Distance Sensor Calibration for Sheet Production
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Solution Overview
Problem
Existing methods for measuring distance between sensors and surfaces in the production of plate or strip materials are temperature-dependent, requiring complex and costly temperature control to maintain accuracy, which is inefficient and resource-intensive.
Innovation Solution
A method involving the creation of multiple calibration curves at different temperatures allows for accurate distance measurement across a range of temperatures without the need for precise temperature control, using a control unit to interpolate or extrapolate distance values from known calibration curves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature control is implemented to maintain measurement accuracy, then measurement precision is improved, but device complexity and operational effort increase significantly
Solution Approach 1:
The patent changes the approach from controlling temperature to a fixed value to adapting measurement interpretation to actual temperature variations. Multiple calibration curves are created at different temperatures, and the system dynamically selects or interpolates between these curves based on measured temperature, thereby maintaining accuracy without complex temperature control.
Solution Approach 2:
The patent creates multiple copies of calibration data at different temperatures rather than maintaining a single calibration at a fixed temperature. These calibration curves are stored and selected based on actual operating conditions, eliminating the need for active temperature control while preserving measurement accuracy.
2Measurement precision
If temperature control is implemented to maintain measurement accuracy, then measurement precision is improved, but operational effort and costs increase
Solution Approach 1:
The measurement system performs self-adjustment by automatically detecting the current temperature and selecting or interpolating the appropriate calibration curve. This eliminates the need for operators to manually control temperature or select calibration data, thereby simplifying operation while maintaining accuracy.
Solution Approach 2:
The system incorporates temperature sensing that provides feedback to the measurement processing. Based on this temperature feedback, the system automatically adjusts which calibration curve to use or how to interpolate between curves, maintaining measurement accuracy without requiring manual temperature control or complex operational procedures.
3Adaptability or versatility
If multiple calibration curves at different temperatures are used, then adaptability to temperature variations is improved, but data processing complexity increases
Solution Approach 1:
The patent transitions from static calibration (single temperature) to dynamic calibration (multiple temperatures with automatic selection). The system dynamically adapts to temperature changes by selecting or interpolating between calibration curves based on real-time temperature measurements, thereby achieving broad temperature adaptability with manageable processing 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
This approach enables high-accuracy distance measurement in the production of plates or strip materials across varying temperatures with reduced operational effort, eliminating the need for complex temperature control and ensuring reliable measurements within a defined temperature range.
Implementation Method 1
a laser can be used to determine the distance from one sensor to the underside of the component
Implementation Method 2
the position of a laser spot on the surface is determined
Data Source
Figure 1~2
Figure 3
AI summary
A method for calibrating a sensor (1) for measuring a distance (9) between the sensor (1) and a surface (2) comprising at least the following method steps: a) providing a first calibration curve (12) as a function of the distance (9) between the sensor (1) and the surface (2) on the basis of at least one measurement signal at a prescribed first temperature associated with this first calibration curve (12); b) providing at least one second calibration curve (13) as a function of the distance (9) between the sensor (1) and the surface (2) on the basis of at least one measurement signal at a prescribed second temperature associated with this second calibration curve (13), which second temperature differs from the first temperature and any other second temperature; c) determining at least one third calibration curve (14) from the first (12) and second (13) calibration curves of the sensor (1) that are obtained in steps a) and b) for at least one third temperature, which is different from the first and any second temperature. The described methods and the described arrangement 10 can be used to measure a distance between a sensor 1 and a surface 2 independently of temperature. In this case, the thickness of a component 3 can also be measured. The sensor 1 does not need to be brought to a particular temperature and kept at said temperature by means of complex temperature control.