Additionally or alternatively, the first protrusion extends longitudinally inward from a proximal end of the intermediate component. Additionally or alternatively, the series of protrusion receptacles are defined by an inner region of the endcap body.

Additionally or alternatively, the orientation locking structure has a first protrusion, a first protrusion receptacle defined by the intermediate component and a second protrusion receptacle defined by the endcap body, where the first protrusion receptacle and the second protrusion receptacle are configured to mutually receive the first protrusion. The sensor device of claim <NUM>, where the intermediate component defines a series of protrusion receptacles in circumferential alignment with the first protrusion receptacle. Additionally or alternatively, each of the plurality of sensors are linearly aligned relative to each other. Additionally or alternatively, each of the plurality of sensors are linearly aligned parallel to the longitudinal axis.

Additionally or alternatively, the rail coupler defines a polygonal protrusion and a circular protrusion, each extending longitudinally outward from a distal end of the second endcap. Additionally or alternatively, the polygonal protrusion is hexagonal. Additionally or alternatively, the second endcap has a rod translatably disposed in the sleeve and a spring compressibly disposed between the rod and the sleeve, where the rail coupler is rotatably coupled to the rod about a second axle. Additionally or alternatively, the second axle defines a retaining feature configured to retain the rail coupler thereon. Additionally or alternatively, the intermediate component defines a polygonal protrusion configured to receive a corresponding opening in a conveyor rail. Additionally or alternatively, the polygonal protrusion is hexagonal.

In some example configurations disclosed herein, a sensor device has an elongate sleeve extending along a longitudinal axis, where the elongate sleeve has a first end and a second end. A plurality of sensors are fixed relative to the sleeve, a first endcap has an endcap body coupled to the first end, and an intermediate component is coupled to the first endcap, where the intermediate component is selectively rotatable about the longitudinal axis relative to the endcap body.

In some such embodiments, the sensor device has an orientation locking structure configured to be engaged to selectively fix the orientation of the intermediate component about the longitudinal axis relative to the endcap body. In some of those embodiments, the orientation locking structure is configured to be engaged to selectively fix the intermediate component in each of a plurality of fixed orientations about the longitudinal axis relative to the endcap body. Additionally or alternatively, the intermediate component is linearly translatable relative to the endcap body along the longitudinal axis between a first linear position defining a particular maximum linear distance between the endcap body and the intermediate component and a second linear position defining a minimum linear distance between the endcap body and the intermediate component, where the intermediate component is freely rotatable in the first linear position and the intermediate component has a fixed orientation about the longitudinal axis in the second linear position. Additionally or alternatively, a first axle extends along the longitudinal axis, where the endcap body and the intermediate component are coupled to the first axle.

Additionally or alternatively, the first endcap has a first axle extending along the longitudinal axis, where the intermediate component is slidably and rotatably disposed on the first axle and the first axle has a retaining feature configured to retain the intermediate component on the first axle. In the first linear position the intermediate component abuts the retaining feature and in the second linear position the intermediate component abuts the endcap body. Additionally or alternatively the intermediate component has a first axle extending along the longitudinal axis and the endcap body is slidably and rotatably disposed on the first axle, where the first axle has a retaining feature on a distal end configured to retain the endcap body on the first axle. In the first linear position the endcap body abuts the retaining feature and in the second linear position the intermediate component abuts the endcap body.

Additionally or alternatively, the retaining feature extends radially outward from a distal end of the first axle. Additionally or alternatively, the intermediate component and the first endcap mutually define an orientation locking structure that selectively engages when the intermediate component is in the second linear position and disengages in the first linear position. Additionally or alternatively, the orientation locking structure selectively engages in a plurality of fixed orientations about longitudinal axis when the intermediate component is in the second linear position relative to the endcap body. Additionally or alternatively, the sensor device has a second endcap coupled to the second end of the sleeve, where the second endcap has a rail coupler that is freely rotatable relative to the sleeve.

Additionally or alternatively, the orientation locking structure has a first protrusion extending outward from the endcap body and a series of protrusion receptacles defined by the intermediate component, where the first protrusion has a radial position relative to the longitudinal axis and each of the protrusion receptacles in the series of protrusion receptacles are in circumferential alignment with the first protrusion to selectively receive the first protrusion. Additionally or alternatively, the first protrusion extends longitudinally outward from a distal end of the endcap body. Additionally or alternatively, the series of protrusion receptacles are defined by an inner region of the intermediate component.

Additionally or alternatively, the orientation locking structure has a first protrusion extending from the intermediate component and a series of protrusion receptacles defined by the endcap body, where the first protrusion has a radial position relative the longitudinal axis and each of the protrusion receptacles in the series of protrusion receptacles are in circumferential alignment with the first protrusion to selectively receive the first protrusion. Additionally or alternatively, the first protrusion extends longitudinally inward from the intermediate component. Additionally or alternatively, the series of protrusion receptacles are defined by an inner region of the endcap body.

