Sensor Beam & Levelling Upgrade
Two through-beam sensor assemblies, adjustable for levelling across two line positions
- Sector
- MedTech
- Years
- 2026
- Engagement
- Subcontracted
- Role
- Support mechanical design engineer
- Status
- Design and drawings released; trial installations in progress on site
- Client
- Client and end user withheld under NDA. Description generalised.
SolidWorks 2025
Problem
A medtech production line needed a more robust through-beam sensing arrangement at four positions across two identical lines. Two positions already had completed designs and drawings; the remaining work had to match the client's established, proven mechanisms while fitting two physically different spaces.
Constraints
- Two unique positions, each with a different available space and mounting envelope.
- Two identical production lines, so the solution had to repeat cleanly across both.
- Transmitter and receiver had to be mountable on either side to suit the end client's wiring preference.
- Tried and tested mechanisms already established by the client had to be reused rather than new ones introduced.
Approach
- Designed one complete through-beam sensor solution and finished a second, mostly complete position, reusing the client's proven mechanisms.
- Built in micrometer adjustable levelling for precise, repeatable beam alignment on installation.
- Made the through-beam design more robust and symmetric so transmitter/receiver could sit on either side per wiring preference.
- Produced the full manufacturing drawing pack, plus categorised parts and assemblies.
- Ran design reviews, iterations and revisions and provided ongoing design support.
Gallery
Outcome
Eight sensor beams across four positions on two identical lines, delivered with a complete drawing pack and categorised parts and assemblies. Parts manufactured and awaiting feedback from end clients testing of completed sensors.
Testimonial
“A trusted resource who can reliably convert ideas into accurate manufacturing documentation while maintaining Designwise drawing standards and numbering systems.”
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Further detail
D1Engagement
Two of the four sensor positions already had completed designs and manufacturing drawings when I was contracted in. I designed one complete new solution and finished another position that was mostly done, working entirely within the established, trialed and agreed upon mechanisms, and produced all the engineering drawings for both. The role also covered design reviews, iterations, revisions and general design support across the wider set of positions.
D2The through-beam upgrade
The upgrade replaced the previous sensing arrangement with one that is adjustable for levelling via a built in micrometer, giving precise and repeatable beam alignment. The four similar designs had to drop into four physically different spaces across two identical lines; my involvement extended to only two of these, as noted above.