A coated fabric thickness testing system

Abstract

This invention relates to a system for testing the thickness of coated fabric, comprising: a roller and two distance measuring devices. The fabric moves around the roller to form a wrap angle. The two distance measuring devices are positioned within the same cross-section of the roller, and their measuring directions pass through the point where the fabric adheres to the roller and point towards the center of the cross-section. The two distance measuring devices and the center of the cross-section form a right-angled triangle, with the line connecting the two distance measuring devices included in the side of the right angle. Distance is measured using the two distance measuring devices. Based on the distance measured by the two distance measuring devices and the radius of the roller, the thickness of the fabric is calculated. This invention achieves continuous thickness measurement of coated fabric using non-contact distance measuring devices, protecting operator safety, avoiding product waste, and providing more accurate and standardized results for measuring the thickness of coated fabric.

Description

Technical Field

[0001] This invention relates to the field of fabric thickness testing, and more particularly to a system for testing the thickness of coated fabrics. Background Technology

[0002] Fabric surface coating is an essential and indispensable step in the processing and production of rubber or fabric materials for tires, shoes, and windows. The level and accuracy of thickness measurement directly affect product quality and standards, and may lead to waste of raw materials. Therefore, measuring the coating thickness of fabrics is of paramount importance in the production process. In actual production, many factors affect the coating on the fabric surface, such as temperature, pressure, roller distance, roller speed, and coating condition, resulting in numerous uncertainties. Therefore, accurate and detailed testing of the coating condition of the fabric is essential.

[0003] Currently, most domestic manufacturers use manual offline monitoring for thickness measurement. This method involves workers using a contact-type handheld mechanical thickness gauge to measure the material thickness. Manual offline monitoring requires the operator to cut and sample the material before handing it over to the measurement personnel for thickness testing.

[0004] Another commonly used method for thickness measurement is the ultrasonic thickness gauge. This instrument consists of a main unit and a probe. A high-voltage shock wave generated by the transmitting circuit excites the probe, producing ultrasonic pulse waves. These pulse waves are reflected by the medium interface and received by the receiving circuit. After being processed by a microcontroller, the thickness value is displayed on an LCD screen. This measuring instrument requires the use of a coupling agent to eliminate air between the probe and the object being measured.

[0005] In traditional manual offline monitoring methods, the operator needs to extend their arm above the material detection point. Therefore, the operator's eye is not at the same level as the scale line when taking the reading, leading to significant errors in readings between different operators. While stools or workbenches are provided in inconvenient locations, the fabric is constantly in motion during the adhesive application process. When measuring, the operator needs time to clamp the calendered fabric to take the thickness reading, so their upper body moves with the calendered fabric, while their lower body stands on the stool or workbench in a tilted position, posing a significant safety hazard.

[0006] On the other hand, the process of cutting materials requires operators to press the materials with their hands and cut them. This action will affect the adhesive on the materials before they have cooled down, affecting the thickness and causing errors. Moreover, the cut materials are of no use except for measurement, resulting in waste and affecting production costs.

[0007] In addition, traditional thickness measuring devices have the following two shortcomings: (1) They can only perform point-based measurements on materials and cannot achieve real-time measurement and recording of material thickness. (2) Different operators apply different pressures when measuring the cut samples, which inevitably leads to operational errors. Summary of the Invention

[0008] To address the aforementioned problems, this invention proposes a system for testing the thickness of coated fabrics.

[0009] The specific plan is as follows:

[0010] A system for testing the thickness of coated fabric includes: a roller and two distance measuring devices. The fabric moves around the roller to form a wrap angle. The two distance measuring devices are arranged in the same cross-section of the roller, and the measuring direction of the two distance measuring devices is towards the center of the cross-section after passing through the position where the fabric is in contact with the roller. The two distance measuring devices and the center of the cross-section form a right triangle, and the side forming the right angle includes the line connecting the two distance measuring devices.

[0011] Distance measurement is performed using two distance measuring devices;

[0012] The thickness of the fabric is calculated based on the distances measured by two distance measuring devices and the radius of the roller.