Additionally or alternatively, the orientation locking structure has a first protrusion, a first protrusion receptacle defined by the intermediate component, and a second protrusion receptacle defined by the endcap body, where the first protrusion receptacle and the second protrusion receptacle are configured to mutually receive the first protrusion. Additionally or alternatively, the intermediate component defines a series of protrusion receptacles in circumferential alignment with the first protrusion receptacle.

The present technology may be more completely understood and appreciated in consideration of the following detailed description of various embodiments in connection with the accompanying drawings.

The figures are rendered primarily for clarity and, as a result, are not necessarily drawn to scale. Moreover, various structure/components, including but not limited to fasteners, electrical components (wiring, cables, etc.), and the like, may be shown diagrammatically or removed from some or all of the views to better illustrate aspects of the depicted embodiments, or where inclusion of such structure/components is not necessary to an understanding of the various exemplary embodiments described herein.

The technology disclosed herein generally relates to a sensor device that is configured to be positioned in a conveyor line such as, for example, a portion of a conveyor line <NUM> depicted in <FIG>. The conveyor line <NUM> can have a conveyor surface <NUM>, here defined by a plurality of rollers <NUM>, that is disposed between two conveyor siderails 20a, 20b. The sensor device is configured to be coupled to the opposite siderails 20a, 20b along the conveyor line <NUM>. In various embodiments the sensor device is configured to be positioned below the conveyor surface <NUM> to avoid contact with objects conveyed over the conveyor surface <NUM>. The sensor device can be manually manipulated to be fixed in each of a plurality of particular orientations about its longitudinal axis such that the orientation of the plurality of sensors can be selected by a user. Advantageously, the sensor device itself incorporates components that interface with the siderails, which can simplify adjustability of the sensor device.

<FIG> is an example sensor device consistent with some embodiments of the technology disclosed herein. The sensor device <NUM> can generally be configured to be installed between conveying rollers of a conveyor line. The sensor device <NUM> can generally be configured to sense objects traversing a conveyor line. The sensor device <NUM> generally has an elongate sleeve <NUM>, a plurality of sensors <NUM> fixed relative to the sleeve <NUM>, a first endcap assembly <NUM> coupled to the elongate sleeve <NUM>, and a second endcap <NUM> coupled to the elongate sleeve <NUM>.

The elongate sleeve <NUM> is generally configured to couple to the plurality of sensors <NUM> and extend across a conveyor line. The sensors <NUM> are at a particular orientation about a longitudinal axis L. The elongate sleeve <NUM> generally extends along the longitudinal axis L. The elongate sleeve <NUM> has a first end <NUM> and a second end <NUM>. The second end <NUM> is generally opposite the first end <NUM>. In the current example the elongate sleeve <NUM> is generally cylindrical with a circular cross-section. in other embodiments the elongate sleeve <NUM> can define a prism with a polygonal cross-section. In some other embodiments the elongate sleeve <NUM> can define an elliptical cylinder. Other shapes are certainly contemplated.

The plurality of sensors <NUM> that are fixed relative to the sleeve <NUM> can be a variety of different types and combinations of sensors. In some embodiments an ultrasonic sensor is at least one of the plurality of sensors <NUM>. In some embodiments a photoelectric sensor is at least one of the plurality of sensors <NUM>. In some embodiments at least one of the plurality of sensors <NUM> is a proximity sensor. In some embodiments, an accelerometer is at least one of the plurality of sensors <NUM>. In various embodiments, at least a portion of each of the plurality of sensors is housed by the elongate sleeve <NUM>. In the current example, each of the plurality of sensors <NUM> are linearly aligned relative to each other. In some alternate embodiments, one or more of the plurality of sensors is not aligned with another one of the plurality of sensors. Furthermore, in the current example, each of the plurality of sensors <NUM> are linearly aligned parallel to the longitudinal axis L.

The first endcap assembly <NUM> is coupled to the first end <NUM> of the sleeve <NUM>. The first endcap assembly <NUM> can have a first endcap <NUM> and an intermediate component <NUM>. The first endcap <NUM> is coupled to the first end <NUM> of the sleeve <NUM>. In the current example, the first endcap <NUM> is configured, at least in part, to provide an obstruction through the first end <NUM> of the sleeve <NUM>. In some embodiments, the first endcap <NUM> forms a frictional fit with the first end <NUM> of the sleeve <NUM>. The first endcap <NUM> generally has an endcap body <NUM>. The first endcap <NUM> will be described in more detail below with reference to <FIG> and <FIG>.

