Precision Gap Measurement Device for Plastic Material on Roll

Description: We are seeking the expertise of a skilled individual or company to develop a cutting-edge apparatus for measuring a critical gap in plastic material as it moves from a roll through a small device on a production machine. The plastic material is vital for our manufacturing process, and precise gap measurements are crucial to ensure optimal performance and avoid material wastage. The Challenge: The gap in the plastic strip can vary between 0.6mm to 6mm and is controlled by a pin, which can spontaneously change, resulting in deviations from the required dimensions. This leads to significant production setbacks, as the material becomes unusable, and the whole job needs to be restarted. To maintain production efficiency and minimize material waste, we need a solution that can consistently monitor and adjust the gap in real-time. Our Proposed Solution: We envision a sophisticated non-contact measurement device, possibly employing advanced laser technology or a capacitive sensor, positioned above the gap. This device will continuously monitor the gap width without any physical contact, ensuring seamless production flow. When changes in the gap are detected, the system will send an immediate signal to a control unit. The Control Mechanism: The control unit will communicate with a motor or servo system connected to a precision knob. This knob will be responsible for adjusting the pin’s position, accurately setting the desired gap width. By swiftly reacting to any variations in the gap, we can maintain consistent and precise measurements during production. Technical Considerations: The plastic material moves rapidly from right to left, with a relative speed of approximately 2-3 meters per second. Therefore, the measurement device must be capable of capturing real-time data and transmitting signals with utmost speed and accuracy. Benefits: By implementing this cutting-edge gap measurement apparatus, we aim to achieve the following benefits: 1. Drastically reduce material wastage, leading to cost savings. 2. Improve production efficiency by preventing delays and restarts. 3. Enhance product quality and consistency through precise gap control. 4. Minimize downtime, ensuring a seamless manufacturing process. If you believe you have the expertise and innovative mindset to develop this sophisticated gap measurement device, we eagerly await your proposals. Any alternative solutions or suggestions to achieve our objective are welcome. We have attached a video demonstrating the current process for your better understanding. Video link: [login to view URL]