Winding State Inspection Using 2D Laser Sensor
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Solution Overview
Problem
Existing inspection methods for the winding state of sheet members on forming drums, such as one-dimensional laser sensors, struggle to accurately measure the shape, width, and attachment position of joints over the entire circumference, especially for broad-width sheet members like carcass plies, due to limited detection ranges and alignment challenges.
Innovation Solution
An inspection method and apparatus utilizing a two-dimensional laser sensor with a detection range along the drum circumferential direction, combined with a movement device to move either the sensor or the forming drum in the width direction, allowing for accurate calculation of width-directional opposite end sections and joint states by emitting laser light and processing distance data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a one-dimensional laser sensor is used to measure the sheet member wound on a forming drum, then the measurement can be performed over the entire circumference, but the measurement precision in the width direction is insufficient because only one point of measured value is obtained
Solution Approach 1:
The patent transitions from using a one-dimensional laser sensor to a two-dimensional laser sensor, adding the width direction (drum axial direction) to the measurement capability. This dimensional change enables simultaneous measurement across both the circumferential direction (over 360 degrees) and the width direction, obtaining multiple measured values across the sheet member's width rather than a single point, thereby resolving the contradiction between measurement coverage and width direction measurement accuracy
2Area of stationary object
If multiple two-dimensional laser sensors are installed to measure the joint state over the entire width of a broad-width sheet member, then the detection range is sufficient, but the device complexity and alignment difficulty increase significantly
Solution Approach 1:
The patent employs a single two-dimensional laser sensor that performs multiple functions: it measures both the circumferential direction (rotational position) and width direction (drum axial direction) positions of the sheet member's end sections. This multi-functional sensor replaces the need for multiple sensors, reducing device complexity while maintaining sufficient detection range across the entire width of broad-width sheet members
3Ease of operation
If one-dimensional laser sensors are moved in the width direction to measure end section positions, then the measurement can be performed, but the measurement precision is insufficient for sheet members with discontinuous joint shapes
Solution Approach 1:
The patent upgrades from one-dimensional laser sensors to a two-dimensional laser sensor, which can simultaneously detect positions in both the circumferential direction and width direction. This enables accurate measurement of end section positions even for sheet members with discontinuous joint shapes, as the sensor can capture the two-dimensional spatial information needed to precisely locate joints regardless of their shape complexity
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 precise measurement of the winding state, joint positions, and attachment accuracy over the entire width of the sheet member, effectively addressing the limitations of previous methods by providing high-accuracy detection of end sections and joint states.
Implementation Method 1
emitting laser light to the sheet member wound on a forming drum
Implementation Method 2
obtaining distance data on a distance to a reflecting surface
Data Source
AI summary
Laser light is emitted to a sheet member wound on a forming drum in a range which includes the entire width of the sheet member and distance data on a distance to a reflecting surface is obtained, using a two-dimensional laser sensor which has a detection range along a drum circumferential direction, while moving either the two-dimensional laser sensor or the forming drum in a drum width direction. Further, the positions of width-directional opposite end sections of the sheet member are calculated on the basis of the obtained distance data.