Rope hauler system and method for removing solid debris from a pulping process

Abstract

A winch system for removing solid debris from a pulping machine container in a pulping system is disclosed. The winch system includes a winch operable to pull a tail portion of solid debris from the pulping machine container. The winch includes a pulling mechanism, a pulling drive, a riding roller, and a pressure device for adjusting the pressure on the riding roller at the tail portion between the pulling mechanism and the riding roller. The winch system includes a measuring device for determining the properties of the tail portion, the operating conditions of the pulping system or the winch, or combinations thereof. The winch system includes a control system that utilizes the measuring device to measure input variables, determines the properties or operating conditions of the tail portion based on the input variables, and adjusts the extraction rate, pulling direction, pressure, riding roller rolling torque or speed, or combinations thereof, to maintain the continuity of winch operation.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 148,666, filed February 12, 2021, entitled “Ragger Systems and Methods for Removing Solid Debris from Pulping Processes,” the entire contents of which are incorporated herein by reference. Technical Field

[0003] This specification generally relates to systems and methods for producing paper pulp, and more specifically to systems and methods for removing solid debris from pulp during the pulping process. Background Technology

[0004] In the paper industry, the processes used in papermaking include the production of pulp, which is a pulp of solid fibers such as cellulose fibers or other plant-based fibers in water. Recycled paper can be used as a source of solid fibers. Recycled paper is typically added to the pulping process by adding bundles of recycled paper to the pulping machine. Paper recycling processes may rely primarily on recycled paper products as raw materials for the papermaking process. Bundles of recycled paper may include metal or plastic strips and other solid debris that can contaminate pulping and recycling equipment. Summary of the Invention

[0005] These metal wires and strips, plastics, and other debris can be removed using a ragger. A ragger initially uses a rope dipped in pulp to entangle the metal wires and strips, plastics, and other debris, which attach to the rope and are slowly pulled out of the pulper as a tail. As the end of the rope reaches the ragger, the tail automatically forms, and the ragger continues to pull the tail out of the pulping container. Although the ragger is a very mature product technology, it remains very simple and is not designed to adapt to the normal changes in the operating conditions of today's paper recycling plants. Due to its inability to adapt to changing pulping conditions, raggers often malfunction and require significant manpower for cleaning, maintenance, and reinstatement. When a ragger stops, the pulping process is typically interrupted and shut down.

[0006] Therefore, there is a growing need for winch systems and methods for operating winches that enable the winch to be adjusted to adapt to varying operating conditions in pulping operations. The winch system and method of operating the winch system disclosed herein enable the adjustment of operating parameters of the winch, such as the tail pull-out rate, the direction of the puller drive, the rider roll pressure, the rider roll torque, or the speed, in response to changes in the properties of the tail or changes in the operating conditions of the pulping operation, to prevent tail breakage and maintain continuous operation of the winch. The winch system of this disclosure includes a winch having a driven puller mechanism and a rider roll connected to a pressure device operable to apply pressure to the rider roll in a direction toward the puller mechanism and against a tail disposed between the rider roll and the puller mechanism. The system of this disclosure may include a drive motor operatively connected to the rider roll to drive the rider roll and a puller drive operatively connected to a variable speed drive (VSD) of the puller mechanism. The drive motor on the riding roller and the VSD operatively connected to the pulling mechanism can be used to reduce slippage of the tail pulled from the pulper container by the winch, and to control the operation of the winch in response to the properties of the tail or the operating conditions of the pulping system.

[0007] Furthermore, the rope-winding machine system disclosed herein includes one or more measuring devices and a control system, the control system including at least one processor, at least one memory module, and computer-readable and executable instructions. The measuring devices may include one or more torque sensors, vibration sensors, optical sensors, cameras, weight load sensors, position sensors, pressure sensors, capacitance sensors, ammeters, motor speed sensors, level sensors, flow meters, conveyor speed sensors, temperature sensors, other measuring devices, or combinations thereof, as further described herein. The measuring devices may provide electronic signals to the control system, indicating the tail size, thickness, length, or density; tail slippage relative to the traction mechanism or riding roll; broken tail; metal content of the tail; pulping machine production rate; ratio of recycled pulp to virgin fiber introduced into the pulping machine; liquid level in the pulping machine; pulp consistency and / or temperature; other operating conditions of the pulping machine or rope-winding machine, or combinations thereof. The control system is operable to receive one or more input variables from a measuring device and adjust the pulling rate of the winch pulling the tail from the pulper, the direction of the puller drive, the pressure of the riding roller on the tail, the torque on the riding roller, the speed of the riding roller, the rotational position of the winch relative to the pulper container, other operating parameters of the winch, or combinations thereof. These adjustments to the winch operating parameters by the control system allow the winch system to account for variations in tail properties and / or changes in the operating conditions of the pulping process (e.g., increases or decreases in the amount of strips and debris or production rate) to reduce or prevent the tail from growing too large and clogging the winch, or the tail from becoming too thin, which could lead to tail breakage and falling back into the pulper container. Reducing winch clogging and / or tail breakage can improve the uptime of the winch system and the efficiency of the pulping process compared to existing winch machines.

[0008] According to one or more aspects of this disclosure, a winch system for removing solid debris from a pulping machine container of a pulping system may include a winch operable to pull a tail portion of the debris from the pulping machine container. The winch includes a pulling mechanism comprising a pulling drive operatively coupled to the pulling mechanism and a riding roller spaced apart from the pulling mechanism. The winch also includes a pressure device configured to regulate the pressure of a riding roller disposed on the tail portion between the main roller and the riding roller. The winch system includes at least one measuring device operable to measure one or more input variables indicating one or more properties of the tail portion, one or more operating conditions of the pulping system, or a combination thereof. The winch system may also include a control system comprising a processor, a memory module communicatively coupled to the processor, and machine-readable and executable instructions stored on the memory module. The control system may be communicatively coupled to at least one measuring device. The control system may also be communicatively coupled to the pulling drive, the pressure device, a riding roller drive operatively coupled to the riding roller, or a combination thereof. When executed by a processor, machine-readable and executable instructions can cause the winch system to automatically measure one or more input variables using at least one measuring device, wherein the one or more input variables indicate one or more attributes of the tail, one or more operating conditions of the winch, one or more operating conditions of the pulping system, or a combination thereof; and adjust the tail pull-out rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof based on the measured input variables.

[0009] It is understood that the foregoing summary of the invention and the following detailed description of the embodiments describe various examples and are intended to provide an overview or framework for understanding the nature and characteristics of the claimed subject matter. Attached Figure Description

[0010] The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated in and constitute a part of this specification. The drawings illustrate the various embodiments described herein and, together with the specification, serve to explain the principles and operation of the claimed subject matter.

[0011] Figure 1 A top view of a pulping system according to one or more embodiments shown and described herein is schematically depicted;

[0012] Figure 2 A partial sectional view schematically depicts one or more embodiments shown and described herein. Figure 1 A side view of the pulping system;

[0013] Figure 3 The illustration schematically depicts one or more embodiments shown and described herein. Figure 1 A three-dimensional view of the rope winch of the pulping system;

[0014] Figure 4 The illustration schematically depicts one or more embodiments shown and described herein. Figure 3 Side view of the rope winch;

[0015] Figure 5 The illustration schematically depicts one or more embodiments shown and described herein. Figure 3 A front view of the rope winch;

[0016] Figure 6 A front view of another embodiment of the rope winch according to one or more embodiments shown and described herein is schematically depicted;

[0017] Figure 7 A side view of an embodiment of a rope winch system according to one or more embodiments shown and described herein is schematically depicted;

[0018] Figure 8 A rear view of another embodiment of a rope winch system according to one or more embodiments shown and described herein is schematically depicted;

[0019] Figure 9 A side view of yet another embodiment of a rope winch system according to one or more embodiments shown and described herein is schematically depicted;

[0020] Figure 10 A side view of another embodiment of a rope winch system according to one or more embodiments shown and described herein is schematically depicted;

[0021] Figure 11 A side view of yet another embodiment of a rope winch system according to one or more embodiments shown and described herein is schematically depicted;

[0022] Figure 12 A top view schematically depicting another embodiment of a rope winch system according to one or more embodiments shown and described herein; and

[0023] Figure 13 A partial sectional view schematically depicts a front view of another embodiment of the rope winch according to one or more embodiments shown and described herein. Detailed Implementation

[0024] Reference will now be made in detail to embodiments of systems and methods for removing solid debris from a paper pulping process according to this disclosure. Wherever possible, the same reference numerals will be used to refer to the same or similar parts in all the drawings and detailed embodiments. (Refer to...) Figure 7 and 13A winch system 200 for removing solid debris from a pulper container 20 of a pulping system 10 may include a winch 100 operable to pull a tail 102 of solid debris from the pulper container 20. (See reference...) Figure 7 The rope winch 100 may include a pulling mechanism (e.g., a main roller 110) including a pulling driver 114; and a riding roller 120 including a pressure device 124 operable to adjust the pressure exerted by the riding roller 120 on a tail 102 disposed between the pulling mechanism and the riding roller 120. The rope winch system 200 may also include at least one measuring device operable to measure one or more input variables indicating the operating status of the pulping system 10, the operating status of the rope winch 100, and / or the size, weight, thickness, length, density, metal content, position in the pulping container 20, or a combination thereof, of the tail 102 pulled by the rope winch 100 from the pulping container 20. The rope winch system 200 may also include a riding roller driver 126 operatively coupled to the riding roller 120.

[0025] The winch system 200 may also include a control system 202, which is communicatively connected to at least one measuring device and a traction machine driver 114, a riding roller driver 126, a pressure device 124, and a winch rotating device 180. Figure 12 (or a combination of these.) See reference. Figure 7 and Figure 13 The control system 202 may include at least one processor 204, at least one memory module 206 communicatively coupled to the at least one processor 204, and machine-readable and executable instructions 208 stored on the at least one memory module 206, wherein, when executed by the processor 204, the machine-readable and executable instructions 208 cause the system to automatically measure one or more input variables using measuring devices and adjust the extraction rate of the tail 102, the direction of the main roller 110, the pressure of the pressure device 124, the speed of the riding roller 120, the torque of the riding roller 120, the rotational position of the winch 100 relative to the pulping container 20, or a combination thereof, based on the measured input variables. A method for removing solid debris from the pulping system 10 using the winch system 200 of this disclosure is also disclosed herein.

[0026] Unless otherwise stated, no method described herein is intended to be construed as requiring its steps to be performed in a particular order, nor is it intended to require a particular orientation of any device. Therefore, where the claims of a method do not explicitly describe the order in which the steps of the method are to be followed, or where the claims of any device do not explicitly describe the order or orientation of individual components, or where the claims or specification do not otherwise specifically state that these steps will be limited to a particular order, or where a particular order or orientation of the components of the device is not described, no order or orientation is intended to be inferred in any way. This applies to any possible non-explicit basis of interpretation, including: logical matters concerning the arrangement of steps, operational flow, component order, or component orientation; the obvious meaning derived from grammatical organization or reference numerals; and the number or type of embodiments described in the specification.

[0027] The directional terms used in this article—such as up, down, right, left, front, back, top, bottom—are made only with reference to the accompanying drawings and the provided coordinate axes, and are not intended to imply absolute orientation.

[0028] As used herein, the singular forms of “a,” “one,” and “the” also include plural referents, unless the context explicitly specifies otherwise. Thus, for example, a reference to a component “a” includes aspects having two or more such components, unless the context explicitly specifies otherwise.

[0029] As used herein, the terms “longitudinal” and “axial” can refer to an orientation or direction that is generally parallel to the central axis A of a cylindrical device such as a pulper container, which may be parallel to the + / -Z direction of the coordinate axis in the figure.

[0030] As used herein, the term "radial" can refer to a direction along any radius extending outward from the central axis A of the cylindrical device.

[0031] As used in this article, the term "angle" generally refers to the direction in which the angle increases or decreases around the central axis A of a cylindrical device.

[0032] As used herein, the terms “solid contaminant” or “solid debris” may refer to solid objects such as metal strips, plastic strips, plastic, wood chips, metal flakes, dried adhesives, sand, or other contaminants that are not intended to be present in the pulp produced by the pulping machine and can be distinguished from solid components such as fibers that are intended to be present in a solid suspension.

[0033] As used herein, the term “consistency” refers to the concentration of solid fibers in pulp and is equal to the weight of pulp fibers in the sample volume divided by the total weight of pulp in the sample volume.

[0034] As used herein, the terms “upstream” and “downstream” refer to the position of a component or unit of a system relative to the direction of material flow through the system. For example, if material flowing through the system encounters a first component before encountering a second component, the first component can be considered “upstream” of the second component. If material encounters a second component before encountering the first component, the first component can be considered “downstream” of the second component. For a rope winch, “upstream” and “downstream” are relative to the direction of travel of the rope, tail, or both from the pulper container through the winch and to the cutting station.

[0035] Pulping System

[0036] Now refer to Figure 1 and Figure 2 The diagram schematically depicts a pulping system 10 for producing pulp stock 12 for papermaking. The pulping system 10 typically includes a pulping vessel 20 having a rotor 22 and a rotor motor 24. The rotor 22 can be rotated by the rotor motor 24 and is operable to agitate and mix the pulp stock 12 in the pulping vessel 20. The pulping system 10 may include a washing tank 70 and a waste well 40 fluidly connected to the pulping vessel 20. The waste well 40 is operable to remove any non-filamentous material from the pulp stock 12 that was not previously removed by the rope reel 100. The pulping system 10 may also include a supply conveyor 50 operable to supply bundles 52 of recycled paper stock, virgin paper stock, or both to the pulping vessel 20. The pulping system 10 may also include an inlet pipe 60 positioned and operable to introduce dilution water into the pulping vessel 20. The pulper container 20 may also include a level controller 42, which includes one or more level sensors 44 operatively coupled to the pulper container 20. The level sensors 44 may be any type of commercially available level sensor operable to determine the level of pulp slurry 12 in the pulper container 20. In an embodiment, the level sensor 44 may be a radar sensor. The level controller 42 may be communicatively coupled to a control valve in the inlet pipe 60 to control the addition of dilution water to the pulper container 20, thereby maintaining a constant level in the pulper container 20.

[0037] The pulper container 20 may also include a portion disposed vertically below the rotor 22 (e.g., in...). Figure 2A perforated extraction plate 26 (in the -Z direction of the coordinate axis) is present. The perforated extraction plate 26 can selectively allow good fibers to pass through while retaining other solid waste or debris in the pulper container 20. The perforated extraction plate 26 may be in fluid communication with an outlet 30 of the pulping system 10. The outlet 30 may be downstream of the perforated extraction plate 26 and operable to deliver acceptable pulp slurry out of the pulping system 10. The pulping system 10 may include a pump 32 located downstream of the outlet 30. The pulping system 10 may include one or more consistency measuring devices 260 operable to measure the consistency (i.e., fiber concentration) of the pulp slurry 12 discharged from the pulper container 20. The pulping system 10 also includes a rope winch 100 operable to remove metal wires or strips, plastic strips or sheets, textiles, and other solid debris from the pulp slurry 12 during the pulping process.

[0038] In the operation of the pulping system 10, recycled paper, such as but not limited to waste paper, cardboard, corrugated containers, or other types of recycled paper products and / or virgin fibers, is continuously supplied to the pulper container 20; these together may be referred to as stock. The pulp stock 12 passes through the perforated extraction plate 26 and is continuously removed from the outlet 30 of the pulping system 10 by the pump 32 at a sufficiently fast rate to limit the retention time of the stock in the pulper container 20 to a short interval sufficient to achieve the desired initial decomposition of the stock to produce the pulp stock 12.

[0039] As previously stated, the recycled paper stock going to pulping system 10 may contain solid debris, such as, but not limited to, metal and plastic strips, metal wires, plastic sheets, textiles, paper products that cannot be broken down into fibers in pulping system 10, sand, gravel, wood chips, and other solid debris. Such solid debris must be removed from the pulp stock 12 during the pulping process.

