Coating Thickness Probe With Multi-Profile Calibration Memory
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Solution Overview
Problem
Conventional coating thickness measuring instruments require frequent recalibration due to changes in substrate characteristics and often need an uncoated substrate sample for calibration, which is inconvenient and time-consuming, and are affected by the substrate's surface profile.
Innovation Solution
A coating thickness measuring instrument with an electromagnetic probe and memory that stores multiple sets of calibration data for different surface profiles, allowing users to select the appropriate calibration data based on the surface profile, eliminating the need for specific recalibration and enabling accurate measurements without an uncoated substrate sample.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional calibration methods are used requiring uncoated substrate samples, then measurement accuracy can be maintained, but the process becomes time-consuming and inconvenient
Solution Approach 1:
The instrument performs calibration measurements in advance during manufacturing, storing multiple sets of calibration data corresponding to different surface profiles. This preliminary calibration eliminates the need for users to perform time-consuming recalibration procedures in the field, while maintaining measurement accuracy through pre-validated calibration data.
Solution Approach 2:
The instrument creates digital copies of calibration data for various surface profiles and stores them in memory. Instead of requiring physical calibration samples during use, the system uses stored digital representations of calibration information, allowing rapid selection and application of appropriate calibration data without physical samples.
2Measurement precision
If the instrument is recalibrated for each substrate type, then measurement accuracy is maintained, but the device complexity and user burden increase
Solution Approach 1:
The instrument is designed with universal calibration capability, storing multiple sets of calibration data that can be applied to different substrate types and surface profiles. A single instrument can handle various substrates by selecting from pre-stored calibration sets, eliminating the need for multiple specialized calibration procedures or instruments.
Solution Approach 2:
The system manages complexity by changing the parameter of calibration data selection rather than requiring physical recalibration. The processor selects appropriate calibration data from stored sets based on substrate characteristics, transforming a complex physical recalibration process into a simple parameter selection operation.
3Measurement precision
If calibration is performed manually for each measurement scenario, then measurement accuracy improves, but productivity decreases
Solution Approach 1:
The instrument performs self-calibration by automatically selecting and applying the appropriate calibration data set from its stored memory based on the substrate being measured. This self-service capability eliminates the need for manual calibration intervention, maintaining accuracy while enabling continuous high-speed measurements.
Solution Approach 2:
The system incorporates feedback mechanisms where the processor evaluates substrate characteristics and automatically selects the matching calibration data set. This closed-loop approach ensures accurate measurements are maintained while eliminating manual calibration steps, thereby increasing productivity.
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
The instrument provides accurate and efficient coating thickness measurements across various surface profiles without the need for frequent recalibration, saving time and reducing user error, by using pre-stored calibration data associated with different surface profiles.
Implementation Method 1
Conventional coating thickness measuring instruments comprise an electromagnetic probe. A tip of the probe is placed in contact with the surface of a coating on a substrate. The instrument determines the distance between the probe tip and the substrate
Data Source
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AI summary
A coating thickness measuring instrument has a probe 8 for measuring the thickness of a coating applied to a substrate and producing an output relating to the measured thickness; a memory 5 storing calibration data; and a processor 2 arranged to process the output produced by the probe, together with calibration data stored by the memory, and produce a coating thickness measurement. The memory stores at least two sets of calibration data, each set associated with a different surface profile value and a user may select the set of calibration data to be used by the processor according to the surface profile of the substrate on which a measurement is to be made. This enables a user to make coating thickness measurements on substrates with at least two different, known, surface profiles without having to calibrate the instrument specifically for those surfaces.