Optical Sensor Device for Brake Disc Coating Thickness Measurement
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Solution Overview
Problem
Current methods for determining the layer thickness of coatings on brake discs, such as laser cladding, face challenges with achieving uniformity and precision, especially with thick and optically non-transparent layers, leading to slow and imprecise measurement processes.
Innovation Solution
A sensor device with a first optical sensor system that simultaneously determines position-related measured values from coated and uncoated areas, using a difference measurement approach to calculate layer thickness with high local resolution, and compensates for wobbling behavior, allowing for inline monitoring during the coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measurement methods are used for thick and optically non-transparent coating layers, then measurement can be performed, but measurement precision and speed deteriorate
Solution Approach 1:
The patent replaces mechanical contact measurement methods with optical measurement systems. The optical sensor system uses light reflection and interference patterns to measure layer thickness non-contactly, enabling high-speed measurements without mechanical wear or contamination. This substitution allows precise measurement of thick, optically non-transparent coatings while maintaining high measurement speed.
Solution Approach 2:
The patent employs multiple measurement wavelengths and adjusts optical parameters (such as polarization state and incident angle) to optimize measurement conditions for different coating types and thicknesses. By dynamically changing measurement parameters, the system achieves high precision across varying coating properties while maintaining fast measurement cycles.
2Measurement precision
If conventional measurement methods are used for thick and optically non-transparent coating layers, then measurement can be performed, but measurement time increases
Solution Approach 1:
The patent implements continuous optical measurement during the coating process rather than discrete post-coating inspections. The optical sensor system continuously monitors layer thickness in real-time, allowing immediate detection and correction of coating deviations. This continuous measurement approach eliminates idle time between measurement cycles and provides instantaneous feedback for process optimization.
Solution Approach 2:
The system performs preliminary measurements during the coating application process itself, before the coating is complete. This allows early detection of thickness deviations and enables corrective actions to be taken during the remaining coating time, preventing the need for time-consuming re-coating or post-processing adjustments.
3Manufacturing precision
If detailed inspection is performed to ensure uniform layer thickness, then coating quality improves, but production time increases
Solution Approach 1:
The patent implements a closed-loop feedback system where optical measurements are continuously fed back to the coating control system. The system compares measured thickness values against target specifications and automatically adjusts coating parameters (such as spray rate, scan speed, or powder feed rate) to maintain uniform thickness. This real-time feedback eliminates the need for slow, detailed post-coating inspection while ensuring high coating quality.
Solution Approach 2:
The measurement system is integrated directly into the coating process, allowing the coating machine to self-monitor and self-correct its performance. The system performs its own quality control functions without requiring separate inspection equipment or manual measurement steps, thereby maintaining high production speed while ensuring manufacturing precision.
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 quick and precise determination of layer thickness, reducing production time and material waste by providing accurate, real-time monitoring of the coating process, even on thick and optically challenging layers.
Implementation Method 1
a first optical sensor system (110) for simultaneously determining at least one first position-related measured value (121, 122) and a second position-related measured value (123, 124)
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a sensor device for inspecting the coating of a disc during a coating process. The sensor device comprises a first optical sensor system for determining the layer thickness of the coating applied to the disc and a rotation device. The invention is characterized in that the first optical sensor system is configured to simultaneously determine at least one first position-related measurement and a second position-related measurement, wherein the first and second position-related measurement represent the distance of the sensor systems to the surface of the disc. The sensor system is thus configured such that the first position-related measurement is determined from a coated area of the disc and the second position-related measurement is determined from an uncoated area of the disc.Furthermore, the first optical sensor system has at least one linear guide extending from the central area to the edge. Additionally, a control and evaluation unit is provided for calculating the layer thickness of the disk at the position of the first position-related measured value using the first and second position-related measured values. The invention also relates to a coating method for a disk, including a coating inspection for determining the layer thickness of the coating applied to the disk.