[0040] Rope winch

[0041] Reference Figure 2 The pulping system 10 includes a winch 100 operable to remove or pull a tail 102 of solid debris from the pulper container 20. The winch 100 may be configured to gradually pull the tail 102 from the pulper container 20 at a pull rate that allows the tail to continue forming within the pulper container 20 without becoming too large. The winch 100 may include a pulling mechanism. The pulling mechanism may include one or more driven rollers, driven belts, or other mechanisms operable to pull the tail 102 from the pulper container 20. Figure 1-13The main roller 110 is depicted and described throughout the written description of the main roller 110. However, it will be understood that the pulling mechanism may include multiple rollers, belts, or other means capable of pulling the tail 102 out of the pulper container 20. The winch 100 also includes a riding roller 120 attached to a riding roller arm 122. The riding roller arm 122 is operable to pivot the riding roller 120 relative to the main roller 110 or other pulling mechanism to change the position of the riding roller 120 relative to the main roller 110, such as by moving the riding roller 120 closer to or further away from the main roller 110. The main roller 110 and the riding roller arm 122 may be coupled to the winch frame 130. The winch 100 may also include a guide arm 140 having a guide roller 142 disposed at an end of the guide arm 140. The winch 100 may include a rope 150 for actuating the winch 100. The rope winch 100 may also include a cutting station 160 located downstream of the main roller 110 and the riding roller 120.

[0042] Now refer to Figure 3 , 4 Figures 5 and 6 schematically depict an embodiment of the rope winch 100 of this disclosure. The main roller 110 may have a plurality of teeth 112 that, as the main roller 110 rotates during operation of the rope winch 100, are operable to grip the tail 102 to pull the tail 102 through the rope winch 100. The teeth 112 may project outwardly from the outer surface of the main roller 100. In an embodiment, the main roller 110 may be cylindrical, such that the outer surface of the main roller 110 may be flat. Referring now to... Figure 6 In an embodiment, the main roller 110 may have an outer surface whose profile tapers toward the central axis of the main roller 110 to form a V-shape when viewed along a longitudinal section (e.g., a section taken along a vertical plane extending from the central axis of the main roller 110 in the + / -Z direction). In other words, the main roller 110 may appear V-shaped when viewed from the front or rear of the winch 100. Figure 6 As shown. Other shapes of the main roller 110 can be envisioned. The V-shape of the main roller 110 can improve the traction between the tail 102 and the main roller 110 during the operation of the rope winch 100, which can reduce the occurrence of slippage between the tail 102 and the main roller 110.

[0043] Refer again Figure 3 , 45. The main roller 110 or other pulling mechanism (e.g., belt, multiple pulling rollers, etc.) may be driven by the pulling mechanism driver 114. The pulling mechanism driver 114 may be operatively coupled to the pulling mechanism, such as the main roller 110, via a drivetrain 116, which may include one or more of a gearbox, torque arm, drive shaft, coupling, journal, bearing, etc. As used herein, the term "drivetrain" may refer to a collection of structures and components that operatively couple a driver to a mechanism, such as coupling the pulling mechanism driver 114 to the main roller 110 to enable the driver to rotate the roller. The pulling mechanism driver 114 may be an electric motor, a hydraulic driver, or other type of driver capable of rotating the main roller 110. For a conventional winch, the pulling mechanism driver 114 may be operable to rotate the main roller 110 at a fixed speed at specified time intervals. The frequency and duration of the time intervals of operation of the pulling mechanism driver 114 may be adjusted to increase or decrease the rate at which the tail 102 is pulled from the pulper container 20.

[0044] Refer again Figure 3-5 The riding roller 120 can be vertically positioned above the main roller 110 (e.g., along...). Figure 4 The riding roller 120 (in the +Z direction of the coordinate axis) can be coupled to the riding roller arm 122. The riding roller 120 is spaced apart from the main roller 110. The riding roller 120 may be generally parallel to the main roller 110, such as having a rotation axis parallel to the rotation axis of the main roller 110. The riding roller 120 may have a plurality of riding roller teeth 121, which are operable to provide traction with the tail 102 when the riding roller 122 engages with the tail 102. The riding roller 120 can be driven, such as operatively coupled to the riding roller driver 126. In some embodiments, the riding roller 120 may be an idle roller that can rotate freely by contact with the tail 102 or by contact with the drive roller. Figure 3 and 5 As shown, in this embodiment, the riding roller 120 may be cylindrical, such that the outer surface of the riding roller 120 is axially ( Figure 5 The coordinate axes (in the + / -Y direction) are flat. In other words, in these embodiments, the outer surface of the riding roller 120 may be parallel to the axis of rotation of the riding roller 120. Now refer to Figure 6 In one embodiment, the riding roller 120 may have an outer surface profiled such that it is not parallel to the axis of rotation of the riding roller 120 along its entire length. In another embodiment, the outer surface of the riding roller 120 may have a profile complementary to that of the main roller 110. In yet another embodiment, the riding roller 120 may be conical, with the outer surface having its maximum diameter at the axial center of the riding roller 120, and the diameter decreasing toward each end of the riding roller 120. Other shapes of the riding roller 120 are conceivable.

[0045] Refer again Figure 3 , 4 5. Riding roller arm 122 is connected to frame 130 at a pivot point that allows riding roller arm 122 to pivot relative to frame 130 and main roller 110. The pivoting of riding roller arm 122 can be operated to move riding roller 120 closer to or further away from main roller 110. Riding roller 120 and main roller 110 form a gap therebetween. During operation of the winch 100, the gap between riding roller 120 and main roller 110 pulls tail 102 and rope 150 out of pulper container 20 during startup.

[0046] The riding roller arm 122 may include a position sensor 128 positioned to measure the position of the riding roller arm 122 relative to the main roller 110. In an embodiment, the position sensor 128 may be positioned to measure the riding roller arm angle θ relative to the frame 130. Figure 4 The riding roller arm angle θ indicates the distance between the outer surface of the riding roller 120 and the outer surface of the main roller 110 (i.e., the dimension between the riding roller 120 and the main roller 110). The position sensor 128 is operable to output an electrical signal indicating the position of the riding roller arm 120, which may be related to the distance between the riding roller 120 and the main roller 110 (i.e., the size of the roll gap). The position sensor 128 may be physically coupled to the riding roller arm 122, the frame 130, or both. The position sensor 128 may be any commercially available position sensor capable of determining the riding roller angle θ of the riding roller arm 122. In an embodiment, the position sensor 128 may be operable to measure the linear distance between a point on the frame 130 and a point on the riding roller arm 122 and generate an electronic signal indicating that distance or the riding roller angle θ calculated based on that distance. Additionally or alternatively, the position sensor 128 may be a rotary encoder coupled to a joint or shaft at which the riding roller arm 122 is pivotally coupled to the frame 130. Other types of sensors operable to measure the position of the riding roller arm 122 relative to the frame 130 may be included.

[0047] The riding roller 120 may include a pressure device 124 operable to pivot the riding roller arm 122 toward the main roller 110 to apply pressure to the tail portion 120 disposed between the riding roller 120 and the main roller 110. The pressure of the riding roller 120 against the tail portion 102 improves the engagement of the tail portion 102 with the teeth 112 of the main roller 110 or other pulling mechanism to assist in pulling the tail portion 102 out of the pulper container 20. In one embodiment, the pressure device 124 may be a hydraulic system including one or more hydraulic cylinders. In another embodiment, the pressure device 124 may be a pneumatic pressure system. Other types of devices for the pressure device 124 are contemplated. The pressure device 124 may include a pressure sensor 125 operable to measure the pressure of the riding roller 120 on the tail portion 102 and output an electronic signal indicating the pressure of the riding roller 120 on the tail portion 102. The pressure sensor 125 can be any commercially available pressure sensor capable of measuring the output pressure of the pressure device 124 or the pressure of the riding roller 120 on the main roller 110.

[0048] Now refer to Figure 4 The riding roller 120, riding roller arm 122, or both may include a rotation sensor 129 operable to determine whether the riding roller 120 is rotating relative to the riding roller arm 122. The rotation sensor 129 may be coupled to the riding roller arm 122, riding roller 120, or both. The rotation sensor 129 is operable to generate an output signal indicating whether the riding roller 120 is rotating. In an embodiment, the rotation sensor 129 may be a rotary encoder. The output from the rotation sensor 129 may be combined with the operating state of the main roller 110 to determine whether the tail 102 is slipping in the winch 100. Specifically, tail slippage may be indicated by the main roller 110 being driven to rotate, while the rotation sensor 129 indicates that the riding roller 120 is stationary and not rotating.

[0049] Refer again Figure 3-5 The main roller 110 and the riding roller arm 122 can be connected to the frame 130 in such a way that the main roller 110 can rotate relative to the frame 130 and the riding roller arm 122 can pivot relative to the frame 130. In an embodiment, the frame 130 may include two vertical walls, each disposed on one side of the main roller 110 and the riding roller arm 122. Referring now to 6, in an embodiment, the frame 130 may include a single vertical wall disposed on one side of the main roller 110 and the riding roller arm 122, and the main roller 110 and the riding roller arm 122 can be cantilevered to this single vertical wall.

[0050] Refer again Figure 3 The vertical wall of frame 130 can be connected to a base including upper substrate 132 and lower substrate 134, both of which can be substantially horizontal (e.g., parallel to). Figure 3(The XY planes of each coordinate axis in the diagram). The lower substrate 134 can be mounted to a base plate or support structure adjacent to the pulper container 20. The upper substrate 132 may include a plurality of curved slots 136, which allow the upper substrate 132 to be connected to the lower substrate 134 while being rotatable relative to the lower substrate 134. (Refer to...) Figure 1 In one embodiment, the rope winch 100 may include a base plate actuator 180 operatively coupled to an upper base plate 132, a lower base plate 134, or both. The base plate actuator 180 is operable to pivot the upper base plate 132 relative to the lower base plate 134, thereby causing the orientation of the main roller 110 of the rope winch 100 to rotate relative to the pulper container 20.

[0051] Reference Figure 4 The rope winch 100 may also include a guide arm 140, which includes a guide roller 142. The guide arm 140 may be rigidly connected to the frame 130. See again Figure 2 The guide arm 140 can be horizontally outward from the frame 130 in the direction of the pulper container 20 (e.g., along the direction of the frame 130). Figure 2 The guide roller 142 extends along the +X direction of the coordinate axis, such that at least a portion of the guide roller 142 is directly disposed on a portion of the pulper container 20 (i.e., a vertical line extending downward from a point on the guide roller 142 enters into the pulp stock disposed within the pulper container 20). The guide roller 142 may be an idle roller that rotates freely relative to the guide arm 140. When the tail 102 is pulled by the main roller 110, the guide roller 142 can rotate by contacting the tail 102.

[0052] The rope winch 100 may include a rope 50 for initially forming the tail 102 during startup of the rope winch 100. The rope 50 may be a natural or synthetic rope. Although described herein as having a rope 50, it will be understood that other types of elongated strands may be used, such as barbed wire having a surface that helps to loop and entangle metal and plastic debris in the pulp slurry 12 to initially form the tail 102. The rope 50 may pass between the main roll 110 and the riding roll 120 and may extend downward over the guide roll 142 and into the pulper container 20 during startup.

[0053] Refer again Figure 2 The rope winch 100 may further include a cutting station 160 disposed downstream of the main roller 110 and the riding roller 120. The cutting station 160 may be vertically disposed below the rope winch 100 and on the side of the rope winch 100 away from the pulping container 20. A chute 162 may be positioned between the rope winch 100 and the cutting station 160 to provide a passage for the tail 102 to exit the rope winch 100 and travel downwards from the rope winch 100 to the cutting station 160. The cutting station 160 is operable to periodically cut the tail 102 into multiple pieces.

[0054] Rope winch operation

[0055] Refer again Figure 2 The general operation of the rope winch 100 will now be described. The pulping system 10 operates by adding water and pulp to the pulper container 20. Recycled materials, such as, but not limited to, paper, cardboard, or corrugated boxes, can be bundled 52 as part of the pulp via a feed conveyor 50 to the pulper container 20. Recycled materials may include solid debris, such as, but not limited to, strips or threads of metal and plastic, plastic sheets, textiles, and / or other solid debris. While the pulper container 20 is operating, the rope 150 of the rope winch 100 is immersed in the pulp slurry 12 in the pulper container 20. The rope 150 captures and collects solid debris, such as strips and threads of metal and plastic, plastic sheets, textiles, and other solid debris, which form an attachment to the tail 102 of the rope 150. The rope 150 extends over the guide roller 142 and passes through the roll gap between the main roller 110 and the riding roller 120 of the rope winch 100. The main roller 110 is rotated forward by the puller drive 114 to slowly pull the rope 150 out of the pulper container 20. As the rope 150 is pulled out of the pulper container 20, it also pulls the debris tail 102 out of the pulper container 20. The tail 102 can be self-formed after its end, meaning that the tail 102 itself acts as a piece that collects other solid debris and continues to grow in length. At the end of the rope 150, the main roller 110 and the riding roller 120 engage directly with the tail 102 and continue to slowly pull the tail 102 out of the pulper container 20. When actuated by the pressure device 124, the riding roller 120 applies downward pressure on the tail 102 to provide additional traction between the main roller 110 and the rope 150, and the tail 102, or both.

[0056] The puller drive 114 may operate on a time-based basis as previously described, or it may be a variable-speed drive capable of continuously rotating the main roll 110 to gradually extract the tail 102 from the pulper container 20 at a rate that allows the tail 102 to continue forming in the pulper container 20 as it is extracted. Thus, as the tail 102 is slowly extracted from the pulper container 20, it continues to grow by picking up more solid debris from the pulp stock 12. The thickness, density, and length of the tail 102 may depend on the speed at which the tail 102 is extracted from the pulper container 20, the production rate of the pulping system 10, the ratio of recycled pulp to the total pulp introduced into the pulper container 20, the level of solid debris and contaminants in the recycled pulp, or a combination thereof. The amount and type of solid debris in the recycled pulp may also change over time, which may affect the thickness, density, and length of the tail 102. Specifically, the source of recycled paper may change, leading to variations in the type of straps used to secure the bale 52 and in different types and quantities of other solid debris within the bale 52.

[0057] Tail 102 exits the roll gap between main roller 110 and riding roller 120 and passes down through chute 162 to cut station 160, where tail 102 is periodically cut into pieces for disposal.

[0058] Operating a conventional twisting machine requires a high degree of operator involvement to maintain operational continuity. The operability of the twisting machine largely depends on the properties of the pulp introduced into the pulper container 20, which can change over time. Specifically, the bales 52 of the pulp poured into the pulper container 20 can have varying amounts of debris. Furthermore, the twisting machine may be sensitive to the production rate of the pulping system 10. The production rate can affect the rate of tail 102 growth. The twisting machine may also be sensitive to the fluid level in the pulper container 20 and / or the consistency of the pulp slurry 12 within the pulper container 20. The fluid level and consistency of the pulp slurry 12 can alter flow conditions within the pulper container 20, such as by changing the turbulence of fluid agitation within the pulper container 20, which can alter the forces acting on the portion of the tail 102 submerged in the pulp slurry 12. Additionally, the fluid level and consistency can also affect how much support the pulp slurry 12 provides to the tail 102. A decrease in fluid level and / or consistency can reduce the support for tail 102, which can increase the risk of tail breakage, while an increase in fluid level and / or consistency can increase the support for tail 102. When faced with the challenges of constantly changing stock and operating conditions in the pulping system 10, the rope winch provides inconsistent operation with its fixed speed and time-periodic traction.

[0059] Due to these constantly changing conditions, operators need to check the operation of the conventional rope winch every 10-15 minutes to ensure proper functioning. Skilled operators frequently adjust the pull and wait timers on the winch to maintain the tail size and keep the machine running. Despite these checks, the winch still requires manual intervention from the operator 3-4 times or more per day, each requiring a 1-2 hour or longer downtime in the pulping system to correct the winch and get it back into operation. These manual intervention issues can lead to significant downtime in the pulping system. A control system has not yet been developed to provide adequate control for these conventional rope winches, and their operation remains inherently highly manual.

[0060] Reference Figure 2 One drawback of conventional rope winch operation is that the rope 150 and / or tail 102 may not have sufficient traction with the main roll 110 and may slip when engaged with it. Slippage of the rope 150 and / or tail 102 can result in the rope 150 and / or tail 102 not being pulled when the main roll 110 rotates. This can, in turn, cause the tail 102 to remain in the pulp slurry 12 for an extended period, leading to an increase in its length and / or thickness. To prevent slippage, the riding roll 120 is typically operated under very high pressure to increase the traction between the tail 102 and the main roll 110. However, the increased pressure on the riding roll 120 can deform or collapse the tail 102, significantly increasing friction between the tail 102 and the winch 100. This can cause interference with the tail 102's passage through the winch 100. In some cases, the increased pressure on the riding roller can even cause the tail section 102 to break, leading to pulper shutdown and reduced pulping efficiency.

