Supercontinuum Laser Web Gauging System
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Solution Overview
Problem
Existing web gauging systems are unable to achieve 100% web inspection due to limited measurement area coverage, which results in manufacturers making process control adjustments based on small sample sizes, leading to inefficiencies and potential quality issues.
Innovation Solution
The implementation of a supercontinuum (SC) Laser-based web gauging system that uses a beam expander to illuminate a large area of the web, allowing for the detection of web parameters across a broader surface while maintaining high throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a traditional sensor with limited spot size is used to scan the web, then the measurement system is simple and cost-effective, but the area coverage is insufficient and cannot achieve 100% web inspection
Solution Approach 1:
The patent transitions from a single-point measurement approach to a multi-point simultaneous measurement approach by using an array detector. This dimensional change in measurement capability allows the system to cover a much larger area of the web at once, achieving near 100% inspection coverage without proportionally increasing system complexity.
Solution Approach 2:
The web measurement area is divided into multiple discrete measurement points arranged in an array pattern. Each point in the array independently measures web parameters, and the results are combined to provide comprehensive coverage. This segmentation allows the system to achieve large area coverage while maintaining a relatively simple overall system architecture.
2Productivity
If the scan speed is increased to measure more web area, then the productivity improves, but vibrations and oscillations affect measurement accuracy
Solution Approach 1:
The patent replaces the mechanical scanning system (moving sensor across the web) with a stationary array detector system. This substitution eliminates the mechanical vibrations and oscillations that occur during high-speed scanning, allowing the system to maintain high productivity while preserving measurement accuracy. The array detector captures data from multiple points simultaneously without requiring physical movement.
3Area of stationary object
If the sensor spot size is increased to cover more area, then the area coverage improves, but the measurement precision at each point decreases
Solution Approach 1:
Instead of using a single large spot sensor that would reduce precision, the patent segments the measurement area into multiple smaller spots arranged in an array. Each spot maintains high measurement precision while the collective array provides extensive area coverage. This segmentation strategy resolves the trade-off between area coverage and measurement precision.
Solution Approach 2:
The patent combines multiple high-precision point measurements from the array detector into a comprehensive area measurement system. By merging the data from multiple precise point measurements, the system achieves both large area coverage and high measurement precision simultaneously, rather than having to choose one over the other.
4Area of stationary object
If multiple sensors are added to increase coverage, then the area coverage improves, but the device complexity and cost increase significantly
Solution Approach 1:
The patent uses a single array detector that performs multiple measurement functions simultaneously across different points on the web. This multi-functional detector replaces what would otherwise require multiple separate sensors and scanning mechanisms, achieving extensive coverage while minimizing device complexity and cost.
Solution Approach 2:
The patent merges multiple measurement capabilities into a single array detector unit. Instead of using separate sensors for different measurement points, the array detector integrates all measurement functions in one component, reducing overall system complexity while maintaining comprehensive web inspection coverage.
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
This solution enables the scanning of a large portion of a moving web while maintaining high throughput, effectively increasing the area of web coverage beyond what traditional systems can achieve, thereby improving inspection efficiency and quality control.
Implementation Method 1
a beam expander configured to expand the light beam and provide an expanded beam to a sample illumination area
Implementation Method 2
a detector unit configured to detect a sample light from the illumination area
Data Source
AI summary
A web gauging system and methods of using the web gauging system are described. The web gauging system includes a supercontinuum Laser providing a light beam. A beam expander is configured to expand the light beam and provide an expanded beam to a sample illumination area. A detector unit configured to detect a sample light from the illumination area. A moving web can be placed in the illumination area, where the web gauging system measures parameters of the web.