Tissue Web Stretch Measurement via Optical Position and Tilt Detection
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Solution Overview
Problem
Conventional methods for measuring the stretch property of tissue webs are laboratory-based and destructive, making it difficult to adjust manufacturing processes in real-time, leading to production losses and variations in web quality.
Innovation Solution
A system using sensors to measure the vertical position and tilt angle of tissue webs during production, allowing for online estimation of stretch properties through mathematical correlations with laboratory measurements, enabling real-time process adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laboratory-based destructive testing is used to measure stretch properties, then measurement precision is improved, but productivity deteriorates due to production interruptions and material waste
Solution Approach 1:
The patent replaces mechanical contact-based destructive testing with a non-contact optical measurement system using light sources and sensors to detect web position and calculate stretch properties, eliminating the need to physically test and destroy sample materials
Solution Approach 2:
The system creates an optical copy or representation of the web's physical state through light reflection and sensor detection, allowing measurement of stretch properties without physically interacting with or damaging the actual web material
2Productivity
If real-time monitoring is implemented, then productivity is improved through continuous production, but device complexity increases due to additional sensors and processing equipment
Solution Approach 1:
The measurement system is integrated into the existing web handling infrastructure, allowing the same optical components to serve multiple functions including stretch measurement, position monitoring, and process control across different production stages
Solution Approach 2:
The system uses the web's own interaction with existing rollers and guides to provide measurement information, where the web's natural movement and positioning against known reference surfaces generates the measurement data without requiring separate active probing mechanisms
3Productivity
If non-destructive online measurement is used, then productivity is improved by eliminating production interruptions, but measurement precision may deteriorate compared to laboratory methods
Solution Approach 1:
The system continuously feeds back measurement data to the control system, allowing for real-time validation and adjustment of measurements, which maintains precision by comparing online data against expected ranges and laboratory-established baselines
Solution Approach 2:
The system performs preliminary calibration and validation against laboratory measurements before full production deployment, establishing accurate reference models that enable precise online measurements throughout continuous operation
Data Source
AI summary
A method includes, using at least one processing device, obtaining position measurements and/or tilt angle measurements associated with a tissue web and identifying a stretch measurement associated with the tissue web using the obtained measurements. Identifying the stretch measurement could include using one or more mathematical formulas to calculate the stretch measurement associated with the tissue web using the obtained measurements. The one or more mathematical formulas could be defined using laboratory stretch values of multiple training webs. Different mathematical formulas can be associated with training webs having different characteristics, and the method may further include selecting at least one of the mathematical formulas based on one or more characteristics of the tissue web.