[0061] Another drawback of conventional pulpers is that the fixed pull rate of the main roll 110 may be inconsistent with the quantity and nature of solid debris and contaminants in the pulper container 20 or with operating conditions of the pulping process, such as the total pulp production rate. Conventional rope winding units typically cannot respond to continuous changes in operating conditions of the pulping process, such as, but not limited to, the pulp production rate, the proportion of recycled paper added to the pulp stock 12, and / or the quantity or nature of solid debris and / or contaminants in the pulper container 20. As a result, the tail 102 may become too large or too small. The tail 102 may become too large (e.g., too thick or too heavy) when it is not pulled fast enough to address the level of solid debris and / or contaminants, or when the pulp stock 12 production rate increases. When the tail 102 becomes large, its size can cause problems through the rope winding machine 100, such as blockages, which can disrupt the operation of the rope winding machine 100 and the pulping process. If the tail section 102 becomes too large and clogs the winch 100, the operator must somehow wind the strip around the tail section 102 (between the winch 100 and the pulper stock level) and use a crane to drag the tail section 102 over the lip of the pulper container 20 and to the operating floor. Once on the floor, the tail section 102 must be cut into manageable blocks and these blocks are moved to the waste bin.

[0062] Furthermore, increasing the size of the tail 102 increases the resistance exerted on the tail 102 by the pulp slurry 12 in the pulper container 20. Specifically, as the diameter of the tail 102 increases, the fluid resistance on the tail 102 in the pulper container 20 also increases, regardless of density. The same applies to the length of the tail 102. As the length of the tail 102 increases, the resistance on the tail 102 caused by the pulp slurry 12 in the pulper container 20 also increases. The resistance on the tail 102 may exert forces on the tail 102, which may increase the risk of tail 102 breakage.

[0063] When the level of debris / contaminants or the pulp production rate decreases and the tail 102 is pulled out too quickly, preventing the thickness of the tail 102 from increasing, the tail 102 may become too thin. When the tail 102 becomes too thin, it will break off and fall back into the pulper container 20.

[0064] Refer again Figure 2A breakage of the tail section 102 is a serious problem for the operation of a conventional rope winch unit and can adversely affect the operational continuity of the pulping system 10. When the tail section 102 breaks, the pulping system 10 must be shut down and the rotor 22 in the pulper container 20 must be stopped to remove energy from the system. The pulper container 120 is kept full of pulp slurry 12 to save time. When the rope winch 100 and the pulping system 10 are shut down, the downstream paper recycling plant can also be shut down. Therefore, a breakage of the tail section 102 could lead to a complete shutdown of the entire paper recycling plant.

[0065] Before the pulping process can be restarted, the broken tail 102 must be removed from the winch 100 and / or pulper container 20. If the tail 102 has broken and fallen back into the pulper container 20, the operator must attach a hook to an overhead crane and "retrieve" the tail 102 from the pulp slurry 12 contained in the pulper container 20. Once captured, the tail 102 must be lifted and dragged over the lip of the pulper container 20 to the operating floor. Once on the floor, the tail 102 must be cut into manageable pieces and these pieces are moved to the waste bin. Typically, any portion of the tail 102 left in the winch 100 may be too short to restart, so the operator must install a new starting rope 150 through the winch 100 and into the pulper container 20. The rope 150 is heavy and difficult to handle. The initial formation of the tail 102 is the most difficult and labor-intensive part of operating the winch 100. Therefore, reducing the number of times the rope winch 100 must be started can greatly improve the uptime and labor utilization of the pulping system 10.

[0066] Manual interaction and operation of the tail section 102 is a practice to be avoided. The tail section 102 is typically made of metal wire mixed with plastic, textiles, sand, grit, etc., and is uneven and difficult to handle. From an efficiency standpoint, the fewer requirements placed on the operator maintaining the rope winch 100, the better.

[0067] Rope winch system

[0068] The rope winch 100 and rope winch system of this disclosure solve these problems associated with the operation of conventional rope winch machines. Specifically, the rope winch 100 of this disclosure can reduce slippage of the tail 102 relative to the main roller 110 by modifying the rope winch 100 to include a riding roller driver 126 operatively coupled to the riding roller 120, increasing the size of the riding roller teeth 121 on the riding roller 120, and installing a VSD for the traction machine driver 114. Furthermore, this disclosure includes a rope winch system comprising the rope winch 100, one or more measuring devices / sensors, and a control system, wherein the rope winch system is operable to adjust the operating parameters of the rope winch 100 in response to one or more characteristics of the tail 102 or the operating conditions of the pulping system 10. Specifically, the rope winch system of this disclosure is operable to measure one or more input variables indicating the weight, size, thickness, length, density, position, and / or metal content of the tail 102, and adjust the operation of the rope winch 100 based on the measured input variables. The rope winch system disclosed herein can also be operated to adjust the operation of the rope winch 100 in response to one or more operating conditions of the pulping system 10, such as, but not limited to, the throughput of pulp 12, the proportion of recycled paper added to the pulper container 20, the level of solid debris or contaminants in the recycled paper, the fluid level and / or consistency of the pulp 12 in the pulper container 20, the temperature of the pulp 12, or other operating parameters of the pulping system 10. Adjusting the operation of the rope winch 100 in response to the characteristics of the tail 102 and / or the operating parameters of the pulping system 10, such as, but not limited to, the pull-out rate (e.g., traction rate) of the tail 102, the rotation direction of the main roll 110, the rotational position of the rope winch 100 relative to the pulper container 20, the pressure of the riding roll 120, the torque of the riding roll 120, or combinations thereof, can reduce or prevent breakage of the tail 102 during the start-up and operation of the rope winch 100. Reducing or preventing breakage of the tail section 102 can improve the uptime and efficiency of the pulping process.

[0069] Refer again Figure 3-5 As previously described, the winch 100 of this disclosure may include a riding roller driver 126 operatively coupled to the riding roller 120, larger riding roller teeth 121 on the riding roller 120, and / or a VSD for the traction machine driver 114. These modifications to the winch 100 of this disclosure reduce slippage of the tail 102 in the winch 100 without increasing the pressure of the pressure device 124 to the point of significantly deforming or crushing the tail 102. Therefore, the winch 100 can operate at reduced pressure compared to conventional winch machines. The reduced pressure reduces friction between the tail 102 and the main roller 110 and the riding roller 120, allowing the tail 102 to pass more easily through the roll gap between the main roller 110 and the riding roller 120.

[0070] The riding roller 120 may include a riding roller driver 126 operatively coupled to the riding roller 120. The riding roller driver 126 may be a constant speed driver or a variable speed driver. The riding roller driver 126 may be an electric driver, a hydraulic driver, or other type of driver operable to rotate the riding roller 120. The riding roller driver 126 may be operable to rotate the riding roller 120 in a direction of rotation opposite to that of the main roller 110, so as to cooperate with the main roller 110 to pull the tail 102 through the gap therebetween. The riding roller driver 126 is separate from and distinct from the pulling machine driver 114, and may be configured to drive the riding roller 120 independently of the main roller 110. In an embodiment, the riding roller driver 126 may be synchronized with the pulling machine driver 114 such that the speed of the riding roller 120 reflects the speed of the main roller 110. Driving the riding roller 120 with the riding roller driver 126 may increase the tension applied to the tail 102 by the winch 100. In one embodiment, driving the riding roller 120 using the riding roller driver 126 can double the tension applied to the tail 102 by the winch 100. Operating the riding roller driver 126 to rotate the riding roller 120 can reduce or prevent slippage of the tail 102 in the roll gap during operation of the winch 100.

[0071] When the riding roller driver 126 is independent of the traction machine driver 114, the riding roller driver 126 can be used as a controlled variable to control the operation of the winch in response to changing properties of the tail 102 or changing operating conditions of the pulping system 10. In embodiments, the riding roller driver 126 can be operated to increase or decrease the torque on the riding roller 120, the rotational speed of the riding roller 120, or both, in response to changing properties of the tail, changing operating conditions of the winch 100, changing operating conditions of the pulping system 10, or a combination thereof.

[0072] The puller drive 114 can be a variable speed drive (VSD) in the rope winch 100 of this disclosure. When the puller drive 114 is a VSD, it is operable to cause the main roller 110 to rotate continuously, although the main roller can rotate at a slower speed. During operation of the rope winch 100, the VSD can be continuously adjusted to regulate the rotational speed of the main roller 110. When the puller drive 114 is a VSD, the rate at which the tail 102 is pulled from the pulper container 20 can be determined by the speed of the VSD. The puller drive 114 as a VSD can reduce slippage of the tail 102 relative to the main roller 110 during operation of the rope winch 100 by reducing or eliminating the start and stop of the rotation of the main roller 110 associated with the periodic time operation of the rope winch 100. When the main roller 110 transitions from a stopped state to a rotating state using a constant-speed motor for the puller driver 110, the starting and stopping caused by the stepper drive operation of the main roller 110 can lead to slippage of the tail 102. Starting and stopping caused by the operation of the constant-speed driver can also cause tension on the tail 102, which can potentially lead to breakage of the tail 102. Therefore, installing a VSD as the puller driver 114 can also help reduce the occurrence of tail breakage by reducing or eliminating the starting and stopping of the tail 102 pulled from the pulper container 20.

[0073] Rope winch control system

[0074] In addition to adding a riding roller driver 126, increasing the size of the riding roller teeth 121, and installing a VSD as a traction machine driver 114, this disclosure also relates to a rope winch system including a rope winch 100 and a control system, the control system being operable to adjust the operating parameters of the rope winch 100 in response to changes in operating conditions in the pulping system 10 and / or measured properties of the tail 102, which can reduce or prevent downtime of the rope winch 100 and the pulping system 10 due to excessive tail size or tail breakage. Referring now... Figure 7The diagram schematically depicts one embodiment of the rope winch system 200 of this disclosure. The rope winch system 200 may include a rope winch 100, one or more measuring devices (e.g., torque measuring device 210, riding roller torque measuring device 212, position sensor 128, rotation sensor 129, vibration sensor, weighing scale, optical measuring device, camera, capacitance sensor, level sensor, motor speed sensor, ammeter, pressure sensor, consistency sensor, temperature sensor, conveyor speed sensor, etc.), and a control system 202 communicatively coupled to the rope winch 100 and the measuring devices. The rope winch 100 may have any of the features previously discussed for the rope winch 100. The measuring device may include one or more sensors, such as, but not limited to, a position sensor 128 on the riding roller arm 122, a rotation sensor 129 on the riding roller arm 122, a pressure sensor 125 on the pressure device 124, a pressure sensor on the cutter 160, a torque measuring device 210 for the traction mechanism, a riding roller torque measuring device 212, an ammeter for measuring current on various drives and motors, motor speed sensors (e.g., riding roller drive 126, traction drive 114, pulper drive motor, etc.), a weighing scale, a capacitance sensor, a vibration sensor, an optical sensor or a camera, a level sensor on the pulper container 20, a consistency sensor, a speed sensor on the feed conveyor, a flow meter, a temperature sensor, other sensors associated with the pulping system 10 or the winch 100, or combinations of sensors. The control system 202 may be communicatively coupled to any combination of one or more measuring devices.

[0075] The control system 202 may include at least one processor 204, at least one memory module 206 communicatively connected to the processor 204, and machine-readable and executable instructions 208 stored on the memory module 206. When executed by the processor 204, the machine-readable and executable instructions 208 may cause the winch system 100 to automatically perform any of the method steps described herein. The control system 202 may be communicatively connected to the traction machine driver 114, the riding roller driver 126, the pressure device 124, and the base plate actuator 180. Figure 12 (or one or more of these combinations) are communicatively connected to the winch 100.

[0076] Refer again Figure 7The winch system 200 is operable to adjust one or more operating parameters of the winch 100 in response to changing conditions in the pulping system 10 and / or changing properties of the tail 102, such as, but not limited to, the rate at which the tail 102 is drawn from the pulping container 20, the direction of the puller drive 114, the pressure of the pressure device 124 biasing the riding roller 120 against the tail 102, the torque on the riding roller 120, the speed of the riding roller 120, the rotational position of the winch 100 relative to the pulping container 20, or combinations thereof. For a winch 110 having a variable speed drive for the puller drive 114, the rate at which the tail 102 is drawn from the pulping container 20 can be controlled by adjusting the rotational speed of the puller drive 114. For a winch 110 having a fixed speed puller drive 114, the rate at which the tail 102 is drawn can be adjusted by adjusting the switching time of the puller drive 114. Specifically, the winch system 200 can be operated to receive one or more input signals from one or more measuring devices indicating the condition of the pulping system 10, the condition or properties of the tail section 102, or both, and to adjust the speed of the puller drive 114, the opening and closing time of the puller drive 114, the speed of the riding roller drive 126, the pressure of the pressure device 124, the rotation direction of the main roller 110 and / or the riding roller 120, the rotational position of the winch 100 relative to the pulping container 20, or a combination thereof, based on the received input signals. The pressure of the riding roller 120 against the tail section 102 can be adjusted by increasing or decreasing the pressure of the pressure device 124 operatively coupled to the riding roller arm. The torque on the riding roller 120 and / or the speed of the riding roller 120 can be adjusted by changing the operating parameters of the riding roller drive 126, such as by changing the speed of the riding roller drive 126.

[0077] The received input signals can indicate the size of tail 102, the density of tail 102, the weight of tail 102, the length of tail 102, the metal content of tail 102, the position of tail 102, the resistance on tail 102, the production rate of pulping system 10, the proportion of recycled paper introduced into pulping system 10, the level of solid debris in recycled paper, the consistency of pulp 12, the level of pulp 12 in pulper container 20, the temperature of pulp 12, other parameters, or combinations thereof. The properties of tail 102, such as density, thickness, weight, length, and metal content, can be relative to a reference tail and may not be true values ​​of these properties. The reference tail can be an average tail (e.g., tail 102 with average thickness, weight, density, length, and metal content) or an ideal tail, which is a tail with thickness, length, weight, density, and metal content that causes the winch 100 to operate stably at its optimal efficiency without clogging or tail breakage. In some embodiments, the attributes of the tail 102 can be actual values ​​of attributes, such as actual measurements of thickness or thickness profile or actual measurements of length.

[0078] The rope winch system 200 of this disclosure can monitor changes in the conditions of the pulping system 10, changes in the properties of the tail 102, or both, and adjust one or more operating parameters of the rope winch 100 in response to changes in the conditions of the pulping system 10 and / or the tail 102. This automatic control of the rope winch 100 can reduce or prevent downtime caused by the tail 102 growing too large and clogging the winch, or becoming too small and breaking. Therefore, the automatic control of the rope winch 100 by the rope winch system 200 can reduce the attention required by the operator to inspect, operate, and restart the rope winch 100.

[0079] The measuring device may include, but is not limited to, one or more torque measuring devices 210 operable to measure the torque applied by the tail 102 to the traction mechanism (e.g., main roller 110); one or more riding roller torque measuring devices 212 on the riding roller 120 or riding roller driver 126; one or more vibration sensors operable to measure the frequency of the back-and-forth swaying of the tail 102 relative to the winch 100; one or more weighing gauges for measuring the relative weight of the tail 102; one or more motor speed sensors; one or more ammeters; a position sensor 128; a rotation sensor 129; a pressure sensor 125; and one or more optical sensors or cameras operable to measure the tail 102 torque. The dimensions, thickness, length, and / or position of 102; a capacitive sensor for measuring the capacitance of tail 102; a cutter pressure sensor on the hydraulic system of cutter 160; a blade position sensor for cutter 160; a flow meter operable to measure the production rate of pulp from pulping system 10; one or more consistency sensors; one or more level sensors coupled to pulper container 20; one or more temperature sensors in pulper container 20; a conveyor speed sensor operable to measure the rate at which recycled paper is supplied to pulper container 20; a rotor torque sensor operable to measure the torque on the rotor of pulper container 20; other measuring devices; or combinations thereof. Each measuring device and control strategy will be described in more detail herein. For clarity, each type of measuring device and control strategy is discussed separately. However, it should be understood that any measuring device and control strategy can be combined with any other measuring device and control strategy to control winding machine system 200 in response to changes in the operation of pulping system 10. Furthermore, any control strategy disclosed herein can be implemented by the control system using machine-readable and executable instructions stored on the memory module of the control system and executed by the processor of the control system.

