Ultrasonic Tape Film Winding State Evaluation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for evaluating the winding state of tape films rely on subjective sensory evaluations, which are unreliable and can lead to deformation or unwinding during transportation and storage, as they do not provide an objective or quantitative assessment of the winding quality.
Innovation Solution
The method involves generating ultrasonic waves parallel to the core's axis and analyzing the attenuation rate of these waves to determine the winding state, allowing for objective and quantitative evaluation of the tape film's winding quality, and adjusting the winding conditions based on these results to prevent deformation and unwinding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensory evaluation methods (visual observation or manual contact) are used to assess winding state, then the evaluation process is simple and requires no special equipment, but the evaluation is subjective and unreliable, leading to deformation or unwinding during transportation and storage
Solution Approach 1:
The patent replaces the mechanical sensory evaluation system (human vision and touch) with an ultrasonic wave-based detection system. Ultrasonic waves are transmitted through the tape film wound on the core, and the attenuation characteristics of these waves are measured to objectively assess the winding state, thereby eliminating subjectivity while maintaining practical device complexity
Solution Approach 2:
The patent changes the evaluation parameter from subjective sensory indicators to objective physical parameters by measuring the attenuation rate of ultrasonic waves. This parameter change enables quantitative and reproducible assessment of winding quality, directly improving reliability without requiring overly complex equipment
2Manufacturing precision
If variable rotational torque of winding motor is applied to continuously change tension force during winding, then the winding quality can be improved, but the control system becomes more complex and difficult to optimize
Solution Approach 1:
The patent implements a feedback mechanism where the ultrasonic attenuation rate is measured after winding, and this measurement is fed back to adjust the winding conditions. This closed-loop feedback system enables continuous optimization of winding precision without requiring overly complex real-time control during the winding process
Solution Approach 2:
The patent performs preliminary winding with standard conditions, then uses ultrasonic measurement to evaluate the winding state before making adjustments. This preliminary action approach allows optimization of winding precision through iterative adjustments based on objective measurements rather than complex real-time control
3Stability of the object's composition
If touch roller position is adjusted according to winding diameter to maintain support, then the winding stability can be improved, but the mechanical adjustment mechanism becomes more complex
Solution Approach 1:
The patent replaces the mechanical touch roller adjustment system with an ultrasonic wave-based detection and evaluation system. By measuring ultrasonic attenuation characteristics, the system can objectively assess winding stability without requiring complex mechanical adjustments during the winding process
4Manufacturing precision
If press roller pressure is controlled at beginning and end of winding process, then the winding quality at critical points can be improved, but the control system requires additional sensors and actuators
Solution Approach 1:
The patent uses ultrasonic attenuation measurements to provide feedback on the winding state, including at critical points like the beginning and end of the winding process. This feedback enables optimization of press roller pressure control without requiring additional complex sensing and actuation systems beyond the ultrasonic 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 enables precise and objective determination of the tape film's winding state, optimizing the winding conditions to ensure a stable and secure winding that prevents unwinding during transport and storage.
Implementation Method 1
generating ultrasonic waves toward a tape film wound onto a core, in a direction parallel to an axis of rotation of the core, receiving the reflected or transmitted waves, to determine an attenuation rate of the ultrasonic waves due to the tape film
Data Source
AI summary
A winding state evaluation method of a tape film includes a step of determining the attenuation rate of ultrasonic wave for the tape film (2) by sending an ultrasonic wave to the tape film (2) in parallel with the direction of the axis of rotation of a core (1) and receiving its reflected wave or transmitted wave, and a step of evaluating the winding state of the tape film (2) from the distribution state of the attenuation rate in the tape film (2). The method can judge the winding state of the tape film objectively by presenting its numerical representation concretely without relying upon sensual evaluation.