Embedded Sensor Roller Manufacturing Process
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Solution Overview
Problem
Existing rollers with integrated sensors face stability issues, leading to sensor damage or interference with roller function, preventing their commercial use.
Innovation Solution
A process for manufacturing a roller with embedded sensors involves providing a core with a reference layer, mounting sensors on a conductive film, routing electrical connections along the core, coating with elastomeric materials, and connecting to evaluation electronics, ensuring the sensors are protected and functional.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are integrated into rollers, then operational data can be obtained for optimal adjustment and extended service life, but the sensors are damaged due to mechanical stress from elastic deformations
Solution Approach 1:
The patent applies beforehand cushioning by embedding the sensors within the elastomeric material of the roller core or reference layer before operation. This embedding provides protective cushioning against the mechanical stresses and elastic deformations that occur during roller operation, preventing sensor damage while enabling reliable data collection throughout the roller's service life.
2Loss of information
If sensors are integrated into rollers, then valuable operational data can be collected, but the sensors interfere with the use of the rollers
Solution Approach 1:
The patent applies merging by integrating the sensors directly into the roller structure through embedding them in the elastomeric material. This combines the sensing function with the roller's operational structure, allowing both data acquisition and roller functionality to coexist without interference. The sensors become part of the roller system rather than separate components.
Solution Approach 2:
The elastomeric material serves as an intermediary between the sensors and the external environment. It allows the sensors to be protected within the roller structure while still enabling the roller to perform its operational functions. The elastomeric material mediates between the need for sensor protection and the need for roller functionality.
3Measurement precision
If conventional sensors are used in rollers, then basic measurement capability is achieved, but the sensors lack sufficient stability for commercial use
Solution Approach 1:
The patent applies beforehand cushioning by embedding the sensors within the elastomeric material before operation. This protective embedding provides the necessary stability and protection against mechanical stresses, enabling the sensors to maintain measurement precision throughout their operational life and making the system suitable for commercial use.
Solution Approach 2:
The patent applies composite materials by combining the sensors with the elastomeric material to create a composite structure. This composite construction provides both the measurement capability of the sensors and the mechanical stability and protection of the elastomeric material, achieving the reliability needed for commercial applications.
Data Source
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AI summary
A method for manufacturing a roller with an embedded sensor comprising the steps of: - providing a roller core or a roller core with at least one reference layer - providing one or more electronic sensors on a conductive film with an electrical connection - mounting the one or more electronic sensors on the roller core or the reference layer, wherein the electrical connection is routed along the roller core - coating with a roller covering made of rubber or polyurethane - grinding the roller surface - connecting the electrical connection to an evaluation electronics.