Sheet Thickness Measurement Device Using Zero-Adjustment
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Solution Overview
Problem
Current sheet thickness measurement devices face limitations in measurement density and accuracy, particularly when measuring diverse sheet materials like those used in lithium-ion batteries, due to the use of single sensors and potential errors from magnetic sensor fluctuations and material unevenness.
Innovation Solution
A sheet thickness measurement device equipped with multiple sensors, including magnetic and optical sensors, that perform independent scans and employ zero-reading and zero-adjustment processes to correct for sensor output variations, ensuring high accuracy and density measurements without direct contact with the sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a single sheet thickness sensor unit is used to measure sheet thickness, then the device complexity is low, but the measurement density is limited
Solution Approach 1:
The patent divides the measurement system into multiple independent sheet thickness sensor units (first sensor unit and second sensor unit), each capable of independent scanning. This segmentation allows simultaneous measurement at multiple locations, increasing measurement density without requiring a single complex sensor to cover the entire area.
2Productivity
If the sensor scanning speed is increased to improve productivity, then the measurement coverage increases, but the measurement accuracy deteriorates due to magnetic sensor fluctuations
Solution Approach 1:
The patent combines multiple sensor units (magnetic sensors and optical sensors) to perform measurements simultaneously. By merging the capabilities of different sensor types and multiple units, the system achieves both high productivity through parallel measurements and high accuracy through the complementary strengths of different sensing technologies.
Solution Approach 2:
The patent implements a zero-reading correction mechanism where baseline measurements are taken and stored, then used to correct subsequent measurements. This feedback approach compensates for magnetic sensor fluctuations and drift, maintaining measurement accuracy even when scanning speed increases and measurement coverage expands.
3Adaptability or versatility
If magnetic sensors are used for thickness measurement, then the measurement capability is extended to diverse materials, but measurement errors increase due to magnetic field fluctuations and material unevenness
Solution Approach 1:
The patent merges magnetic sensors and optical sensors into a unified measurement system. The magnetic sensors provide versatility for measuring diverse materials including battery components, while optical sensors provide accurate reference measurements. By combining these different sensing modalities, the system achieves both broad material adaptability and high measurement precision.
Solution Approach 2:
The patent uses zero-reading correction where baseline measurements are taken on each material type and used to correct subsequent measurements. This feedback mechanism compensates for magnetic field fluctuations and material-specific variations, maintaining measurement accuracy across diverse materials while preserving the versatility of magnetic sensing.
4Speed
If the sensor moves quickly over the sheet surface to increase measurement speed, then the productivity increases, but the measurement accuracy deteriorates
Solution Approach 1:
The patent performs preliminary zero-readings to establish baseline measurements before actual thickness measurements are taken. This preliminary action captures the magnetic field characteristics and sensor drift at each position, enabling accurate correction of subsequent measurements even when the sensor scans quickly, thus maintaining precision at high scanning speeds.
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 device achieves increased measurement density and accuracy over the entire sheet surface, reducing measurement errors to less than 1 μm and enabling precise thickness feedback for improved sheet quality control.
Implementation Method 1
a magnetic sensor and an optical sensor, to measure a thickness of a sheet based on output signals from the magnetic sensor and the optical sensor
Implementation Method 2
a magnetic sensor and an optical sensor, to measure a thickness of a sheet based on output signals from the magnetic sensor and the optical sensor
Data Source
AI summary
Provided is a sheet thickness measurement device capable of increasing measurement density and measurement accuracy over the entirety of a sheet to be measured. Based of a difference between a sheet thickness signal at a position of a backup roll where the sheet exists, and a sheet thickness signal at a position of the backup roll where the sheet does not exist, the sheet thickness signals from the plurality of sheet thickness sensors are zero-adjusted in association with the position of the surface of the backup roll. Based on an output signal from a magnetic sensor in a state in which the sheet is not present on the backup roll, the sheet thickness signals from the plurality of sheet thickness sensors in a state in which the sheet is present on the backup roll are corrected in association with the position of the surface of the backup roll. This enables high-density and accurate sheet thickness measurement.