Radiation Thickness Measurement with Faulty A/D Converter Exclusion
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Solution Overview
Problem
Conventional thickness measuring devices face inaccuracies due to malfunctions and non-normal outputs from A/D converters over time, which affect the reliability of thickness measurements in sheet metal rolling processes.
Innovation Solution
A thickness measuring device is designed with multiple A/D converters connected to a radiation detector, an anomaly detector to identify malfunctioning converters, and an excluder to exclude them from calculations, ensuring accurate thickness measurement by using only normal output values from functioning converters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple A/D converters are used to expand measurement range and improve accuracy, then measurement precision is improved, but reliability deteriorates due to increased probability of converter malfunction
Solution Approach 1:
The radiation detector is divided into multiple detector channels, each connected to a separate A/D converter. This segmentation allows the system to process signals from different regions of the detector independently, enabling accurate thickness measurement across a wide range while providing redundancy if one converter malfunctions.
Solution Approach 2:
The system dynamically changes the parameter of which A/D converter is active based on the measured thickness. For thin objects, one converter is used; for thick objects, another converter is activated. This parameter change allows the system to maintain high measurement precision across different thickness ranges while managing the reliability risk of individual converters.
2Productivity
If A/D converters operate continuously over time, then productivity is maintained, but reliability deteriorates due to deterioration and malfunction
Solution Approach 1:
The system prepares multiple A/D converters in advance, so when one converter deteriorates or malfunctions during continuous operation, another pre-configured converter can immediately take over. This beforehand preparation ensures continuous productivity without interruption while compensating for the natural deterioration of converters over time.
Solution Approach 2:
The control unit continuously monitors the output signals from A/D converters and provides feedback on their operational status. When abnormal readings or malfunctions are detected, the system uses feedback to switch to a different converter, ensuring continuous reliable measurement and maintaining productivity despite individual converter deterioration.
3Productivity
If all A/D converter outputs are used in calculation, then productivity is improved through parallel processing, but measurement precision deteriorates due to inclusion of abnormal readings
Solution Approach 1:
The control unit extracts and identifies abnormal readings from A/D converter outputs using anomaly detection algorithms. These abnormal values are then excluded from the thickness calculation process. This extraction of harmful data ensures that only valid measurements are used, maintaining high measurement precision while still utilizing multiple converters for improved productivity.
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
This solution enables accurate thickness measurement by excluding anomalous A/D converters, thereby improving measurement reliability and reducing noise components, even when individual converters malfunction.
Implementation Method 1
a radiation detector that is disposed facing the radiation source across the measurement object, and that detects the radiation having transmitted through the measurement object
Data Source
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AI summary
A thickness measuring device according to an embodiment includes a radiation source that irradiates a measurement object with radiation; a radiation detector that is disposed facing the radiation source across the measurement object, and that detects the radiation having transmitted through the measurement object; A/D converters individually connected to the radiation detector, that convert output signals from the radiation detector to digital values; a thickness calculator that calculates a thickness of the measurement object based on the digital values from the A/D converters; an anomaly detector that individually detects anomaly of the A/D converters; and an excluder that excludes an A/D converter having an anomaly detected by the anomaly detector, from subjects of the calculation by the thickness calculator.