Calibration Unit for Roller Nip Gauge Sensors
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Solution Overview
Problem
Existing roller nip gauge sensors face challenges in maintaining accurate measurements over time due to changes in roller characteristics, such as elasticity and hardness, which affect nip width and pressure profiles, necessitating a reliable calibration method to ensure consistent performance.
Innovation Solution
A calibration unit comprising two main parts, a lower part for sensor placement and an upper part that applies a predetermined and traceable length or force, using adjustable beams and springs to ensure precise alignment and force application, allowing for adaptable calibration of sensors measuring different nip lengths and forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is placed in the nip between rollers to measure nip width or pressure profile, then measurement capability is achieved, but measurement precision deteriorates over time due to changes in roller characteristics
Solution Approach 1:
The calibration unit applies a predetermined and traceable force or length to the sensor before actual measurements are taken. This preliminary calibration action establishes a reference state for the sensor, compensating for variations in roller characteristics and ensuring measurement accuracy is maintained over time.
Solution Approach 2:
The calibration unit modifies the physical parameters (force or length) applied to the sensor in a controlled and traceable manner. By changing these parameters systematically during calibration, the sensor's response can be adjusted to account for changes in roller elasticity and hardness, thereby maintaining measurement precision.
2Adaptability or versatility
If the calibration unit is designed to accommodate different sensor sizes and forces, then adaptability is improved, but device complexity increases
Solution Approach 1:
The calibration unit is designed with a universal lower part featuring a sunken surface that can accommodate sensors of different sizes. The upper part can apply both force and length calibration, making the device multi-functional. This universality allows one calibration unit to serve multiple calibration needs without requiring separate dedicated devices for each sensor type or calibration parameter.
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 repeatable and accurate calibration of roller nip gauge sensors, ensuring consistent measurement performance by maintaining precise alignment and force application, accommodating variations in sensor sizes and forces, and facilitating traceable and automatic adjustments.
Implementation Method 1
The force controlled beam is suspended in such a way that it is practically free floating and will automatically adapt its position to the position of the sensor to be calibrated, as received inside the calibration unit. The applied force is also important in order to have a repeatable and true calibration and this is accomplished by means of a compression spring
Implementation Method 2
the force controlled beam is suspended in a plate of spring steel, allowing the pressure beam to adjust itself to the lower part and thereby accomplish a perfect hitting surface for the activation beams
Data Source
Figure 1~3
Figure 4~6
Figure 7~10
AI summary
The present invention concerns a calibration unit (1, 37) for a roller nip gauge. The roller nip gauge has sensors for length or force measurement. The calibration unit (1, 37) comprises an upper part (3) and a lower part (2). The calibration unit (1, 37) has means to place a part acting on a sensor element (26) of a sensor (25) during calibration in parallel with a surface (9) of the calibration unit (1, 37) receiving the sensor (25).