Sheet and Foil Basis Weight Profiling With X-Ray Ultrasonic Calibration
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Solution Overview
Problem
Existing non-destructive measurement systems struggle to provide quantitatively accurate basis weight profiles of flat products with unknown compositions and strong topological variations, such as coating edges, especially in laboratory settings where sensor calibration is impractical or infeasible due to process variability.
Innovation Solution
Combining X-ray and ultrasonic measurements to calibrate X-ray data using ultrasonic measurements, where the calibration coefficient is determined from areas free of topological singularities, allowing for accurate basis weight profiling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional single-sensor measurement systems are used, then device complexity is reduced, but measurement precision deteriorates for products with unknown compositions and topological variations
Solution Approach 1:
The patent combines two different measurement systems (X-ray absorption measurement and ultrasonic intensity wave measurement) into a single integrated system. The X-ray sensor provides basis weight information while the ultrasonic sensor provides density information, and by merging these measurements with a calibration coefficient, the system achieves accurate basis weight measurement for heterogeneous products that single sensors cannot measure precisely.
2Measurement precision
If sensor calibration is performed for every new batch of tests in laboratory settings, then measurement precision is improved, but productivity deteriorates due to process interruptions
Solution Approach 1:
The system performs self-calibration by using the ultrasonic measurement data to automatically calculate a calibration coefficient that corrects the X-ray measurement data. This self-service calibration mechanism eliminates the need for manual calibration interventions, allowing the system to adapt to different product compositions and maintain measurement accuracy continuously without stopping the fabrication process.
Solution Approach 2:
The ultrasonic measurement system provides feedback information about the product's density and physical properties, which is used to calculate a calibration coefficient that adjusts the X-ray measurement readings. This feedback loop enables real-time correction of measurement errors caused by variations in product composition, maintaining measurement precision without requiring external calibration operations.
3Measurement precision
If X-ray measurements alone are used, then device complexity is reduced, but measurement precision deteriorates for products with solvent content variations and coating patterns
Solution Approach 1:
The ultrasonic measurement system acts as an intermediary that provides additional information about the product's physical state, density, and acoustic properties. This intermediary data is used to calculate a calibration coefficient that mediates and corrects the X-ray measurement data, enabling accurate basis weight measurement even when the product contains solvent variations or coating patterns that would otherwise interfere with X-ray measurements alone.
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 quantitatively accurate basis weight profiles of products with varying compositions and topological features without interrupting the fabrication process, by using simultaneous X-ray and ultrasonic measurements to correct X-ray data with a live calibration method.
Implementation Method 1
performing an X-ray absorption measurement based on transmission of X-rays through the product
Implementation Method 2
performing an ultrasonic intensity wave measurement on the product based on a reaction of the product to an ultrasonic wave directed towards the product
Data Source
Figure 1(a)~2
Figure 3~5(c)
Figure 6~8(b)
AI summary
Method of performing an X-ray characterization of a product comprising the steps of performing an X-ray absorption measurement and an ultrasonic wave measurement on the product so as to obtain X-ray measurement data and ultrasonic wave measurement data over a width of the product, calculating a calibration coefficient (C) based on a ratio between the X-ray measurement data flin_XRPat and the ultrasonic wave measurement data flin_USPat , and calculating corrected values of the X-ray measurement data by multiplication of the X-ray measurement data by the calibration coefficient.