Sensor Calibration via 2D Areal Averaging for Thickness Measurement
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Solution Overview
Problem
Existing methods for calibrating sensors used in measuring the thickness and surface weight of material sheets are not precise enough, particularly in contact-free measurements, and there is a need for improved calibration techniques to enhance measurement accuracy.
Innovation Solution
A method involving a two-dimensional calibration process using a calibration sample with known surface weight, where transmission and reflection values are measured at multiple positions to generate an average calibration value, reducing errors and improving precision in thickness and surface weight measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single-point calibration method is used, then the calibration process is simple and quick, but the measurement precision and accuracy are insufficient
Solution Approach 1:
The calibration process is segmented into multiple measurement points distributed across the calibration sample. Instead of using a single calibration point, the method divides the calibration area into multiple positions where transmission and reflection values are measured separately, then combined to form a comprehensive calibration result that reduces positional errors.
Solution Approach 2:
The calibration method transitions from one-dimensional single-point calibration to two-dimensional areal calibration. Multiple measurement points are distributed across the surface area of the calibration sample, utilizing both spatial dimensions to capture variations in the calibration sample and improve overall measurement accuracy.
2Reliability
If transmission measurement is used, then the measurement can be performed through the material sheet, but the calibration requires precise knowledge of the calibration sample properties
Solution Approach 1:
The method uses feedback from both transmission and reflection measurements to improve calibration reliability. By measuring both the transmitted signal through the calibration sample and the reflected signal from it, the system obtains complementary information that allows for more robust calibration factor determination and reduces the impact of uncertainties in calibration sample properties.
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
The method significantly enhances the accuracy of sensor calibration, allowing for more precise measurements of material sheet thickness and surface weight by averaging deviations across a calibration sample, thereby improving the reliability of the measurement process.
Implementation Method 1
the transmission absorption of an ultrasonic beam emitted through a sheet material is determined using an ultrasonic transmitter and ultrasonic receiver
Implementation Method 2
The surface weight is calculated using the absorption and a calibration factor
Implementation Method 3
the layer thickness is determined based on the signal reflected by the material sheet
Data Source
AI summary
A method is provided for calibrating a sensor used for surface weight measurement or thickness measurement on a material sheet via transmission measurement and/or reflection measurement. The method may include: providing a two-dimensional calibration sample with a known surface weight; detection of the transmission values and/or the reflection values of the calibration sample via the sensor on a plurality of different positions two-dimensionally or areally distributed across the surface of the calibration sample; and the detection of the calibration value for the sensor via calculation of average from the plurality detected transmission values and/or reflection values and the composition of the average transmission and reflection values with the known surface weight of the calibration sample. Also provided is a method for measurement of layer thickness and/or surface weight of material sheets using the calibration method, as well as an apparatus for layer thickness measurements and/or surface weight measurement.