Development of measurement system for simultaneous detection of copper strip width, thickness and encapsulation thickness
Introduction
Copper busbars, also known as copper platoons or copper conductors, are long, flat metallic components typically made of copper. They have a rectangular or chamfered (rounded) cross-section, with modern versions often using rounded shapes to prevent tip discharge. These conductors serve as essential elements in electrical systems, carrying high currents and connecting various electrical devices and equipment.
As a key component in electrical engineering, copper busbars are widely used in both high and low voltage applications, such as switchgear, power distribution systems, and busway installations. They are also extensively utilized in industrial settings like metal smelting, electroplating, and chemical electrolysis processes that require high current flow. The advantages of copper busbars include their low resistivity and high flexibility, making them ideal for use in power distribution units and other critical electrical systems. This article focuses on the measurement of copper strip dimensions, specifically its width, thickness, and encapsulation thickness.
1. Width and Thickness Gauge
The width and thickness gauge is a device that employs two sets of photoelectric sensors to measure both the width and thickness of a copper strip simultaneously.
1.1 Measurement Principle
The device uses a point light source within the emitting lens, which projects a parallel light beam onto the object being measured. This light passes through the receiving lens, focusing on a CCD chip. When the copper strip passes through the field of view, it casts a shadow on the CCD, allowing the system to calculate the width and thickness based on the length of the shadow. The CCD converts the optical signal into an electrical one, which is then amplified, digitized, and sent to a microcontroller for processing.
1.2 Control System
The gauge communicates with the industrial computer via RS422 or RS485 interfaces, ensuring reliable signal transmission. It can output a 0–10V analog signal to control the speed of the extrusion or traction motor, thus adjusting the final dimensions of the copper bar. In case of deviations, the system triggers sound and light alarms, which are installed in the main control cabinet for immediate operator response.
2. Installation Location
The system consists of two measuring gauges, small control cabinets, an embedded industrial computer, alarm units, and communication modules. It is installed along the copper busbar production line, with the gauges positioned before and after the extruder. The main control cabinet and computer are placed in a controlled environment, free from temperature and humidity fluctuations.
Both the gauges and the control cabinet are mounted on adjustable stands, allowing height adjustments between 740mm and 1030mm. This ensures optimal positioning for accurate measurements. Power and data lines connect the gauge to the control unit, enabling remote operation and real-time data transmission to the industrial computer for further analysis.
3. Interlock Control Mode
The system uses two gauges to measure the width and thickness of the copper strip at different positions. The data is compared with set standards, and a PID controller adjusts the extrusion process accordingly. The steps involved are:
(1) Measure the width and thickness of the encapsulated copper strip using gauge K1 and H1
(2) Measure the width and thickness of the copper strip using gauge K2 and H2
(3) Calculate the encapsulation width: K = (K1 - K2)/2
Calculate the encapsulation thickness: H = (H1 - H2)/2
Based on the real-time values of K and H, the system compares them to the standard values. If discrepancies are found, the control circuit adjusts the extruder to bring the dimensions back to the desired range. This closed-loop process continues until the product meets the required specifications.
4. Width and Thickness Detection
To ensure precise control of the copper strip's dimensions, especially when rubber eccentricity is a concern, the system measures the thickness of all four sides using laser technology. This allows for online monitoring and prevents uneven thickness distribution.
Conclusion
After implementation, the copper busbar width gauge has proven highly effective, offering improved repeatability and significantly reduced measurement errors compared to manual methods. It provides fast, accurate, and real-time measurements, making it suitable for continuous production environments. With dual linkage capabilities, it not only detects the width and thickness of the copper strip but also controls the size by adjusting the tractor or extruder speed. This makes it a reliable, efficient, and high-precision tool for quality assurance in copper busbar manufacturing.
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Xiaogan Yueneng Electronic Technology Co., Ltd. , https://www.xgsensor.com