US20090059244A1 - Web Measurement Device - Google Patents

Web Measurement Device Download PDF

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Publication number
US20090059244A1
US20090059244A1 US12/200,196 US20019608A US2009059244A1 US 20090059244 A1 US20090059244 A1 US 20090059244A1 US 20019608 A US20019608 A US 20019608A US 2009059244 A1 US2009059244 A1 US 2009059244A1
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United States
Prior art keywords
sensor
web
optical
sensor head
inductor
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US12/200,196
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English (en)
Inventor
Ake Hellstrom
Rambod Naimi
Michael O'Hora
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ABB Ltd Ireland
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ABB Ltd Ireland
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Priority to US12/200,196 priority Critical patent/US20090059244A1/en
Assigned to ABB LTD. reassignment ABB LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HELLSTROM, AKE, NAIMI, RAMBOD, O'HORA, MICHAEL
Publication of US20090059244A1 publication Critical patent/US20090059244A1/en
Abandoned legal-status Critical Current

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/86—Investigating moving sheets
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
    • G01B11/06—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
    • G01B11/0691—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material of objects while moving
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
    • G01B11/026—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness by measuring distance between sensor and object
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B7/00—Measuring arrangements characterised by the use of electric or magnetic techniques
    • G01B7/02—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness
    • G01B7/023—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness for measuring distance between sensor and object
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B7/00—Measuring arrangements characterised by the use of electric or magnetic techniques
    • G01B7/02—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness
    • G01B7/06—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness for measuring thickness
    • G01B7/10—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness for measuring thickness using magnetic means, e.g. by measuring change of reluctance
    • G01B7/107—Measuring arrangements characterised by the use of electric or magnetic techniques for measuring length, width or thickness for measuring thickness using magnetic means, e.g. by measuring change of reluctance for measuring objects while moving
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
    • G01N33/34—Paper
    • G01N33/346—Paper paper sheets
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B2210/00—Aspects not specifically covered by any group under G01B, e.g. of wheel alignment, caliper-like sensors
    • G01B2210/40—Caliper-like sensors
    • G01B2210/44—Caliper-like sensors with detectors on both sides of the object to be measured
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B2210/00—Aspects not specifically covered by any group under G01B, e.g. of wheel alignment, caliper-like sensors
    • G01B2210/50—Using chromatic effects to achieve wavelength-dependent depth resolution

Definitions

  • This invention relates to web measurement systems.
  • Sheet materials such as paper are produced in thin continuous webs and require highly accurate thickness (caliper) measurement and control. Commonly, these measurements are accomplished by means of sensors that physically contact the web at both the top and bottom side. Also, various non-contacting sensors have been developed that may be fully non-contacting (no physical contact), or sensors that contact physically contact sheet at only one side.
  • Non-contacting sensors offer an advantage as they minimize the risks of such damage. Further, non-contacting sensors eliminate issues related to dirt buildup and wear that may cause measurement inaccuracies, thereby leading to frequent maintenance.
  • Non contacting thickness sensor solutions include single sided and dual sided air-bearings with magnetic distance measurement, single sided and dual sided laser triangulators with magnetic distance measurement, as well as other supplemental devices to improve sensor accuracy and stabilize the moving web.
  • a sensor in accordance with the present invention for monitoring the thickness of a moving web.
  • the sensor includes a first sensor head positioned on a first side of the moving web, a second sensor head positioned on a second side of the moving web, opposed to the first side, an inductor positioned in the first sensor head and including a ferrite core and a winding, a contacting plate secured to the second sensor head and adapted to contact the second side of the moving web, a target plate secured proximate to the contacting plate, wherein the inductor is adapted to measure the distance to the target plate, and an optical sensor probe, positioned in the first sensor head, and including an objective lens having an axial chromatism, the optical sensor being adapted to measure the distance to the first side of the moving web using confocal chromatic aberration.
  • a sensor for monitoring the thickness of a moving web.
  • the sensor includes a first sensor head positioned on a first side of the moving web and including an optical measuring device adapted to measure the distance to the moving web.
  • a second sensor head is positioned on a second side of the moving web, opposed to the first side.
  • An inductor is positioned in the first or the second sensor head and includes a ferrite core and a winding.
  • a contacting plate is secured to the second sensor head and includes a plurality of suction slots.
  • a target plate is secured to the first or second sensor head opposed from the inductor, wherein the inductor is adapted to measure the distance to the target plate.
