Gap and displacement magnetic sensor system for scanner heads in paper machines or other systems

1. A method comprising:

generating a magnetic field;

capturing, by multiple magnetic field orientation sensors, measurements of the magnetic field by:

measuring, by a first magnetic field orientation sensor, a field angle of the magnetic field in a first direction with reference to a reference field angle, wherein the first magnetic field orientation sensor is disposed substantially in alignment with a centerline of the magnetic field; and

measuring, by a second magnetic field orientation sensor, a field angle of the magnetic field in a plane defined by the first direction and a second direction, the first and second directions orthogonal to each other, wherein the second magnetic field orientation sensor is disposed offset from the centerline of the magnetic field such that an output from the second magnetic field orientation sensor represents a combination of (i) a displacement of first and second scanning sensor heads in the first direction and (ii) a gap separation of the first and second scanning sensor heads in the second direction; and

identifying, using the measurements of the magnetic field, (i) the displacement of the first and second scanning sensor heads in the first direction and (ii) the gap separation of the first and second scanning sensor heads in the second direction.

2. A method comprising:

generating a magnetic field;

capturing, by multiple magnetic field orientation sensors, measurements of the magnetic field; and

identifying, using the measurements of the magnetic field, (i) a displacement of first and second scanning sensor heads in a first direction and (ii) a gap separation of the first and second scanning sensor heads in a second direction;

wherein:

at least one of the magnetic field orientation sensors is disposed offset from a centerline of the magnetic field such that an output from the at least one magnetic field orientation sensor represents a combination of the displacement and the gap separation;

each of the magnetic field orientation sensors is calibrated to operate within a calibration range in which a voltage output from the magnetic field orientation sensor is related to a field angle measurement of the magnetic field;

within the calibration range, the field angle measurement of the magnetic field accurately represents a linear distance from an alignment reference point;

at limit points of the calibration range, (i) a minimum field angle measurement accurately represents a first linear distance from the alignment reference point and (ii) a maximum field angle measurement accurately represents a second linear distance from the alignment reference point in an opposite direction; and

a tolerance corresponding to a specified nominal target gap separation is disposed between the limit points of the calibration range.

3. The method of claim 1 , wherein the first and second magnetic field orientation sensors are disposed in a common plane or in parallel planes.

4. The method of claim 1 , further comprising:

moving the first and second scanning sensor heads across a surface of a web of material and;

capturing measurements associated with the web.

5. The method of claim 4 , further comprising:

adjusting the measurements associated with the web based on at least one of:

the displacement of the first and second scanning sensor heads in the first direction; and

the gap separation of the first and second scanning sensor heads in the second direction.

6. A multiple-sensor assembly comprising:

multiple magnetic field orientation sensors configured to capture measurements of a magnetic field in order to identify (i) a displacement of first and second scanning sensor heads in a first direction and (ii) a gap separation of the first and second scanning sensor heads in a second direction, the magnetic field orientation sensors comprising:

a first magnetic field orientation sensor configured to measure a field angle of the magnetic field in the first direction with reference to a reference field angle, wherein the first magnetic field orientation sensor is disposed substantially in alignment with a centerline of the magnetic field; and

a second magnetic field orientation sensor configured to measure a field angle of the magnetic field in a plane defined by the first and second directions, the first and second directions orthogonal to each other, wherein the second magnetic field orientation sensor is disposed offset from the centerline of the magnetic field such that an output from the second magnetic field orientation sensor represents a combination of the displacement and the gap separation.

7. A multiple-sensor assembly comprising:

multiple magnetic field orientation sensors configured to capture measurements of a magnetic field in order to identify (i) a displacement of first and second scanning sensor heads in a first direction and (ii) a gap separation of the first and second scanning sensor heads in a second direction;

wherein:

at least one of the magnetic field orientation sensors is disposed offset from a centerline of the magnetic field such that an output from the at least one magnetic field orientation sensor represents a combination of the displacement and the gap separation;

each of the magnetic field orientation sensors is calibrated to operate within a calibration range in which a voltage output from the magnetic field orientation sensor is related to a field angle measurement of the magnetic field;

within the calibration range, the field angle measurement of the magnetic field accurately represents a linear distance from an alignment reference point;

at limit points of the calibration range, (i) a minimum field angle measurement accurately represents a first linear distance from the alignment reference point and (ii) a maximum field angle measurement accurately represents a second linear distance from the alignment reference point in an opposite direction; and

a tolerance corresponding to a specified nominal target gap separation is disposed between the limit points of the calibration range.

8. The multiple-sensor assembly of claim 6 , wherein the first and second magnetic field orientation sensors are disposed in a common plane or in parallel planes.

9. The multiple-sensor assembly of claim 8 , wherein the magnetic field orientation sensors further comprise:

a third magnetic field orientation sensor configured to measure a field angle of the magnetic field in a third direction in order to identify a displacement of the first and second scanning sensor heads in a third direction;

wherein the third magnetic field orientation sensor is disposed in a plane that is orthogonal to the common plane or to the parallel planes.

10. A system comprising:

first and second scanning sensor heads each configured to move across a surface of a web of material and capture measurements associated with the web, wherein:

the first scanning sensor head includes a magnet configured to generate a magnetic field; and

the second scanning sensor head includes multiple magnetic field orientation sensors configured to capture measurements of the magnetic field in order to identify (i) a displacement of the first and second scanning sensor heads in a first direction and (ii) a gap separation of the first and second scanning sensor heads in a second direction, the magnetic field orientation sensors comprising:

a first magnetic field orientation sensor configured to measure a field angle of the magnetic field in the first direction with reference to a reference field angle, wherein the first magnetic field orientation sensor is disposed substantially in alignment with a centerline of the magnetic field; and

a second magnetic field orientation sensor configured to measure a field angle of the magnetic field in a plane defined by the first and second directions, the first and second directions orthogonal to each other, wherein the second magnetic field orientation sensor is disposed offset from the centerline of the magnetic field such that an output from the second magnetic field orientation sensor represents a combination of the displacement and the gap separation.

