Online Thickness Detection Platform Using Sliding Laser Sensors
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Solution Overview
Problem
Existing methods for detecting the thickness of multilayer stacked plates, such as those with PTC material layers and metal layers, often require offline detection, leading to waste due to inaccuracies and the need for discarding partially produced materials if thickness deviations exceed preset values.
Innovation Solution
An online thickness detection platform featuring a C-typed frame with sliding laser sensors that move back and forth without contacting the product, utilizing a driving mechanism with a ball screw and motor for precise detection within the surface area of the metal layers, and an alarm system to prevent production of unqualified products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If offline detection is used to detect thickness with high accuracy, then measurement precision is improved, but productivity deteriorates due to discontinuous production and material waste
Solution Approach 1:
The patent replaces offline mechanical measurement systems with online laser-based optical detection. The laser sensors (including vertical laser sensors for thickness measurement and horizontal laser sensors for positioning) enable continuous non-contact measurement during production, eliminating the need to stop production for offline detection and thereby maintaining both high measurement precision and continuous productivity
Solution Approach 2:
The system performs preliminary positioning using horizontal laser sensors to identify the metal layer boundaries before thickness measurement begins. This preliminary action ensures that the vertical laser sensors only measure within the valid metal layer area, preventing waste of partially qualified materials while maintaining continuous production flow
2Manufacturing precision
If offline detection is used to ensure thickness quality, then manufacturing precision is improved, but loss of substance increases due to discarding materials with thickness deviations
Solution Approach 1:
The system implements real-time feedback control by continuously monitoring thickness during production and providing immediate feedback to the control unit. When thickness deviations are detected, the system can alert operators or adjust parameters instantly, preventing the production of large quantities of defective materials and thereby reducing material waste while maintaining high manufacturing precision
Solution Approach 2:
The horizontal laser sensors perform preliminary positioning to identify the exact boundaries of the metal layer before thickness measurement. This preliminary action ensures that measurement only occurs within the valid area, allowing continuous production without discarding materials that might have borderline thickness variations outside the measurement zone
3Productivity
If continuous production is implemented to improve productivity, then productivity is improved, but measurement precision deteriorates without online detection capability
Solution Approach 1:
The patent employs laser-based optical measurement systems that enable non-contact thickness measurement during continuous production. The vertical laser sensors measure thickness by detecting the position of the product surface, while horizontal laser sensors continuously track the metal layer boundaries, allowing high-precision measurement to be maintained throughout continuous production without interruption
Solution Approach 2:
The system dynamically adjusts the measurement process by continuously moving the laser sensors across the product surface in real-time. The horizontal laser sensors dynamically identify the metal layer boundaries, and the vertical laser sensors dynamically measure thickness at multiple points, enabling both continuous production and high measurement precision through dynamic real-time adaptation
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 real-time, accurate thickness monitoring and immediate detection of deviations, reducing waste by allowing for continuous production and ensuring products meet thickness specifications, thus improving efficiency and reducing material loss.
Implementation Method 1
a first laser sensor and a second laser sensor mounted on the first arm and the second arm of the C-typed frame, respectively... configured to detect a thickness of a product passing between the first arm and the second arm
Data Source
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AI summary
An online thickness detection platform, including: a main frame having a first beam and a second beam extending in a first horizontal direction and opposite to each other in a vertical direction perpendicular to the first horizontal direction; a C-typed frame slidably mounted on the main frame and having a first arm and a second arm extending in the first horizontal direction and opposite to each other in the vertical direction; a first laser sensor and a second laser sensor mounted on the first arm and the second arm of the C-typed frame, respectively; and a driving mechanism mounted on the main frame and adapted to drive the C-typed frame to slide back and forth in the first horizontal direction, wherein the first laser sensor and the second laser sensor are configured to detect a thickness of a product passing between the first arm and the second arm and moving in a second horizontal direction perpendicular to the first horizontal direction, wherein the first laser sensor and the second laser sensor do not contact the product during detecting the thickness of the product. In the present disclosure, since the thickness of the product may be detected online by the online thickness detection platform, the thickness of the product may be monitored in real-time. Once the thickness of the product exceeds an allowed value range, it may alarm and stop production of the product in time. Thereby, it may avoid producing a large number of unqualified products with a thickness out of the allowed value range and waste is prevented.