[0080] drive torque

[0081] Refer again Figure 7The winch system 200 is operable to measure the torque on the puller drive 114, which indicates the relative size of the tail 102 being pulled by the winch 100 from the pulper container 20. The torque on the puller drive 114 may also include a portion of the resistance exerted by the pulp slurry 12 on the portion of the tail 102 immersed in the pulp slurry 12. A larger torque on the main roll 110 and / or the puller drive 114 may indicate a larger tail 102, which may have a greater relative weight per unit length, a greater total length, greater resistance with the pulp slurry, or a combination thereof. A smaller torque may indicate a tail 102 having a lighter relative weight per unit length, a shorter total length, less resistance with the pulp slurry, or a combination thereof. The pulling rate of the winch 100 may increase with increasing tail 102 size and decrease with decreasing tail 102 size.

[0082] The winch system 200 may include one or more torque measuring devices 210 operable to measure torque on a traction mechanism (e.g., main roller 110, belt, traction roller, or other traction mechanism), a traction drive 114, a drivetrain 116 for the traction mechanism, or a combination thereof. The torque measuring device 210 may include a strain gauge coupled to the drivetrain 116 of the main roller 110, an output from the traction drive 114, an ammeter coupled to the traction drive 114 to measure the current consumed by the traction drive 114, or a combination thereof. Other types of torque measuring devices 210 are conceivable. When the torque measuring device 210 includes a strain gauge, the strain gauge may be coupled anywhere along the drivetrain 116, such as to a journal of the main roller 110, the drive shaft of the main roller 110, the torque arm 115 of the traction drive 114, and / or other points on the drivetrain 116. In this embodiment, the torque measuring device 210 can be coupled to the main roller 110 or the drive shaft of the main roller 110 to directly measure the torque. Coupling the torque measuring device 210 to the main roller 110 or the drive shaft of the main roller 110 can produce higher torque measurement accuracy compared to measuring the torque at the traction machine driver 114, especially for systems with high gear ratios. Without intending to be bound by any particular theory, it is believed that torque measurement at the traction machine driver 114 introduces torque measurement errors due to the complex system of forces transmitted to the motor of the traction machine driver 114 via the transmission system 116 and gearbox.

[0083] If the traction drive 114 is an electric drive, the torque measuring device 210 may further include an ammeter operable to measure the current load on the traction drive 114, combined with a motor speed sensor for measuring the rotational speed of the motor. The speed and ampere readings can be combined to determine the torque on the traction drive 114. As the size of the tail 102 increases, the torque on the main roll 110 may increase due to the greater weight of the tail 102, greater resistance in the portion of the pulp slurry 12 containing the tail 102, or both. This increase in torque results in the traction drive 114 requiring a larger current to maintain the rotation of the main roll 110 at a given rotational speed. Therefore, measuring the rotational speed of the traction drive 114 and the current consumed by the traction drive 114 can indicate the torque on the traction drive 114, which can be correlated with the relative size of the tail 102. In an embodiment, the traction machine driver 114 may also be a hydraulic driver, and the torque measuring device 210 may be a device that is operable to measure one or more operating conditions of the hydraulic driver, such as, but not limited to, hydraulic pressure, speed, etc., to determine the torque.

[0084] Refer again Figure 7 The torque measuring device 210 is communicatively connected to the control system 202. The torque measuring device 210 is operable to measure or determine the torque applied to the main roller 110, the traction machine drive 114, or both, and transmits a torque signal, as an electronic signal indicating the measured torque, to the control system 202. The control system 202 can receive the torque signal from the torque measuring device 210 and adjust the traction rate of the winch 100, the rotation direction of the main roller 110, the pressure of the pressure device 124, the torque or speed of the riding roller drive 120, or a combination thereof, based on the electronic signal representing the measured torque. As previously described, the control system 202 can increase the traction rate of the winch 100 in response to an increase in the torque measured on the main roller 110, which can indicate a larger size and weight of the tail 102 and / or greater resistance on the tail 102. Increasing the traction rate of the winch 100 when the tail 102 is larger can help reduce or prevent the tail 102 from growing too large to pass through the winch 100. Conversely, the control system 202 can reduce the pulling rate of the winch 100 in response to a decrease in the torque applied to the main roller 110. This can be indicated by the smaller size and / or weight of the tail 102, less resistance on the tail 102, or both. A smaller tail 102 may be more prone to breakage. Therefore, the pulling rate of the winch 100 can be reduced to allow the tail 102 to be thickened and reinforced, thereby reducing or preventing the likelihood of tail 102 breakage.

[0085] In response to the decreasing size of the tail 102, the control system 202 can reverse the direction of the winch 100 to push the tail 102 back into the pulp slurry 12, which can result in an increase in the size and / or thickness of the tail 102. The control system 202 can also increase or decrease the pressure of the pressure device 124 in response to a torque signal received from the torque measuring device 210. The control system 202 can also be configured to adjust the torque on the riding roller 120, the speed of the riding roller 120, or both, in response to changes in the tail's properties. When the control system 202 indicates tail thickening or predicts tail thickening from the operating conditions of the pulping system 10, the control system 202 can adjust the riding roller driver 126 to adjust the torque on the riding roller 120. The torque on the riding roller 120 or the speed of the riding roller 120 can increase the tension of the winch 100. Conversely, when the control system 202 identifies or predicts that the tail 102 is thinning based on the operating conditions of the pulping system 10, the control system 202 can reduce the torque or speed of the riding roller 120 to reduce the tension on the tail 102 and thus avoid breakage.

[0086] Variations in torque on the main roll 110 or the traction drive 114 can also be caused by changing processing conditions in the pulper container 20, such as changes in the consistency or level of the pulp slurry 12 or greater turbulence in the pulper container 20. In an embodiment, the control system 202 may combine the torque signal from the torque measuring device 210 with one or more operating conditions from the pulping system 10 (e.g., pulp consistency, recycled paper feed rate, load on the motor 24 coupled to the rotor 22, level in the pulper container 20, production rate of the pulping system 10, etc.) to account for the influence of flow conditions in the pulper container 20 on the measured torque indicated by the torque signal.

[0087] The control system 202 is also operable to receive torque signals from the torque measuring device 210 and identify slippage conditions of the tail 102. As previously described, slippage of the tail 102 refers to a situation where the main roller 110 rotates but the tail does not move through the winch 100. Conversely, the tail 102 slips against the main roller 110 and is not pulled through the winch 100 by the main roller 110. Very low torque measured by the torque measuring device 210 can indicate slippage of the tail 102 in the winch 100. When an electronic signal indicating torque generated by the torque measuring device 210 indicates a very low torque suggesting a potential slippage condition, the control system 202 can generate a slippage alarm signal and output the slippage alarm signal to one or more output devices, such as an operator display or a visual or audible alarm indicator. Additionally or alternatively, in response to an electronic signal indicating very low torque from torque measuring device 210, control system 202 may generate a pressure control signal and send it to pressure device 124, which may cause pressure device 124 to increase the pressure of riding roller 120 against tail 102 to reduce or eliminate slippage. Control system 202 may also adjust the rotational speed of traction machine driver 110, reverse the direction of traction machine driver 110, adjust the torque or speed of riding roller 120, or perform other corrective actions to correct slippage. In an embodiment, control system 202 may be operated to reduce the torque of riding roller 120 by adjusting riding roller driver 126 in response to the identification of slippage. Reducing the torque or speed of riding roller 120 may assist in re-establishing the grip of main roller 110, riding roller 120, or both on tail 102.

[0088] Even a very low torque measured by torque measuring device 210 can indicate a breakage of the tail 102. Control system 202 is operable to determine the tail-breakage condition of the winch 100 based on an electronic signal indicating the torque generated by torque measuring device 210. Control system 202 is further operable to generate a tail-breakage alarm signal, which can be output to one or more output devices, such as an operator display or a visual or audible alarm indicator. Control system 202 may take other actions in response to the tail-breakage alarm signal, such as, but not limited to, stopping the traction machine drive 114 and / or the riding roller drive 126, reducing the pressure of pressure device 124, reducing the torque or speed of riding roller 120, changing one or more operating conditions of the pulping system 10, or other actions.

[0089] Refer again Figure 7In an embodiment, the winch system 200 may further include a riding roller torque measuring device 212 on the riding roller driver 126. The riding roller torque measuring device 212 for the riding roller driver 126 may be any device previously described for the torque measuring device 210 for the main roller 110, such as, but not limited to, any combination of strain gauges, ammeters, motor speed sensors, or other torque measuring devices. The riding roller torque measuring device 212 for the riding roller 120 or the riding roller driver 126 may be configured to measure the torque on the riding roller 120 or the riding roller driver 126 and generate a riding roller torque signal indicating the torque on the riding roller 120 or the riding roller driver 126. The riding roller torque measuring device 210 for the riding roller 120 may be communicatively coupled to the control system 202 to transmit the riding roller torque signal to the control system 202.

[0090] Measuring the torque on the riding roller drive 126 can be used to determine the slippage condition of the tail 102. A very low torque on the riding roller drive 126, measured by the riding roller torque measuring device 212, can indicate slippage at the tail 102 in the winch 100. When the riding roller torque signal indicates a very low torque suggesting a potential slippage condition, the control system 202 can generate a slippage alarm signal and output the slippage alarm signal to one or more output devices, such as an operator display or a visual or audible alarm indicator. Additionally or alternatively, in response to a riding roller torque signal indicating a very low torque from the riding roller torque measuring device 212, the control system 202 can generate a pressure control signal and send it to the pressure device 124, which can cause the pressure device 124 to increase the pressure of the riding roller 120 against the tail 102 to reduce or eliminate the slippage condition.

[0091] Additionally or alternatively, in response to a very low torque on the riding roller 120 indicating slippage, the control system 202 may be configured to adjust the torque applied to the riding roller 120 by the riding roller driver 126, such as by changing the speed of the riding roller driver 126. In an embodiment, when the riding roller torque measuring device 212 indicates slippage, the control system 202 may control the riding roller driver 126 to reduce the torque on the riding roller 120, the speed 120 of the riding roller, or both. Reducing the torque or speed of the riding roller 120 may facilitate the restoration of traction on the tail section 102 of the main roller 110, the riding roller 120, or both, to correct the slippage. The control system 202 may also adjust the rotational speed of the traction machine driver 110, reverse the direction of the traction machine driver 110, increase the pressure of the pressure device 124, or perform other corrective actions to correct the slippage. In addition, the torque measured on the riding roller 120 can be used to identify the condition of the broken tail, and the control system 202 can generate a broken tail alarm or adjust the operation of the winch 100 as described above.

[0092] Vibration and tail sway

[0093] Now refer to Figure 8 During the operation of the winch 100 pulling the tail 102 of the debris from the pulper container 20, when the tail 102 is pulled by the winch 100, the tail 102 can be laterally (i.e., along) within the pulper container 20. Figure 8 The coordinate axes (in the + / -Y direction) swing back and forth. Figure 8 In the diagram, the back-and-forth oscillation of the tail 102 is indicated by double-headed arrow 222. This lateral back-and-forth oscillation of the tail 102 is likely caused by the agitation force acting on the tail 102 within the pulper container 20 when the tail 102 is being pulled. The back-and-forth oscillation of the tail 102 is characterized by its oscillation frequency and amplitude, both of which depend on the size and / or weight of the tail 102, the production rate of the pulping process 10, the consistency of the pulp 12, the level of the pulp 12 in the pulper container 20, and the level of waste and debris in the pulper container 20. Regarding the size and / or weight of the tail 102, it has been found that larger tails 102 oscillate at a lower frequency compared to lighter tails 102. Regarding the production rate of the pulping system 10, when the pulping system 10 operates at a higher production rate, the pulp 12 in the pulper container 20 can have a greater consistency (i.e., a greater amount of solid fibers) and a greater thickness (i.e., a greater viscosity). At higher production rates, the greater consistency and thickness of the pulp slurry 12 will result in a lower frequency of back-and-forth oscillation of the tail 102. Similarly, at lower production rates, the pulp slurry 12 has a lower consistency and is thinner, which exerts less resistance on the movement of the tail 102, resulting in a higher oscillation frequency of the tail 102. Therefore, the frequency of the back-and-forth oscillation of the tail 102 can be used as an input variable for the control system 202 to control the pull rate, the rotation direction of the main roll 110, the pressure of the pressure device 124, the torque on the riding roll 120, the speed of the riding roll 120, or a combination thereof. The amplitude of the back-and-forth oscillation of the tail 102 can depend on the degree of turbulence in the pulper container 102, which can depend on the fluid level and consistency of the pulp slurry 12 in the pulper container 102. Specifically, when the fluid level in the pulper container 20 decreases, the energy level and turbulence in the pulper container 20 increase.

[0094] The oscillation frequency of tail section 102 can be determined by measuring the vibrations experienced by the pulper system 200 and filtering out background vibrations and other background noises attributable to the pulper container 20 and rotor 22, puller drive 100, riding roller drive 126. (Refer to...) Figure 8In an embodiment, the rope winch system 220 may include one or more vibration sensors 220 coupled to the rope winch 100. The vibration sensors 220 may include, but are not limited to, one or more of the following: piezoelectric accelerometers, strain gauges, capacitive displacement sensors, or other types of vibration sensors. The vibration sensors 220 may be coupled to the guide arm 140, guide roller 142, frame 130, base plate 132, main roller 110, drive system 116 for the main roller 110, riding roller 120, riding roller arm 122, or a combination thereof. In an embodiment, the vibration sensors 220 may be attached to the guide arm 140 and / or guide roller 142.

[0095] Vibration sensor 220 can be used to measure the vibration experienced by the winch 100. Vibration sensor 220 is communicatively coupled to control system 202 and can be used to transmit vibration signals to control system 202, wherein the vibration signal is an electronic signal indicating the vibration experienced by the winch 100. Control system 202 can receive vibration signals from vibration sensor 220, process the vibration signals from vibration sensor 220 to determine the oscillation frequency of adjusting tail 102, and adjust the pull-out rate of tail 102, the rotation direction of main roller 110, the pressure of pressurizing device 124, the torque and / or speed of riding roller 120, the rotational position of winch 100 relative to pulper container 20, or combinations thereof, based on the determination of the oscillation frequency of tail 102. Control system 202 can filter background vibration from the vibration signals received from vibration sensor 220. Control system 202 can increase the pull rate, the pressure of winch 100, the torque and / or speed of riding roller 120, or combinations thereof, in response to a decrease in tail oscillation frequency. Conversely, the control system 202 may reduce the pull rate, the pressure of the winch 100, and the torque and / or speed of the riding roller 120 in response to an increase in the oscillation frequency of the tail 102. The rotation direction of the main roller 110 and the rotational position of the winch 100 relative to the pulper container 20 may also be modified in response to the frequency and / or amplitude of the oscillations (e.g., tail sway) of the tail 102. When adjusting the pull rate of the winch 100, the rotation direction of the main roller 110, the pressure of the pressure device 124, the torque and / or speed of the riding roller 120, or a combination thereof, the adjustment may be based on the operating conditions of the pulping system 10, such as the consistency of the pulp 12, the temperature of the pulp 12, the level in the pulper container 20, the percentage of recycled pulp in the pulp 12, other operating parameters of the pulping system 10, or a combination thereof.

[0096] The oscillation frequency at the tail can also be determined based on electronic signals generated by other measuring devices, such as, but not limited to, information about... Figure 7 The torque measuring device 210 described below, will then be discussed regarding Figure 9 The described weighing scale 230, and subsequently regarding Figure 10The optical measuring device 240 or a combination thereof is described. In embodiments, the winch system 200 may include a torque measuring device 210, such as a strain gauge, coupled to the main roller 110, the traction machine drive 114, or a drivetrain for the main roller 110. The torque measuring device 210 may also be operated to generate a vibration signal (i.e., an electronic signal indicating the vibration measured by the torque measuring device 210) and transmit that vibration signal to the control system. Additionally or alternatively, variations in the output of a weighing gauge 230 disposed between the base plate 132 and the operating base plate or on the journal bearings of the main roller 110 may also be processed by the control system 202 to determine the oscillation frequency of the weighing gauge 230. The oscillation frequency of the tail 102 may also be measured using a position sensor or an optical sensor to measure the physical displacement of the tail 102 caused by the back-and-forth swaying, rather than measuring the vibration caused by the physical swaying of the tail 102. Position sensors, optical sensors, or cameras can also be used to measure the amplitude of tail sway, which can be used to adjust the operation of the rope winch 100 or to adjust the level and / or consistency of the pulp slurry 12 in the pulper container 20.

