Web Position Sensor

A web edge sensor is disclosed. The web edge sensor has a light source directing light incident to an edge of a web. The edge of the web scatters the light and a sensor array that detects a first portion of the light scattered from the edge of the web and rejects a second portion to determine a position of the web edge.

This paper discusses the development of a linear quadratic optimal control algorithm for web guides, and implementation of the control algorithm using web lateral position feedback from a new, experimental fiber optic sensor. The lateral dynamic model of the web and the measurement characteristics of the fiber optic sensor are conducive for a linear quadratic regulator design. The performance of the optimal control algorithm with web lateral position feedback from the fiber optic edge sensor is evaluated by conducting experiments on a web platform. Experiments were also conducted using the same controller but with an existing industrial infrared sensor for web lateral position measurement. Results from a series of comparative experiments indicate that the optimal control algorithm with feedback from the fiber optic sensor provides accurate lateral position regulation in the presence of disturbances, at various web transport speeds, and with web materials with different mechanical, physical and geometric properties. Based on the analysis of the web lateral dynamic model, recommendations for proper guide operation and selection of appropriate web transport conditions for good guiding performance are also discussed.

A new sensor for web flutter measurement is proposed in this paper. The sensor is based on the principle of scattering of light and directional properties of optical fibers. A collimated beam of light is incident on the web edge and scattered light from the web edge is collected using a linear array of optical fibers. As the web flutters the point of scattering moves. Due to the directional property of the optical fibers, each fiber collects scattered light that is incident on it at certain angles. The motion of the scattering point as the web flutters is directly related to which fibers are being illuminated within the fiber array. The other end of the fiber array is terminated onto a linear array of photodiodes (pixels). Based on which fibers in the array are receiving scattered light and the amount of light received, the transverse displacement (web flutter) of the web can be determined. This paper describes the construction and working of the new sensor for web flutter measurement. Experiments conducted on a web platform show that the sensor is capable of accurately measuring web flutter. The frequency response of the sensor is limited only by the scanning rate of the pixel array and not by the flutter measurement method. A dedicated signal processing circuit can be used to obtain a desired scanning rate, thus, a desired frequency response.

Existing edge sensors use the concept of blocking/unblocking for measuring web lateral position. The most commonly used sensors employ either ultrasonic or infrared signals to detect the web edge position by measuring the amount of signal attenuation due to blocking/unblocking of the signal. The main drawback of this sensing method is nonuniform signal attenuation due to web material variations and opacity. The research in this paper develops a new sensor which utilizes the phenomena of light scattering from the web edge and the directional sensitivity of optical fibers. A collimated laser beam is incident on the web edge and scattered light is collected by a linear array of fibers spatially positioned above the web edge. The theory of operation and the development of the sensor is described. Experiments are conducted with different web materials to validate the proposed sensing method. A representative sample of the results are presented and discussed.

A novel sensor to measure web flutter is proposed in this letter. The sensing principle is based on scattering of light and directionally sensitive coupling properties of optical fibers. A linear array of optical fibers, oriented appropriately, is used to collect light scattered from a web. The flutter amplitude is determined by observing the amount of light transmitted by the fibers in the fiber array. Experiments were conducted to demonstrate the ability of the proposed sensing strategy in measuring web flutter with different kinds of web material.

This paper presents an optimal web guiding strategy based on the dynamic analysis of the lateral web behavior and a new fiber optic lateral web position measurement sensor. First, a lateral dynamic model of a moving web is revisited with an emphasis on correct application of appropriate boundary conditions.