  • An optical reference body is positioned on the second sensor head, centrally of the contacting plate and is axially aligned with the optical measuring device, the optical reference body is positioned closer to the first sensor head than the contacting plate and the suction slots are spaced from the optical body.
  • FIG. 2 shows a section view of the target plate and elevated optical reference body
  • FIG. 3 shows a section view of the target plate and optical reference body
  • FIG. 4 shows top view of the contacting plate, target plate and optical reference body
  • FIG. 5 shows a sectional view of a sensor according to an alternate embodiment of the present invention
  • FIG. 5A shows an elevated view of the target plate of the embodiment of FIG. 5 ;
  • FIG. 5B shows an elevated view of the first sensor head having an air bearing arrangement
  • FIG. 5C shows an elevated view of the first sensor head having an alternate air bearing arrangement
  • FIG. 6 shows a sectional view of a sensor according to a second alternate embodiment of the present invention.
  • FIG. 7 shows an enlarged sectional view of the sensor of FIG. 6 ;
  • FIG. 8 shows a sectional and partially schematic view of the sensor of FIG. 6 ;
  • FIG. 9 shows an enlarged view of the floating guides proximate to the web
  • FIG. 10 shows a sectional view of a sensor according to a third alternate embodiment of the present invention.
  • FIG. 11A shows a section view of one embodiment of a fiber optic cable according to the present invention.
  • FIG. 11B shows a section view of a second embodiment of a fiber optic cable according to the present invention.
  • FIG. 11C shows a section view of a third embodiment of a fiber optic cable according to the present invention.
  • FIG. 12 shows a top view of the web and representations of the surface coverage using the fiber optic cable of FIG. 11B or 11 C.
  • FIG. 13 shows a 2d imaging spectrograph
  • FIG. 14 shows a close-up side section view of the surface of a web
  • FIG. 15A shows a displacement graph representing the surface of a slow moving web
  • FIG. 15B shows a spectral graph representative of a point on the slow moving web
  • FIG. 16A shows a displacement graph representing the surface of a fast moving web
  • FIG. 16B shows a spectral graph representative of a point on the fast moving web.
  • a gauge measurement device (hereinafter device 10 ) is shown and generally indicated by the numeral 10 .
  • Device 10 may be installed and used in a web making process line, for example, a paper making line. When installed, device 10 is positioned in close proximity to a moving web 12 for measurement thereof. Though the present invention is particularly useful for paper making applications, device 10 may be used to measure any type of continuously produced web. Further, one or more devices 10 may be positioned at any point along the continuous web production process to continuously measure web thickness at multiple points in the process.
  • the web 12 may move at high speeds through device 10 in the machine direction D.
  • production line speeds in paper manufacturing can reach 100 km per hour or more.
  • Device 10 contacts a bottom surface 14 of web 12 , while a top surface 16 is not contacted and is measured optically.
  • a pair of opposed sensor heads cooperate to measure the thickness, or caliper, of web 12 .
  • a first sensor head 18 is positioned above top surface 16 and does not contact web 12 .
  • a second sensor head 20 contacts web 12 at bottom surface 14 and, as will become apparent, serves as a reference point for the measurement devices in first head 18 .
  • First head 18 includes an optical displacement sensor probe 22 that employs a confocal chromatic aberration method to determine the distance from the probe to the top surface 16 of web 12 .
  • Probe 22 includes an objective lens 24 having axial chromatism, which results from the variation of the refractive index as a function of wavelength.
  • Such a lens if exposed to a point source of broad spectrum white light (such as from a fiber optic cable), will produce a continuum of monochromatic image points distributed along the optical axis A.
  • a singular monochromatic point image is focalized at M.
  • each interface between adjacent layers reflects light at a different wavelength, and the spectrum of the detected light is composed of a series of spectral peaks.
  • Such probes are configured and calibrated so that each spectral peak indicates a specific distance from the probe.
  • a light source and optical spectrograph 26 communicate with lens 24 through a fiber optic cable 30 .
  • White light travels through cable 30 , is directed through objective lens 24 and onto the web 12 .
  • the reflected light that is focused back to the fiber optic cable 30 corresponds to the wavelength at that specific distance from lens 24 . All other wavelengths will be out of focus.
  • the spectrograph 26 produces a distance measurement 32 which represents the distance from probe 22 to the top surface 16 of web 12 .
