Sensor module, sensor belt, sensor roller and method

Abstract

The invention relates to a sensor module comprising at least one sensor pair having a first sensor and a second sensor, the first sensor and the second sensor each having an electrode E1, for example a ground connection, and an electrode E2, for example a signal connection, and the first sensor and the second sensor each having a second electrode E3, for example a signal connection. The sensor module has at least one earth conductor and a first signal conductor and a second signal conductor, the first signal conductor being connected to an electrode E2 of the first sensor (11) and the second signal conductor being connected to an electrode E2 of the second sensor. And the grounding lead is connected with the electrode E1 of the first sensor and the electrode E1 of the second sensor. According to the invention, the sensor module extends in a longitudinal direction L from a starting end to a terminating end, and the earth conductor and the first and second signal conductors extend from the starting end to the terminating end of the sensor module without crossing each other.

Description

[0001] The present invention relates to a sensor module according to the preamble of claim 1, a sensor belt having such a sensor module, a sensor roller having such a sensor belt, and a method for measuring pressure distribution using the sensor roller.

[0002] In equipment used to manufacture and process fiber webs—hereafter referred to as a “paper machine” for simplicity—the web typically passes through multiple processing gaps in which it is, for example, dewatered, coated, or calendered. These processing gaps are also called “pressing zones.” Pressing zones are typically formed here by rolls and mating elements (especially mating rolls).

[0003] Such processing gaps also appear in many other application areas, especially in the manufacture or processing of nonwoven fabrics, textiles, films, metal strips or similar strip materials.

[0004] For example, in the textile industry, calenders are used for finishing textiles. Printing on substrates is also done through appropriate transfer pressing zones.

[0005] The fiber web can be, in particular, paper web, paperboard web or pulp web.

[0006] The pressure and temperature conditions within the compression zone are crucial to the processing results. This involves not only average values, but also the distribution of these values ​​across the width of the compression zone or material strip. In modern equipment, this width can reach 10 m or more.

[0007] Therefore, it is known from the prior art that, in order to measure the pressure distribution, multiple pressure sensors are arranged in a manner distributed along the width of the paper web in the roller that forms the processing gap.

[0008] Document EP 2331923 B1 recommends using fiber optic sensors for this purpose. This involves arranging optical fibers with Bragg gratings between the roll sleeve or the core. While these systems can provide accurate measurements, they are relatively expensive and require a significant amount of installation work.

[0009] Piezoelectric sensors have proven to be an economical and practical alternative. The use of piezoelectric sensors in sensor rolls of paper machines is also known in the prior art, as described, for example, in document EP 1 753 912. Here, a series of piezoelectric sensors are connected to a common ground wire and a common signal wire. An electrical signal is generated by the pressure in the pressure zone, which can be acquired via the signal wire. Such sensor rolls are relatively inexpensive to manufacture, but they have some drawbacks.

[0010] However, the described ceramic sensor is relatively thick and inflexible. The risk of delamination and consequently, roller damage is relatively high during the continuous loading and unloading cycles of the sensor roller's operation.

[0011] Because all signals must be transmitted through the same signal conductor, special measures must be taken to ensure a clear correspondence between the signal and the sensor. In particular, it is essential to ensure that only one sensor is located in the pressure zone at any given time. Setting up separate signal and ground conductors for each sensor is not only extremely complex but also further increases the risk of delamination and damage, especially when individual conductors cross paths.

[0012] As an improvement to this technology, utility model document FI 12489 suggests replacing ceramic piezoelectric sensors with printed sensors. Such printed piezoelectric sensors are known in the prior art, for example, as described in document WO 2014037016 A1. However, those skilled in the art cannot learn from document FI 12489 how these sensors should be specifically designed for simple and efficient application in sensor rollers.

[0013] Therefore, the technical problem to be solved by the present invention is to overcome the above-mentioned technical problems in the prior art.

[0014] Another technical problem of the present invention is to provide a sensor system that is simple and inexpensive to manufacture, and can be easily and risk-free installed in a sensor roller.

[0015] The technical problem described herein is solved by the embodiments described in the independent claims. Other advantageous embodiments of the invention are found in the dependent claims.

[0016] A sensor module is proposed herein, comprising at least one sensor pair having a first sensor and a second sensor, wherein the first sensor and the second sensor each have an electrode E1, for example a ground terminal, and an electrode E2, for example a signal terminal. Furthermore, the sensor module has at least one central conductor, particularly a ground conductor, and a first signal conductor and a second signal conductor, wherein the first signal conductor is connected to the electrode E2 of the first sensor, the second signal conductor is connected to the electrode E2 of the second sensor, and the central conductor (e.g., the ground conductor) is connected to the electrodes E1 of both the first and second sensors.

