Optical Roller Gap Measurement via Interference Pattern Analysis
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Solution Overview
Problem
Conventional roller gap measurement technologies face challenges in accurately measuring narrow gaps between rollers in roll-to-roll processing equipment, especially in the central portion, where contact methods are difficult to apply and precise non-contact methods are lacking.
Innovation Solution
A roller gap measurement system utilizing a light source, refractive part, and image processing system to generate and analyze a complex interference pattern, allowing for non-contact measurement of narrow gaps by extracting features from the imaged pattern while accounting for parameters like alignment errors and surface roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If contact measurement methods (dial gauge, expandable measuring unit) are used to measure roller gap, then measurement can be performed with simple equipment, but measurement precision deteriorates when gap becomes narrow and device complexity increases for central portion measurement
Solution Approach 1:
The patent replaces mechanical contact measurement methods with an optical measurement system. A light source emits light that passes through the roller gap, and a sensor detects the transmitted light pattern. This optical system eliminates the need for physical contact tools like dial gauges or expandable measuring units, enabling precise measurement of narrow gaps without mechanical interference or device insertion complexity.
Solution Approach 2:
The patent introduces light as an intermediary medium to measure the roller gap indirectly. Instead of directly contacting or physically measuring the gap, the system uses light transmission through the gap and analyzes the resulting optical pattern. This intermediary approach allows measurement of extremely narrow gaps without requiring the measurement device to physically fit into or contact the gap space.
2Measurement precision
If conventional measurement technologies are applied to narrow gaps, then equipment simplicity is maintained, but measurement precision deteriorates due to difficulty in applying contact methods
Solution Approach 1:
The patent replaces mechanical contact measurement methods with an optical measurement system. A light source emits light that passes through the roller gap, and a sensor detects the transmitted light pattern. This optical system eliminates the need for physical contact tools like dial gauges or expandable measuring units, enabling precise measurement of narrow gaps without mechanical interference or device insertion complexity.
3Measurement precision
If non-contact light measurement is used to measure narrow gaps, then measurement precision improves, but device complexity increases due to need for light source, refractive part, and image processing system
Solution Approach 1:
The patent employs the natural optical phenomena of diffraction and interference that occur when light passes through the roller gap. The gap itself creates the measurement pattern through these physical effects, eliminating the need for complex external measurement devices. The system leverages the gap's own geometric properties to generate the measurement signal, reducing the need for additional complex components.
4Adaptability or versatility
If contact measurement methods are used, then equipment simplicity is maintained, but adaptability to various gap sizes deteriorates when gap narrows
Solution Approach 1:
The patent creates a universal measurement system that can measure various gap sizes using the same optical configuration. By adjusting the light source wavelength, position, or sensor parameters, the system adapts to different gap widths without requiring different measurement tools. The optical setup serves multiple measurement functions across a range of gap sizes, from very narrow to wider gaps.
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 accurate and effective measurement of narrow gaps, including those in the central portion, ensuring precise control over workpiece thickness, even when the gap is very narrow, and accommodating various gap sizes using a single light source.
Implementation Method 1
the incident light provided from the light source may be diffracted, transmitted, reflected or scattered with passing through the gap between the first and second rollers, and may be formed as the complex light
Implementation Method 2
measuring a roller gap in a roll-to-roll equipment in a non-contact manner using a complex interference pattern generated when the light passes through the gap between the rollers
Implementation Method 3
The refractive part is configured to receive a complex light passing through the gap between the first and second rollers, and configured to refract the complex light
Data Source
AI summary
In a roller gap measurement system and a roller gap measurement method using the roller gap measurement system, the roller gap measurement system includes a light source, a refractive part, a sensor part and an image processing part. The light source is configured to provide an incident light toward the gap between first and second rollers. The refractive part is configured to receive a complex light passing through the gap between the first and second rollers, and configured to refract the complex light. The sensor part is configured to receive the refracted light and configured to image a complex pattern. The image processing part is configured to obtain a gap information between the first and second rollers, based on the imaged complex pattern.