Real transverse web scanning device

Abstract

Apparatus and methods direct web material to move in a first direction and a second direction. Sensor signals are transmitted from a source module that is slidably attached to a first rail and positioned at an angle to and between web material moving in the first direction and the second direction. A first receiver module and a second receiver module are each slidably attached to a second rail and a third rail positioned in alignment with the first rail. The sensor module cooperates with the first receiver module to slidably travel along the first rail and the second rail to capture measurements associated with the web material in the first direction, and the sensor module cooperates with the second receiver module to slidably travel along the first rail and the third rail to capture measurements associated with the web material in the second direction.

Description

Technical Field

[0001] This disclosure relates throughout to scanning measurement systems. More specifically, this disclosure relates to a scanning apparatus for web materials, the scanning apparatus having scanning sensor assemblies arranged in a stacked manner and fixed to the web material at an angle. Background Technology

[0002] Sheet or other web materials are used in a variety of ways across a variety of industries. These materials can include paper, multi-layer paperboard, and other products manufactured or processed in webs. As a specific example, long paper sheets can be manufactured and collected in rolls.

[0003] When manufacturing or processing webs, it is often necessary or desirable to measure one or more properties of the web material. The manufacturing or processing system can then be adjusted to ensure that the properties remain within the desired range. Measurements are typically performed using one or more scanning heads that move back and forth across the width of the web. Summary of the Invention

[0004] This disclosure relates to a scanning sensor device and method arranged in a stacked manner and fixed to a web material at a certain angle.

[0005] A device is disclosed comprising a web material guided to move in a first direction and arranged to be guided to move in a second direction. A source module configured to transmit sensor signals is slidably attached to a first guide rail. The first guide rail is angled to and located between the web materials in the first and second directions. A first receiver module for receiving sensor signals from the source module is slidably attached to a second guide rail. The second guide rail is aligned with and positioned on a first side of the web material in the first direction. The second receiver module for receiving sensor signals from the source module is slidably attached to a third guide rail. The third guide rail is aligned with and positioned on a first side of the web material in the second direction. A sensor module cooperates with the first receiver module to slidably travel along the first and second guide rails to capture measurements associated with the web material in the first direction, and cooperates with the second receiver module to slidably travel along the first and third guide rails to capture measurements associated with the web material traveling in the second direction.

[0006] A method is also disclosed, comprising guiding web material to move in a first direction and also in a second direction. Sensor signals are transmitted from at least one sensor slidably attached to a first guide rail. The first guide rail is angled to and located between the web material moving in the first and second directions. The method further includes slidably attaching a first receiver to a second guide rail aligned with the first guide rail and located on a first side of the web material in the first direction. The first receiver is arranged to receive sensor signals from the at least one sensor, and a second receiver is slidably attached to a third guide rail aligned with the first guide rail and located on a first side of the web material in the second direction. A second receiver is arranged to receive sensor signals from the at least one sensor, wherein the first receiver cooperates with the at least one sensor to slidably travel along the first and second guide rails to capture measurements associated with the web material moving in the first direction, and the second receiver cooperates with the at least one sensor to capture measurements associated with the web material moving in the second direction.

[0007] Other technical features will be apparent to those skilled in the art from the following figures, description and claims. Attached Figure Description

[0008] To gain a more complete understanding of this disclosure, reference is now made to the following description in conjunction with the accompanying drawings, in which:

[0009] Figure 1 This is a schematic diagram of an exemplary real lateral measurement system according to the present disclosure.

[0010] Figure 2 It is based on this disclosure Figure 1 A diagram illustrating the true CD measurement profile generated by the true lateral measurement system. Detailed Implementation

[0011] The figures discussed below, as well as the various embodiments used to illustrate the principles of the invention in this patent document, are merely illustrative and should not be construed as limiting the scope of the invention in any way. Those skilled in the art will understand that the principles of the invention can be implemented in any type of suitably arranged device or system.