[0017] According to the present invention, the sensor module extends longitudinally from the starting end to the ending end, and the central wire (e.g., grounding wire) and the first signal wire and the second signal wire extend from the starting end to the ending end of the sensor module without crossing each other.

[0018] Since the central conductor is designed as a grounding conductor in most conventional applications, the term "grounding conductor" will be used as a synonym for the general term "central conductor" in the following sections of this application unless otherwise expressly stated. In particular, it should be noted that the concepts described herein are not limited to implementations using a grounding conductor.

[0019] In this type of sensor module, two sensors can share a common ground wire, but each has its own independent signal wire. Therefore, the signal within the sensor module always corresponds precisely to the respective sensor. Using a common ground wire is harmless in this respect. This approach reduces workload and is itself an advantage compared to a solution where each sensor has its own independent ground wire.

[0020] However, this invention does not preclude the sensor module from having other components, particularly other wires. For example, it may be specified that a second grounding wire is also provided and that each sensor has an independent grounding wire.

[0021] However, the sensor module is not limited to two sensors. In an advantageous embodiment, for example, the sensor module may be specified to have a number of sensor pairs n>1, wherein n is preferably equal to 2, 3 or 4, and wherein each of the n sensor pairs has a first sensor i1 and a second sensor i2, a first signal wire and a second signal wire, and a ground wire, and wherein all n*3 wires extend from the start end to the end end of the sensor module without crossing each other.

[0022] The sensors can be advantageously arranged sequentially along the longitudinal direction of the sensor module.

[0023] At least one, and in particular all, of the sensors can be pressure-sensitive sensors, especially piezoelectric sensors. The invention will be described within the scope of this application based on this sensor type. However, other sensors may also be used alternatively or additionally. Thus, for example, a temperature sensor may also be used. Temperature distribution measurements can also be performed without setting a processing gap. The use of other sensors, such as FSRs (“force resistors”, i.e., piezoresistive sensors), is also possible.

[0024] In principle, such sensor modules can be designed to be large enough to cover the entire width of the material, such as the width of a fiber or the roller. However, this would result in a significant increase in the number of wires required. Assuming a roller with a width of 10m and a desired resolution of 25cm between adjacent sensors, a sensor module with n=20 sensor pairs would be needed, requiring 40 signal wires and 20 ground wires. This would result in a very wide sensor module, especially when it is necessary to avoid wire crossings or overlapping.

[0025] Therefore, the sensor module is designed such that the grounding wire and signal wire are continuously connected longitudinally from the start to the end of the sensor module. This allows multiple such sensor modules to be connected in series to form a sensor strip. Thus, a single sensor module can remain relatively small, for example, two or three sensor pairs, while sensor strips of arbitrary length can still be obtained by linking multiple sensor modules. The number of wires does not increase but remains comparable to the number of wires in a single sensor module.

[0026] The sensor module has a width direction B, and the grounding wire, the first signal wire, and the second signal wire occupy the same position in the width direction B at the starting end of the sensor module as they do at the ending end, thereby making this connection particularly simple to implement.

[0027] In a preferred embodiment, the sensor and the wires may be arranged on a carrier medium, particularly a carrier film.

[0028] In a particularly preferred embodiment, the wires and sensors are printed on a carrier medium.

[0029] The printing of such electrical or electronic structures is not a new technology in itself.

[0030] For measuring pressure distribution in a pressure zone, piezoelectric sensing elements are an obvious solution. For example, document US 8479585 B2 describes a single pressure measurement point on a non-planar surface. It illustrates a method using piezoelectric copolymers as a single sensor and matrix.

[0031] To use PVDF-based piezoelectric polymers, pre-stretched films composed of pure polymers can be used, or copolymers whose ferroelectric phase (β phase), especially ferroelectrically active stereochemical chains, can self-form, such as P(VDF-TrFE). Due to the self-orientation of the polymer, the material can also be printed using methods such as screen printing and inkjet printing. A proven printing formulation is described, for example, in document EP 2609142 B1. In principle, other printing processes, such as gravure printing, flexographic printing, or offset printing, can also be used.

[0032] There are numerous other publications on the printing of piezoelectric polymers and the fabrication of piezoelectric sensors, such as WO20074075 A1 or WO 2014037016 A1.

[0033] Here, the structure of the long sensor strip composed of multiple short sensor modules proposed according to various aspects of the present invention has proven to be very advantageous because roll-to-roll printing can be performed using one or more printing rollers. For this purpose, (roller) screen printing is preferred.