The intermediate component <NUM> is generally configured to couple the first end <NUM> of the sleeve <NUM> to a conveyor system, such as a conveyor rail. The intermediate component <NUM> is generally configured to selectively rotate relative to the first endcap <NUM> and the sleeve <NUM>. For example, the intermediate component <NUM> is freely rotatable about the longitudinal axis L relative to the first endcap <NUM> in a first position, and, in a second position, the intermediate component <NUM> is non-rotatable about the longitudinal axis L relative to the first endcap <NUM>. Such functionality and configurations will be described in more detail below.

In the current example, the intermediate component <NUM> defines a rail mating feature <NUM> that is configured to mate with a corresponding surface defined by the conveyor rail. In the current example, the rail mating feature <NUM> is a protrusion that extends longitudinally outward from the sleeve <NUM>. The protrusion can be a polygonal protrusion such as, in the example depicted, a hexagonal protrusion. The hexagonal protrusion can be configured to mate with a corresponding hexagonal recess defined by the conveyor rail. In some other embodiments the mating feature can be a recess that is configured to receive a corresponding protrusion of a conveyor rail. Example structures of the intermediate component <NUM> will be described in more detail below.

The second endcap <NUM> is coupled to the second end <NUM> of the sleeve <NUM>. In the current example, the second endcap <NUM> is generally configured to, at least in part, provide an obstruction through the second end <NUM> of the sleeve <NUM>. The second endcap <NUM> has a rail coupler <NUM> that is generally freely rotatable about the longitudinal axis L relative to the sleeve <NUM>. Example structures and configurations consistent with the second endcap <NUM> will be described in more detail below.

When the sensor device <NUM> is properly installed between conveyor rails (such as conveyor siderails 20a and 20b depicted in <FIG>) in a conveyor line and the intermediate component <NUM> is in the first position (enabling relative rotation between the intermediate component <NUM> and the sleeve <NUM>), a user can rotate the sleeve <NUM> relative to the intermediate component <NUM> and the rail coupler <NUM> to position the plurality of sensors <NUM> in the desired orientation about the longitudinal axis L. When the desired orientation of the plurality of sensors <NUM> is achieved, the intermediate component <NUM> can be shifted to the second position, such that the sleeve <NUM> is non-rotatable relative to the intermediate component <NUM>.

<FIG> is a perspective view of an example first endcap assembly <NUM> consistent with a sensor device of <FIG>, where the intermediate component <NUM> and the first endcap <NUM> are components of the first endcap assembly <NUM>. <FIG> is a disassembled perspective view of an example first endcap assembly <NUM> consistent with <FIG>. <FIG> is a cross-sectional view of the first endcap assembly when the first endcap and the intermediate component are in a first position relative to each other and <FIG> is a cross-sectional view of the first endcap assembly when the first endcap and the intermediate component are in a second position relative to each other. Each of these drawings will be referenced with the description here.

Referring first to <FIG>, the first endcap <NUM> is configured to be coupled to the first end <NUM> of the sleeve <NUM> (see <FIG>). A sleeve insertion portion <NUM> is configured to be inserted into the first end <NUM> of the sleeve <NUM>. In some other configurations the first endcap <NUM> can be configured to cover the first end <NUM> of the sleeve <NUM>. In various embodiments the first endcap <NUM> frictionally engages the sleeve <NUM>. In various additional or alternative embodiments the first endcap <NUM> is coupled to the sleeve <NUM> through the use of an adhesive, fasteners (such as screws or bolts), and the like.

The intermediate component <NUM> is coupled to the first endcap <NUM> and is selectively rotatable relative to the first endcap <NUM>. In particular, as best visible in <FIG>, the first endcap <NUM> has an endcap body <NUM> and a first axle <NUM> coupled to the endcap body <NUM>. The first axle <NUM> extends outwardly from the endcap body <NUM>. The first axle <NUM> extends along the longitudinal axis L. The intermediate component <NUM> is rotatably disposed about the first axle <NUM>. More specifically, the intermediate component <NUM> defines an axle opening <NUM> that receives the first axle <NUM>.

In the current example, the first axle <NUM> defines a retaining feature <NUM> that is configured to retain the intermediate component <NUM> on the first axle <NUM>. In particular, the retaining feature <NUM> extends radially outward from a distal end of the first axle <NUM> and has an outer dimension D<NUM> that exceeds an outer diameter D<NUM> of the axle opening <NUM> (see <FIG>), where the outer dimension and the outer diameter are perpendicular to the longitudinal axis L. As such, the intermediate component <NUM> is rotatably disposed between the endcap body <NUM> and the retaining feature <NUM>. It is noted that a "distal end" as used herein is defined as an end of the relevant component that is configured to be situated furthest from the sleeve <NUM> and is distinguished from a "proximal end" that is configured to be situated closest to the sleeve <NUM>.