  • First sensor head 18 includes a second displacement measurement sensor in the form of an inductor 33 having a ferrite cup core 34 and a winding 36 .
  • Core 34 is annular and coaxial with lens 24 , defining a center aperture 38 that provides an optical path between lens 24 and web 12 . It is important to know the relative distances between inductor 33 and probe 22 , thus ferrite cup core 34 is spaced from probe 22 by a spacer 40 , the size of which is precisely known so that the exact distance to lens 24 is known.
  • Inductor 33 magnetically measures the distance to a ferrite target plate 42 in second sensor head 20 which is in physical contact with bottom surface 14 of web 12 . The inductance is converted to a displacement measurement 44 by electronic unit 46 .
  • first and second head 18 and 20 may be permanently fixed a predetermined distance apart. In such cases, magnetic measurement between heads 18 and 20 may be unnecessary.
  • Web thickness is thus determined by calculating the difference between the inductive sensor displacement measurement 44 (plus the height of spacer 40 ) and the optical sensor measurement 32 .
  • Second sensor head 20 includes a contacting plate 60 within which resides ferrite target plate 42 .
  • Contacting plate 60 includes a plurality of suction slots 62 that are in communication with a vacuum chamber 63 positioned beneath contacting plate 60 .
  • a vacuum generator 64 draws air from vacuum chamber 63 which effectively draws air into chamber 63 through suction slots 62 .
  • vacuum generator 64 may be a venturi based vacuum generator operable with compressed air.
  • Contacting plate 60 may also support an optical reference body 66 that is co-axial with lens 24 .
  • a linear motion actuator 68 is included in second sensor head 20 , and is utilized for calibration as well as vertical adjustment to attain the best operating distance/gap.
  • Linear motion actuator 68 is capable of moving up or down a frame 69 that supports contacting plate 60 , target plate 42 and reference body 66 .
  • linear motion actuators such as lead screw equipped stepper motors or piezoelectric linear positioners are capable of reliably moving frame 69 a known distance with a high degree of accuracy.
  • Calibration can be performed when the web 12 is not present.
  • the actuator 68 may move reference body 66 , along with target plate 42 , to a plurality of positions.
  • the resulting responses from the optical and magnetic signals may then be compared.
  • the magnetic gap measurement 44 may then be calibrated using the optical sensor 22 for a reference displacement measurement.
  • the magnetic measurement may be forced to equal the optical measurement at each measurement point.
  • the calibration can, for instance, involve a fine stepping linear motion of 3 mm total range while reading the optical and magnetic sensor signals every 0.01 mm of travel. In this way a continuous calibration curve can be periodically determined to correct for various issues such as drift, physical wear and misalignment.
  • optical reference body 66 may be positioned a known distance e slightly above ferrite target plate 42 .
  • optical reference body 66 extends above the top surface of target plate 42 by up to 0.5 mm. This arrangement enables more intimate contact of web 12 against optical reference body 66 at the point of optical measurement due to local stretching.
  • the web 12 moving in direction D may advantageously be subjected to multiple suction slots 60 before passing over the reference body 66 .
  • the suction slots 60 in conjunction with the elevated reference body 66 , combine to provide improved web contact with reference body 66 .
  • the web 12 has to slide over, for instance, three different suction zones 70 a, 70 b, and 70 c, before reaching the reference body 66 where measurement takes place. This helps remove boundary layer air from disturbing the measurements, even at high speeds.
  • the outermost suction slots 62 extend outwardly at an angle ⁇ from the machine direction D.
  • the angle ⁇ is twenty five (25) degrees.
  • the angle ⁇ may be from one (1) to five (5) degrees.
  • This shallow angle acts to stretch the web 12 in the cross-machine direction to eliminate fluctuations and wrinkles.
  • the multiple suction zones 70 a, 70 b and 70 c ensure that there is no loss of suction when measuring near the edge of web 12 . It should be appreciated that other suction arrangements may be employed including, for example, concentric annular slots or other patterns such as plural holes.
  • the contacting plate 60 , ferrite target plate 42 and optical reference body 66 are made of very smooth, low friction and wear resistant materials.
  • the top surface of reference body 66 may be made from solid ceramic, sapphire, synthetic diamond or the like.
  • Ferrite target plate 42 and contact plate 60 may include a smooth coating such as diamond film, plasma sprayed and lapped ceramics, or a thin ceramic sapphire cover that is post-machined and lapped.