[0013] Furthermore, the formula for calculating the thickness d of the fabric is:

[0014]

[0015] Where h represents the distance between the two distance measuring devices, S1 and S2 represent the distances measured by the two distance measuring devices respectively, and S2 is greater than S1, and r represents the radius of the roller.

[0016] Furthermore, it also includes two rollers. Before the fabric travels to the rollers, the fabric passes between the two rollers, causing the two rollers to rotate in opposite directions.

[0017] Furthermore, multiple sets of distance measurement components are set up, each set of distance measurement components includes two distance measurement devices, and different distance measurement components are distributed in different cross sections of the roller, and the average value of all thickness measurement results is taken as the final measured thickness.

[0018] Furthermore, the rollers use Class 2 precision bearings.

[0019] Furthermore, the distance measuring device uses an ultrasonic sensor. The calculation of fabric thickness also includes corrections to the distances S1 and S2 measured by the ultrasonic sensor. The correction formula is as follows:

[0020]

[0021] Where L represents the distance measured by the ultrasonic sensor, H represents the corrected distance, and M represents half the distance between the transmitting and receiving probes inside the ultrasonic sensor.

[0022] The present invention adopts the above technical solution, which avoids the cutting and sampling and contact measurement of traditional thickness measurement methods through non-contact distance measurement. This measurement method ensures the safety of operators, eliminates the manual process of employees, standardizes the measurement of materials, and avoids the waste caused by cutting products. It has the advantages of simple operation, low installation cost and strong functionality. Attached Figure Description

[0023] Figure 1 The diagram shown is a schematic diagram of the thickness measurement principle in an embodiment of the present invention.

[0024] Figure 2 The diagram shown is a schematic of multiple distance measurement components in this embodiment.

[0025] Figure 3 The diagram shown illustrates the principle of ultrasonic sensor deviation correction in this embodiment. Detailed Implementation

[0026] To further illustrate the various embodiments, the present invention provides accompanying drawings. These drawings are part of the disclosure of the present invention, primarily used to illustrate the embodiments, and can be used in conjunction with the relevant descriptions in the specification to explain the operating principles of the embodiments. With reference to these drawings, those skilled in the art should be able to understand other possible implementations and the advantages of the present invention.

[0027] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments.

[0028] Example 1:

[0029] This invention provides a system for testing the thickness of coated fabrics, such as... Figure 1 As shown, it includes: a roller and two distance measuring devices. The fabric moves around the roller to form a wrapping angle, and the two distance measuring devices are set on the same cross-section of the roller (e.g., ...). Figure 1 Within the circular surface, the measuring directions of the two distance measuring devices are directed towards the center of the cross-section after passing through the contact point between the fabric and the roller. The two distance measuring devices and the center of the cross-section form a right-angled triangle, and the side forming the right angle includes the line connecting the two distance measuring devices.

[0030] Distance measurements are performed using two distance measuring devices (measuring the distance to the fabric surface).

[0031] Calculate the fabric thickness d based on the distances measured by the two distance measuring devices and the radius r of the roller:

[0032]

[0033] Where h represents the distance between the two distance measuring devices, S1 and S2 represent the distances measured by the two distance measuring devices, and S2 is greater than S1.

[0034] Furthermore, this embodiment also includes two rollers. Before the fabric travels to the rollers, the fabric passes between the two rollers, causing the two rollers to rotate in opposite directions, so that the fabric adheres to the rollers.

[0035] Furthermore, to make the measured thickness more accurate, this embodiment provides multiple sets (e.g., 3 sets) of distance measuring components. Each set of distance measuring components includes the two distance measuring devices mentioned above, and the different distance measuring components are distributed in different cross-sections of the roller (e.g., ...). Figure 2 As shown in the figure, the average value of all thickness measurement results is taken as the final measured thickness.

[0036] Furthermore, this embodiment employs high-precision bearings to improve measurement accuracy. Bearing accuracy is mainly classified into six levels: 0, 6X, 6, 5, 4, and 2. Among them, level 2 bearings are the highest precision level and are mostly used in the aerospace field. Their rotational accuracy is less than 5µm. Using a level 2 bearing can control the radial and axial runout of the inner and outer rings within 5µm, which is sufficient to meet the required measurement accuracy.