The intermediate component <NUM> and the first axle <NUM> of the first endcap <NUM> can form a snap fit in various embodiments, where the first axle <NUM> is elastically compressed to pass through the axle opening <NUM> and, once through the axle opening <NUM>, the first axle <NUM> expands to retain the intermediate component <NUM> on the first axle <NUM>. In the current example, the first axle defines a first portion 152a, a second portion 152b, and a clearance <NUM> that separates the first portion 152a and second portion 152b. The first portion 152a and/or the second portion 152b are configured to flex towards the clearance <NUM> and compress to pass through the axle opening <NUM>. Upon passage through the axle opening <NUM>, the first portion 152a and second portion 152b (and the corresponding retaining features 154a and 154b) are configured to spring outward, to expand away from the clearance <NUM>, which secures the intermediate component <NUM> on the first axle <NUM>.

The retaining feature 154a, 154b is generally configured to retain the intermediate component <NUM> on the first endcap <NUM> under normal operating conditions and forces, such as during installation and removal of the sensor assembly <NUM> from a conveyor line. The retaining feature 154a, 154b is generally configured to retain the intermediate component <NUM> on the first endcap <NUM> absent the application of pressure and force on the intermediate component <NUM> and the first endcap <NUM> sufficient to decouple the intermediate component <NUM> and the first endcap <NUM>. Such a configuration improves handleability of the sensor device <NUM> during installation, as an intermediate component that is a separate component from the first endcap would need to be manually positioned separately from the rest of the sensor device <NUM>. It will be appreciated that the retaining feature 154a, 154b can have alternate configurations as well, one of which will be described with reference to <FIG>, below, and another of which will be described with reference to <FIG>, below.

The intermediate component <NUM> is generally linearly translatable in the longitudinal direction L<NUM>, L<NUM> along the first axle <NUM> relative to the endcap body <NUM>. In the current example, the intermediate component is linearly translatable between the endcap body <NUM> and the retaining feature <NUM>. <FIG> depicts the intermediate component <NUM> in a first linear position relative to the first endcap <NUM>, and <FIG> depicts the intermediate component <NUM> in a second linear position relative to the first endcap <NUM>. The first linear position can define a particular maximum linear distance dmax between the intermediate component <NUM> and the first endcap <NUM> and the second linear position can define a minimum linear distance dmin between the intermediate component <NUM> and the first endcap <NUM>. In the first linear position relative to the endcap body <NUM> (<FIG>), the intermediate component <NUM> is freely rotatable about the longitudinal axis L. In the second linear position relative to the endcap body <NUM> (<FIG>), the intermediate component <NUM> has a fixed orientation about the longitudinal axis L.

As best visible in <FIG>, the intermediate component <NUM> and the first endcap <NUM> mutually define an orientation locking structure <NUM>, <NUM> that selectively engages when the intermediate component <NUM> is in the second linear position (as depicted in <FIG>) and is disengaged in the first linear position (as depicted in <FIG>). In this example, the orientation locking structure <NUM>, <NUM> is defined by mating features on the intermediate component <NUM> and the first endcap <NUM>. The orientation locking structure <NUM>, <NUM> can disengage when the intermediate component <NUM> is in the first linear position relative to the endcap body <NUM> (as depicted in <FIG>).

The orientation locking structure <NUM>, <NUM> is generally configured to selectively fix the orientation of the intermediate component about the longitudinal axis relative to the endcap body <NUM>. The orientation locking structure <NUM>, <NUM> can selectively fix the orientation of the intermediate component <NUM> about the longitudinal axis L (relative to the endcap body <NUM>) to each of a plurality of discrete, fixed orientations about the longitudinal axis L when the intermediate component <NUM> is in the second linear position relative to the endcap body <NUM>. The orientation locking structure <NUM>, <NUM> can selectively engage in each of a plurality of fixed orientations about the first axle <NUM> when the intermediate component <NUM> is in the second linear position relative to the endcap body <NUM>.

The orientation locking structure <NUM>, <NUM> can have a variety of different configurations, but in the example associated with <FIG>, the first endcap <NUM> defines a first protrusion <NUM> that extends longitudinally outward from the endcap body <NUM>. The intermediate component <NUM> defines a series of protrusion receptacles <NUM> that are each configured to receive the first protrusion <NUM> (<FIG>). The series of protrusion receptacles <NUM> are configured to be rotated into linear alignment with the first protrusion <NUM>. The series of protrusion receptacles <NUM> are positioned circumferentially about the axle opening <NUM> and are equidistant from the axle opening <NUM> and, as such, the protrusions receptacles <NUM> are in circumferential alignment. Similarly, the series of protrusion receptacles <NUM> are positioned circumferentially about the axle opening <NUM> and are equidistant from the longitudinal axis L<NUM>.