  • Ferrite target plate 60 and inductor 33 may also be mounted with exchanged locations between first sensor head 82 and second sensor head 84 .
  • Sensor 80 is adapted to measure web thickness without any direct contact with either side of web 12 .
  • sensor 80 may be positioned in close proximity to a moving web 12 .
  • the web thickness, or caliper is measured by means of a first sensor head 82 that does not contact web 12 and an opposed second sensor head 84 that also does not contact web 12 .
  • first sensor head 82 that does not contact web 12
  • second sensor head 84 that also does not contact web 12 .
  • non-contact means that the measurements themselves do not require physical contact between the web 12 and either of the sensor heads.
  • First head 82 includes an optical displacement sensor probe 86 that employs the confocal chromatic aberration method to determine the distance to the top surface 16 of web 12 .
  • Probe 86 includes an objective lens 88 which varies the refractive index as a function of wavelength.
  • a light source and optical spectrograph (not shown) communicate with lens 88 through a fiber optic cable 94 .
  • Sensor probe 86 outputs a distance measurement which represents the distance from the lens 88 to top surface 16 of web 12 .
  • First sensor head 82 further includes an inductor 98 having a ferrite cup core 100 with a winding 102 .
  • Core 100 is annular, defining a center aperture 104 that provides an optical path between lens 88 and web 12 . It is important to know the relative distances between inductor 98 and probe 86 , thus ferrite cup core 100 is spaced from probe 86 by a spacer 106 , the size of which is precisely known so that the exact distance to lens 24 is known.
  • Inductor 98 is coaxial with lens 88 and is utilized to magnetically measure distance to a ferrite target plate 108 in second sensor head 84 . The inductance is converted to a displacement measurement by an electronic unit (not shown). As with the previous embodiment, inductor 98 and target plate 108 may be switched, with the target plate in first head 82 and the inductor positioned in he second head 84 . Also, other magnetic measurement methods may be employed.
  • Second head 84 also includes an optical displacement sensor probe 114 that employs a confocal chromatic aberration method to determine the distance to the bottom surface 14 of web 12 .
  • Probe 114 includes an objective lens 116 which varies the refractive index as a function of wavelength.
  • Probe 114 views the bottom surface 14 of web 12 through an aperture 115 in target plate 108 .
  • the optical axis of second probe 114 is advantageously coaxial with the optical axis of first probe 86 .
  • a light source and optical spectrograph (not shown) communicate with lens 116 through a fiber optic cable 122 .
  • Sensor probe 114 produces a distance measurement which represents the distance from the lens 116 to the bottom surface 14 of web 12 .
  • the thickness of web 12 may be measured.
  • Air-bearing arrangement 126 includes guide bars 128 a and 128 b that extend in the cross-machine direction and are positioned at opposed upstream and downstream ends of first sensor head 82 .
  • guide bar 128 may be circular, extending circumferentially around the entire sensor 80 (see FIG. 5C ).
  • guide bars 128 a and 128 b may each be arced or curved.
  • Guide bars 128 direct compressed air through a plurality of holes 129 downwardly toward web 12 .
  • First head 82 also includes a port 130 that communicates with a chamber 132 located between lens 88 and web 12 . Air is supplied through port 130 , into chamber 132 and through aperture 104 toward web 12 . As will be hereinafter discussed, this promotes the removal of wrinkles from web 12 at the area of measurement. Also, the evacuation of air through aperture 104 helps prevent contaminates from entering chamber 132 and dirtying lens 88 .
  • Second sensor head 84 includes a port 134 that communicates compressed air to a peripheral chamber 136 that feeds a slot 138 at the periphery of ferrite target plate 108 .
  • Slot 138 may be annular and is positioned inwardly of guide bar 128 and may extend the entire periphery of the target plate 108 .
  • Slot 138 may be angled to direct air upwardly and outwardly.
  • a ring 139 may be positioned outwardly of slot 138 that, in cross-section, curves away from web 12 .
  • ring 138 includes an upwardly convex profile.
  • Chamber 136 communicates with a central chamber 140 , located in front of lens 116 , through a channel 142 .
  • the web 12 will, by this arrangement, float a small distance above ferrite target plate 108 .
  • the ratio of air flowing through aperture 115 and peripheral slot 134 may be controlled by a control valve 144 . This ratio should be balanced to just barely lift web 12 away from contacting the central area of bottom head 84 while not deforming the local shape of web 12 . Air flowing through the aperture 136 helps keep lens 88 clean and offers additional airbearing lift, to stretch web 12 without physically contact.