[0034] Here, the size of the printed image is limited by the circumference of the printing cylinder. The circumference of such printing cylinders is typically between 30cm and 2m. However, the sensor rollers used for these sensor strips are usually significantly wider than 2m. For example, textile calenders with a width of 7m are not uncommon. Paper machine rollers frequently reach widths of 10m or more. To print a 10m long sensor strip in this manner, a printing cylinder with a diameter exceeding three meters must be used. This is impractical.

[0035] Within the scope of this invention, the length of the sensor module can be adjusted to match the circumference of an existing printing cylinder, for example, making the length of the sensor module exactly equal to the circumference of the printing cylinder.

[0036] If the grounding wire and the first and second signal wires are positioned at the same width direction at the starting end of the sensor module as they are at the ending end, the printed image will iteratively repeat with each rotation of the printing cylinder. The leads to each sensor are interconnected with each rotation of the printed image, thus forming a very long (e.g., 150 m) sensor strip with continuous contact wires, capable of contacting a defined number of printed elements in each rotation if necessary. These very long printed images can be precisely registered and aligned with the printed structure through the screen in each rotation cycle, ensuring that offsets along the transverse and longitudinal directions of the roller remain within certain tolerances.

[0037] Because the number of wires does not increase arbitrarily, but remains consistent with the number of wires in a single sensor module, the sensor strip is therefore kept very narrow. This is advantageous because it allows the use of most commercially standard printing rollers, such as rollers with a width of 60cm.

[0038] The conductors may have a width between 1 mm and 3 mm, preferably between 1.5 mm and 2.6 mm. The distance between these conductors may particularly be between 0.5 mm and 3 mm, preferably between 1 mm and 2.6 mm.

[0039] The sensor size is scalable and can be non-circular if needed.

[0040] The components of a sensor module are typically printed in multiple layers. The sensor module according to various aspects of the present invention can, for example, be printed in five layers:

[0041] Layer 1: Printed wires

[0042] Layer 2: Electrode E1 (e.g., grounded)

[0043] Layer 3: Sensing Layer 1

[0044] Layer 4: Sensing Layer 2

[0045] Layer 5: Electrode E2 (e.g., signal)

[0046] If the sensor module is to be implemented as a piezoelectric sensor, the third and / or fourth sensing layers may contain a piezoelectric polymer.

[0047] The third and / or fourth layers can serve as insulation, especially in piezoelectric sensors, to isolate electrodes E1 and E2 from each other. However, when using piezoresistive sensors (FRS sensors), the third and fourth layers are typically not insulating.

[0048] In addition, more layers can be set.

[0049] For example, the sensor module may also include:

[0050] 6th layer: Protective layer.

[0051] The final protective layer can protect the electrodes and printed wires during operation (e.g., loading into the rollers) and during the operation of the sensor module.

[0052] Depending on the application requirements, more layers can be added, such as an adhesive layer for fixing to the substrate.

[0053] Each of the aforementioned functional layers can be manufactured individually through a single printing process. Alternatively, it may be specified that one or more functional layers are manufactured through multiple overlapping printing processes, thereby possessing a layered structure.

[0054] How to implement suitable wiring according to various aspects of the present invention will be explained later with the aid of the accompanying drawings.

[0055] To avoid wire crossings, it is advantageous to arrange the wires such that, for each sensor pair, each ground wire extends from the start end to the end end of the sensor module in the width direction B between the corresponding first signal wire and second signal wire.

[0056] The sensors can then be arranged such that the first sensor is located between the first signal wire and the ground wire, while the second sensor is located between the ground wire and the second signal wire. Therefore, the three wires themselves will not cross, and the connections between the sensors and the wires will not intersect.

[0057] According to various aspects of the sensor modules and sensor strips of the present invention, sensor pairs and their arrangement are core elements. Typically, a sensor module or sensor strip consists of a certain number of sensor pairs, thus having an even number of sensors. This is generally the most advantageous implementation, but not a mandatory requirement.

[0058] A sensor module having several sensor pairs may, for example, still include one or more additional individual sensors. A sensor strip including multiple sensor modules may also additionally have more individual sensors. The accompanying drawings exemplarily illustrate variations of such sensor modules or sensor strips.

[0059] According to another aspect of the invention, a sensor strip is proposed for use in rollers of machines that manufacture or process webs, particularly fiber webs, wherein the sensor strip comprises at least two, particularly five or more, sensor modules according to one aspect of the invention, wherein the sensor modules are arranged sequentially along a longitudinal direction L on a common carrier medium, particularly on a common carrier film.

[0060] Preferably, the sensor modules are of the same type, and the grounding wire and signal wire at the termination end of the previous sensor module are connected to the corresponding wire at the starting end of the subsequent module.

