Sensor Controller for Web Edge Detection and Tension Control
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Solution Overview
Problem
Current web handling systems lack the capability to simultaneously guide and tension material webs based on multiple edge locations while ensuring improved quality inspection in an automated setting, with existing sensors having limited field of view and precision.
Innovation Solution
A sensor controller system utilizing natural interaction sensors, including depth sensors and image processing, to analyze sequences of data frames and generate location signals for precise web edge detection and tension control, enabling automated web handling and quality inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If C shape sensors with small gaps are used for edge detection, then measurement precision is improved, but the acceptable web plane deviations are limited
Solution Approach 1:
The sensor system employs an articulable element (moving sensor guide) that allows the C shape sensors to dynamically adjust their position and orientation in response to changes in web width and plane deviation, enabling small gap sensors to accommodate larger web variations without losing measurement precision
Solution Approach 2:
Multiple C shape sensors are distributed across the web width, with each sensor handling a specific section, allowing the system to maintain high precision edge detection across the entire web while tolerating local plane deviations through collective measurement
2Productivity
If multiple C shape sensors are used to detect opposing edges simultaneously, then productivity is improved, but device complexity increases
Solution Approach 1:
Each C shape sensor is designed to perform multiple functions: detecting edge position, determining web width, and identifying plane deviations, allowing a single sensor to provide comprehensive web characterization data that simplifies the overall system architecture
Solution Approach 2:
The system combines measurements from multiple sensors through a unified controller that processes data from all sensors simultaneously, merging edge detection, width measurement, and plane deviation detection into a single integrated control system that maintains high productivity
3Measurement precision
If line sensors with limited field of view are used, then measurement precision is improved, but the ability to guide based on multiple edge locations is lost
Solution Approach 1:
The system transitions from one-dimensional line sensor measurements to two-dimensional area sensor measurements, capturing both lateral edge positions and longitudinal pattern locations simultaneously, enabling comprehensive web guidance based on multiple features across the entire web surface
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 system effectively guides and tensions material webs with high precision, improving quality inspection by accurately detecting web edges and tension, and enabling real-time adjustments for optimal web handling.
Implementation Method 1
depth sensors which respond to emitted radiation, such as infrared (IR) frequency wavelengths of light to measure distances between an object and the sensor
Implementation Method 2
emitted radiation, such as infrared (IR) frequency wavelengths of light
Implementation Method 3
analyze the sequence of data frames having the first group of data points depicting the feature of the web, and a second group of data points depicting a background transverse to the feature
Implementation Method 4
The tension in the web is detected by a load cell bearing on the web of material
Implementation Method 5
a brake or clutch system that can vary the rate of movement of a roller for feeding and/or retrieving of the web of material
Data Source
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AI summary
A sensor controller (22) for web handling applications is described. The sensor controller (22) is provided with a first port (56), a second port (58), a computer readable medium (52), and a processor (50). The first port (52) receives a sequence of data frames capturing an area of a material web having a width to height ratio between .10 and 100. The computer readable medium (52) stores logic indicative of identifying properties of a first group of data points of a feature of the material web extending in a web direction of travel. The processor (50) scans the sequence of data frames to locate a transition between a property of the first group of data points and a property of a second group of data points in the data frames and generates a series of location signals indicative of lateral locations of the transition within the data frames. The second port (56) outputs the location signals.