Coil End Detection Using Stationary Optoelectronic Sensor
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Solution Overview
Problem
Existing packaging machines face challenges in reliably detecting the end of film material on a coil, leading to inefficient use and unnecessary waste, as detection methods are often dependent on the core diameter and may fail to recognize the end accurately.
Innovation Solution
A packaging machine equipped with a stationary optoelectronic sensor and a radially movable capacitive sensor that detect the film material's outer circle and radial height, respectively, generating a control signal when the film material's thickness falls below a predetermined threshold, ensuring reliable end detection independent of core diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stationary optoelectronic sensor is used to detect the end of film material, then detection reliability is improved, but device complexity increases
Solution Approach 1:
The detection system is divided into two independent sensor components: a stationary optoelectronic sensor for detecting the outer circle of the film material, and a radially movable capacitive sensor for detecting radial height. Each sensor handles a specific detection task, improving overall reliability while keeping individual sensor complexity low.
Solution Approach 2:
The stationary optoelectronic sensor serves as an intermediary detection element that monitors the film material's outer circle position without requiring physical contact or movement. This non-contact detection method improves reliability while avoiding the complexity of mechanical moving parts.
2Adaptability or versatility
If detection is made independent of core diameter, then adaptability is improved, but measurement precision requirements increase
Solution Approach 1:
The detection system transitions from measuring a single parameter (core diameter) to measuring two independent parameters: the outer circle position via optoelectronic sensor and radial height via capacitive sensor. This dimensional change allows the system to adapt to different core diameters while maintaining measurement precision through multiple measurement points.
Solution Approach 2:
The sensor system is designed with universal applicability to detect film material ends across different core diameters. The stationary optoelectronic sensor detects the outer circle regardless of core size, and the radially movable capacitive sensor adjusts to measure radial height, making the system adaptable to various spool configurations.
3Loss of substance
If film material is used up to the core, then loss of substance is reduced, but detection difficulty increases
Solution Approach 1:
The stationary optoelectronic sensor is positioned to detect the outer circle of the film material before it completely unwinds to the core. This preliminary detection allows the system to identify when film material is approaching depletion, enabling timely spool replacement and preventing waste while maintaining simple detection geometry.
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
This solution allows for cost-effective, efficient, and reliable detection of the film material's end, preventing premature coil changes and minimizing waste by ensuring the film is used up to its full potential.
Implementation Method 1
A sensor arrangement (2) is provided that serves to detect an outer circle (18) of the film material (12) on the spool (10)
Implementation Method 2
A sensor arrangement (2) is provided that serves to detect an outer circle (18) of the film material (12) on the spool (10)
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The device has a sensor arrangement for detecting an end of a sheet material (12) on a coil (10), where the sheet material is wound on a core (8) of the coil. The sensor arrangement comprises an optoelectronic sensor (14) i.e. line sensor, that is arranged stationary with respect to a front end (7) of the coil on a mandrel (4) to optically detect a portion of the front end of the coil. The detected portion of the front end of the coil comprises an air gap (25) that is formed between the mandrel and the core.