[0061] To produce such sensor strips, a very long master roll (e.g., 100m or longer) with repeating sensor modules can be printed. The required length can then be cut from this master roll as a sensor strip. Therefore, sensor printing can be completely separated from the application. This results in cost advantages and reduced production time, as the sensor strip is available immediately upon order placement, without waiting for the printing process.

[0062] The width of the sensor strip may vary depending on the application, but it is typically less than 60cm, and especially less than 40cm.

[0063] Finally, a sensor roller is proposed for a machine used to manufacture or process webs, such as fiber webs, textile webs, plastic webs, or metal webs. The sensor roller includes a roller core and a roller sleeve made of a polymer material. Here, the sensor roller includes at least one sensor belt according to one aspect of the invention.

[0064] The sensor strip can be positioned in different locations. For example, the sensor strip can be arranged between the roller core and the roller sleeve. Alternatively, it can be embedded in the polymer material of the roller sleeve.

[0065] Finally, a sensor strip can also be placed on the surface of the roller. This is particularly advantageous for maintenance work because the sensor strip can be used as a mobile measuring system to properly adjust the pressure distribution in the processing gap. The sensor strip can then be removed again. Therefore, it is also possible to measure rollers that were not pre-installed with sensor strips during manufacturing.

[0066] Since each sensor module typically has sensors connected to each signal wire, care must be taken when arranging the sensor strip so that at any given time, only one connected sensor can cross the processing gap on each signal wire, ensuring reliable signal distribution to the corresponding sensor. This can be achieved, for example, by arranging the sensor strip in a spiral manner within or on the sensor roller. The spiral angle can be chosen to be relatively gentle, as multiple sensors connected to different signal wires can cross the processing gap simultaneously without issue.

[0067] In a preferred embodiment, the sensor roller may be equipped with an evaluation unit configured to receive and evaluate the sensor signal via a signal wire.

[0068] The evaluation unit can be directly mounted on the roller, for example, on the end face cover. Alternatively, it can be specified that only one data unit is mounted on the roller, which transmits the acquired signals to the actual evaluation unit. This transmission can be particularly wireless.

[0069] Data or signal transmission to the evaluation unit can be continuous. Alternatively, transmission can be performed only at discrete points in time, especially when explicitly required. In this way, the sensor system can be implemented more energy-efficiently.

[0070] The evaluation unit can determine and / or display the distribution, particularly the pressure distribution with respect to the material width or the width of the processing gap, based on the received signals.

[0071] The task at this point is for the evaluation unit to determine which sensor the signal on the signal wire originates from. This can be achieved using one of the methods known in the prior art. For example, the roller can have an independent sensor that determines the roller's current rotational position (Hall sensor, accelerometer, etc.).

[0072] Alternatively or additionally, this can also be achieved through the arrangement of the sensor strip. If the sensor strip is laid in a uniform spiral, the angular distance between two adjacent sensors on a signal wire is always equal. The spiral strip can now be laid so that its rotation around the roller is significantly less than 360°. Thus, the angular distance between the last sensor and the first sensor will be greater than the other distances. Therefore, the evaluation unit can very easily determine which signal comes from the first sensor of the sensor strip. The correspondence of the remaining sensors becomes simple. For this implementation, it is highly advantageous that the sensor strip according to this invention can be laid in a very gentle spiral. Thus, even on longer rollers, it can be ensured that the sensor strip extends around the roller by significantly less than 360°.

[0073] Furthermore, it can be specified that the sensor roller and the second mating element form a second processing gap. If the spiral belt is arranged smoothly enough, two processing gaps can be measured using the same sensor belt.

[0074] In a preferred embodiment, two sensor strips may be mounted on a single sensor roller. For example, one strip may be used in conjunction with the other as a backup. This improves the system's fault tolerance without significantly increasing costs.

[0075] Finally, a method is proposed for measuring the pressure distribution in at least one processing gap during a process of processing fiber webs, nonwoven fabrics, woven fabrics, films, metal strips, or other webs, wherein the processing gap is constituted by sensor rollers and mating elements, particularly mating rollers. It is specified here that the sensor rollers are designed according to one aspect of the invention, and each sensor generates a signal corresponding to the pressure in the processing gap as it passes through the processing gap.

[0076] The fiber web can be, in particular, a paper web, a paperboard web, or a pulp web.

[0077] Preferably, the process for processing nonwoven fabrics, woven fabrics, films, metal strips or other strip-shaped materials is selected from the group consisting of:

[0078] • Coating process

[0079] - Packaging technology, especially in the photovoltaic field

[0080] Packaging technology, especially food packaging

[0081] - Battery manufacturing, especially in the production of anodes, cathodes, and separators.