11. A system comprising:

first and second scanning sensor heads each configured to move across a surface of a web of material and capture measurements associated with the web;

wherein:

the first scanning sensor head includes a magnet configured to generate a magnetic field;

the second scanning sensor head includes multiple magnetic field orientation sensors configured to capture measurements of the magnetic field in order to identify (i) a displacement of the first and second scanning sensor heads in a first direction and (ii) a gap separation of the first and second scanning sensor heads in a second direction;

at least one of the magnetic field orientation sensors is disposed offset from a centerline of the magnetic field such that an output from the at least one magnetic field orientation sensor represents a combination of the displacement and the gap separation;

each of the magnetic field orientation sensors is calibrated to operate within a calibration range in which a voltage output from the magnetic field orientation sensor is related to a field angle measurement of the magnetic field;

within the calibration range, the field angle measurement of the magnetic field accurately represents a linear distance from an alignment reference point;

at limit points of the calibration range, (i) a minimum field angle measurement accurately represents a first linear distance from the alignment reference point and (ii) a maximum field angle measurement accurately represents a second linear distance from the alignment reference point in an opposite direction; and

a tolerance corresponding to a specified nominal target gap separation is disposed between the limit points of the calibration range.

12. The system of claim 10 , wherein the first and second magnetic field orientation sensors are disposed in a common plane or in parallel planes.

13. The system of claim 10 , further comprising:

processing circuitry configured to identify, using the measurements of the magnetic field, the displacement and the gap separation.

14. The system of claim 13 , wherein the processing circuitry is further configured to adjust the measurements associated with the web based on at least one of:

the displacement of the first and second scanning sensor heads in the first direction; and

the gap separation of the first and second scanning sensor heads in the second direction.

15. The system of claim 10 , wherein:

each of the magnetic field orientation sensors is calibrated to operate within a calibration range in which a voltage output from the magnetic field orientation sensor is related to the associated field angle measurement of the magnetic field;

within the calibration range, the field angle measurement of the magnetic field accurately represents a linear distance from an alignment reference point;

at limit points of the calibration range, (i) a minimum field angle measurement accurately represents a first linear distance from the alignment reference point and (ii) a maximum field angle measurement accurately represents a second linear distance from the alignment reference point in an opposite direction; and

a tolerance corresponding to a specified nominal target gap separation is disposed between the limit points of the calibration range.

16. The system of claim 11 , wherein the magnetic field orientation sensors comprise:

a first magnetic field orientation sensor configured to measure a field angle of the magnetic field in the first direction with reference to a reference field angle, wherein the first magnetic field orientation sensor is disposed substantially in alignment with the centerline of the magnetic field; and

a second magnetic field orientation sensor configured to measure a field angle of the magnetic field in a plane defined by the first and second directions, wherein the second magnetic field orientation sensor is disposed offset from the centerline of the magnetic field.

17. The method of claim 1 , wherein:

each of the magnetic field orientation sensors is calibrated to operate within a calibration range in which a voltage output from the magnetic field orientation sensor is related to the associated field angle measurement of the magnetic field;

within the calibration range, the field angle measurement of the magnetic field accurately represents a linear distance from an alignment reference point;

at limit points of the calibration range, (i) a minimum field angle measurement accurately represents a first linear distance from the alignment reference point and (ii) a maximum field angle measurement accurately represents a second linear distance from the alignment reference point in an opposite direction; and

a tolerance corresponding to a specified nominal target gap separation is disposed between the limit points of the calibration range.

18. The method of claim 2 , wherein capturing the measurements of the magnetic field comprises:

measuring, by a first magnetic field orientation sensor, a field angle of the magnetic field in the first direction with reference to a reference field angle, wherein the first magnetic field orientation sensor is disposed substantially in alignment with the centerline of the magnetic field; and

measuring, by a second magnetic field orientation sensor, a field angle of the magnetic field in a plane defined by the first and second directions, wherein the second magnetic field orientation sensor is disposed offset from the centerline of the magnetic field.

19. The multiple-sensor assembly of claim 6 , wherein:

each of the magnetic field orientation sensors is calibrated to operate within a calibration range in which a voltage output from the magnetic field orientation sensor is related to the associated field angle measurement of the magnetic field;

within the calibration range, the field angle measurement of the magnetic field accurately represents a linear distance from an alignment reference point;

at limit points of the calibration range, (i) a minimum field angle measurement accurately represents a first linear distance from the alignment reference point and (ii) a maximum field angle measurement accurately represents a second linear distance from the alignment reference point in an opposite direction; and

a tolerance corresponding to a specified nominal target gap separation is disposed between the limit points of the calibration range.

20. The multiple-sensor assembly of claim 7 , wherein the magnetic field orientation sensors comprise:

a first magnetic field orientation sensor configured to measure a field angle of the magnetic field in the first direction with reference to a reference field angle, wherein the first magnetic field orientation sensor is disposed substantially in alignment with the centerline of the magnetic field; and

a second magnetic field orientation sensor configured to measure a field angle of the magnetic field in a plane defined by the first and second directions, wherein the second magnetic field orientation sensor is disposed offset from the centerline of the magnetic field.