  • Air bearing arrangement 126 stretches web 12 to control flatness and parallelism for optical measurement.
  • Guide bars may be adjusted to force web 12 to pass through sensor 80 in a zigzag or serpentine pattern in the gap between first sensor head 82 and second sensor head 83 .
  • This arrangement is effective in making the sheet flat by bending it in opposite directions as it passes through the sensor.
  • the web stretching, at the optical point of measurement, is further promoted by an elevated lip 146 , which is attached to target plate 108 surrounding aperture 115 and promotes a slight rise in the web at the area of the optical measurement.
  • Lip 146 may be made of a smooth, non-magnetic and non-conductive material so that it does not interfere with magnetic measurements.
  • sensor 150 may be positioned in close proximity to a web 12 moving in direction D.
  • the web thickness, or gauge is measured by means of a first sensor head 152 that does not contact web 12 and a second sensor head 154 that also does not contact web 12 .
  • First head 152 includes an optical displacement sensor probe 156 that employs a confocal chromatic aberration method to determine the distance to the top surface 16 of web 12 .
  • Probe 156 includes an objective lens 158 which varies the refractive index as a function of wavelength.
  • a light source and optical spectrograph (not shown) communicate with lens 158 through a fiber optic cable 160 .
  • Sensor probe 156 measures the distance from the lens 158 to the top surface 16 of web 12 .
  • First sensor head 152 further includes a first floating guide 162 that floats on a cushion of air above web 12 .
  • Floating guide 162 may be a body of rotational symmetry to assure symmetry and parallel lift of the air cushion.
  • Guide 162 includes an inductor 164 having an annular ferrite cup core 166 with a winding 168 .
  • Core 166 defines a center aperture 170 , within which is positioned a thin window 171 .
  • Window 171 may be a transparent or semitransparent material. In one or more embodiments window 171 is made of glass or sapphire.
  • Inductor 164 is utilized to magnetically measure distance to a ferrite target plate 172 in a second floating guide 174 . The inductance is converted to a displacement measurement by an electronic unit (not shown).
  • First floating guide 162 includes an outer body 176 that forms an interior chamber 178 .
  • a collar 180 extends upwardly from body 176 and is received in a bore 182 .
  • a spherical section 184 extends radially outwardly from collar 180 with a small clearance to bore 182 , and by a small amount of escaping air forming a friction free airbearing around the spherical section 184 to allow free angular and axial articulation of guide 162 in the bore 182 .
  • the friction free suspension together with pneumatic force balance permits the guide 162 to achieve an equilibrium position parallel to, and at a relatively constant distance from the upper surface of web 12 .
  • Compressed air is received through a port 186 in first head 152 .
  • first guide 162 is maintained above web 12 in a self-adjusting fashion.
  • Second head 154 includes an optical displacement sensor probe 192 , axially aligned with probe 156 , that employs a confocal chromatic aberration method to determine the distance to the bottom surface 14 of web 12 .
  • Probe 192 includes an objective lens 194 which varies the refractive index as a function of wavelength.
  • Probe 192 views the bottom surface 14 of web 12 through a window 196 located centrally on target plate 172 .
  • Window 196 may be a transparent or semitransparent material. In one or more embodiments window 196 is made of glass or sapphire.
  • a light source and optical spectrograph (not shown) communicate with lens 194 through a fiber optic cable 198 .
  • Sensor probe 192 measures the distance from the lens 194 to the bottom surface 14 of web 12 .
  • Second floating guide 174 includes an outer body 200 that forms an interior chamber 202 .
  • a spherical section 208 extends radially outwardly from collar 204 with a small clearance to bore 206 , and by a small amount of escaping air forming a friction free airbearing around the spherical section 208 to allow free angular and axial articulation of guide 174 in the bore 206 .
  • the friction free suspension together with pneumatic force balance permits the guide 174 to achieve an equilibrium position parallel to, and at a relatively constant distance from the lower surface of web 12 .
  • Compressed air is received through a port 210 in second head 154 .
  • the air is thereafter communicated to chamber 202 through the inlet formed by collar 204 .
  • a plurality of spaced holes or slots 212 are located on the top surface 214 of body 200 so that the compressed air is directed from chamber 202 upwardly toward web 12 . In this manner, second guide 174 is maintained below web 12 in a self-adjusting fashion.
