Dual-Sensor Web Thickness Measurement With Supported Contact Zone
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Solution Overview
Problem
Existing non-contact thickness measurement methods for flexible and coated material webs suffer from inaccuracies due to vibrations, shimmering, and dependence on the concentricity and vibrations of supporting rollers, leading to unreliable measurement results.
Innovation Solution
A device and method that supports the material web with a contact body during measurement, using two sensors to measure the top and bottom surfaces simultaneously, with the second sensor positioned below the contact area to eliminate influencing factors and prevent vibrations, and employs a cylindrical rolling element with openings to enhance stability and concentricity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the material web is freely suspended during measurement, then the measurement setup is simple, but vibrations and shimmering occur that distort measurement results
Solution Approach 1:
A contact body (support roller) is introduced as an intermediary element between the material web and the measurement system. This roller supports the material web in the measurement area, preventing vibrations and shimmering that would otherwise occur with freely suspended material, thereby improving measurement precision without significantly complicating the overall setup
2Device complexity
If a single sensor measures the material web thickness from one side, then the device structure is simple, but measurement results depend on contact body concentricity and vibrations
Solution Approach 1:
Two sensors are combined to measure both the top and bottom surfaces of the material web simultaneously. By merging these measurement operations into a single integrated system, the patent eliminates the dependence on contact body concentricity and vibrations, as the thickness is determined by the difference between the two sensor measurements rather than by the absolute position relative to a potentially vibrating contact body
3Device complexity
If the second sensor is positioned above the contact area, then the device structure is simpler, but influencing factors from the contact body cannot be eliminated
Solution Approach 1:
The second sensor is positioned below the contact area, utilizing the vertical dimension to place the sensor on the opposite side of the contact body. This spatial arrangement allows the sensor to measure the bottom surface of the material web without being influenced by the contact body, effectively eliminating contact body-induced errors from the measurement
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
Provides accurate and stable thickness measurements by supporting the material web, eliminating vibrations and concentricity errors, ensuring precise calculation of thickness without reliance on roller characteristics.
Implementation Method 1
a first sensor (5) directed towards a material web top surface (7)
Implementation Method 2
a second sensor (6) directed opposite the first sensor towards a material web bottom surface (8)
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3
AI summary
The invention relates to an arrangement for non-contact thickness measurement of a continuous, in particular flexible, elastic and/or coated, material web, comprising: a material web guided over a surface of a contact body, in particular at least partially cylindrical; a sensor arrangement for measuring the material web thickness, wherein at least a first sensor is directed towards a material web top surface and at least a second sensor is directed opposite the first sensor towards a material web under surface; characterized in that the second sensor is arranged at least partially below the contact area between the material web and the contact body.