[0097] Weighing scale and tail size

[0098] Now refer to Figure 9 The winch system 200 may include one or more weighing gauges 230, positioned such that the output from the weighing gauge indicates the force exerted by the tail 102 on the winch 100. The force exerted by the tail 102 on the winch 100 may be measured by the weighing gauge 230 and may indicate the size of the tail 102, the magnitude of the resistance at the tail, or a combination thereof. The relative weight and / or size of the tail 102 may be determined by the weighing gauge 230 and may then be used in a feedback control method to control the pull rate of the winch 100, the rotational direction of the main roller 110, the pressure of the pressure device, the torque and / or speed of the riding roller 120, the rotational position of the winch 100 relative to the pulper container 20, or a combination thereof, to maintain the size and / or weight of the tail 102 within a desired range. Measuring the force applied to the winnowing machine 100 by the tail 102 and adjusting the pull rate, the rotation direction of the main roller 110, the pressure of the riding roller 120, the torque and / or speed of the riding roller 120, the rotational position of the winnowing machine 100 relative to the pulper container 20, or a combination of these, can reduce or prevent the tail 102 from becoming too large (e.g., unable to pass through the winnowing machine 100 or other downstream processes) or too small (e.g., insufficient strength, which may cause the tail 102 to break and fall back into the pulper container 20).

[0099] Weighing gauge 230 can be positioned to measure the downward force applied to the winch 100 by the tail 102, such as that applied to the main roll 110 of the winch 100. The downward force applied to the winch 100 by the tail 102 can be proportional to the weight of the tail 102 and the resistance of the pulp slurry 12 on the tail 102. Therefore, weighing gauge 230 can provide an indication of the relative size and / or weight of the tail 102. Weighing gauge 230 can be any type of commercially available weighing gauge. Weighing gauge 230 can be positioned on the feet of the winch 100 (i.e., between the base plate 132 and the operating base plate), on the support bearings for the main roll 110, on the journals of the main roll 110, or a combination thereof. In an embodiment, weighing gauge 230 can be positioned on the feet of the winch 100, between the lower base plate 134 and the operating base plate of the winch 100. In some embodiments, the weighing scale 230 may be positioned on all the legs of the rope winch 100.

[0100] In other embodiments, the weighing scale 230 may be positioned on a leg of the winch 100 closest to the pulper container 20, and other legs of the winch 100 may be rigidly attached to the operating base plate. In this configuration, the force applied by the tail 102 causes the winch 100 to be vertical (i.e., along) about the cantilever point (e.g., where the winch 100 is rigidly attached to the operating base plate). Figure 9 The winch 100 pivots (in the + / -Z direction of the coordinate axis) to engage with the weighing gauge 230 on the leg closest to the pulper container 20. In an embodiment, the leg of the winch 100 closest to the pulper container 20 is rigidly connected to the operating base plate, while the weighing gauge 230 is positioned below the leg furthest from the pulper container 20. In this case, the force applied by the tail 102 causes the winch 100 to be vertically (i.e., along) the cantilever point at the leg closest to the pulper container 20. Figure 9 The coordinate axis (in the + / -Z direction) pivots to engage the weighing gauge 230 on the foot furthest from the pulper container 20. In an embodiment, the weighing gauge 230 may be coupled to the guide arm 140, the guide roller 142, or both, such that the weighing gauge 230 measures the force applied by the tail 102 to the guide arm 140, the guide roller 142, or both. In an embodiment, the weighing gauge 230 may be disposed between the upper base plate 132 and the lower base plate 134. When the weighing gauge 230 is disposed between the upper base plate 132 and the lower base plate 134, the weighing gauge 230 may be positioned according to any configuration discussed regarding the placement of the weighing gauge 230 under the foot of the winch 100.

[0101] The weighing gauge 230 is communicatively connected to the control system 202. The weighing gauge 230 is operable to measure the force applied by the tail 102 to the base plate 132, main roller 110, guide arm 140, or guide roller 142 of the winch 100. The weighing gauge 230 is operable to transmit a weighing gauge signal to the control system 202, which may be an electronic signal indicating the force applied by the tail 102 on the winch 100. The control system 202 is operable to receive the weighing gauge signal indicating the force applied by the tail 102 and adjust the pulling rate of the winch 100, the rotation direction of the main roller 110, the pressure of the pressure device 124, the rotational position of the winch 100, or a combination thereof, based on the force applied by the tail 102. The control system 202 may include one or more force targets stored in one or more memory modules 204, and is operable to compare a measured force applied by the tail 102 with the force targets, and adjust the pull rate, the rotation direction of the main roller 110, the pressure, the rotation position of the winch 100, or a combination thereof based on the comparison. In an embodiment, the control system 202 is operable to receive one or more force targets input by an operator using an input device and store the one or more force targets in the memory modules. When a received weighing signal increases to indicate an increase in the relative size and / or weight of the tail 102, the control system 202 may respond by increasing the pull rate of the winch 100 to prevent the tail 102 from becoming too large and clogging the winch 100, or to reduce the weight of the tail 102. When a received weighing signal decreases to indicate a decrease in the relative size or weight of the tail 102, the control system 202 may respond by decreasing the pull rate of the winch 100, thereby increasing the size and weight of the tail 102 to reduce or prevent breakage of the tail 102. The control system 202 can also adjust the pressure of the pressure device 124, the torque on the riding roller 120, the speed of the riding roller 120, or a combination thereof in response to the measured weight of the tail 102.

[0102] Riding roller position and tail size

[0103] The dimensions of the tail section 102 can also be determined based on the position of the riding roller 120 relative to the main roller 110, and the dimensions determined thereby can be used to control the pulling rate of the winch 100 to prevent the tail section 102 from being too large or too small. The dimensions of the tail section 102, determined by the position of the riding roller 120 relative to the main roller 110, can also be used to adjust the pressure of the pressure device 124, the torque on the riding roller 120, the speed of the riding roller 120, or a combination thereof. (See again...) Figure 7As previously described, the rope winch 100 may include a position sensor 128 operable to determine the position of the riding roller 120 relative to the main roller 110. The position sensor 128 may be communicatively coupled to the control system 202. In one embodiment, the position sensor 128 may be operable to determine the angle θ (a) of the riding roller arm relative to the frame 130. Figure 4 The angle θ indicates the position of the riding roller 120 relative to the main roller 110. Additionally or alternatively, in embodiments, the riding roller system 200 may include other types of sensors capable of determining the relative position of the riding roller arm 122, such as, but not limited to, rotary encoders, linear encoders, other sensors, or combinations of these sensors. The riding roller arm angle θ may indicate the shortest distance between the outer surface of the riding roller 120 and the outer surface of the main roller 110 (i.e., the size of the roll gap between the riding roller 120 and the main roller 110, which is determined by the thickness of the tail 102 disposed between the main roller 110 and the riding roller 120). The size and / or thickness of the tail 102 can be determined based on the riding roller arm angle θ. The riding roller arm 122 must open to allow a larger tail 102 to pass through the roll gap between the main roller 110 and the riding roller 120. The riding roller arm 122 may also allow the riding roller 120 to pivot closer to the main roller 110 when the tail 102 becomes thinner. As the size and thickness of the tail 102 increase, the riding roller arm angle θ can increase, and as the size of the tail 102 decreases, the riding roller arm angle θ can decrease. Therefore, the riding roller arm angle θ can be used to determine the relative size and / or thickness of the tail 102.

[0104] Position sensor 128 is operable to output a riding roller position signal, which may be an electronic signal indicating the position of riding roller 120 relative to main roller 110. In an embodiment, the riding roller position signal may be an electronic signal indicating the riding roller arm angle θ. The position of riding roller 120 relative to main roller 110, such as, but not limited to, the riding roller arm angle, may be related to the thickness of the tail 102 (i.e., the size of the roll gap) disposed between main roller 110 and riding roller 120. Position sensor 128 may be physically coupled to riding roller arm 122, frame 130, or both. Position sensor 128 may be any commercially available position sensor. Position sensor 128 is operable to transmit the riding roller position signal to control system 202.

[0105] The control system 202 is operable to receive a riding roller position signal and, in response to the riding roller position signal, adjust the pulling rate of the winch 100, the pressure of the pressure device 124, the torque on the riding roller 120, the speed of the riding roller 120, or a combination thereof. In an embodiment, the control system 202 is operable to determine the thickness of the tail 102 based on the riding roller position signal received from the position sensor 128. The control system 202 may be configured to adjust the extraction rate of the tail 102, the rotation direction of the puller drive, the pressure of the pressure device, the torque on the riding roller 120, the speed of the riding roller 120, or a combination thereof, in response to the weight of the tail 102. When the received riding roller position signal increases to indicate an increase in the size or thickness of the tail 102, the control system 202 may respond by increasing the pulling rate of the winch 100, thereby reducing or preventing the tail 102 from becoming larger and clogging the winch 100. When the received riding roller position signal decreases to indicate a decrease in the size or thickness of the tail 102, the control system 202 can respond by reducing the pulling rate of the winch 100 or reversing the rotation direction of the main roller 110 to allow the tail 102 to grow larger, which can make the tail 102 stronger and reduce or prevent tail 102 breakage. The control system 100 can be operable to adjust the pulling rate of the winch 100 to maintain a consistent riding roller arm angle (i.e., maintain a consistent size / thickness of the tail 102).

[0106] Tail density

[0107] In an embodiment, the winch system 200 can determine the density of the tail 102 and adjust the pull-out rate of the tail 102, the rotation direction of the main roller 110, the pressure of the pressure device 124, the torque on the riding roller 120, the speed of the riding roller 120, the rotational position of the winch 100 relative to the pulper container 20, or a combination thereof, based on the density of the tail 102. At a fixed thickness of the tail 102, an increase in the density of the tail 102 can indicate a larger proportion of metal, such as metal strips, in the tail 102 relative to the amount of plastic or other non-metallic debris. The strength of the tail 102 can depend on the proportion of metal to plastic in the tail 102. When the amount of metal is greater, the tail 102 is stronger. When the density of the tail 102 is greater, the tail 102 can be stronger and less likely to break. Therefore, a higher density tail 102 can be narrower and can be pulled by the winch 100 at a greater rate with a lower risk of breakage. Furthermore, a higher density tail 102 can be stronger, which allows for increased pressure from the pressure device 124 and increased torque and / or speed from the riding roller 120 without causing the tail 102 to break. Conversely, a lower density tail 102 can indicate a reduced proportion of metal in the tail 102, suggesting that the tail 102 may be weaker and more prone to breakage. Additionally, a lower density tail 102 can indicate that the tail 102 is too loose and may be more easily pulled apart by the pulling force applied to it by the winch 100. Therefore, the relative density of the tail 102 can be used to control the pulling rate of the winch 100, the pressure from the pressure device 124, the torque on the riding roller 120, the speed of the riding roller 120, or a combination thereof. Density as referred to herein can be relative density, such as a density index or density variation, which conveys an indication of the tail's density relative to an average density rather than an absolute density.

[0108] Refer to the reference again. (As shown...) Figure 7As shown, the density of the tail 102 can be determined or calculated based on the position of the riding roller 120 relative to the main roller 110, such as, but not limited to, the riding roller arm angle θ measured by the position sensor 128 and the pressure applied by the pressure device 124. The measuring device of the winch system 200 may include the position sensor 128. In some embodiments, the measuring device may include a pressure sensor 125 coupled to the pressure device 124. The position sensor 128 and the pressure sensor 125 may be communicatively coupled to the control system 202. The position sensor 128 may have any of the features previously discussed with respect to the position sensor 128 and may be any type of device operable to measure the position of the riding roller arm 122 relative to the frame 130 or the main roller 110. Specifically, the position sensor 128 may be operable to output a riding roller position signal or transmit a riding roller position signal to the control system 202. When present, the pressure sensor 125 may have any of the features previously described herein with respect to the pressure sensor 125. Pressure sensor 125 may be operable to transmit a pressure signal to control system 202, wherein the pressure signal may be an electronic signal indicating the pressure of pressure device 124 operatively coupled to riding roller arm 122. In an embodiment, pressure device 124 may be a pneumatic pressure device and may not include pressure sensor 125. Control system 202 may be operable to send a pressure control signal to pressure device 124, wherein the pressure control signal may be an electronic signal indicating the pressure setting of pressure device.

[0109] The control system 202 is operable to determine the density of the tail 102 by adjusting the pressure of the pressure device 124 and measuring the position of the riding roller 120 relative to the main roller 110 for each pressure of the pressure device 124, such as measuring the riding roller arm angle θ. The control system 202 can transmit a pressure control signal to the pressure device 124, which can cause the pressure device 124 to change the pressure applied to the tail 102 by the riding roller 120. The control system 202 can receive a riding roller position signal from the position sensor 128 under the new setting of the pressure device 124. The control system 202 can then determine the relative density of the tail 102 based on the change in the riding roller arm angle signal in response to the pressure change of the pressure device 124. The relative density of the tail 102 can refer to a value representing the change in tail density compared to a standard density of the tail 102 based on average tail size and tail components.

[0110] Now refer to Figure 11The density of tail 102, the metal content of tail 102, or both, can also be determined based on a hydraulic distribution profile as a function of the blade position during the cutting process by cutter 160 of tail 102 into pieces. Cutter 160 may include a cutter pressure sensor 290 and a blade position sensor 295 coupled to and communicatively coupled to control system 202. In an embodiment, pressure sensor 290 may be coupled to a hydraulic system that powers cutter 160. Cutter pressure sensor 290 may be operable to measure the pressure of the hydraulic system during the cutting process. Cutter 160 may include a guillotine blade, and blade position sensor 295 may be positioned to measure the position of the blade during the cutting process. The higher the density and / or metal content of tail 102, the greater the force required to cut tail 102, and the less tail 102 is compressed before being cut. Therefore, measuring the pressure of cutter 160 and blade position can be used to determine the relative density and / or metal content of tail 102. As described in further detail herein, the relative density can also be determined by measuring the capacitance of the tail 102 using conductivity or ultrasonic methods.

[0111] The control system 202 can be operated to increase or decrease the pulling rate of the winch 100 (i.e., the extraction rate of the tail 102), the rotation direction of the main roller 110, the pressure of the pressure device 124, the torque on the riding roller 120, the speed of the riding roller 120, the rotational position of the winch 100 relative to the pulper container 20, or a combination thereof, based on a determined density of the tail 102. In an embodiment, the control system 202 can be operated to increase the pulling rate of the winch 100 in response to an increase in the determined relative density of the tail 102, and to decrease the pulling rate of the winch 100 in response to a decrease in the determined relative density of the tail 102. Increasing the pulling rate for a larger density tail 102 can reduce or prevent the tail 102 from becoming too large, while decreasing the pulling rate for a smaller density tail 102 can reduce or prevent the tail 102 from breaking due to its weakness.

[0112] Optical sensors

[0113] Now refer to Figure 10The dimensions and / or thickness of the tail 102 can also be directly measured using one or more optical measuring devices 240, such as one or more optical sensors or cameras, positioned to directly measure the dimensions and / or thickness of the tail 102. The optical measuring devices 240 may be attached to the frame 130, guide arm 140, wall of the pulper container 20, or other structures that enable the optical measuring devices 240 to directly measure one or more dimensions of the tail 102. In one embodiment, the optical measuring devices 240 may be suspended above the pulper container 20, a position that allows the optical measuring devices 240 to capture an image of the tail 102 from above as it emerges from the pulp stock 12 in the pulper container 20. In another embodiment, the optical measuring devices 240 may be positioned within the pulper container 20, such that the optical measuring devices 240 can capture an image of the tail 102 as it emerges from the pulp stock in the pulper container 240. The winch system 200 may include one or more optical measuring devices 240. Optical measuring device 240, such as an optical sensor and / or camera, may be communicatively coupled to control system 202 to transmit one or more dimensional signals, image data, or both to control system 202.

