Web Thickness Measurement Using Magnetic Field Intermediary
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Solution Overview
Problem
Conventional web thickness measuring equipment for secondary batteries faces challenges in maintaining accuracy due to roll deformation and pattern interference, leading to unreliable thickness measurements.
Innovation Solution
A web thickness measuring equipment that includes a rotatable roller, a detection unit capable of detecting light and magnetic fields, and a processor unit to generate profile data and displacement data, allowing for real-time comparison of external and internal surface displacements to accurately determine web thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional optical equipment is used to measure web thickness by acquiring images around a rolled web, then the measurement process is simple and continuous, but roll deformation and pattern interference cause measurement errors and reduced reliability
Solution Approach 1:
The patent introduces a magnetic field as an intermediary measurement medium. Instead of directly measuring the web surface which is affected by patterns and roll deformation, the system measures the magnetic field distribution around the web. The magnetic field acts as a mediator that can detect web thickness variations without being influenced by surface patterns or roll deformation, thereby maintaining continuous measurement capability while improving measurement reliability
Solution Approach 2:
The patent replaces the conventional optical measurement system with a magnetic field-based measurement system. The optical system that directly images the web surface is substituted with magnetic field sensors that detect changes in magnetic flux caused by web thickness variations. This substitution eliminates the problems of pattern interference and roll deformation affecting optical measurements, while maintaining the ability to perform continuous thickness monitoring
2Productivity
If a roll is used to wind and move the web for continuous measurement, then continuous production flow is maintained, but the roll deforms over time causing systematic measurement errors
Solution Approach 1:
The magnetic field serves as an intermediary that measures web thickness without direct contact with the rolled web surface. By measuring magnetic flux density variations around the web, the system can detect thickness changes without being affected by roll deformation. This allows continuous web processing to proceed while maintaining accurate thickness measurements despite the roll's mechanical deformation over time
Solution Approach 2:
The patent transitions from surface-based measurement (2D image analysis of web surface) to field-based measurement (3D magnetic field distribution around the web). By measuring magnetic field characteristics in the space surrounding the web rather than analyzing the web surface directly, the system eliminates errors caused by roll deformation, enabling continuous processing with maintained measurement accuracy
3Device complexity
If optical imaging is used to detect web thickness through light amount distribution, then the measurement setup is straightforward, but patterns on the web surface interfere with accurate thickness detection
Solution Approach 1:
The patent replaces the optical imaging system with a magnetic field detection system. Instead of using light to image the web surface and analyze intensity variations, the system uses magnetic field sensors to detect changes in magnetic flux density caused by web thickness variations. This substitution eliminates pattern interference completely while maintaining relatively simple device complexity, as the magnetic field measurement approach is more direct and less susceptible to surface variations
Solution Approach 2:
The magnetic field acts as an intermediary measurement medium that penetrates through the web material without being affected by surface patterns. The magnetic flux density distribution around the web provides direct information about thickness variations, bypassing the pattern interference problem that plagues optical surface imaging methods. This approach maintains measurement system simplicity while dramatically improving thickness detection accuracy
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
Improves the reliability of web thickness measurements by enhancing uniformity and detecting changes in web thickness, reducing errors associated with roll deformation and pattern interference.
Implementation Method 1
an optical displacement sensor configured to detect in real time light amounts of the outer circumferential surface of the roller and the external surface of the web according to a light amount distribution change of the light irradiated from the light source unit
Implementation Method 2
a Hall sensor on the transfer frame and configured to detect in real time a magnitude of a magnetic field between the target internal surface of the web and the magnetic member
Data Source
AI summary
A web thickness measuring equipment and a method of measuring a web thickness. A web thickness measuring equipment includes: a roller that is rotatable and configured to wind a web; a detection unit that detects a light amount on an outer circumferential surface of the roller or an external surface of the web wound on the roller, and detects a magnetic field of an internal surface of the web opposite to the external surface; and a processor unit configured to obtain a thickness of the web by generating profile data of the outer circumferential surface of the roller, generating displacement amount data of a target external surface of the web, generating displacement amount data of a target internal surface of the web, and comparing the displacement amount data of the target external surface of the web with the displacement amount data of the target internal surface of the web.