[0012] Scanning systems used in web fabrication or other web-related processes typically employ a translational scanning head that houses a sensor and moves back and forth across each side of the web. A web can refer to any suitable material being manufactured or processed as a moving sheet or other web. For example, webs can include paper, multi-layered cardboard, cardboard, plastic, film, textile, or metal webs. In many systems, the scanning head is mechanically coupled to a belt system mounted to a frame and is driven by one or more motors. Two pairs of rollers are used to convey the web through a portion of the scanning system. For example, a roller pair may pull the web from an earlier stage of the web fabrication or web handling system and feed the web to a later stage. The roller pair moves the web in a direction known as the longitudinal direction (MD).

[0013] The scanning system includes one or more scanning sensor assemblies positioned between rollers. Each scanning sensor assembly may include one or more sensors capable of measuring at least one characteristic of the web. For example, the scanning sensor assembly may include sensors for measuring the web's moisture content, thickness, anisotropy, basis weight, color, gloss, luster, haze, surface features (such as surface roughness, morphology, or orientation distribution), or any other or additional characteristics. Generally, the characteristics of the web can vary along its length in the longitudinal direction and / or across its width in the transverse direction (CD). Typically, in such scanning systems, a transverse scan is performed across the web while it is being conveyed in the longitudinal direction, thereby providing an angular scan profile from one edge of the web to the opposite edge, which depends on the speed at which the web is conveyed in the longitudinal direction and the displacement speed of the scanning head in the transverse direction from one edge of the web to the other.

[0014] This invention proposes a novel method for lateral scanning involving a stacked array of scanning sensor assemblies that scan at a fixed angle to the web material, thereby allowing the generation of a true lateral (true CD) scan pattern when the web velocity matches the longitudinal component of the scanning head velocity. This allows for lateral profile measurements independent of longitudinal variations, as well as longitudinal profile measurements less affected by lateral variations compared to conventional scanning systems. The true CD scanning system can also be used in patch coating measurement applications, providing scan profiles that avoid coating gaps. Since longitudinal space is very valuable in web manufacturing systems, the true CD scanning system of this disclosure can be implemented using a vertically oriented scanning frame, wherein the web material passes through gaps in guide rails attached to the frame at a 90-degree through-angle to reach the stacked sensor assembly, such as... Figure 1 As shown

[0015] Figure 1An exemplary embodiment of a real CD scanning system 100 of this disclosure is illustrated. The scanning system 100 includes three feed rollers 110, 112, and 114 attached to a frame (not shown for clarity) that move web material 120 through a scanning assembly 200. The scanning assembly 200 is fixed at an angle α of approximately 45 degrees to the MD illustrated by arrow 125. The scanning assembly 200 includes a stacked scanning system arrangement comprising a source module 210 and two receiver modules 212, 214. Receiver modules 212, 214 are located on either side of the source module 210. A first scan head is formed by the source module 210 and receiver module 212, and a second scan head is formed by the source module 210 and receiver module 214.

[0016] Source module 210 includes any suitable structure for carrying one or more web sensors arranged to transmit sensor signals through the material conveyed by web 120 and received by receiver modules 212 and 214. Receiver modules 212 and 214 receive sensor signals passing through the material to capture measurements associated with web 120. Each web sensor may include any suitable structure for transmitting a specific measurement associated with one or more characteristics of web 120. Each receiver module 212 and 214 may include any suitable structure for receiving sensor signals transmitted by source module 210. A web sensor may represent a contact sensor that measures the web via contact with web 120 or a non-contact sensor that measures the web without contact with web 120.

[0017] Power can be supplied to source module 210 and receiver modules 212, 214 in any suitable manner. For example, source module 210 and receiver modules 212, 214 can be coupled to one or more cables that supply power to modules 210, 212, and 214. The scanning assembly 200 may also include an internal power source, such as a battery or induction coil for wirelessly receiving power.

[0018] Each receiver module 212, 214 of the scanning assembly 200 can transmit sensor measurement data to an external controller 300. The controller 300 can use the measurement data in any suitable manner. For example, the controller can use the measurement data to generate a CD profile of the web 120. The controller can then use the CD profile to determine how to adjust the characteristics of the web 120. The controller can also use the CD profile or measurement data to support monitoring applications, process history applications, or other process control-related applications.