[0082] - OLED and optical layer

[0083] - Scratch-resistant coating, dust-resistant coating, electrostatic coating

[0084] • Adhesive bonding process, lamination process, calendering process

[0085] • Lamination

[0086] - Packaging

[0087] - Multilayer composite materials

[0088] - PCB laminate

[0089] - Packaging or bags

[0090] - Battery manufacturing and fuel cell manufacturing

[0091] - Wound capacitors

[0092] - Flexible electronic circuits and solar cells, displays

[0093] - Medical applications, especially in the manufacture of adhesive bandages or test strips.

[0094] Assembly process

[0095] - Electronic components

[0096] • Grinding roller equipment

[0097] • Conveyor belt

[0098] - Recycle

[0099] - Sorting

[0100] • Extrusion equipment

[0101] - Thin film manufacturing

[0102] • Printing process

[0103] - Graphic Printing

[0104] - Newspaper printing, paper printing, label printing

[0105] - Currency printing

[0106] - Printed Electronics

[0107] - Offset printing, gravure printing, flexographic printing, engraving printing, OLED and optical applications

[0108] • Imprinting process

[0109] - Nanoimprint lithography

[0110] - Hot stamping, especially for anti-reflective coatings

[0111] • Material width operation optimization

[0112] - Material tension measurement

[0113] - Tensile force measurement

[0114] Vacuum coating, especially for metals, is also used in food.

[0115] • Textile finishing, especially through printing, coating or dyeing

[0116] • Steel and metal strip manufacturing

[0117] • Condition monitoring of large substrates, especially wind turbine blades.

[0118] As another possible application of the sensor strip according to the invention, an application is also proposed in which the sensor strip is mounted on a fixed surface for large-area detection of collisions within a specific area. To determine the location information of the collision, the velocity and start time of the moving colliding object (=test object) or the velocity vector component parallel to the sensor surface can be used. This can be advantageously used, for example, in drop towers.

[0119] Compared to sensor strips known in the prior art where all sensors are connected to the same signal wire and the same ground wire, the sensor strip according to aspects of the present invention can more accurately determine the point of impact. This is possible because the location of the sensor generating the signal can be precisely determined within the sensor module. For example, for large test objects, it is possible to more accurately determine which part of the test object caused the collision.

[0120] Alternatively or additionally, the sensor strip according to the invention can also correct inaccuracies in position determination. Such inaccuracies may arise from deviations from the ideal trajectory, for example, due to friction or impact pulses—especially when multiple collisions occur during motion. Therefore, the sensor strip according to the invention can not only determine the collision location but also correct errors in position determination.

[0121] The listed applications are intended to illustrate the possible applications of the invention. The invention is not limited to these applications.

[0122] The present invention is described below with reference to the accompanying drawings, but the invention is not limited to these embodiments. In the drawings:

[0123] Figure 1 A sensor module according to one aspect of the present invention is shown.

[0124] Figure 2a A sensor module according to another aspect of the invention is shown.

[0125] Figure 2b A sensor module according to another aspect of the invention is shown.

[0126] Figure 2cA sensor module according to another aspect of the invention is shown.

[0127] Figure 3 A sensor strip according to another aspect of the invention is shown.

[0128] Figure 4 An apparatus for implementing a method according to another aspect of the invention is shown.

[0129] Figure 1 A simplified variation of sensor module 1 is shown. Here, sensor module 1 has a sensor pair 10 consisting of a first sensor 11 and a second sensor 12. Viewed along the longitudinal direction L, they are arranged sequentially. Furthermore, sensor module 1 has a first signal wire 15, a second signal wire 16, and a ground wire 17.

[0130] Here, the first sensor 11 is connected to the first signal wire 15 and the ground wire 17, while the second sensor 12 is connected to the second signal wire 16 and the ground wire 17.

[0131] The three wires 15, 16, and 17 extend primarily in the longitudinal direction L, from the starting end A of the sensor module 1 to the ending end O. To avoid the wires 15, 16, and 17 crossing, the signal wires 15 and 16 extend outwards along the width direction B, and the two sensors 11 and 12 of the sensor pair 10 are arranged between the signal wires 15 and 16.

[0132] Grounding wire 17 also extends between signal wires 15 and 16. Here, grounding wire 17 extends below the first sensor 11 and then above the second sensor 12.

[0133] Sensors 11 and 12 are designed such that electrode E2 of the first sensor 11 points upward and electrode E1 points downward; while the second sensor 12 is the opposite, with electrode E1 pointing upward and electrode E2 pointing downward.

