Coating Amount Measurement Using Profile Matching
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Solution Overview
Problem
Existing methods for measuring the amount of a coating applied to a substrate sheet, such as carbon paper for fuel cells, are prone to errors due to substrate deflection and uneven mass distribution, leading to inaccuracies in calculating the applied coating amount.
Innovation Solution
A method that generates profiles of irregularities before and after coating application using sensors upstream and downstream of the coating machine, with a control unit matching these profiles to correct for positional deviations and accurately calculate the coating amount.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the amount of coating is calculated using sensors that measure the substrate sheet before and after coating application, then the coating amount can be determined from measurement value differences, but measurement accuracy deteriorates when substrate deflection causes positional deviations between measurement points
Solution Approach 1:
The system uses the irregularity profile detected by the first sensor as feedback to correct the positional deviation in the measurement values from the second sensor. The correction amount is determined based on the detected irregularity shape, enabling accurate coating amount calculation even when substrate deflection occurs during conveyance.
Solution Approach 2:
The irregularity profile acts as an intermediary element that bridges the gap between the first and second measurement values. By detecting the substrate's irregular shape before coating and using it to correct the after-coating measurements, the system compensates for positional deviations caused by substrate deflection.
2Measurement precision
If substrate sheet deflection is considered in the measurement system, then measurement accuracy can be maintained, but system complexity increases due to additional profile generation and matching steps
Solution Approach 1:
The first sensor serves multiple functions: it detects the substrate's irregularity profile for correction purposes and simultaneously provides the baseline measurement value. This multi-functionality reduces the need for separate correction mechanisms, simplifying the overall system while maintaining measurement accuracy.
Solution Approach 2:
The system uses the substrate's own irregularity profile, detected by the first sensor, to correct the measurement errors introduced by deflection. The substrate effectively serves itself by providing the correction data needed to maintain measurement accuracy, eliminating the need for external correction devices.
Data Source
AI summary
The method includes: a first profile generation step of generating a first profile of irregularities in a measurement range set on the substrate sheet (2), based on first measurement information acquired at a location upstream of the coating machine (30) and indicating a shape of irregularities of the substrate sheet (2); a second profile generation step of generating a second profile of irregularities in the measurement range, based on second measurement information acquired at a location downstream of the coating machine (30) and indicating the shape of the irregularities of the substrate sheet (2); and a coating amount calculation step of calculating the amount of the applied coating from a difference between the first measurement information and the second measurement information, based on a positional relationship in which the shape of the first profile of irregularities and the shape of the second profile of irregularities are matched to each other.