[0019] Source module 210, first receiver module 212, and second receiver module 214 are each slidably attached to a corresponding one of guide rails 220a, 220b, and 220c, which are fixed at an angle across the web 120. Source module 210 and each of the first receiver modules 212 and second receiver modules 214 may be attached to a bracket (not shown). Each bracket may traverse back and forth along guide rails 220a-220c to independently move source module 210, the first receiver module, and the second receiver module across the web 120 in direction 128. Each guide rail 220a-220c typically includes a bracket and any suitable structure on which the attached modules 210, 212, 214 can move, such as a strip, shaft, or beam formed of metal or another suitable material. Each bracket includes any suitable structure for movement along guide rails 220a-220c. Each module 210, 212, 214 is arranged to be driven by any suitable means to travel along guide rails 220-220c, thereby scanning back and forth over the web 120 individually or as a scan head pair. For example, the source module may be arranged to travel as a stacked pair with a first receiver module as a first scan head, or as a stacked pair with a second receiver module as a second scan head. Additionally, source module 210 is also arranged to travel within a stacked assembly including both source module and receiver modules 212, 214. The web 120 in MD 125 traverses between the source module 210 and receiver module 212 at the first head and the source module 210 and receiver module 214 at the second head.

[0020] In another embodiment, the scanning assembly 200 may comprise only a pair of scanning rails. For example, the source module 210 and the first receiver module 212 may each be slidably attached to one of the corresponding rails 220b and 220c to attach to a bracket (not shown), thereby traversing back and forth along rails 220b-220c as the first scanning head moves across the web 120 in direction 128. The first scanning head moves along the web 120 during forward scanning 125 to produce only the true CD outline. In another embodiment, a multi-axis motion system (not shown) can be used to move the source 210 and receiver modules 212, 214 along the true CD scanning pattern described herein. However, for simplicity, Figure 1 The vertical orientation shown will be used to explain this disclosure. Furthermore, the operation of the scanning assembly 200 will be explained using a source module 210 and a receiver module 212 including a first scanning head, and a source module 210 and a receiver module 214 including a second scanning head.

[0021] The web 120 passes between the source and receiver modules of the first and second scanning heads at a vertical through-line angle. Distance "d1" is the sheet distance between the low-end scanning point 222 and the high-end scanning point 224 established by guide rails 220a-220c. Distance "d2" is the sheet distance between the first and second scanning heads when they are at the high-end scanning point 224.

[0022] exist Figure 1 In the illustrated embodiment, when the scanning speed (e.g., the speed at which the scanning head traverses guides 220a-220c) is set to (1 / sin(α)) multiplied by the speed of the web 120 in the MD direction 125, each of the first and second scanning heads can be made to follow the angular scanning path 128 across the web 120. In the simplest case, the scanning speed set by the 45° tilt angle α is √2 times the web speed at a constant rate when crossing the web 120. The first scanning head will move along the web 120 during forward scanning, thereby producing a true CD profile. The second scanning head will perform the same operation during reverse scanning as the web 120 moves in the direction illustrated by arrow 126.

[0023] Figure 2 Examples are given for Figure 1 The first and second scanning heads of the embodiment cross the scanning path of the web 120. When both the first and second scanning heads are at the low-end scanning point 222, the sheet distance between them is d1+d2+d1. During forward scanning in direction 125, the first scanning head moves along the actual CD path across the web 120 in direction 128 with the web 120. The second head moves in a cross path as in a conventional scanner. At the end of the forward scan, both the first and second heads are at the high-end scanning point 224 and are separated by a distance d2. During reverse scanning of the web 120 in direction 126, the second head moves along the actual CD path with the MD. The first scanning head moves in a conventional cross path. When both the first and second heads reach the first low-end scanning point 222, the sheet distance between the heads will again be the sheet distance d1+d2+d1.

[0024] like Figure 2 As shown in the diagram, through each of the first and second scanning heads, every (2 A true CD measurement profile is generated by the intervals d1-d2 and d2. By adjusting the sheet path so that distance d2 equals distance d1, a true CD measurement result with uniform intervals can be generated. It can be seen that when distance d2 is an odd multiple of distance d1, a true CD measurement result with uniform intervals can also be generated, as described in Table 1.

