Ultrasonic Sensor Calibration for Coating Thickness Accuracy
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Solution Overview
Problem
Existing ultrasonic measuring systems for coating thickness measurement face inaccuracies due to temperature variations in the air layer and self-heating of sensors, leading to inconsistent calibration and reduced measurement accuracy.
Innovation Solution
The implementation of a dual ultrasonic sensor set system, comprising actual-measurement and calibration sensors, which perform real-time calibration to account for temperature changes and self-heating, using flat-type sensors to transmit and receive unfocused ultrasonic waves, ensuring accurate measurement of coating thickness by adjusting for sound velocity, density, and acoustic impedance in the air layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If calibration is performed before or after ultrasonic measurement, then measurement errors in ultrasonic sensors can be reduced, but temperature variations and self-heating cause inconsistent calibration results
Solution Approach 1:
The patent performs calibration action continuously during the measurement process rather than before or after. The calibration ultrasonic sensor set operates simultaneously with the actual-measurement ultrasonic sensor set, performing real-time calibration to account for temperature variations and self-heating effects that occur during measurement.
Solution Approach 2:
The patent implements feedback by using the calibration ultrasonic sensor set to continuously monitor and provide correction values for the actual-measurement ultrasonic sensor set. The correction values are fed back to adjust the measurement results in real-time, compensating for temperature and self-heating variations.
2Productivity
If ultrasonic sensors are used to measure coating thickness, then measurement can be performed during production line operation, but temperature changes in air layer and sensor self-heating reduce measurement accuracy
Solution Approach 1:
The patent introduces a calibration ultrasonic sensor set as an intermediary element. This calibration sensor set acts as a mediator between the actual-measurement sensor set and the measurement object, providing real-time correction values that compensate for temperature variations and self-heating effects in the air layer.
Solution Approach 2:
The patent accounts for parameter changes by continuously monitoring temperature variations and self-heating effects, and adjusting the measurement parameters in real-time. The correction values obtained from the calibration sensor set are used to modify the measurement results, compensating for changes in sound velocity, density, and acoustic impedance due to temperature.
3Device complexity
If a single ultrasonic sensor set is used for both calibration and measurement, then device complexity is reduced, but measurement accuracy is compromised due to self-heating and temperature effects
Solution Approach 1:
The patent segments the ultrasonic sensor system into two distinct sets: a calibration ultrasonic sensor set and an actual-measurement ultrasonic sensor set. This segmentation allows each set to perform its specific function optimally, with the calibration set dedicated to providing correction values and the measurement set dedicated to actual coating thickness measurement.
Solution Approach 2:
The patent merges the calibration and measurement functions into a unified system that operates simultaneously. Both sensor sets are positioned to measure the same coating thickness, and the calibration sensor set provides real-time correction values for the measurement sensor set, combining the benefits of dedicated calibration with continuous measurement capability.
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 approach significantly enhances the accuracy of coating thickness measurement by minimizing errors caused by temperature changes and self-heating, allowing for precise measurement of coating thickness across a wide range with high reliability.
Implementation Method 1
transmitting ultrasonic waves between the first ultrasonic sensor and the second ultrasonic sensor
Implementation Method 2
measuring a thickness of the coating material by transmitting ultrasonic waves between the first ultrasonic sensor and the second ultrasonic sensor
Implementation Method 3
adjusting for sound velocity, density, and acoustic impedance in the air layer
Implementation Method 4
temperature changes and self-heating
Data Source
AI summary
An ultrasonic measuring method and an ultrasonic measuring system use or include at least one actual-measurement ultrasonic sensor set each consisting of a first ultrasonic sensor and a second ultrasonic sensor, for measuring the basis weight of an electrode paste, and a calibration ultrasonic sensor set consisting of a pair of first calibration ultrasonic sensor and second calibration ultrasonic sensor. The calibration ultrasonic sensor set performs calibration during measurement of the thickness of the electrode paste, and the actual-measurement ultrasonic sensor set calculates the basis weight of the electrode paste, using a measurement condition value obtained by the calibration ultrasonic sensor set.