[0134] like Figure 1 As shown, this arrangement is advantageous because the actual signal lines 15, 16, 17 and the connections between the sensors 11, 12 and the signal lines do not intersect throughout the entire sensor module 1.

[0135] Figure 2a The diagram shows a sensor module 1 consisting of two sensor pairs 10 and 20. Judging from the systematic arrangement of signal wires 15, 16, 25, 26 and grounding wires 17, 27, this sensor module 1 is similar to... Figure 1The sensor module 1 is doubled. Three wires 15, 16, and 17 are led to the termination end O of the sensor module 1 after the second sensor 12 and above the first signal wire 25 of the second sensor pair 20, while the wires 25, 26, and 27 of the second sensor pair 20 are led from the start end A of the module 1 to the second sensor pair 20 below the second signal wire 16 of the first sensor pair 10.

[0136] Technicians will understand that sensor modules 1 with more sensor pairs can also be achieved in this way and through this method, where the number of wires increases without crossing. However, due to the increase in the number of wires, such sensor modules 1 will continuously become wider.

[0137] In this sensor module 1, four sensors 11, 12, 21, and 22 are arranged sequentially along the longitudinal direction L of the sensor module 1. These sensors are arranged at the same height along the width direction B of the sensor module 1. To avoid crossing, the wires 15, 16, 17, 25, 26, and 27 are arranged such that for each sensor pair 10 and 20, from the starting end A to the ending end O of the sensor module 1, the grounding wire 17 is located between the first signal wire 15 and the second signal wire 16 along the width direction B, and the grounding wire 27 is located between the first signal wire 25 and the second signal wire 26 along the width direction B.

[0138] All grounding wires 17, 27 and signal wires 15, 16, 25, 26 are guided such that their positions along the width direction B at the starting end A of sensor module 1 are the same as their positions along the width direction B at the ending end O. This facilitates the connection of multiple sensor modules 1 into a sensor strip 2.

[0139] Sensors 11, 12, 21, 22 and wires 15, 16, 17, 25, 26, 27 are all arranged on the carrier medium 5, which is usually the carrier film 5.

[0140] This type of sensor module 1 can be manufactured very efficiently through printing processes, such as roller screen printing.

[0141] Figure 2b The sensor module 1 shown is one possible implementation, wherein the sensor module 1 is not only composed of sensor pairs 10 and 20, but also includes additional sensors.

[0142] Figure 2b Sensor module 1 in the middle is largely related to Figure 2aThe corresponding sensor module includes two sensor pairs 10 and 20. The only difference is that sensor module 1 also includes an additional sensor 11a. In this case, the additional sensor 11a is the same as the first sensor 11 of the first sensor pair 10 and is arranged similarly, also connected to the ground wire 17 and the first signal wire 15. Obviously, multiple additional sensors 11a can also be placed in other locations in this manner. Such additional sensors 11a may be advantageous, for example, to obtain a redundant system so that measurements can continue to be acquired even if the first sensor 11 fails.

[0143] Figure 2c Another implementation is also shown, in which sensor module 1 is not solely composed of sensor pairs 10 and 20. Figure 2a Compared to sensor module 1, Figure 2c The second sensor 22 of the second sensor pair 20 is omitted for example.

[0144] Figure 2a , 2b The embodiments described in section 2c exemplify how sensor modules according to various aspects of the present invention can be constructed in diverse ways. The invention is not limited to the alternatives shown herein.

[0145] Figure 3 The sensor strip 2 is shown, which consists of multiple (three in this case) sensor modules 1, as shown. Figure 2a These sensor modules 1 are printed on a common carrier medium 5. The sensor modules 1 are designed to match the printing roller, allowing the entire number of sensor modules 1 to fit the printing roller. Sensor strips 2 of virtually any length can be pre-printed on the roll as stock. For specific applications, sensor strips 2 of the required length can be cut and processed from the roll.

[0146] The conductors 15, 16, 17, 25, 26, and 27 may have a width, particularly between 1 mm and 3 mm, and preferably between 1.5 mm and 2.6 mm. The distance between the conductors 15, 16, 17, 25, 26, and 27 may have a width, particularly between 0.5 mm and 3 mm, and preferably between 1 mm and 2.6 mm.

[0147] Figure 4 An apparatus for implementing a method according to another aspect of the invention is shown. The apparatus may be, for example, a calender or a coating unit. The apparatus has a processing gap (“pressing zone”) 7, which is formed by mating elements in the form of sensor rollers 8 and mating rollers 9.