[0025] Table 1 below lists the scans for various odd multiples of distance d2 being distance d1. Note that when the multiple of d1 to d2 is greater than 1, it may be necessary to reorder the real CD scans based on the MD position. For this purpose, the MD position measurement assigned to controller 300 can be used to reorder the scans. Also note that when the multiple of d1 to d2 is greater than 1, consecutive real CD scans are at a distance of (d1 to d2 - 1) from the first real CD scan. It starts after distance d1.

[0026]

[0027] Furthermore, a traditional cross profile can also be generated by each head between the true CD profile, which can be used to generate the true MD profile by removing the average CD profile from it. Since the true CD profile measurement is available, this process can produce much better MD profile measurements compared to conventional scanning systems.

[0028] By reducing the tilt angle α to approximately 30 degrees, the distance d1 can be reduced to provide a more closely spaced CD profile. However, the speed at which the first and second scanning heads traverse the guide rails (head speed) must be increased to twice the speed of the web 120 on the MD (1 / sin(30)) to achieve the same functionality. Another advantage of the smaller tilt angle compared to 45 degrees is that the frame will require a smaller vertical height and a shorter frame length, resulting in a lower frame cost.

[0029] Conversely, by increasing the tilt angle α, the head velocity can be reduced. A tilt angle of approximately 60 degrees requires 1.1547 times (1 / sin(60)) the sheet velocity. However, this setup would require more vertical space and more frame material, thus increasing the overall cost of the scanning system.

[0030] The tilt angle of the scanning assembly 200 can be used to provide linear product coverage. Linear product coverage is the total scan length per unit distance of the product manufactured by the web fabrication process. Table 2 compares the linear product coverage of two tilt angles, 45 degrees and 30 degrees, with a conventional scanning head orthogonal to the moving sheet scanning at the same scanning speed. The total length of frame material required for each case is compared. The results shown in Table 2 utilize the fact that the vertical setup described above with a tilt angle α° is equivalent to two horizontal frames at an angle of (90-α)° to the MD of the web 120.

[0031]

[0032] Figure 1One application of the real CD scanning system is in sheet manufacturing systems involving the measurement of patch coatings, such as intermittent, patterned, or discontinuous patches used, for example, in the manufacture of lithium-ion battery anodes and cathodes. When using conventional scanners to measure the patch coating process, gaps between patches in the coating will appear in different locations in each scan. This makes it difficult to construct the entire coating profile and to use the measurement in control applications. The aforementioned real CD scanning method can be used to eliminate coating gaps when scanning patch coatings. Conventional scanners can be arranged to scan diagonally across patches, but this requires much larger patches. The real CD scanning method of the present invention avoids coating gaps, even for narrow patches. The real CD of the scanning assembly 200 can be arranged to scan over alternating patches, or, if the patches are very narrow, over different patches. A return scan after each real CD scan ensures that some portion of all patches is scanned.

[0033] The true CD scanning method also offers benefits for addressing the MD variation aliasing problem. When the frequency of MD variations matches the scan frequency, MD variations can be aliased into CD profile measurements. In these cases, MD variations and CD variations cannot be correctly distinguished. Because the true CD profile provides the full magnitude of the step changes in the first scan, it is inherently unaffected by MD aliasing.

[0034] It may be advantageous to define certain words and phrases used throughout this patent document. The term “communication” and its derivatives encompass both direct and indirect communication. The terms “comprising” and “including” and their derivatives mean, but are not limited to, this. The term “or” is inclusive, meaning and / or. The phrase “associated with” and its derivatives may mean, including, contained within, interconnected with, contained, contained in, connected to or connected with, linked to or connected with, able to communicate with, cooperate with, interleaved, juxtaposed, close to, combined with or combined with, having, possessing the attributes of, having a relationship with or having a relationship with, etc. When used with a list of items, the phrase “at least one of” means that different combinations of one or more of the listed items may be used, and only one item in the list may be required. For example, “at least one of A, B, and C” includes any of the following combinations: A, B, C, A and B, A and C, B and C, and A and B and C.