  • guides 162 and 174 may be chosen so that each is maintained at about 100 ⁇ m away from the respective surface of web 12 . Because guides 162 and 174 are maintained relatively close to web 12 (and consequently to each other) the inductor 164 and ferrite target plate 172 are likewise held in close proximity, and can therefore be designed to be highly accurate, as well as small in size.
  • windows 171 and 196 may be glass, sapphire or the like and may be used to calibrate sensor 150 .
  • windows 171 and 196 may be, for example 5 mm in diameter and precision machined to 0.2 mm thickness.
  • the chromatic aberration optical paths 216 a, 216 b and 216 c that will return to the fiber optic cable in focus originate from three different locations; 216 a is reflected from top surface 16 of web 12 , 216 b is reflected from the bottom surface 218 of window 171 and 216 c is reflected from the top surface 220 of window 171 .
  • the chromatic paths of second probe 192 reflect from the bottom surface 14 of web 12 , as well as the top and bottom surface 222 and 224 of window 196 .
  • Probes 156 and 192 can distinguish multiple surface reflections simultaneously and determine each surface location separately. By this method, as guides 162 and 174 articulate, each of the three surfaces can be located and measured using the optical spectrograph. By also knowing the distance between each guide 162 and 174 using the inductor 164 and target plate 172 , web thickness may be derived.
  • top and bottom spectrographs 226 a and 226 b respectively.
  • the spectrograph 226 a indicates three peaks for the three optical interfaces g 1 , g 2 and D top for the top device and g 3 , g 4 and D bot for the bottom device 226 b.
  • these additional signals g 1 , g 2 , g 3 , and g 4 can be used to dynamically correct for web tilt. Also, these signals can be used to determine the height of the guides 162 and 174 while measuring web 12 .
  • the floating guides 162 and 174 are free to move with the moving web 12 , and as a result may experience a varying degree of tilt during measurement. As a result, the optical axis and magnetic axis may no longer be parallel, which may cause measurement errors. With reference to FIG. 9 , a method is shown to dynamically correct the resulting error when the optical axis is not normal to the moving web 12 .
  • the measured apparent thickness t m g1 and the actual thickness t a g1 of window 171 are used to dynamically determine the actual perpendicular distance d a AB1 between the guide 162 and the moving web 12 .
  • the measured distance between top and bottom glass surfaces 218 and 220 or 222 and 224 may be used to determine the tilt angle ⁇ AB1 and ⁇ AB2 of the respective floating guides 162 and 174 .
  • the actual guide height d a AB1 and d a AB2 is then calculated by the trigonometric steps below, using the measured guide heights d m AB1 and d m AB2 .
  • ⁇ g1 arccos( t g1 a /t g1 m )
  • ⁇ AB1 arcsin( n sin( ⁇ g1 )
  • ⁇ g2 arccos( t g2 a /t g2 m )
  • ⁇ AB2 arcsin( n sin( ⁇ g2 )
  • guides 162 and 174 can articulate to track local web tilt and flutter while still providing accurate measurements. It is also noted that the measured glass thickness will always be greater or equal to the actual thicknesses of the windows. It should be appreciated, however, that a suitable optical density correction may be required because a portion of the optical path is through a medium other than air.
  • sensor 230 may be positioned in close proximity to a web 12 .
  • the web thickness, or gauge is measured by means of a first sensor head 232 that does not contact web 12 and a second sensor head (not shown) that may generally mirror first head 232 .
  • First head 232 includes an optical displacement sensor probe 234 that employs a confocal chromatic aberration method to determine the distance to the top surface 16 of web 12 .
  • Probe 234 includes an objective lens 236 which varies the refractive index as a function of wavelength.
  • a light source and optical spectrograph (not shown) communicate with lens 236 through a fiber optic cable 238 .
  • First sensor head 232 further includes a first guide 240 that floats on a cushion of air above web 12 .
  • Guide 240 includes an inductor 242 having an annular ferrite cup core 244 with a winding 246 .
  • Core 244 defines a center aperture 248 , within which is positioned an annular plate 250 .
  • Inductor 242 is utilized to magnetically measure distance to a ferrite target plate (not shown) in the second guide (not shown) on the opposed side of web 12 . The inductance is converted to a displacement measurement by an electronic unit (not shown).
  • Guide 240 is substantially similar to guide 162 with the exception that annular plate 250 is positioned within center aperture 248 instead of a window 171 . This provides a non-obstructed view of the moving web surface 16 without a window that could potentially collect dirt and require regular cleaning.