The first protrusion <NUM> has a radial position relative to the first axle <NUM> and/or the longitudinal axis L, and each of the protrusion receptacles <NUM> have a corresponding radial position relative to the first axle <NUM> and/or the longitudinal axis L such that the protrusion receptacles <NUM> are in circumferential alignment with each other and with the first protrusion <NUM>. The first protrusion <NUM> has a radial distance R<NUM> (see <FIG> and <FIG>) from the longitudinal axis L<NUM> that is equal to the radial distance R<NUM> between each of the protrusion receptacles <NUM> and the longitudinal axis L<NUM>, where the distance is measured based on a center point of the first protrusion <NUM> and the protrusion receptacles <NUM>.

In the current example, the orientation locking structure <NUM>, <NUM> is considered engaged when one of the series of protrusion receptacles <NUM> receives the first protrusion <NUM>, which prevents rotation of the first endcap <NUM> relative to the intermediate component <NUM>. In the first linear position (<FIG>) the first protrusion <NUM> is outside each of the protrusion receptacles <NUM> such that the intermediate component <NUM> and the first endcap <NUM> are rotatable relative to each other. In the current example, in the first linear position, the intermediate component <NUM> abuts the retaining feature <NUM>. In the second linear position (<FIG>) the first protrusion <NUM> is received by the protrusion receptacle 144a such that the intermediate component <NUM> and the first endcap <NUM> are non-rotatable relative to each other. In this example, in the second linear position, the intermediate component <NUM> abuts the endcap body <NUM>.

While the series of protrusion receptacles <NUM> are currently defined by an inner region of the intermediate component <NUM> and the first protrusion <NUM> is currently defined by an inner region of the first endcap <NUM>, other configurations are certainly contemplated. In some embodiments, such as the example endcap assembly <NUM> depicted in <FIG>, an intermediate component <NUM> has a first protrusion <NUM> that extends longitudinally inward (towards the sleeve <NUM>) and the first endcap <NUM> defines a series of protrusion receptacles <NUM> (only one of which is visible in <FIG>) configured to receive the first protrusion <NUM>. Such an orientation locking structure can be defined by corresponding inner regions of the intermediate component <NUM> and the first endcap <NUM>. In some embodiments the first endcap and the intermediate component define an orientation locking structure on corresponding outer regions.

Furthermore, in <FIG>, while the first endcap <NUM> has the first axle <NUM> and the intermediate component <NUM> defines the axle opening <NUM>, in some embodiments, such as the one depicted in <FIG>, an intermediate component <NUM> can define a first axle <NUM> and a first endcap <NUM> can define the axle opening <NUM>. In such an example, the intermediate component <NUM> and the first endcap <NUM> can have similar linear translatability and rotatability relative to each other as has been described in reference to <FIG>, above.

<FIG> is a perspective view of an example second endcap <NUM> consistent with <FIG>. The second endcap <NUM> is configured to be coupled to the second end <NUM> of the elongate sleeve <NUM> (<FIG>). The second endcap <NUM> is configured, at least in part, to provide an obstruction through the second end <NUM> of the sleeve <NUM>. In the current example, the second endcap <NUM> has a sleeve coupler <NUM> and a rail coupler <NUM>.

The sleeve coupler <NUM> can have a variety of configurations, but in the current example is configured to be inserted into the second end <NUM> of the sleeve <NUM> (<FIG>). The sleeve coupler <NUM> can be configured to frictionally engage the sleeve <NUM>. In the current example, the outer surface of the sleeve coupler <NUM> frictionally engages an inner surface of the sleeve <NUM>, and frictional forces between those surfaces maintains the position of the sleeve coupler <NUM> relative to the sleeve <NUM>. In some other embodiments, the sleeve coupler <NUM> can be configured to cover the second end <NUM> of the sleeve <NUM>. The sleeve coupler <NUM> can additionally or alternatively be coupled to the second end of the sleeve through the use of an adhesive, fasteners (such as screws or bolts), and the like. In various embodiments, the sleeve coupler <NUM> is non-rotatable and non-translatable relative to the sleeve <NUM>.