[0114] The optical measuring device 240 may be an optical profile sensor, a laser displacement sensor, an optical micrometer, an interferometer, a light detection and ranging device (LIDAR), a camera, other optical sensors capable of measuring the thickness or dimensions of the tail 102, or a combination thereof. In an embodiment, the optical measuring device 240 may include a camera positioned to capture an image of the tail 102. In an embodiment, the winch system 200 may include multiple cameras positioned at different locations and angles to capture images of various aspects of the tail 102. The camera may be positioned above the pulper container 20, the winch 100, or both, or may be positioned within the pulper container 20. When positioned above the pulper container 20, the winch 100, or both, the camera may capture a top view of the tail 102 as it emerges from the pulp stock and is pulled past the winch 100. The image from above may focus on any portion of the tail 102 from the point where it emerges from the pulp stock to the main roll 110. In one embodiment, the camera may be positioned above the pulper container 20 and / or the rope winch 100, at which point the camera may capture images of the tail 102 as it enters the rope winch 100, such as the portion of the tail 102 from the guide arm 140 to the main roller 110 of the rope winch 100.

[0115] In an embodiment, the camera can be positioned within the pulper container 20, close to or just above the pulp level within the container. When positioned at or just above the pulp level, the camera can capture a horizontal or side view image of the tail 102, particularly a side view image of the tail 102 as it emerges from the pulp. Positioning the camera within the pulper container 20 has the added advantage of using the inner surface of the container as a background for capturing the image of the tail 102. The inner surface of the container 20 is generally smoother and more consistent than the top surface of the agitated pulp within the container or the background of the manufacturing facility above the container. Using the inner surface of the container 20 as a background behind the tail 102 improves the contrast in the image of the tail 102 captured by the camera, which can improve the accuracy of various properties of the tail 102, such as, but not limited to, thickness, determined from the captured image. The winch system 200 may additionally include an illumination system to provide sufficient light to capture an image of the tail 102. In an embodiment, the camera may include a translation device (not shown) operable to move the camera in sync with the oscillations of the tail 102. As the tail 102 moves, the camera system can maintain the tail 102 within a specific area of ​​the camera's capture field, which can improve the accuracy of capturing the properties of the tail 102 using the camera.

[0116] The optical measuring device 240 is operable to generate dimensional signals, image data, or both, and transmit them to the control system 202, wherein the dimensional signals may be electronic signals indicating the thickness, length, or other dimensions of the tail 102. The optical measuring device 240 is operable to determine the thickness or other properties of the tail 102 at one or more points between the point where the tail 102 emerges from the pulp slurry 12 and the point where the tail 102 contacts the master roll 110. In an embodiment, the optical measuring device 240 may be positioned to capture an image of the tail 102 or to measure the thickness of the tail 102 at the point where the tail 102 emerges from the pulp slurry 12. Image data may include images captured by a camera and transmitted to the control system 202 for processing. The control system 202 is operable to receive dimensional signals, image data, or both from the optical measuring device 240, and adjust the operation of the winch 100 in response to the received information, such as by adjusting the pull rate of the winch 100, the rotation direction of the main roller 110, the pressure of the pressure device 124, the amount of torque on the riding roller 120, the speed of the riding roller 120, the rotational position of the winch 100 relative to the pulper container 20, or a combination thereof.

[0117] The camera or control system 202 may include image analysis software capable of processing images captured by the camera to produce a thickness profile or length of the tail 102. The thickness profile of the tail 102 may include a profile of the tail thickness along the exposed length of the tail 102. The exposed length of the tail 102 refers to the tail length extending from the point on the tail 102 appearing in the pulp stock 12 to the master roll 110, or any subset of points along the length of the tail 102 between the pulp stock 12 and the master roll 110. One or more cameras may be positioned to capture at least 50%, at least 75%, at least 90%, or even at least 95% of the exposed length of the tail 102. The control system 202 is operable to capture one or more images of the tail 102 with the camera, wherein each captured image shows at least 50%, at least 75%, at least 90%, or even at least 95% of the exposed length of the tail 102. In an embodiment, the winch system 200 may include multiple cameras, and the control system 202 may coordinate the operation of the multiple cameras to produce multiple simultaneously captured images that collectively show at least 50%, at least 75%, at least 90%, or even at least 95% of the exposed length of the tail 102.

[0118] The control system 202 may be configured to process the captured image to generate a thickness profile of the tail 102. The thickness profile of the tail 102 may include the thickness as a function of position along the length of the tail 102. The thickness profile of the tail 102 may include the thickness of the tail at each location along the exposed length of the tail 102. The control system 202 may also be configured to further analyze or process the thickness profile of the exposed length of the tail 102 to determine the rate of change of the thickness of the tail 102 at each location along the exposed length of the tail 102. In an embodiment, the control system 202 may be configured to generate a 3D model of the exposed length of the tail 102 from the captured image.

[0119] In one embodiment, the control system 202 may be configured to determine the total length of the tail 102, wherein the total length of the tail 102 includes the distance from the main roll 110 to the end of the tail 102 that is remote from the winder 100 and immersed in the pulp slurry 12. In another embodiment, the total length of the tail 102 may be determined based on an image of the tail 102 capturing the exposed length of the tail 102 from the main roll 110 to the point where the tail 102 appears in the pulp slurry. The length of the tail 102 may be determined based on the exposed length of the tail 102 and the thickness profile of the tail 102. The total length of the tail 102 may also be determined by analyzing the rate of change of the thickness of the tail 102 as a function of the position along the exposed length of the tail 102.

[0120] The rate of change of the thickness of the tail 102 can be used to determine areas where the thickness of the tail 102 increases or decreases, allowing the operation of the winch 100 to be adjusted accordingly. In an embodiment, the control system 202 can be configured to determine the rate of change of the thickness of the tail 102 at each location along the exposed length of the tail 102 from a thickness profile or directly from a captured image. The control system 202 can then be configured to identify one or more locations along the exposed length of the tail 102 where the magnitude of the rate of change of the thickness of the tail 102 exceeds a thickness change rate threshold. This identification may include comparing the magnitude of the measured rate of change of the thickness of the tail 102 with the thickness change rate threshold. The control system 202 can be configured to identify one or more trends in the thickness of the tail 102 over time, such as a trend of increasing or decreasing tail thickness, based on the rate of change of the thickness of the tail 102 along the exposed length of the tail 102 over time. The control system 202 can be configured to identify a thickening or thinning trend in the tail 102, wherein the thickening or thinning trend is identified as a change in the thickness of the tail 102 along its exposed length exceeding 10%. When a thickness change or trend in the tail 102 is identified, the control system 202 can generate control signals to adjust the extraction rate of the tail 102, the direction of the traction machine driver 114, the pressure of the pressure device 124, the torque on the riding roller 120, the speed of the riding roller 120, or a combination thereof, based on a thickness change rate exceeding a thickness change rate threshold. The direction of adjustment of the control variables can be determined based on the direction of the rate of change, which is either a positive direction indicating thickening of the tail 102 or a negative direction indicating thinning of the tail 102.

[0121] The control system 202 is operable to identify one or more thin or reduced areas of the tail 102 as it emerges from the pulp stock 102, wherein the thin or reduced areas of the tail 102 may represent potential weak points that could lead to tail breakage. A thin or reduced area of ​​the tail 102 is defined as an area where the thickness of the tail 102 is at least 10% less than the average thickness of the tail 102 along its exposed length. In embodiments, the thin or reduced areas of the tail 102 have a thickness at least 15%, at least 20%, or even at least 25% less than the average thickness of the tail 102 along its exposed length. In embodiments, in response to a thin or reduced area of ​​the tail 102, the control system 202 may cause the winch system 200 to reverse the rotation of the main roll 110 to immerse the thin area of ​​the tail 102 back into the pulp stock 12, allowing the tail 102 to grow larger in the thin area. In one embodiment, in response to a thin region of tail 102 and based on the position of the thin region relative to the main roll 110, the control system 202 can cause the winch system 200 to increase the pull-out rate of tail 102 (e.g., increase the rotational speed of the main roll 110) to pull the thin region through the nip before the thin region may cause tail 102 to break. The control system 202 can also adjust the pressure of the pressure device 124 or change the torque and / or speed of the riding roll 120 in response to the identification of a thin or thinned region of tail 102. For weak points, the control system 202 can reduce the pressure of the pressure device 124 or reduce the torque and / or speed of the riding roll 120 to reduce the force acting on tail 102 in the winch 100, thereby reducing the likelihood of tail breakage. In another embodiment, the control system 202 can identify thick or thickened regions of tail 102 emerging from the pulp slurry 12 and can increase the pull-out rate of tail 102 in response to preventing thick regions from growing too large to fit through the winch 100. The control system 202 may also be configured to change the pressure of the pressure device 124 or the torque and / or speed of the riding roller 120 in response to identifying one or more thick or variable thick regions of the tail 102.

[0122] As previously discussed, the control system 202 is operable to generally identify thickening or thinning of the tail 102 based on dimensional signals, image data, or both received from the optical measuring device 240. When the control system 202 identifies a thickening trend in the tail 102, it may increase the pulling rate of the winch 100, which in turn may result in a reduction in the thickness of the tail 102. When the control system 202 identifies a thinning trend in the tail 102, it may decrease the pulling rate of the winch to allow for the growth of the thickness and weight of the tail 102. In an embodiment, the control system 202 may include feedback control operable to maintain the thickness of the tail 102 within a specified range based on dimensional signals, image data, or both received from the optical measuring device 240.

[0123] In an embodiment, the control system 202 is operable to identify one or more locations of sudden thickness expansion along the tail 102 and adjust the operation of the winch 100 to accommodate these locations. The location of sudden thickness expansion of the tail 102 is a position along the tail 102 where the tail 102 is at least 20% thicker relative to other adjacent portions of the tail 102. The sudden change in thickness at the location of the sudden thickness expansion can occur over a length of less than 4 feet, less than 3 feet, or even less than 2 feet of the tail 102, after which the thickness of the tail 102 can return to normal. The location of the sudden thickness expansion is essentially a bump in the tail 102 where the tail 102 suddenly and significantly thickens over a short distance. The location of the sudden thickness expansion may be caused by a knot formed in the tail 102 or some other thickness anomaly. When the location of the sudden thickness expansion reaches the roll gap between the traction mechanism (e.g., main roll 110) and the riding roll 120, the greater thickness of the tail 102 at the location of the sudden thickness expansion may not be suitable for entering the roll gap, which can lead to slippage. The control system 202 may be configured to use an imaging device, such as one or more cameras, to detect the location of a sudden thickness expansion and adjust the operation of the winch 100 to accommodate that location. The control system 202 may reduce the pressure of the pressure device 124, reduce the extraction rate of the tail 102, adjust the torque and / or speed of the riding roller 120, or a combination thereof, to allow the location of the sudden thickness expansion of the tail 102 to pass through the winch 100. In an embodiment, the control system 202 may be configured to capture one or more images of the tail; identify one or more locations of sudden thickness expansion of the tail from the captured images; and adjust the extraction rate of the tail, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on the identification of the location of the sudden thickness expansion from the one or more images.

[0124] Reference Figure 10 The optical measuring device 240 can be positioned to capture an image of the tail 102 in the pulper container 20, from which the position of the tail 102 relative to the winch 100 can be determined. The control system 202 can process the image data received from the optical measuring device 240 to determine the position of the tail 102 in the pulper container 20 relative to the winch 100. (See reference...) Figure 12 In response to the position of the tail 102 relative to the winch 100, the control system 202 can adjust the rotational position of the winch 100 relative to the pulper container 20 to better align the position of the winch 100 with the tail 102. Figure 12The double-headed arrow 182 indicates the rotation of the rope winch 100 relative to the pulper container 20. The control system 202 can send a control signal to the base plate actuator 180, which causes the base plate actuator 180 to rotate the upper base plate 132 of the rope winch 100 to reposition the rope winch 100 in response to the position of the tail 102.

[0125] Additionally or alternatively, in embodiments, the winch system 200 may include a detection or imaging system based on electromagnetic waves other than those in the visible or near-visible spectrum. During operation, the pulping system 10 may generate mist or vapor above the pulper container 20, especially when the pulping system 10 operates at higher temperatures. This mist or vapor may interfere with the operation of the optical measuring device. To overcome these limitations, as an addition to or alternative to the optical measuring device 240, devices based on other types of electromagnetic waves, such as radio waves, may be used. In embodiments, the winch system 200 may include a radar measuring system operable to determine the size, shape, and / or position of the tail 102. In embodiments, the optical measuring device 240 may include one or more thermal imaging cameras operable to capture thermal images of the tail 102.

[0126] In one embodiment, a camera and image analysis software can be used to monitor the position of a reference point across the width of the tail 102 and correlate the oscillations of the reference point's position across the width of the tail 102 with other input variables such as the properties of the tail 102 or the operating conditions of the winch 100 or the pulper container 20. (See again...) Figure 10 The reference point P can be any quantifiable point on the width W of the tail 102. For example... Figure 10 As shown, the width W of the tail 102 is measured along... Figure 10 The distance across the tail in the + / -Y direction of the coordinate axis. In an embodiment, reference point P can be the center point of the measurement of the width W of the tail 102. In an embodiment, reference point P can be either endpoint P1 or P2 of the measurement of the width W of the tail 102. Reference point P can be any other point between points P1 and P2 on the width W. (Refer to...) Figure 12 The control system 202 can use a camera to capture multiple images of the tail 102 and determine the width of the tail 102 and the position of a reference point for the width measurement of the tail 102 for each of the multiple images, to generate a dataset including the position of the reference point for the width measurement of the tail 102 as a function of time. This dataset of the positions of the reference points of the tail 102 as a function of time can indicate the back-and-forth oscillation of the tail 102 during the operation of the winch 100.

[0127] The control system 202 can be operated to collect a dataset and store it in a memory module of the control system 202, the dataset including the position of a reference point of the tail 102 as a function of time. The control system 202 can also be configured to process the dataset or a portion thereof including the position of the reference point of the tail 102 as a function of time, using a Fast Fourier Transform (FFT) algorithm to determine the oscillation frequency and amplitude of the tail 102 during operation of the winch 100. The oscillation frequency and amplitude of tail 102, obtained through FFT analysis of the position of the reference point of tail 102 as a function of time, can be correlated with other system variables, such as the properties of tail 102 (e.g., width, length, metal content, density, weight, etc.), the operating conditions of the winch 100 (e.g., the pull-out rate of tail 102, the rotation direction of the main roller 110, the pressure of the pressure device, the torque on the traction machine driver 114, the torque or speed of the riding roller 120, the position of the riding roller 120 relative to the main roller 110, or other operating conditions of the winch 100), the operating conditions of the pulper container 20 (e.g., production rate, level, pulp consistency, pulp temperature, feed conveyor speed, rotor motor torque, etc.), or combinations thereof. The control system 202 can store these correlations in a memory module. The correlation between the frequency and amplitude of the oscillations at the position of the reference point of tail 102 and the properties of tail 102 or the operating conditions of the winch 100 or pulper container 20 can be periodically updated based on further data collection.

[0128] In one embodiment, the control system 202 may be configured to perform an FFT analysis on all or a portion of a dataset including the position of a reference point of the tail 102 as a function of time, to determine the frequency and amplitude generated by the oscillations of the tail 102. The control system 202 may then be configured to determine one or more properties of the tail 102, one or more operating conditions of the winch 100, one or more operating conditions of the pulper container 20, or a combination thereof, based on the frequency and amplitude data generated from the FFT analysis. These determined input variables can then be used to adjust the operation of the winch 100, such as by adjusting the pull-out rate of the tail 102, the rotational direction of the main roller 110, the pressure of the pressure device 124, the torque on the riding roller 120, the speed of the riding roller 120, the rotational position of the winch 100 relative to the pulper container 20, or a combination thereof. The control system 202 may be configured to perform an FFT analysis on a dataset (or a portion thereof) including the position of a reference point of the tail 102 as a function of time, at time intervals of approximately 1 second to approximately 1 minute.