[0035] The description in this application should not be construed as implying that any particular element, step, or function is a fundamental or essential element that must be included within the scope of the claims. The scope of the subject matter for patent protection is defined only by the permitted claims. Furthermore, none of the claims is intended to invoke 35 U.S.C. with respect to any of the appended claims or claim elements. 112(f), unless the exact words of "means for..." or "steps for..." which are participle phrases that identify a function are explicitly used in a particular claim. The use of terms such as (but not limited to) "mechanism," "module," "device," "unit," "component," "element," "building block," "device," "machine," "system," or "controller" in the claims is understood to refer to structures known to a person skilled in the art, as further modified or enhanced by features of the claims themselves, and is not intended to invoke 35 USC. 112(f).

[0036] While this disclosure has described certain embodiments and generally associated methods, variations and substitutions of these embodiments and methods will be apparent to those skilled in the art. Therefore, the foregoing description of exemplary embodiments does not limit or restrict this disclosure. Other changes, substitutions, and modifications are possible without departing from the spirit and scope of this disclosure as defined in the following claims.

Claims

1. An apparatus, the apparatus comprising: Web material, the web material being guided to move in a first direction; A source module configured to transmit sensor signals, the source module being slidably attached to a first guide rail, the first guide rail being positioned at an angle to the web material in the first direction and located between the web materials; A first receiver module, configured to receive the sensor signal from the source module, is slidably attached to a second guide rail, which is aligned and positioned with the first guide rail and located on a first side of the web material in the first direction. The source module cooperates with the first receiver module to slide along the first and second guide rails to capture measurements associated with the web material in the first direction.

2. The apparatus of claim 1, wherein the web material is arranged to move in a second direction, and the apparatus further comprises: A second receiver module, configured to receive the sensor signal from the source module, is slidably attached to a third guide rail, which is aligned and positioned with the first guide rail and located on a first side of the web material in the second direction. The source module cooperates with the second receiver module to slide along the first and third guide rails to capture measurements associated with the web material traveling in the second direction.

3. The apparatus of claim 2, wherein the web material is guided by at least a first roller and a second roller, the first roller guiding the web material to move in the first direction and the second roller guiding the web material to move in the second direction, wherein the second direction is opposite to the first direction.

4. The apparatus of claim 3, wherein the first guide rail is located in the transverse direction of the web material in the first and second directions between the first roller and the second roller, and the first guide rail includes a low-end scanning point positioned by the first roller and a high-end scanning point positioned by the second roller.

5. The apparatus of claim 4, wherein the second guide rail is stacked and aligned with the web material in the transverse direction, wherein the web material in the first direction passes between the first guide rail and the second guide rail.

6. The apparatus of claim 5, wherein the third guide rail is stacked and aligned with the web material in the transverse direction, wherein the web material in the second direction passes between the first guide rail and the third guide rail.

7. The apparatus of claim 6, wherein the source module and the first receiver module travel in a lateral direction as a first scanning head, the first scanning head cooperating to capture measurement results associated with the web material from a first side of the web material moving in the first direction, and wherein the source module and the second receiver module travel in a lateral direction as a second scanning head, the second scanning head cooperating to capture measurement results associated with the web material from a first side of the web material moving in the second direction.

8. The apparatus of claim 2, wherein the first guide rail, the second guide rail and the third guide rail are positioned at an angle of 90 degrees or less to the first direction and the second direction of the web material.

9. A method, the method comprising: Guide the web material to move in the first direction; Sensor signals are transmitted from at least one sensor that is slidably attached to a first guide rail, the first guide rail being positioned at an angle to and between the web material moving in the first direction; A first receiver is slidably attached to a second guide rail, which is aligned and positioned with the first guide rail and located on a first side of the web material in the first direction. The first receiver is arranged to receive sensor signals from the at least one sensor. The first receiver cooperates with the at least one sensor to slide along the first and second guide rails to capture measurements associated with the web material in the first direction.

10. The method of claim 9, wherein the web material is guided in a second direction, and the method further comprises: The second receiver is slidably attached to a third guide rail, which is aligned and positioned with the first guide rail and located on a first side of the web material in the second direction. The second receiver is arranged to receive sensor signals from the at least one sensor. The second receiver cooperates with the at least one sensor to capture measurement results associated with the web material from the web material in the second direction.

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