[0148] At least one sensor strip 2 according to one aspect of the invention is provided in the sensor roller 8. The sensor strip may be arranged, for example, inside or below the polymer sleeve of the sensor roller 1. It is also possible to arrange it (usually temporarily) on the surface of the roller.

[0149] The sensor belt 2 extends to cover the entire width of the pressing zone 7, or the entire width of the material to be processed, such as the fiber web. Because the sensor belt 2 is arranged in a spiral manner, its length can be greater than the width of the roller 8.

[0150] like Figure 4 As shown, the spiral can be very gentle, and can be described as significantly less than one turn around the sensor roller 8. The spiral arrangement is essentially designed to ensure that two sensors 11, 12, 21, 22 using the same signal wires 15, 16, 25, 26 will never be located in the pressure zone 7 simultaneously. This is achieved through the very gentle spiral winding of the sensor band 2.

[0151] The longer the sensor module 1 used, the smoother the spiral winding can be. For example, if using Figure 1 The sensor module in the middle must ensure that the sensors 11 and 12 that are directly adjacent to each other in any case are still in the pressure zone 7, because the next sensor has used the same signal wires 15 and 16 again.

[0152] for Figure 2a The sensor module 1 in the middle can have four sensors 11, 12, 21, and 22 simultaneously located in the pressure zone 7 without any problems. Therefore, a smoother winding can be used.

[0153] In extreme cases (which are usually not technically advantageous), if the entire sensor band 2 consists of only a single sensor module 1, then each sensor has its own signal wire. In this case, the spiral processing can be completely abandoned.

[0154] The starting end A of sensor belt 2 is located at the front end of sensor roller 8. Here, wires 15, 16, 17, 25, 26, and 27 can be connected to data unit 6, which transmits the acquired signals to evaluation unit. Transmission is preferably wireless. Advantageously, data unit 6 also includes a power supply to ensure, for example, data transmission. Evaluation unit 6 is configured to receive and evaluate the sensor signals. It is also advantageous if data unit 6 is also designed as evaluation unit 6, so that at least some data evaluation can be performed directly on the roller.

[0155] List of reference numerals

[0156] 1. Sensor Module

[0157] 2 sensor bands

[0158] 5. Carrier Thin Film

[0159] 6 Data Units / Evaluation Units

[0160] 7. Handling gaps / “compression zones”

[0161] 8 sensor rollers

[0162] 9 Paired Rollers

[0163] 10 First sensor pair

[0164] 11 The first sensor pair of the first sensor

[0165] Additional sensors in the 11a sensor module

[0166] 12 The second sensor of the first sensor pair

[0167] 15 First signal wire

[0168] 16 Second signal wire

[0169] 17. Central conductor; grounding conductor

[0170] 20 Second sensor pair

[0171] 21 The first sensor of the second sensor pair

[0172] 22 The second sensor pair of the second sensor

[0173] 25 First signal wire

[0174] 26 Second signal wire

[0175] 27 Grounding conductor

[0176] L longitudinal

[0177] B Width direction

[0178] A. Starting end

[0179] O Termination

Claims

1. Sensor module (1) comprising at least one sensor pair (10) with a first sensor (11) and a second sensor (12), wherein the first sensor (11) and the second sensor (12) each having an electrode E1, for example a ground terminal, and an electrode E2, for example a signal terminal, and wherein the sensor module (1) has at least one ground conductor (17) and a first signal conductor (15) and a second signal conductor (16), wherein the first signal conductor (15) is connected to the electrode E2 of the first sensor (11), the second signal conductor (16) is connected to the electrode E2 of the second sensor (12), and the ground conductor (17) is connected to the electrode E1 of the first sensor (11) and the second sensor (12), characterized in that the sensor module (1) extends in a longitudinal direction L from a starting end (A) to an end (O), and the ground conductor (17) and the first signal conductor (15) and the second signal conductor (16) extend from the starting end (A) to the end (O) of the sensor module (1) without intersecting one another.

2. The sensor module (1) according to any one of the preceding claims, characterized in that The sensor module (1) has a number n > 1 of sensor pairs (10, 20), wherein n is preferably equal to 2, 3 or 4, and wherein each of the n sensor pairs (10, 20) has a first sensor (11, 21) and a second sensor (12, 22), a first signal conductor (15, 25) and a second signal conductor (16, 26) and a ground conductor (17, 27), and wherein all n*3 conductors extend from the starting end (A) to the end (O) of the sensor module (1) without intersecting one another.

3. The sensor module (1) according to any one of the preceding claims, characterized in that The sensor module (1) has a width direction B, and the ground conductors (17, 27) and the first signal conductors (15, 25) and the second signal conductors (16, 26) each occupy the same position in the width direction B at the starting end (A) of the sensor module (1) as they do at the end (O).

