CCD Sensor Assembly for Slitting Knife Clearance Detection
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Solution Overview
Problem
Current methods for detecting knife clearance in slitting knives are inefficient and lack controllable detection precision, affecting product quality in battery production.
Innovation Solution
A detection device comprising a support unit and a CCD sensor assembly is used to measure the knife clearance, enabling precise and efficient detection through a movable CCD sensor assembly and additional features like slide rails and clamping members to stabilize the sensor during the detection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual inspection method is used to determine knife clearance, then the device complexity is low, but the measurement precision and detection efficiency are poor
Solution Approach 1:
The patent replaces the manual visual inspection method with a CCD sensor-based optical detection system. The CCD sensor assembly captures images of the knife clearance, and a processor analyzes these images to determine the actual knife clearance value, substituting mechanical human inspection with an automated optical-mechanical system that provides higher precision while maintaining manageable device complexity.
Solution Approach 2:
The patent uses a CCD sensor to create an optical copy (image) of the knife clearance gap. By capturing the visual information of the clearance and processing this copied image data, the system can measure the clearance precisely without direct physical contact, thereby improving measurement precision while keeping the detection device relatively simple.
2Productivity
If experienced operator adjusts knife clearance after visual inspection, then the device complexity is low, but the productivity is low and detection accuracy is uncontrollable
Solution Approach 1:
The patent replaces the manual operation of experienced operators with an automated detection system comprising CCD sensors and a processor. This automated system can rapidly capture and analyze knife clearance data without human intervention, significantly improving productivity while maintaining controlled and repeatable detection accuracy through systematic image processing algorithms.
Solution Approach 2:
The detection device performs self-measurement and self-judgment of knife clearance. The CCD sensor assembly automatically captures images, the processor analyzes the images to determine clearance values, and the system can automatically compare against standard ranges to determine pass/fail status, enabling the device to serve itself without requiring operator expertise for adjustment decisions.
3Measurement precision
If CCD sensor assembly is used to detect knife clearance, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The CCD sensor assembly serves multiple functions: it captures images of the knife clearance, provides illumination through the light emitting end, and the processor performs both image analysis and clearance determination. This multi-functionality reduces the need for separate components, thereby improving measurement precision while limiting the increase in overall device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Improves detection efficiency and precision, ensuring higher product quality by accurately measuring the gap between slitting knives.
Implementation Method 1
The CCD sensor assembly faces the slitting knife to detect the knife clearance of the slitting knife
Data Source
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AI summary
This application provides a detection device for a knife clearance of a slitting knife. The device includes a support unit and a detection unit. A knife holder of the slitting knife is disposed on the support unit. The detection unit is connected to the support unit. The detection unit includes a charge-coupled device (CCD) sensor assembly. The CCD sensor assembly faces the slitting knife. The CCD sensor assembly is configured to detect the knife clearance of the slitting knife. Compared with the manual visual method for determining the knife clearance, using the CCD sensor assembly to detect the knife clearance of the slitting knife can improve the detection efficiency and the detection precision, thereby ensuring the product quality.