Material Web Tear Detection via Drive Unit Vibration
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Solution Overview
Problem
Existing methods for identifying tears in material webs during high-speed production are inefficient due to uncontrolled web movement, contamination, and delayed or missed tear detection, particularly in harsh manufacturing conditions, where optical sensors accumulate dirt and are limited in rapid identification and localization.
Innovation Solution
A method that captures and evaluates mechanical vibrations propagating over the material web using drive units with converters, transforming these vibrations into electrical measurement signals to identify web tears without additional sensors, allowing for continuous operation and accurate localization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If optical sensor systems are used to identify tears in material web, then tear detection capability is provided, but the sensors accumulate dirt quickly in harsh manufacturing conditions requiring frequent cleaning and readjustment
Solution Approach 1:
The patent replaces optical sensor systems with a mechanical vibration-based detection system. Drive units equipped with vibration sensors detect changes in vibration patterns of the material web to identify tears. This mechanical approach eliminates the dirt accumulation problem inherent in optical sensors while maintaining reliable tear detection capability throughout harsh manufacturing conditions.
2Ease of operation
If optical sensors are positioned at specific points on the machine, then installation is simplified, but rapid identification and accurate localization of tears is prevented
Solution Approach 1:
The patent divides the material web monitoring into multiple segments by placing vibration sensors at various drive units distributed along the machine. Each drive unit independently monitors its local section, enabling both simplified installation at discrete points and accurate localization of tears through the segmented monitoring architecture. The system identifies which specific segment experiences the tear based on which drive unit detects the vibration change.
3Productivity
If material web moves at high speeds to increase productivity, then production throughput increases, but uncontrolled tears occur more frequently causing machine stoppage
Solution Approach 1:
The patent implements a real-time feedback system where vibration sensors continuously monitor the material web during high-speed operation. When a tear is detected through vibration pattern analysis, the system immediately signals the control unit to stop the machine, preventing uncontrolled web movement and damage. This rapid feedback loop enables maintaining high productivity through continuous operation while preventing tears from causing extended stoppages.
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
Enables rapid and accurate identification of web tears, reducing production delays and machine damage by using mechanical vibrations to detect tears without optical sensors, allowing for real-time maintenance and maintaining continuous operation.
Implementation Method 1
the vibration of the material web is measured by the converter of the first drive unit and transformed into an electrical measurement signal
Data Source
AI summary
A method for operating a machine for producing and/or processing a material web, wherein a first drive unit is supplied by a converter with a current, a vibration propagating over the material web is captured via the first drive unit, the vibration is measured and transformed into a measurement signal that is examined for presence of a signature that differs from the basic waveform of the current, a web tear is thus identified if the signature propagating over the material web is missing during the evaluation of the electrical measurement signal, whereby no further sensors, in particular optical sensors, are required to capture the measurement signal, and the measurement also occurs independently of a torque, a speed or speed development of drive motors over time and, moreover, the detection of the web tear does not require a comparison measurement at the machine without a continuous material web.