The rail coupler <NUM> is generally consistent with the discussions above. In the current example, the rail coupler <NUM> defines a polygonal protrusion 162a extending longitudinally outward from a distal end of the second endcap <NUM>. The polygonal protrusion 162a can be configured to engage a corresponding opening in a siderail of a conveyor system. In the current example, the polygonal protrusion 162a is hexagonal, but other polygonal shapes could certainly be used, as has been discussed above with reference to the intermediate component <NUM>. In the current example the rail coupler <NUM> also defines a circular protrusion 162b extending longitudinally outward from a distal end of the second endcap <NUM>. The circular protrusion 162b is also configured to engage a corresponding opening in a siderail of a conveyor system. Because the rail coupler <NUM> has a polygonal protrusion 162a and a circular protrusion 162b, the rail coupler <NUM> can be coupled to siderails of conveyor systems having differently-shaped openings. In some embodiments one of the polygonal protrusion 162a and the circular protrusion 162b can be omitted.

In the current example, the second endcap <NUM> also has a rod <NUM> that the rail coupler <NUM> is coupled to. The rod <NUM> has a second axle <NUM> extending longitudinally outward from the rod <NUM>, and the rail coupler <NUM> is rotatably disposed on the second axle <NUM>. The second axle <NUM> is configured consistently with the description of the first axle <NUM>, discussed above with reference to <FIG>. For example, the second axle <NUM> can define a retaining feature <NUM> extending radially outward from a distal end of the second axle <NUM>, which is configured to retain the rail coupler <NUM>. The second axle <NUM> and the rail coupler <NUM> can be configured to form a snap fit connection, also as discussed above with respect to the first axle <NUM>.

The rod <NUM> is linearly translatable along the longitudinal axis L relative to the sleeve coupler <NUM> and, therefore, the sleeve <NUM>. As such, the rail coupler <NUM> is linearly translatable along the longitudinal axis L relative to the sleeve coupler <NUM> and the sleeve <NUM>. A spring <NUM> is compressibly disposed between the rod <NUM> and the sleeve coupler <NUM> and, therefore, the spring <NUM> is compressibly disposed between the rail coupler <NUM> and the sleeve. The spring <NUM> can bias the rail coupler <NUM> in an extended configuration. Such a configuration can facilitate installation of the sensor device <NUM> between rails in a conveyor line such that when the rail coupler <NUM> is translated towards the sleeve <NUM> along the longitudinal axis L, the sensor device <NUM> can be positioned between the conveyor rails, and when the rail coupler <NUM> is released, the sensor device <NUM> lengthens to engage each conveyor rail. The spring <NUM> can exert sufficient outward force on the conveyor rail to create positive engagement between the sensor device and the conveyor rails.

The spring <NUM> allows the sensor device to accommodate various distances between siderails of the conveyor. Additionally, to select the radial orientation of the plurality of sensors <NUM> about the longitudinal axis L of the sleeve <NUM>, a user translates the first endcap <NUM> away from the intermediate component <NUM> (by overcoming the biasing force of the spring <NUM>) to introduce a clearance between the first protrusion <NUM> and the intermediate component <NUM> (such as depicted in <FIG>). The first endcap <NUM> (and therefore the sleeve <NUM>, sleeve coupler <NUM>, and the sensors <NUM>) are rotated relative to the intermediate component <NUM> to axially align the first protrusion <NUM> with a particular protrusion receptacle 144a of the intermediate component <NUM>. Such rotation is enabled, in part, by the free rotation of the sleeve <NUM> and sleeve coupler <NUM> relative to the rail coupler <NUM>. The first protrusion <NUM> is then inserted into the selected protrusion receptacle <NUM>, which can be facilitated by the spring force when the first endcap <NUM> is released by the user. Once positioned, the spring <NUM> exerts a biasing force sufficient to maintain the position of the first protrusion <NUM> in the particular protrusion receptacle 144a of the intermediate component <NUM>.

In an alternative example, the rail coupler can be slidably disposed on the second axle, and a spring can be disposed between the rail coupler and the rod. In some examples, a spring can be disposed between the sleeve and the sleeve coupler, and the sleeve coupler is slidable relative to the sleeve.

<FIG> depicts an alternate example second endcap <NUM> having a sleeve coupler <NUM> and a rail coupler <NUM> and lacking a spring. The second endcap <NUM> can be coupled to the second end of the sleeve (such as the second end <NUM> of the sleeve <NUM> depicted in <FIG>). The rail coupler <NUM> has a polygonal protrusion 262a and a circular protrusion 262b as discussed above with reference to <FIG>. The sleeve coupler <NUM> is configured to couple to a second end of a sleeve, as discussed above with reference to <FIG>. Unlike the example in <FIG>, here the sleeve coupler <NUM> has a second axle <NUM>. The rail coupler <NUM> is rotatably disposed on the second axle <NUM>. Similar to the example of <FIG>, the second axle <NUM> defines a retaining feature <NUM> that is configured to retain the rail coupler <NUM>.

