Automated Sheet Stock Thickness Measurement System
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Solution Overview
Problem
Manual measurement of sheet stock thickness and width is time-consuming and costly, leading to significant production line downtime in processing large rolls of sheet stock.
Innovation Solution
An automated system with distance-measuring sensors and a transport device that moves synchronously across the sheet stock, using a gauge block to correct for frame deflections and accurately measure thickness and width, incorporating energy beam emitting sensors and an optical reader for edge detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement methods are used with stationary sheet metal, then measurement accuracy can be achieved, but production time is significantly increased
Solution Approach 1:
The patent replaces manual mechanical measurement tools (vernier caliper, micrometer) with automated optical/laser distance-measuring sensors that can measure thickness and width continuously as the sheet stock moves through the system, eliminating the need for stationary manual measurement
Solution Approach 2:
The system performs measurements in advance during the normal flow of material processing, using pre-positioned sensors that measure thickness and width as the material passes through, rather than requiring separate manual measurement steps after the material is stationary
2Reliability
If multiple measurements are taken at multiple locations for each strip, then measurement completeness is improved, but measurement complexity increases
Solution Approach 1:
The measurement system is divided into multiple independent sensor units, each capable of measuring at a specific location. Multiple sensors are positioned at different transverse locations across the sheet stock width, allowing simultaneous measurement at multiple points without requiring a single complex multi-functional device
Solution Approach 2:
The distance-measuring sensors are designed to perform multiple functions: they can measure both thickness and width dimensions, and can operate at multiple transverse positions across the sheet stock, eliminating the need for separate measurement tools for different parameters
3Productivity
If automated measurement systems are implemented, then productivity is improved, but measurement precision may be compromised
Solution Approach 1:
A gauge block with precisely known dimensions is introduced as an intermediary reference standard. The system measures the gauge block's known dimensions to calculate and compensate for any errors in the distance-measuring sensors, thereby maintaining high precision in automated thickness measurements of the sheet stock
Solution Approach 2:
The system uses the gauge block measurements to provide feedback for calibration and error compensation. By comparing the measured gauge block dimensions against its known precise dimensions, the system automatically adjusts sensor readings to maintain accuracy throughout the measurement process
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 significantly reduces measurement time and cost by enabling precise, automated measurement of sheet stock dimensions, ensuring accuracy within tight tolerances and minimizing production downtime.
Implementation Method 1
The first and second sensors are energy beam emitting sensors, for example light emitting lasers
Implementation Method 2
incorporating energy beam emitting sensors and an optical reader for edge detection
Data Source
AI summary
A system is provided for measuring at least a thickness of a strip of material extending between two oppositely facing surfaces comprising a frame having an opening for receiving the material and a transport device coupled to the frame and movable transverse to the material. First and second distance-measuring sensors are coupled to the device for synchronous movement across the frame transverse to the material, each positioned proximate one of the surfaces of the material when it is within the frame opening. The system further includes a gauge block having two oppositely facing surfaces and a known thickness therebetween. The gauge block is coupled to the device for movement with the sensors across the frame and is movable between a measuring position wherein the gauge block is positioned between the sensors and a stowed position wherein the gauge block is positioned out from between the sensors.