4. The sensor module (1) according to any one of the preceding claims, characterized in that The sensors and the conductors are arranged on a carrier medium (5), in particular a carrier film (5).

5. The sensor module (1) according to claim 4, characterized in that The conductors and the sensors are in particular printed on the carrier medium (5) by means of screen printing or inkjet printing.

6. The sensor module (1) according to any one of the preceding claims, characterized in that For each sensor pair (10, 20), the respective ground conductor (17, 27) extends in the width direction B between the respective first signal conductor (15, 25) and the second signal conductor (16, 26) from the starting end (A) to the end (O) of the sensor module (1).

7. The sensor module (1) according to claim 6, characterized in that For at least one, in particular each sensor pair (10, 20), the first sensor (11, 21) is arranged between the first signal conductor (15, 25) and the ground conductor (17, 27), while the second sensor (12, 22) is arranged between the ground conductor (17, 27) and the second signal conductor (16, 26), wherein the three conductors (15, 16, 17; 25, 26, 27) and the connecting lines of the sensors (11, 12; 21, 22) to these conductors (15, 16, 17; 25, 26, 27) are free of crossings.

8. The sensor module (1) according to any one of the preceding claims, characterized in that At least one, in particular all sensors are pressure-sensitive sensors, in particular piezoelectric sensors.

9. A sensor band (2) for use in a roll in a machine for manufacturing or processing a web, in particular a fibrous web, wherein The sensor strip (2) comprises at least 2, in particular 5 or more sensor modules (1) according to any of the preceding claims, and wherein the sensor modules (1) are arranged in succession along the longitudinal direction L on a common carrier medium (5), in particular on a common carrier film (5).

10. The sensor band (2) according to claim 9, characterized in that The sensor modules (1) are sensor modules (1) of the same type, and the ground conductor and the signal conductor at the end of termination (O) of a preceding sensor module (1) are connected to the corresponding conductors at the start (A) of a subsequent module.

11. Sensor roll (8) for a machine for manufacturing or processing a web, in particular a fibrous web, comprising a roll core and a roll cover made of a polymeric material, characterized in that The sensor roll (8) comprises at least one sensor strip (2) according to claim 9 or 10.

12. The sensor roll (8) according to claim 11, characterized in that The sensor strip (2) is arranged in a spiral manner within or on the sensor roll (8).

13. The sensor roll (8) according to claim 11 or 12, characterized in that The sensor roll (8) is equipped with an evaluation unit (6) which is designed to receive and evaluate the signals of the sensors via the signal conductors.

14. A method for measuring the pressure distribution in at least one processing gap (7) in a process for processing a fibrous web, a nonwoven, a fabric, a film, a metal strip or other web, wherein The processing gap (7) is formed by the sensor roll (8) and a counter element (9), in particular a counter roll (9), characterized in that the sensor roll (8) is designed according to any of claims 11 to 13, and each sensor generates a signal corresponding to the pressure in the processing gap (7) when passing through the processing gap (7).

15. The method of claim 14, wherein, The process for processing a fibrous web, a nonwoven, a fabric, a film, a metal strip or other web is selected from the following group: • coating processes - encapsulation processes, in particular in the field of photovoltaics - packaging technology, in particular food packaging - battery production, in particular in the production of anodes, cathodes and separators - OLED and optical layers - scratch-resistant coatings, dirt-repellent coatings, static-electricity coatings • bonding processes, film coating processes, calendering processes • lamination - encapsulation - multilayer composites - PCB laminates - packaging or bags - battery production and fuel cell production - wound capacitors - flexible electronic circuits and solar cells, displays - medical applications, in particular the production of plasters or test strips • assembly processes - electronic components • grinding roller apparatuses • conveyor belts - recycling - sorting • extrusion apparatuses - film production • printing processes - graphic printing - newspaper printing, paper printing, label printing - currency printing - printed electronics - offset printing, intaglio printing, flexographic printing, engraving printing, OLED and optical applications • embossing processes - nanoimprint lithography - hot embossing, in particular antireflection coatings • web run optimization - web tension measurement - tensile force measurement - vacuum coating, especially of metals, also for food • finishing of textiles, especially by printing, coating or dyeing • steel, metal strip production • condition monitoring of large substrates, especially of wind turbine blades.

16. A method for determining the location of a collision of a moving test body with a fixed surface, wherein, The test body is moved parallel to the fixed surface, and wherein a sensor strip according to claim 8 or 9 is mounted on the fixed surface, and wherein the impact position is determined from the sensor signals and, if necessary, with the starting time and speed of the test body.

Images