Modular Linear Light Source for Material Web Inspection
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Solution Overview
Problem
Existing systems for detecting defects and irregularities on a material web guided along a measurement plane face challenges in maintaining simplicity, longevity, and achieving high light intensity, particularly at increased material web speeds, due to complex designs and limited light sensitivity of cameras.
Innovation Solution
A modular light-emitting device with multiple module elements, each carrying LEDs or light guides, is designed for easy maintenance and replacement, featuring a traverse for alignment, cooling systems for enhanced performance, and a lens system with a diffuser and mirror plates to increase light intensity and output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a high number of LEDs are used to increase radiation power, then light intensity is improved, but the risk of failure and device complexity increases
Solution Approach 1:
The device is divided into multiple independent module elements, each containing a subset of LEDs. If one module fails, the others continue to operate, reducing the overall failure risk while maintaining high light intensity through the combined output of all modules.
2Illumination intensity
If a high number of LEDs are used to increase radiation power, then light intensity is improved, but device complexity increases
Solution Approach 1:
The device is divided into multiple independent module elements, each containing a subset of LEDs. If one module fails, the others continue to operate, reducing the overall failure risk while maintaining high light intensity through the combined output of all modules.
3Ease of repair
If module elements are made freely accessible and replaceable, then ease of repair is improved, but device complexity increases
Solution Approach 1:
The device is divided into multiple independent module elements that can be individually accessed and replaced. This segmentation allows maintenance technicians to work on single modules without disassembling the entire device, simplifying repair procedures despite the increased number of components.
Solution Approach 2:
Individual module elements are extracted as separate, self-contained units that can be independently removed and replaced. This extraction approach enables simple maintenance operations where only the defective module needs to be taken out and replaced, without affecting the rest of the device.
4Illumination intensity
If cooling systems are added to increase light output, then light intensity is improved, but device complexity increases
Solution Approach 1:
The cooling function is merged with the existing module element structure. Cooling elements are integrated into each module, allowing heat dissipation to support higher light output without requiring separate, complex cooling systems for the entire device.
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 modular design extends the service life and increases light intensity along the material web, allowing for higher material web speeds while ensuring seamless optical transitions and efficient defect detection.
Implementation Method 1
The device has a lens system, in particular one or more rod lenses, for bundling the light that emerges from the devices for emitting light
Implementation Method 2
The module elements can rest against the traverse in such a way that the waste heat is transferred to the traverse by thermal conduction
Implementation Method 3
The module elements can have cooling ribs, for example, so that heat can be dissipated by the surrounding air
Data Source
Figure 1~2
Figure 3
AI summary
A linear light emitter has modules (2) supporting the linear light emission units (3, 4) which fit exactly along their edges and guides and comprise several LEDs (Light Emitting Diodes) on circuit boards with fin cooling and water cooling attached to the cross piece (5) : Independent claims are included for error detection systems using the light emitter and the light emission unit supports.