<FIG> depicts another example first endcap assembly <NUM> consistent with some examples. <FIG> is a perspective view of such an assembly <NUM>, <FIG> is a perspective view of the disassembled components of the assembly, <FIG> is a cross-sectional view of <FIG>, and <FIG> is a partially exploded cross-sectional view consistent with <FIG>. Each of these drawings will be referenced with the description here. The first endcap assembly <NUM> has a first endcap <NUM> having an endcap body <NUM> and an intermediate component <NUM> coupled to the first endcap <NUM>.

The first endcap <NUM> is configured to be coupled to a first end of a sleeve, such as a sleeve consistent with that described above with reference to <FIG>. A sleeve insertion portion <NUM> of the first endcap <NUM> is configured to be inserted into a first end of such a sleeve. In some embodiments, the first endcap <NUM> can be configured to cover the first end of the sleeve. The first endcap <NUM> can be coupled to the sleeve through approaches discussed herein above.

The intermediate component <NUM> is configured to couple the first endcap <NUM> to a conveyor rail (such as conveyor rail 20a depicted in <FIG>), and can have one or more rail mating features 342a, 342b (visible in <FIG>) that are each configured to mate with a corresponding structure of the conveyor rail (20a in <FIG>, for example). The intermediate component <NUM> is selectively rotatable relative to the first endcap <NUM>. The intermediate component <NUM> and the first endcap <NUM> are coupled to a first axle <NUM> such that the intermediate component <NUM> is selectively rotatable about a longitudinal axis L relative to the first endcap <NUM>. In particular, as best visible in <FIG>, the intermediate component <NUM> is coupled to a first axle <NUM> extending along its longitudinal axis L<NUM>. The first axle <NUM> extends longitudinally inward from the intermediate component <NUM>. The first endcap <NUM> has an endcap body <NUM> and defines axle opening <NUM>, where the axle opening <NUM> extends along the longitudinal axis L<NUM> of the first endcap <NUM>. The axle opening <NUM> is configured to receive the first axle <NUM>. The intermediate component <NUM> is rotatably disposed about the longitudinal axis L relative to the first endcap <NUM>.

The first axle <NUM> defines a retaining feature <NUM> that is configured to retain the intermediate component <NUM> to the first endcap <NUM>, and the first endcap <NUM> on the first axle <NUM>. In particular, the retaining feature <NUM> extends radially outward from a proximal end of the first axle <NUM> and has an outer dimension D<NUM> (<FIG>) that exceeds an outer diameter D<NUM> (best visible in <FIG>) of the axle opening <NUM>, where the outer dimension D<NUM> and the outer diameter D<NUM> are perpendicular to the longitudinal axis L. The axle opening <NUM> is defined by a circumferential flange <NUM> having an outer diameter D<NUM> that retains the first axle <NUM> within the axle opening <NUM>. The first axle <NUM> is rotatable within the axle opening <NUM> and, as such, the intermediate component <NUM> is rotatable about the longitudinal axis L relative to the first endcap <NUM>.

As discussed above with regard to previous example embodiments, the first axle <NUM> and the axle opening <NUM> can form a snap fit, where the first axle <NUM> is elastically compressed to pass through the axle opening <NUM> and, once through the axle opening <NUM>, the first axle <NUM> expands to retain the intermediate component <NUM> on the first axle <NUM>. In the current example, the first axle <NUM> is cumulatively defined by a series of prongs <NUM> arranged circumferentially about the longitudinal axis L<NUM> (<FIG>) and their respective retaining features <NUM>, where a clearance <NUM> is defined between each of the prongs in the series of prongs <NUM>. Each of the prongs in the series of prongs <NUM> are configured to flex towards the longitudinal axis L<NUM> to compress to pass through the axle opening <NUM>. Upon passage through the axle opening <NUM>, each prong in the series of prongs <NUM> are configured to spring radially outward, which secures the intermediate component <NUM> to the first endcap <NUM> because the circumferential flange <NUM> blocks the retaining feature <NUM> from translating out of the axle opening <NUM>.

Similar to previous examples, the retaining feature <NUM> is generally configured to retain the intermediate component <NUM> on the first endcap <NUM> under normal operating conditions. Such a configuration improves handleability of the sensor device (such as a sensor device depicted in <FIG>) during installation, as an intermediate component that is a separate component from the first endcap would need to be manually positioned separately from the rest of the sensor device.

In some embodiments consistent with the current example, the intermediate component <NUM> is not linearly translatable in the longitudinal direction L relative to the endcap body <NUM>. In some other embodiments, the intermediate component <NUM> can be linearly translatable in the longitudinal direction L relative to the endcap body <NUM>.

