Sheet Scanner Position Profiling for Zigzag Measurement Traceability
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Solution Overview
Problem
Current sheetmaking processes face challenges in accurately tracing on-line measurements of sheet materials back to specific locations on the finished electrochemical cell or battery electrodes due to the zigzag measurement pattern and lack of synchronization between upstream and downstream scanners, making it difficult to identify and address defects in the production of anodes and cathodes.
Innovation Solution
The implementation of a machine direction (MD) position profile measurement system that records the MD position of each cross-direction measurement, using time-stamped MD speed signals and synchronized scanning sensors to generate a MD position profile, allowing for precise correlation of measurements and improved traceability of sheet properties along the production line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If scanning sensors periodically traverse back and forth across the sheetmaking machine in the cross direction, then cross-directional variations in sheet properties can be detected, but the measurements do not align exactly perpendicular to the longitudinal edges of the sheet due to finite sheet velocity, creating a zigzag measurement pattern that complicates traceability
Solution Approach 1:
The patent introduces a new dimension of time stamping to the measurement data. Each measurement point is recorded with a precise time stamp and machine direction position, transforming the traditional two-dimensional cross-directional profile into a three-dimensional dataset that includes the temporal and longitudinal position information. This allows reconstruction of the exact measurement path and alignment with specific locations on the finished product.
Solution Approach 2:
The system performs preliminary recording of machine direction position and time stamps for each measurement point as the scan is being taken. This preliminary action captures the exact position and timing information that will be needed later for traceability, rather than attempting to correct or analyze the zigzag pattern after the fact.
2Quantity of substance
If multiple scanners are used to monitor sheet properties at different machine direction positions, then more comprehensive quality data is collected, but there is no synchronization between scanners to correlate when a piece of sheet is actually measured at each location
Solution Approach 1:
The system uses time stamps and machine direction position tracking as a feedback mechanism to synchronize multiple scanners. Each scanner records the MD position and time of each measurement, allowing the system to correlate measurements from different scanners to the same physical location on the sheet by matching their temporal and positional data.
Solution Approach 2:
The patent creates a universal reference framework using machine direction position and time stamps that can be applied to any number of scanners at any positions along the production line. This universal system allows any scanner to be correlated with any other scanner through their shared reference to MD position and time, enabling comprehensive multi-point traceability.
3Ease of manufacture
If the sheet is traversed from edge to edge during each scan at constant speed, then the scanning process is simple and repeatable, but the finite sheet velocity causes the scanning sensor to travel diagonally across the sheet surface rather than perpendicular to the edges
Solution Approach 1:
The patent replaces the mechanical assumption of perpendicular scanning with a computational model that accounts for the actual diagonal scanning path. Instead of mechanically adjusting the scanner to scan perpendicular to the sheet edges, the system uses time stamps and MD position data to mathematically reconstruct the true measurement locations, substituting computational correction for mechanical precision.
Data Source
AI summary
A machine direction (MD) position profile measurement of a moving sheet records the MD position of each of the cross direction (CD) measurements. A sheet monitoring system includes means for measuring the MD speed of the sheet of material; means for associating measured MD speed with time to generate time-associated MD speeds; means for recording the time-associated MD speeds; a first scanning sensor for measuring a first characteristic of the sheet material wherein the first scanning sensor is located at a first position along the MD and the first scanner sensor traverses back and forth along a CD; and means for associating first characteristic measurements with time to generate time-associated first characteristic measurements. Single and multiple scanning sensors can be employed. For multiple scanner systems where the scanners are synchronized, the technique enables recreation of the real zig-zag measurement path and same spot measurements.