[0129] Capacitor and metal content at the tail

[0130] Furthermore, in the embodiments, the relative metal content of the tail 102 can be measured and used to determine the relative strength of the tail 102. The metal content of the tail 102 can be directly related to the strength of the tail 102. As previously discussed regarding the density of the tail 102, the greater the amount of metal, such as metal wire or metal strip, in the tail 102, the greater the strength of the tail 102. Therefore, a tail 102 with a higher metal content can be pulled by the winch 100 at a greater pulling rate compared to a tail 102 with a lower metal content without concern about breakage. Furthermore, a higher metal content in the tail 102 compared to a tail 102 with a lower metal content can allow the tail 102 to have a smaller overall size or thickness without breaking. In an embodiment, if the metal content of the tail 102 at the thin point is sufficiently high to maintain the pulling rate without causing the tail 102 to break, then determining the metal content of the tail 102 allows the winch 100 to maintain the pulling rate, pressure, torque, and / or speed of the riding roller 120 even when a thin section of the tail 102 is identified. Therefore, the relative metal content of the tail 102 can be measured, and the pulling rate of the winch 100, the pressure of the pressure device 124, the torque and / or speed of the riding roller 120, or a combination thereof, can be adjusted in response to increasing or decreasing the metal content in the tail 102.

[0131] The relative metal content of the tail section 102 can be measured by measuring the capacitance of the tail section 102. Now refer to Figure 10 The winch system 200 may include a capacitance sensor 250, which is physically coupled to the winch 100 and communicatively coupled to the control system 202. The capacitance sensor 250 may be an electrical sensor, an ultrasonic sensor, or other type of sensor capable of determining the capacitance of the tail 102. The capacitance sensor 250 may be any type of commercially available sensor capable of determining the capacitance of the tail 102. The capacitance sensor 250 may be coupled to the winch 100 at any location convenient for measuring the capacitance of the tail 102. In an embodiment, the capacitance sensor 250 may be coupled to the guide arm 140, the guide roller 142, or both. In an embodiment, the capacitance sensor 250 may be coupled to the frame 130. In an embodiment, the capacitance sensor 250 may be coupled to the main roller 110, the riding roller 120, or both.

[0132] The capacitance sensor 250 is operable to generate a capacitance signal and transmit it to the control system 202. The capacitance signal indicates the capacitance of the tail 102, which may be related to the metal content of the tail 102. The control system 202 is operable to receive the capacitance signal and adjust the operation of the winch 100 in response to the capacitance signal. When the capacitance signal indicates an increase in the metal content of the tail 102, the control system 202 is operable to increase the pulling rate of the winch 100 because the increased metal content provides increased strength to the tail 102. Conversely, when the capacitance signal indicates a decrease in the metal content of the tail 102, the control system 202 is operable to decrease the pulling rate of the winch 100 to reduce or prevent the tail 102 from weakening and breaking due to the decreased metal content.

[0133] Capacitance measurements can be combined with dimensional measurements of the tail 102 to fine-tune the control of the winch 100. In an embodiment, in response to dimensional measurements indicating a thinning of the tail 102 and capacitance measurements indicating an increase in the metal content of the tail 102, the control system 202 can maintain or increase the pulling rate of the winch 100. This is because, although the tail 102 is thinner, the increased metal content makes the tail 102 stronger and thus able to withstand the force of the current pulling rate or an increased pulling rate. Similarly, in an embodiment, in response to dimensional measurements indicating a thickening of the tail 102 and capacitance measurements indicating a decrease in the metal content of the tail 102, the control system 202 can maintain or decrease the pulling rate of the winch 100 to reduce or prevent breakage of the tail 102.

[0134] Integration of pulping system operation status

[0135] Now refer to Figure 11 and 12The rope-winding system 200 can also incorporate input variables related to the operating conditions of the pulping system 10, such as the production rate of the pulping system 10 determined by the speed of the supply conveyor 50, the proportion or amount of recycled paper stock introduced into the pulper container 20, the fluid level in the pulper container 20, the consistency of the pulp slurry 12 in the pulper container 20, the temperature of the pulp slurry 12 in the pulper container, or a combination thereof. The level, consistency, and temperature of the pulp slurry 12 in the pulper container 20 can all affect the turbulence and energy in the pulper container 20, which can influence the formation, growth, and movement of the tail 102 in the pulper container 20. Furthermore, the level, consistency, and temperature of the pulp slurry 12 in the pulper container 20 can each affect the magnitude of the resistance exerted by the pulp slurry 12 on the submerged portion of the tail 102. As previously discussed, increasing the resistance of the pulp slurry 12 on the tail 102 may increase the risk of the tail 102 breaking. Furthermore, the increased resistance may also affect the measured operating parameters of the rope winch 100, such as, but not limited to, the torque on the traction drive 114, vibration, etc. The operation of the rope winch 100 may depend on the level of solid debris in the pulper container 20. The level of solid debris in the pulper container 20 may be a function of the proportion of recycled paper stock introduced into the pulper container 20, the production rate of the pulping system 10, or both.

[0136] Most pulping systems 10 operate with a constant fluid level in the pulper container 20. As a result, the solids concentration in the pulper container 20, such as the concentration of solid fibers in the pulp, is typically increased to improve the production rate. The higher the concentration of solid fibers, solid debris, and contaminants, the greater the power required by the motor driving the rotor 22 of the pulper container 20. The concentration of solid fibers in the pulp stock 12 can also be measured by one or more consistency sensors located at or downstream of the outlet 30 of the pulping system 10. Furthermore, to achieve a greater production rate, the rate at which the stock is added to the pulper container 20 must also be increased. Therefore, the speed at which the feed conveyor 50 transports bundles of recycled paper stock to the pulper container 20 also indicates the production rate of the pulping system 10. In other words, a greater production rate means a greater speed of the feed conveyor 50. Thus, the combined conveyor speed, pulp stock consistency, and power of the motor driving the rotor 22, each individually or in combination, can provide an indication of the production rate of the pulper system 10 and can be used to control the operation of the winnowing machine 100.

[0137] Generally, as the production rate of the pulping system 10 increases, the amount of solid debris in the pulping container increases, which may lead to an increase in the size, weight, thickness, density, metal content, or a combination thereof of the tail 102. Therefore, to increase the production rate, the pulling rate of the winch 100 can be increased to reduce or prevent the tail 102 from growing too large and clogging the winch. The pressure of the pressure device 124, the torque on the riding roller 120, the speed of the riding roller 120, or a combination thereof can also be adjusted to address the greater likelihood of tail 102 slippage caused by the added weight and pulling rate. Conversely, as the production rate of the pulping system 10 decreases, the amount of solid debris in the pulping container decreases, which may lead to a decrease in the size, weight, metal content, thickness, density, or a combination thereof of the tail 102. Therefore, to reduce the production rate, the pulling rate of the winch 100 can be reduced or the rotation direction of the main roller 110 can be reversed to reduce or prevent the tail 102 from weakening to the point that it breaks off and falls back into the pulping container 20. To increase or decrease the resistance on the tail 102, further consideration can be given to adjusting the pull rate, the rotation direction of the main roll 110, the pressure of the pressure device 124, the torque and / or speed of the riding roll 120, or a combination thereof. This can be achieved by changing the thickness or length of the tail 102, the liquid level in the pulper container 20, the consistency of the pulp 12, the temperature of the pulp 12, or a combination thereof.

[0138] Refer again Figure 12 and 13 As shown, the control system 202 is communicatively coupled to one or more consistency sensors 260 positioned at the outlet 30 of the pulping system 10. The consistency sensors 260 may be located upstream or downstream of the outlet 30 of the pulping system 10. The consistency sensors 260 may be any commercially available sensor capable of measuring the consistency (e.g., fiber concentration) of the pulp 12. The consistency sensors 260 may be used to measure the consistency of the pulp 12 discharged from the pulping system 10 and generate a consistency signal that is transmitted to the control system 202. The consistency signal may be an electronic signal indicating the consistency of the pulp 12, which may also indicate the production rate of the pulping system 10.

[0139] The control system 202 can be communicatively coupled to a feed conveyor speed sensor 270 positioned on the feed conveyor 50. In an embodiment, the pulping system 10 may have multiple feed conveyors 50, each feed conveyor including a feed conveyor speed sensor 270, and the control system 202 can be communicatively coupled to each feed conveyor speed sensor 270. Each feed conveyor speed sensor 270 can be any commercially available sensor capable of measuring conveyor speed. Each feed conveyor speed sensor 270 can be operable to measure the speed of the feed conveyor 50 to which it is coupled and generate a conveyor speed signal and transmit it to the control system 202. The conveyor speed signal can be an electronic signal indicating the feed conveyor speed, which can indicate the production rate of the pulping system 10. The feed conveyor speed can also indicate the ratio of recycled paper stock to virgin paper stock in the pulping system 10.

[0140] Now refer to Figure 13 In one embodiment, the control system 202 may be communicatively coupled to the rotor motor 24, which is operatively coupled to the rotor 22 of the pulping vessel 20. Alternatively or additionally, in another embodiment, the control system 202 may be communicatively coupled to one or more motor sensors 280, which are coupled to the motor 24. The motor sensors 280 may include, but are not limited to, ammeters, motor speed sensors, strain gauges, or combinations thereof. The motor 24 or the motor sensors 280 may be operable to generate a power signal and transmit it to the control system 202. The power signal may be an electronic signal indicating the power consumed by the motor 24 driving the rotor 22, which may indicate the production rate of the pulping system 10. The motor sensors 280 may also measure torque, current, and motor speed, all of which may be used individually or in any combination to determine the operating state of the motor 24.

[0141] Refer again Figure 13 The control system 202 can also be communicatively connected to a level controller 42 of the pulper container 20. The level controller 42 is operable to determine the fluid level in the pulper container 20 and transmit a level signal to the control system 202. The control system 202 can be operable to receive the level signal from the level controller 42 and adjust the operation of the winch 100 based at least in part on the level signal received from the level controller 42. In an embodiment, the pulper container 20 may also include one or more temperature sensors 80. The temperature sensors 80 may be located in the pulper container 20 or at the outlet of the pulper container 20 to measure the temperature of the pulp slurry 12. The temperature sensors 80 are communicatively connected to the control system 202 to transmit temperature signals to the control system 202.

[0142] The control system 202 can receive consistency signals, conveyor speed signals, power signals, liquid level signals, temperature signals, or combinations thereof, and responsively adjust the operation of the winch 100, such as by adjusting the pull rate of the winch 100, the rotation direction of the main roller 110, the pressure of the pressure device 124, the torque of the riding roller 120, the rotational position of the winch 100 relative to the pulping container 20, or one or more combinations thereof. When the consistency signal, speed signal, power signal, liquid level signal, temperature signal, or combination thereof indicates an operating condition of the pulping system 10 that may result in a larger size, weight, density, or metal content of the tail 102, the control system 202 can operate to increase the pull rate of the winch 100, which may reduce or prevent the tail 102 from growing too large and clogging the winch 100. If a consistency signal, speed signal, power signal, level signal, temperature signal, or a combination thereof indicates a decrease in the production rate of the pulping system 10, the control system 202 may operate to reduce the pulling rate of the winch 100 or reverse the rotation direction of the main roll 110, both of which can allow the tail 102 to grow larger to reduce or prevent tail 102 breakage. In embodiments, the control system 202 may use the level in the pulper container 20, pulp consistency, pulp temperature 12, feed conveyor speed, torque on rotor 22, production rate, the ratio of recycled pulp in the pulp, or other operating conditions of the pulping system 100 to adjust the measured operating parameters of the winch 100, such as torque on the puller drive 114, vibration, or other operating parameters.

[0143] Although described separately, any operating condition of the pulping system 10 and the weight, thickness, dimensions, metal content, or density of the tail 102 can be combined to control the operation of the winch 100. Various combinations of these input variables are considered to develop control schemes for the winch system 200.

[0144] Controlled variables

[0145] The control system 202 can adjust the pulling rate of the winch 100, the rotational direction of the main roller 110, the pressure of the pressure device 124, the torque of the riding roller 120, the rotational positioning of the winch 100 relative to the pulper container 20, or a combination thereof, in response to one or more input variables measured by one or more measuring devices described herein and transmitted to the control system 202. As previously described, the control system 202 can be communicatively coupled to the winch driver 114, the pressure device 124, the riding roller driver 126, the substrate actuator 180, or a combination thereof. To adjust the pulling rate of the winch 100, the control system 202 can transmit control signals to one or more of the winch driver 114, the pressure device 124, the riding roller driver 126, or a combination thereof. In an embodiment, the control system 202 can transmit a main roller speed control signal to the winch driver 114, wherein the main roller speed control signal indicates the speed of the main roller 110. The traction machine driver 114 can change the rotational rate of the main roller 110 based on a main roller speed control signal received from the control system 202. In an embodiment, the control system 202 can transmit a riding roller torque control signal to the riding roller driver 126, wherein the riding roller torque control signal indicates the torque setting of the riding roller driver 126. The riding roller driver 126 can change the torque on the riding roller 110, the speed of the riding roller 110, or both, based on the riding roller torque control signal received from the control system 202. In an embodiment, the control system 202 can transmit a riding roller speed control signal to the riding roller driver 126, wherein the riding roller speed control signal indicates the speed of the riding roller 120. The riding roller driver 126 can change the rotational rate of the riding roller 110 based on the riding roller speed control signal received from the control system 202. In an embodiment, the control system 202 can transmit a pressure control signal to the pressure device 124, wherein the pressure control signal indicates the pressure of the riding roller 120 against the tail 102. The pressure device 124 can change the pressure of the riding roller 120 against the tail 102 based on a pressure control signal received from the control system 202. In an embodiment, the control system 202 can transmit a position signal to the base plate actuator 180, wherein the position signal indicates the desired rotational position of the winch 100 relative to the pulper container 20. The base plate actuator 180 can rotate the upper base plate 132 of the winch 100 based on the position signal received from the control system 202 to rotatably position the winch 100 relative to the pulper container 20. Input variables and controlled variables can be used in various control schemes, such as feedback control, cascaded feedback control, feedforward control, or other types of control algorithms, to adjust one or more controlled variables based on one or more input variables.

[0146] Embodiments of this disclosure can be embodied in hardware and / or software (including firmware, resident software, microcode, etc.). The control system 202 of the winch system 200 may include at least one processor 204 and a computer-readable storage medium (i.e., memory module 206), as previously described in this specification. The control system 202 may be communicatively coupled to one or more system components (e.g., traction machine driver 114, riding roller driver 126, pressure device 125, pressure sensor 125, position sensor 128, rotation sensor 129, torque measuring device 210, riding roller torque measuring device 212, vibration sensor 220, weighing scale 230, optical measuring device 240, capacitance sensor 250, pulper consistency sensor, rotor torque measuring device, feed conveyor speed sensor, temperature sensor, level sensor, or other components). The computer-usable or computer-readable storage medium or one or more memory modules 206 may be any medium that can contain, store, communicate, propagate, or transmit programs for use by or in conjunction with an instruction execution system, apparatus, or device.

[0147] Computer-usable or computer-readable storage medium or memory module 206 can be, but is not limited to, electronic, magnetic, optical, electromagnetic, infrared, or semiconductor systems, devices, apparatuses, or propagation media. More specific examples (not an exhaustive list) of computer-readable storage medium or memory module 206 will include, but are not limited to, the following: electrical connections having one or more wires, portable computer floppy disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), fiber optics, and portable optical disc read-only memory (CD-ROM). Note that computer-usable or computer-readable storage medium can even be paper or another suitable medium on which programs are printed, as programs can be electronically captured via optical scanning of, for example, paper or other media, and then compiled, interpreted, or processed in a suitable manner if necessary, and then stored in computer memory.

[0148] Computer-readable storage medium or memory module 206 may include machine-readable and executable instructions 208 for performing the operations of this disclosure. The machine-readable and executable instructions 208 may include computer program code that can be written in a high-level programming language such as, but not limited to, C or C++, to facilitate development. Furthermore, the computer program code for performing the operations of this disclosure may also be written in other programming languages, such as, but not limited to, interpreted languages. It is not intended to limit the scope of this disclosure to any particular programming language. Some modules or routines may be written in assembly language or even microcode to enhance performance and / or memory usage. However, the software embodiments of this disclosure do not depend on an implementation using a particular programming language. It is also understood that the functionality of any or all program modules may also be implemented using discrete hardware components, one or more application-specific integrated circuits (ASICs), or a programmable digital signal processor or microcontroller.

[0149] The rope winch system 200 disclosed herein can reduce manual intervention for the rope winch 100 and downtime of the pulping system. The rope winch system 200 disclosed herein can increase the total throughput of the pulping system 10 and reduce operator manpower requirements and the variability in rope winch operation caused by operators using different methods to control the rope winch 100. Furthermore, the rope winch system 200 can be used to retrofit existing rope winches 100 to improve the operation of existing rope winch machines. Other features and advantages of the rope winch system 200 disclosed herein will become apparent through practice of this subject matter.