Similar to previous examples, here the endcap assembly <NUM> has an orientation locking structure <NUM>, <NUM>, <NUM> that is configured to selectively fix the orientation of the intermediate component about the longitudinal axis L relative to the endcap body <NUM>. The orientation locking structure <NUM>, <NUM>, <NUM> can selectively fix the orientation of the intermediate component <NUM> about the longitudinal axis L (relative to the endcap body <NUM>) to each of a plurality of discrete, fixed orientations about the longitudinal axis L. The orientation locking structure <NUM>, <NUM>, <NUM> can selectively engage in each of a plurality of fixed orientations about the longitudinal axis L.

In this example, the endcap assembly <NUM> has a pin assembly <NUM>, where the pin assembly <NUM>, the intermediate component <NUM> and the first endcap <NUM> mutually define the orientation locking structure <NUM>, <NUM>, <NUM> that is selectively engaged and disengaged. In this example, the orientation locking structure <NUM>, <NUM>, <NUM> is defined by mating features on the intermediate component <NUM>, the first endcap <NUM>, and the pin assembly <NUM>. Particularly, the pin assembly <NUM> has a first protrusion <NUM> that is configured to be mutually received by a first protrusion receptacle 344a defined by the intermediate component <NUM> and a second protrusion receptacle <NUM> defined by the first endcap <NUM>, which is depicted in <FIG>. <FIG> shows a partially exploded view with the pin assembly <NUM> decoupled from the intermediate component <NUM> and the first endcap <NUM>.

Here the intermediate component <NUM> defines a series of protrusion receptacles <NUM> that are each configured to receive the first protrusion <NUM>. The series of protrusion receptacles <NUM> are positioned circumferentially about the longitudinal axis L<NUM> and are equidistant from the longitudinal axis L. Each protrusion receptacle in the series of protrusion receptacles <NUM> are in circumferential alignment with the first protrusion receptacle 344a such that each protrusion receptacle in the series of protrusion receptacles <NUM> are configured to be rotated into radial alignment with the second protrusion receptacle <NUM>. When a particular protrusion receptacle, such as the first protrusion receptacle 344a, of the intermediate component <NUM> is rotated into radial alignment with the second protrusion receptacle <NUM> of the first endcap, the first protrusion receptacle 344a and the second protrusion receptacle <NUM> are configured to mutually receive the first protrusion <NUM> of the pin assembly <NUM> to engage the orientation locking structure <NUM>, <NUM>, <NUM>, which fixes the orientation of the intermediate component <NUM> about the longitudinal axis L relative to the first endcap <NUM>. When the orientation locking structure <NUM>, <NUM>, <NUM> is disengaged such that the first protrusion <NUM> is outside of the relevant protrusion receptacles <NUM>, <NUM>, the intermediate component <NUM> is rotatable about the longitudinal axis relative to the first endcap <NUM>.

In embodiments consistent with the current example, the pin assembly <NUM> also has an engagement feature <NUM> and a clamping structure <NUM>. The engagement feature <NUM> is configured to be grasped (manually or otherwise) by a user to insert and remove the pin <NUM> to/from the corresponding protrusion receptacles. The clamping structure <NUM> is configured to frictionally engage one or both of the intermediate component <NUM> and the first endcap <NUM> to maintain the position of the pin <NUM> in the first and second protrusion receptacles 344a, <NUM>.

It should be noted that in some embodiments, such as those consistent with the current example, the clearance <NUM> defined between each of the prongs in the series of prongs <NUM> defining the first axle <NUM> are the protrusion receptacles <NUM>. In some other embodiments the clearance can be distinct from the protrusion receptacles.

It should also be noted that, as used in this specification and the appended claims, the phrase "configured" describes a system, apparatus, or other structure that is constructed to perform a particular task or adopt a particular configuration. The word "configured" can be used interchangeably with similar words such as "arranged", "constructed", "manufactured", and the like.

Claim 1:
A sensor device comprising:
an elongate sleeve (<NUM>) extending along a longitudinal axis (L), wherein the elongate sleeve (<NUM>) has a first end (<NUM>) and a second end (<NUM>);
a plurality of sensors (<NUM>) fixed relative to the sleeve;
said sensor device being characterized by further comprising:
a first endcap (<NUM>, <NUM>, <NUM>) having an endcap body (<NUM>, <NUM>) coupled to the first end (<NUM>);
an intermediate component (<NUM>, <NUM>, <NUM>) coupled to the first endcap (<NUM>, <NUM>, <NUM>), wherein the intermediate component (<NUM>, <NUM>, <NUM>) is selectively rotatable about the longitudinal axis (L) relative to the endcap body (<NUM>, <NUM>); and
a second endcap (<NUM>, <NUM>) coupled to the second end (<NUM>) of the sleeve, wherein the second endcap (<NUM>, <NUM>) has a rail coupler (<NUM>, <NUM>) that is freely rotatable relative to the sleeve.