Wire Coating Detection Cell for Thin-Wire Fluorescence Capture
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Solution Overview
Problem
Current technologies are inadequate for reliably measuring the presence and distribution of optically active coatings on curved surfaces like round wires, as the fluorescent radiation is scattered in all directions and difficult to collect due to the wire's thinness and curvature.
Innovation Solution
A measuring cell with light sources and detectors positioned on cones converging at a central point, allowing for the detection of light interactions with the coating across the wire's circumference, designed to exclude stray light and enhance light collection by using a narrow entrance and exit orifice and a light-absorbing interior coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional flat-surface fluorescence measurement methods are used on round wires, then the measurement setup is simple, but the fluorescent radiation is scattered in all directions and difficult to collect due to the wire's curvature and thinness
Solution Approach 1:
The patent applies spheroidality by using a curved detector array that follows the cylindrical geometry of the wire. The detectors are positioned at various angles around the wire's circumference, allowing them to capture fluorescent radiation emitted in different directions. This curved arrangement matches the natural geometry of the wire surface, enabling efficient collection of scattered fluorescence without requiring complex optical focusing elements.
2Length of moving object
If the wire diameter is reduced to less than one millimetre, then the wire becomes thinner and more flexible, but there is not much fluorescent radiation to be collected
Solution Approach 1:
The patent merges multiple detection elements into a comprehensive detection system. By combining multiple detectors positioned at different angular positions around the wire, the system accumulates fluorescent radiation from all directions. This merging of detection capabilities compensates for the limited total fluorescence emitted by thin wires, as each detector captures a portion of the scattered radiation and the signals are integrated to provide a complete measurement.
3Reliability
If conventional reflection-based measurement is used, then the apparatus can detect flaws, but it does not allow measurement of the much weaker fluorescent radiation
Solution Approach 1:
The patent extracts the fluorescence detection function from the conventional reflection-based measurement system. By specifically designing detectors to capture emitted fluorescent radiation at various angles, the system separates this weak signal from the stronger reflected light. The angularly distributed detector array is specifically configured to collect fluorescence while minimizing interference from reflected excitation light, enabling sensitive detection of weak fluorescent signals.
4Quantity of substance
If a long measurement length is used to collect enough fluorescent radiation, then sufficient signal is obtained, but the measurement time and wire throughput are reduced
Solution Approach 1:
The patent transitions from a one-dimensional linear measurement approach to a three-dimensional volumetric detection approach. By arranging detectors in a three-dimensional array around the wire's circumference and along its length, the system collects fluorescent radiation from multiple spatial dimensions simultaneously. This allows sufficient total signal collection over a short wire segment, maintaining high throughput while obtaining adequate fluorescent radiation through spatial distribution rather than extended measurement length.
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 accurate detection of thin coatings on wires by focusing light interactions at a central point, providing information on the presence and distribution of coatings along the wire's length, even for thin coatings less than one micrometer thick.
Implementation Method 1
The measurement of such fluorescent radiation - and hence the presence and amount of coating - on a foil or web is straightforward as the fluorescent radiation only leaves the foil or web in the half space at the side wherein the excitation beam impinges.
Implementation Method 2
The coating may be very thin for example thinner than ten micrometer, or even thinner than five micrometer for example thinner than one micrometer.
Data Source
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AI summary
The invention relates to a measuring cell for optically verifying the presence of a coating on a wire specifically a steel wire or steel cord. As steel wire or steel cords are generally thin and round measuring the light reflected or emitted from the surface of a wire is difficult. The coating is optically active in that it absorbs or emits radiation in response to impinging light. The measuring cell comprises a dark cavity with an entrance and exit orifice. Two or more sources illuminate the wire towards a central spot. Radiation reflected or emitted from the coating is detected by two are more detectors. Different arrangements for the positioning of the sources and detectors are suggested. The invention further describes a method for using the measuring cell as well as an apparatus to controllably coat the surface of a wire.