[0037] Distance measuring devices can employ various methods such as ultrasonic, laser, and infrared ranging, and this example is not limited to ultrasonic measuring sensors.

[0038] Furthermore, existing ultrasonic ranging methods directly calculate distance by multiplying the speed of sound in air by half the time difference between the transmission and reception of the ultrasonic wave. This method does not account for the distance difference between the transmitting and receiving probes. Therefore, this embodiment corrects for this deviation using an algorithm, such as... Figure 3 As shown, the corrected formula is as follows:

[0039]

[0040] Where L represents the distance measured by the ultrasonic sensor, H represents the corrected distance, and M represents half the distance between the transmitting and receiving probes inside the ultrasonic sensor.

[0041] The above modifications result in a system with high accuracy, good vibration resistance, and ease of operation.

[0042] In this embodiment, the system is controlled by a controller (such as a microcontroller). The basic idea of ​​the controller program is to first reset and initialize each module. After each part is ready, the PWM function of the timer is started to emit a 40kHz square wave to drive the ultrasonic sensor to emit ultrasonic waves. At the same time, the input capture function of the timer is turned on, and the count function of the timer is used to record the count value at this moment. When the ultrasonic sensor receives the echo signal, it is transmitted to the microcontroller. The timer captures its rising edge and generates an interrupt. The timer records the count value at this moment again, thereby obtaining the number of times the ultrasonic wave has traveled this distance. It takes 0.01s for the timer to count 1. The time for the entire ultrasonic wave propagation process can be calculated. Then, the final thickness is calculated using the above distance calculation formula. Finally, the distance value is displayed on the LED screen through the display program.

[0043] Currently, the motor drive speed in the fabric adhesive production workshop is about 40 meters / minute, while this system is set with a timer to measure the thickness every 0.01 seconds. Calculations show that the thickness is measured and recorded every 6.667mm, which fully meets the production workshop's needs for fabric thickness measurement.

[0044] This invention enables continuous thickness measurement of coated fabrics using a non-contact distance measuring device, protecting operator safety, avoiding product waste, and providing more accurate and standardized measurement results for the thickness of the coated fabric.

[0045] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the invention without departing from the spirit and scope of the invention as defined in the appended claims, all of which shall be within the scope of protection of the invention.

Claims

1. An ultrasonic thickness testing system for coated fabrics, characterized in that, include: The system includes a roller and two ultrasonic sensors. The fabric moves around the roller to form a wrap angle. The two ultrasonic sensors are located in the same cross-section of the roller, and the measurement direction of the two ultrasonic sensors is towards the center of the cross-section after passing through the point where the fabric and the roller are in contact. The two ultrasonic sensors and the center of the cross-section form a right triangle, and the side of the right angle includes the line connecting the two ultrasonic sensors. Distance measurement is performed using two ultrasonic sensors; The thickness of the fabric is calculated based on the distance measured by two ultrasonic sensors and the radius of the roller; Fabric thickness The calculation formula is: in, This indicates the distance between two ultrasonic sensors. and These represent the distances measured by the two ultrasonic sensors, and Greater than , Indicates the radius of the roller; Multiple sensor groups are also set up, each group including the two ultrasonic sensors. Different sensor groups are distributed in different cross sections of the roller, and the average value of all thickness measurement results is taken as the final measured thickness.

2. The ultrasonic thickness testing system for coated fabrics according to claim 1, characterized in that: It also includes two rollers. Before the fabric travels to the rollers, the fabric passes between the two rollers, causing the two rollers to rotate in opposite directions.

3. The ultrasonic thickness testing system for coated fabrics according to claim 1, characterized in that: The rollers use Class 2 precision bearings.

4. The ultrasonic thickness testing system for coated fabrics according to claim 1, characterized in that: The calculation of fabric thickness also includes the distance measured by the ultrasonic sensor. and The correction is made, and the correction formula is: Where L represents the distance measured by the ultrasonic sensor, H represents the corrected distance, and M represents half the distance between the transmitting and receiving probes inside the ultrasonic sensor.

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