  • probe 234 may include multiple fibers (of a fiber optic cable) optically viewing through the same lens 236 . These fibers use the same lens 236 for delivery and collection of light, but have offset lateral positions. For example, in FIG.
  • FIG. 11 a an exemplary cross-sectional fiber arrangement is shown having a central fiber 252 that measures the distance to web 12 through the central aperture 254 of annular plate 250 , while a plurality of fibers 256 are circumferentially spaced around central fiber 252 and measure distance to the annular reference plate 250 . These measurements may be used to calculate the tilt of the guide 240 . Because the tilt of guide 240 generally parallels the tilt of web 12 , the measured guide tilt may be used to dynamically correct the measured gauge of web 12 . It should be appreciated that the fiber arrangement of FIG. 11A , as well as FIGS. 11B and 11C may be used with on or more of the previous sensor embodiments.
  • FIG. 11B an alternate fiber arrangement is shown wherein a multitude of fibers 256 are arranged in a row in the cross-machine direction to be focused onto the material in the pattern shown in FIG. 12 .
  • Each individual fiber 256 may be interrogated by an imaging spectrograph.
  • An exemplary resulting graph is shown in FIG. 13 .
  • each fiber is directed onto a different line across the 2D imaging spectrograph (A 1 . . . An) and individual displacements are determined by signal processing.
  • Each individual spectral line provides a high resolution surface profile.
  • the fibers 256 can be arranged to be of comparable width to that of current online caliper measuring devices.
  • the average distance to the material surface can be estimated from the average spectral spread at each integration instance ⁇ x.
  • the line of fibers 256 may be used to measure tilt along the axis of the machine direction, thus enabling automatic correction.
  • measurements taken by fibers 256 may correlate to a roughness, porosity, or runnability measurement.
  • FIG. 11C an alternate fiber arrangement is shown, wherein the fibers 256 are arranged to obtain a two dimensional surface area profile.
  • multiple spectrographs may be separate or combined to make a 2d spectrograph (not shown) measures distance to the sheet at more than one point (i.e. pixels arranged in rows).
  • This arrangement offers measurement of displacement as well as web tilt in both the cross-machine and machine direction. As previously discussed, web tilt can cause the thickness measurement to be in error due to the axial optical displacements combined with any non-concentricity of the two opposed optical probes. The measurement of web tilt permits compensation of measurement errors.
  • the fibers 256 can be arranged to be of comparable width to that of current online caliper measuring devices.
  • the average distance to the material surface may be produced by averaging the output of each fiber 256 .
  • measurements taken by fibers 256 may correlate to a 2D roughness, porosity, or runnability measurement.
  • FIG. 14 a profile is shown of a web 12 with rough surface being probed by the optical beam 258 .
  • the resultant measured displacement 260 is shown in FIG. 15 a which shows the expected spectra detected if the sample is moved at slow speed, or if integration time is very high, to resolve surface variations.
  • the intensity at a given wavelength would be comparably very high in such an arrangement, as shown in FIG. 15 b. If the same surface measurement is taken at a faster web speed or slower integration time, it can be seen in FIG. 16 a that the measured distance is the averaged distance 264 measured by the probe during the spectrograph integration time.
  • FIG. 16 b shows the resultant spectral width 262 widening due to the rough surface integrated measurement.
  • a relationship can be found analytically and/or empirically on the amount of spread as a function of integration distance and surface roughness. This offers multiple benefits, the surface topography can be used as an on-line sheet smoothness or gloss indicator, and the sheet thickness measurement may be corrected for topography induced measurement errors.
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FI127623B (fi) 2018-10-31
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CA2884632A1 (en) 2009-03-12
CN101868689B (zh) 2016-11-02
FI20155193A (fi) 2015-03-20
FI125343B (fi) 2015-08-31
CN101868689A (zh) 2010-10-20
FI20105304A (fi) 2010-03-25
DE112008002244T5 (de) 2010-07-22
FI20135026A (fi) 2013-01-09
US7889342B2 (en) 2011-02-15
FI127396B (fi) 2018-05-15
CA2884632C (en) 2016-10-25
FI123478B (fi) 2013-05-31
US20090056156A1 (en) 2009-03-05
US20090059232A1 (en) 2009-03-05
DE112008002244B4 (de) 2013-07-25
WO2009032094A1 (en) 2009-03-12

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