Sensor controller for interpreting natural interaction sensor for web handling

A sensor controller, comprising:

• a first port configured to receive a data stream having a sequence of data frames captured at distinct instants of time of a material web, the data frames capturing an area of a material web having a width to height ratio between 0.10 and 100;
• one or more non-transitory computer readable medium storing first logic indicative of information identifying a first group of data points of a first feature extending in a web direction of travel of the material web, and second logic indicative of information identifying a second group of data points of a second feature extending in a web direction of travel of the material web;
• one or more processor configured to analyze the data stream with the first group of data points of the first feature, a third group of data points depicting a background transverse to the first feature, and the second group of data points depicting the second feature, the second feature spaced a distance transversely from the first feature, the processor scanning the sequence of data frames to locate a first transition between the first group of data points and the third group of data points in the data frames, and a second transition between the second group of data points and the third group of data points in the data frames, and to generate web handling signals indicative of at least one of the locations of the first and second transitions and a lateral distance between the first and second transitions;
• and
• a second port outputting the web handling signals.

A sensor controller, comprising:

• a first port configured to receive a sequence of signals from a topographic sensor having a field of view encompassing a feature of a web, the sequence of signals including a series of depth maps;
• one or more non-transitory computer readable medium storing web handling information indicative of a desired aspect of the feature of the web;
• one or more processor configured to determine a current aspect of the feature of the web using at least one of the depth maps in the series of depth maps and to determine an error signal indicative of a difference between the desired aspect and the web handling information stored on the one or more non-transitory computer readable medium;
• and
• a second port outputting the error signal.

A sensor controller, comprising:

• a first port configured to receive a sequence of signals from a topographic sensor having a field of view encompassing a feature of a web;
• the sequence of signals including a series of depth maps, the first port also being configured to receive a sequence of video frames of the feature of the web synchronized with the depth maps;
• one or more non-transitory computer readable medium storing web handling information indicative of a feature of the web and desired quality inspection aspect of the web;
• one or more processor configured to determine a current location of the feature of the web using at least one of the sequence of video frames and the depth maps, and to determine a current quality inspection aspect of the feature of the web using at least one of the sequence of video frames and depth;
• and
• a second port outputting the signals indicative of the current location of the feature of the web and a current quality inspection aspect of the web.

A computerized method for guiding a material web, comprising:

• receiving a sequence of signals from a topographic sensor having a field of view encompassing a feature of a web, the sequence of signals including a sequence of depth maps;
• storing web handling information on a non-transient computer readable medium indicative of a desired aspect of the feature of the web;
• determining a current aspect of the feature of the web using at least one of the depth maps in the sequence of depth maps;
• determining an error signal indicative of a difference between the current aspect and the web handling information;
• and
• outputting an error signal.

A computerized method for monitoring a material web, comprising:

• receiving a sequence of signals from a topographic sensor having a field of view encompassing at least a portion of the material web, the sequence of signals including a sequence of data frames;
• storing web handling information indicative of a desired web tension of the material web;
• determining a current web tension of the web using a processor locating edges of the web in the data frames, calculating a width of the material web, and determining a current tension in the web based on the width of the web;
• determining an error signal indicative of a difference between the desired web tension and the current web tension;
• and
• outputting the error signal.

A web handling system for guiding a material web, the web handling system comprising:

• a base;
• a platform mounted to move relative to the base through a predetermined path;
• at least one steering roller being mounted on the platform and disposed transversely of a web direction of travel across the platform;
• a natural interaction sensor supplying a medium to reflect off of a surface of the web, and receiving reflections of the medium from the surface of the web, the natural interaction sensor developing a series of topographical maps indicative of a location of at least one feature extending in a web direction of travel of the material web;
• a sensor controller having a first port configured to receive the topographical maps from the natural interaction sensor, one or more processor coupled to the first port and configured to analyze the topographical maps received from the natural interaction sensor, the one or more processor scanning the topographical maps to locate a transition indicative of a location of the feature of the material web in the one or more topographical maps and to generate a series of location signals indicative of the lateral locations of the transition within the topographical maps, and a second port coupled to the one or more processor and outputting the error signals;
• a web controller configured to generate control signals responsive to the location signals produced by the sensor controller and configured to automatically correct a deviation from a predetermined position of the web;
• and
• a platform drive configured to be responsive to the control signals generated by the controller for pivoting the platform and thereby controlling an angular position of the platform relative to the base.