Web Micro-Perforating Laser Calibration for Target Hole Diameter
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Solution Overview
Problem
Existing methods for calibrating multiple laser sources in a web micro-perforating laser unit are inefficient and material-intensive, lacking a fast and efficient simultaneous calibration process.
Innovation Solution
A method involving estimating pulse times for each laser source, creating calibration patterns, measuring real perforation diameters, defining reference points, calculating a trendline, and operating each laser source with an optimal pulse time to achieve predefined micro-perforations, using a digital camera to analyze images and adjust laser settings for precise micro-perforation diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration methods are used for multiple laser sources, then calibration can be performed, but the process is time-consuming and material-intensive
Solution Approach 1:
The patent combines calibration of multiple laser sources into a single unified process. Multiple laser sources calibrate simultaneously on the same web substrate, sharing common resources (web material, measurement system, processing time) rather than calibrating sequentially. This merging approach reduces total calibration time and material consumption while maintaining precision for each laser source.
2Measurement precision
If traditional calibration methods are used for multiple laser sources, then calibration can be performed, but material consumption is excessive
Solution Approach 1:
The patent merges calibration activities of multiple laser sources onto a single web substrate. Instead of dedicating separate web materials for each laser calibration, all laser sources calibrate concurrently on shared material resources. This significantly reduces web material consumption while ensuring each laser source achieves the required micro-perforation diameter precision.
3Manufacturing precision
If individual calibration of each laser source is performed separately, then precise calibration is achieved, but productivity is reduced
Solution Approach 1:
The patent merges separate calibration operations into a single simultaneous calibration event. Multiple laser sources are calibrated together in parallel rather than sequentially, maintaining manufacturing precision for each source while dramatically improving calibration efficiency and overall productivity.
Solution Approach 2:
The patent enables continuous calibration of multiple laser sources without interruption or sequential waiting. All laser sources undergo calibration in an uninterrupted simultaneous process, eliminating idle time between individual calibrations while maintaining the precision required for consistent micro-perforation diameter across all sources.
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
Enables fast and efficient calibration of multiple laser sources with minimal material waste, ensuring accurate micro-perforations by optimizing pulse times for each laser source.
Implementation Method 1
a laser source (11) of the laser unit (10) emits a laser beam towards the web (30)... considering different estimated pulse times... required to obtain calibration micro-perforations... defining, within a virtual space, reference points each representing a real micro-perforation diameter... calculating... an optimal pulse time... to produce micro-perforations with the target micro-perforation diameter
Data Source
Figure 1~2
Figure 3
AI summary
Calibration method of a web micro-perforating laser unit by estimating, for each laser source (11) of the laser unit (10), different estimated pulse times required to produce calibration micro-perforations (21) of increasing diameters smaller and larger than a predefined target micro-perforation diameter (60); emitting laser beams with each laser source (11) using the estimated pulse times to create at least one calibration pattern (20) of calibration micro-perforations (21) of different diameters; measuring the real micro-perforation diameter of each calibration micro-perforation (21) on a digital image (41) obtained from each calibration pattern (20); defining, within a virtual space (50), reference points (51) representing a real micro-perforation diameter (RD) and the respective pulse time (PT) and calculate a trendline (52) form said reference points (51); and calculating which point of the trendline (52) produces the target micro-perforation diameter (60), obtaining an optimal pulse time (61) to produce the target micro-perforation diameter (60).