[0150] A first aspect of this disclosure relates to a winch system for removing solid debris from a pulping machine container in a pulping system. The winch system includes a winch operable to pull a tail portion of solid debris from the pulping machine container. The winch includes a pulling mechanism including a pulling drive operatively coupled to the pulling mechanism, operable to engage the tail portion and pull it from the pulping machine container. The winch also includes a riding roller spaced apart from the pulling mechanism, and a pressure device configured to regulate the pressure exerted by the riding roller on the tail portion disposed between the pulling mechanism and the riding roller. The winch system further includes at least one measuring device operable to measure one or more input variables indicating one or more properties of the tail portion, one or more operating conditions of the pulping system, or combinations thereof. The winch system may also include a control system including a processor, a memory module communicatively coupled to the processor, and machine-readable and executable instructions stored on the memory module. The control system is communicatively coupled to at least one measuring device. The control system is communicatively connected to the traction machine drive, pressure device, or a combination thereof. When executed by a processor, machine-readable and executable instructions can cause the winch system to automatically measure one or more input variables using at least one measuring device, wherein the one or more input variables indicate one or more attributes of the tail, one or more operating conditions of the winch, one or more operating conditions of the pulping system, or a combination thereof; and adjust the tail pull-out rate, the direction of the traction machine drive, the pressure of the pressure device, or a combination thereof based on the measured one or more input variables.

[0151] A second aspect of this disclosure relates to a winch system for removing solid debris from a pulping machine container of a pulping system. The winch system includes a winch operable to pull a tail portion of solid debris from the pulping machine container. The winch includes a pulling mechanism including a pulling drive operatively coupled to the pulling mechanism. The winch includes a riding roller including a riding roller drive operatively coupled to the riding roller, wherein the riding roller is spaced apart from the pulling mechanism. The winch includes a pressure device configured to regulate the pressure exerted by the riding roller on a tail portion disposed between the pulling mechanism and the riding roller. The winch system also includes at least one measuring device operable to measure one or more input variables indicating one or more properties of the tail portion, one or more operating conditions of the pulping system, or combinations thereof; and a control system including a processor, a memory module communicatively coupled to the processor, and machine-readable and executable instructions stored on the memory module. The control system is communicatively coupled to at least one measuring device. The control system is communicatively connected to the traction machine drive, auxiliary roller drive, pressure device, or a combination thereof. When executed by the processor, machine-readable and executable instructions cause the winch system to automatically measure one or more operating parameters of the riding roller, riding roller drive, or both using at least one measuring device; and to adjust the tail pull-out rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof based on the measured operating parameters.

[0152] The third aspect of this disclosure may include any one of the first or second aspects, wherein one or more measuring devices may include a riding roller torque measuring device operable to measure torque on the riding roller or riding roller driver, a riding roller ammeter operable to measure current consumption on the riding roller driver, a rotation sensor operable to measure rotational speed of the riding roller, a position sensor operable to measure position of the riding roller relative to the main roller, or a combination thereof.

[0153] The fourth aspect of this disclosure may include any one of the first to third aspects, wherein the puller drive may be a variable speed drive, the puller drive may continuously drive the puller mechanism to advance the tail through the winch during operation of the winch, and may not operate to periodically close and open the puller mechanism to advance the tail, and the rate at which the tail is extracted from the pulper container may be controlled by changing the speed of the puller drive.

[0154] The fifth aspect of this disclosure may include any one of the first to fourth aspects, wherein at least one measuring device may include a torque measuring device coupled to the traction machine mechanism, coupled to the traction machine driver, or coupled to a transmission system that connects the traction machine driver to the traction machine mechanism, and when executed by a processor, machine-readable and executable instructions enable the traction machine system to automatically: measure the torque on the traction machine mechanism using the torque measuring device, and adjust the tail pull-out rate, the direction of the traction machine driver, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof based on the measured torque on the traction machine mechanism.

[0155] The sixth aspect of this disclosure may include any one of the first to fifth aspects, wherein the pulling mechanism may include a main roller, and at least one measuring device may include a torque measuring device directly coupled to the main roller, coupled to the pulling mechanism drive, or coupled to a transmission system that connects the main roller to the pulling mechanism drive. When executed, machine-readable and executable instructions may cause the winch system to automatically measure the torque on the main roller using the torque measuring device, and adjust the tail pull-out rate, the direction of the pulling mechanism drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on the measured torque on the main roller.

[0156] The seventh aspect of this disclosure may include the sixth aspect, wherein the torque measuring device may include a strain gauge connected to the main roll or a drive system connected to the main roll, or an ammeter and a motor speed sensor connected to the traction machine drive.

[0157] The eighth aspect of this disclosure may include any one of the first to seventh aspects, and further includes a riding roller driver operatively coupled to the riding roller, wherein, when executed by a processor, computer-readable and executable instructions enable the winch system to automatically adjust the torque on the riding roller, the speed of the riding roller, or both, based on one or more measured input variables.

[0158] The ninth aspect of this disclosure may include any one of the sixth to eighth aspects, wherein at least one measuring device may include a torque measuring device coupled to the pulling mechanism, a riding roller torque measuring device coupled to the riding roller, or both. When executed, machine-readable and executable instructions may cause the winch system to automatically measure the torque on the pulling mechanism, the torque on the riding roller, or both using at least one measuring device; identify a slippage condition of the winch based on the measured torque on the pulling mechanism, the measured torque on the riding roller, or both; and, in response to identifying the slippage condition of the winch, generate a slippage alarm signal indicating the slippage condition of the winch, adjust the tail pull-out rate, adjust the direction of the pulling mechanism drive, adjust the pressure of the pressure device, adjust the torque on the riding roller, adjust the speed of the riding roller, or a combination thereof.

[0159] The tenth aspect of this disclosure may include any one of the sixth to ninth aspects, wherein at least one measuring device may include a torque measuring device coupled to the pulling mechanism, a riding roller torque measuring device coupled to the riding roller, or both. When executed, machine-readable and executable instructions may cause the winch system to automatically measure the torque on the pulling mechanism, the torque on the riding roller, or both using at least one measuring device; identify a tail breakage condition of the winch based on the measured torque on the pulling mechanism, the measured torque on the riding roller, or both; and, in response to identifying the tail breakage condition of the winch, generate a tail breakage alarm signal indicating the tail breakage condition, adjust the tail pull-out rate, adjust the direction of the pulling mechanism drive, adjust the pressure of the pressure device, adjust the torque on the riding roller, adjust the speed of the riding roller, or a combination thereof.

[0160] The eleventh aspect of this disclosure may include any one of the first to tenth aspects, wherein one or more measuring devices may include a position sensor operable to determine the position of the riding roller relative to the traction mechanism.

[0161] The twelfth aspect of this disclosure may include the eleventh aspect, wherein, when executed by a processor, machine-readable and executable instructions enable the winch system to automatically utilize a position sensor to measure the position of the riding roller relative to the traction mechanism, and to adjust the tail pull-out rate, the direction of the traction drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on the position of the riding roller relative to the traction mechanism.

[0162] The thirteenth aspect of this disclosure may include the twelfth aspect, wherein, when executed by a processor, machine-readable and executable instructions enable the winch system to automatically determine the tail thickness based on the position of the riding roller relative to the traction mechanism as measured by a position sensor, and to adjust the tail pull-out rate, the direction of the traction drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on the determination of the tail thickness.

[0163] The fourteenth aspect of this disclosure may include the thirteenth aspect, wherein, when executed, machine-readable and executable instructions enable the winch system to automatically adjust the pressure of the pressure device, measure the position of the riding roller relative to the traction mechanism using a position sensor at each pressure of the pressure device, determine the relative density of the tail based on the pressure of the pressure device and the position of the riding roller relative to the traction mechanism, and adjust the tail extraction rate, the direction of the traction drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof based on the determination of the relative density of the tail.

[0164] The fifteenth aspect of this disclosure may include the fourteenth aspect, wherein, when executed, machine-readable and executable instructions enable the winch system to automatically send control signals to the pressure device, wherein the control signals indicate the pressure applied by the riding roller against the tail, and to periodically change the control signals, wherein changing the control signals results in adjustments to the pressure device to adjust the pressure applied by the riding roller against the tail.

[0165] The sixteenth aspect of this disclosure may include any one of the first to fifteenth aspects, wherein one or more measuring devices include one or more cameras positioned inside or above the pulper container, the rope winch, or both.

[0166] The seventeenth aspect of this disclosure may include the sixteenth aspect, wherein, when executed, machine-readable and executable instructions enable the winch system to automatically capture one or more images of the tail using one or more cameras, determine one or more input variables based on the captured images, and adjust the tail extraction rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on one or more attributes of the tail determined according to the captured images.

[0167] The eighteenth aspect of this disclosure may include any one of the sixteenth or seventeenth aspects, wherein one or more cameras may be positioned to capture images including at least 50%, at least 75%, at least 90%, or even at least 95% of the exposed length of the tail, wherein the exposed length of the tail is the length of the tail from the traction mechanism to the point where the tail enters the pulp container. When executed, machine-readable and executable instructions may cause the winch system to automatically use one or more cameras to capture one or more images of the tail, wherein the captured images show at least 50%, at least 75%, at least 90%, or even at least 95% of the exposed length of the tail; and to process the captured images to produce a thickness profile as a function of position along the length of the tail, wherein the thickness profile may include the tail thickness at each position along the length of the tail.

[0168] The nineteenth aspect of this disclosure may include any one of the sixteenth to eighteenth aspects, wherein, when executed, machine-readable and executable instructions enable the winch system to automatically determine, based on the thickness profile, the rate of change of the tail thickness at each location along the exposed length of the tail; identify one or more locations along the exposed length of the tail where the magnitude of the rate of change of the tail thickness exceeds a thickness change rate threshold; and adjust the tail pull-out rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on the identification of the locations where the magnitude of the tail change rate exceeds the thickness change rate threshold.

[0169] The twentieth aspect of this disclosure may include any one of the sixteenth to nineteenth aspects, wherein, when executed, machine-readable and executable instructions cause the winch system to automatically capture one or more images of the tail; identify a weak point in the tail based on the captured images and the location of a weak point in the tail, wherein the weak point in the tail includes a location along the tail where the tail is at least 10%, at least 15%, at least 20%, or even at least 25% thinner relative to other adjacent portions of the tail; and adjust the tail extraction rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof based on the identification of the weak point in one or more images.

[0170] The twentieth aspect of this disclosure may include the twentieth aspect, wherein, when executed, machine-readable and executable instructions enable the winch system to automatically process one or more images of the tail to generate a thickness profile of the tail and identify thinner regions of the tail, wherein the thinner regions of the tail indicate weak points in the tail.

[0171] The 22nd aspect of this disclosure may include any one of the 16th to 21st aspects, wherein, when executed, machine-readable and executable instructions enable the winch system to automatically use one or more cameras to capture multiple images of the tail as a function of time; process the multiple images to determine the frequency, amplitude, or both of the tail oscillation relative to the winch; and adjust the tail extraction rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on the frequency, amplitude, or both of the tail oscillation.

[0172] The twenty-third aspect of this disclosure may include the twenty-second aspect, wherein, when executed, machine-readable and executable instructions enable the winch system to automatically determine the position of a reference point on the width of the tail for each of a plurality of tail images captured by a camera; generate a dataset for the plurality of tail images, the dataset including the position of the reference point on the width of the tail as a function of time; and process the dataset using a Fast Fourier Transform (FFT) algorithm to generate a frequency and amplitude characterizing the oscillation of the tail relative to the winch.

[0173] The twenty-fourth aspect of this disclosure may include the twenty-third aspect, wherein, when executed, machine-readable and executable instructions enable the winch system to automatically form one or more correlations that associate the frequency and amplitude characteristics of the tail oscillation relative to the winch with one or more attributes of the tail, one or more operating conditions of the winch, one or more operating conditions of the pulper container, or a combination thereof; determine one or more attributes of the tail, one or more operating conditions of the winch, one or more operating conditions of the pulper container, or a combination thereof from the one or more correlations; and adjust the tail pull-out rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof based on the one or more attributes of the tail, one or more operating conditions of the winch, one or more operating conditions of the pulper container, or a combination thereof determined from the one or more correlations.

[0174] The 25th aspect of this disclosure may include any one of the first to 24th aspects, wherein one or more measuring devices may further include a consistency sensor operatively coupled to a pulper container, a level sensor operatively coupled to a pulper container, a pulper torque sensor coupled to a rotor of the pulper container, a temperature sensor operatively coupled to a pulper container, a supply conveyor speed sensor coupled to a supply conveyor of the pulping system, or a combination thereof. When executed, machine-readable and executable instructions enable the rope winch system to automatically: measure the consistency of the pulp using a consistency sensor, measure the level of the pulp using a level sensor, measure the rotor torque on the rotor of the pulper container using a pulper torque sensor, measure the temperature of the pulp using a temperature sensor, measure the speed of the supply conveyor using a supply conveyor speed sensor, or a combination thereof; and adjust the tail pull-out rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on the consistency of the pulp, the level of the pulp, the temperature of the pulp, the torque on the rotor of the pulper container, the speed of the supply conveyor, or a combination thereof.

[0175] The 26th aspect of this disclosure may include any one of the first to 25 aspects, wherein one or more measuring devices further include a consistency sensor disposed in the pulper container of the pulping system, the consistency sensor being operable to measure the consistency of the pulp in the pulper container. When executed, machine-readable and executable instructions cause the winch system to automatically measure the consistency of the pulp in the pulper container using the consistency sensor, and adjust the tail pull rate, the direction of the puller drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof based on the concentration of the pulp in the pulper container.

[0176] The 27th aspect of this disclosure may include any one of the first to 26 aspects, wherein one or more measuring devices may further include a level sensor disposed in the pulper container of the pulping system, the level sensor being operable to measure the level of pulp in the pulper container. When executed, machine-readable and executable instructions may cause the winch system to automatically measure the level of pulp in the pulper container using the level sensor, and adjust the tail pull rate, the direction of the puller drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof based on the level of pulp in the pulper container.

[0177] The twentieth aspect of this disclosure may include any one of the first to twenty-seventh aspects, wherein one or more measuring devices further include a pulper torque sensor coupled to the rotor of the pulper container, the pulper torque sensor being operable to measure the torque on the rotor disposed in the pulper container. When executed, machine-readable and executable instructions may cause the rope winch system to automatically utilize the pulper torque sensor to measure the torque on the rotor in the pulper container, wherein the torque on the rotor indicates the magnitude of the force exerted on the tail by the pulp in the pulper container; and to adjust the tail pull-out rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on the measured torque on the rotor in the pulper container.

[0178] The 29th aspect of this disclosure may include any one of the first to 28 aspects, wherein one or more measuring devices further include a feed conveyor speed sensor coupled to the feed conveyor of the pulping system, the feed conveyor speed sensor being operable to measure the speed of the feed conveyor. When executed by a processor, machine-readable and executable instructions may cause the winding machine system to automatically use the feed conveyor speed sensor to measure the speed of the feed conveyor; determine the production rate of the pulping system, the ratio of recycled paper to virgin paper in the pulping container, or both; and adjust the tail pull-out rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on the production rate of the pulping system, the ratio of recycled paper to virgin paper in the pulping container, or both.

[0179] The thirtieth aspect of this disclosure may include any one of the first to twenty-ninth aspects, wherein one or more measuring devices may include a capacitive sensor coupled to the winch, wherein the capacitive sensor is configured to measure the capacitance at the tail end. In embodiments, the capacitive sensor may be coupled to a pulling mechanism, a riding roller, the frame of the winch, or a combination thereof. In embodiments, the winch includes a guide arm having a guide roller, and the capacitive sensor may be coupled to the guide arm or the guide roller.

[0180] The thirty-first aspect of this disclosure may include the thirtieth aspect, wherein, when executed, machine-readable and executable instructions enable the winch system to automatically measure the capacitance of the tail using a capacitance sensor; determine the relative metal content of the tail based on the measured capacitance, wherein the relative metal content of the tail indicates the strength of the tail; and adjust the tail extraction rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on the relative metal content of the tail.

[0181] The thirty-second aspect of this disclosure may include any one of the first to thirty-first aspects, wherein the pulling mechanism may include a main roller, and one or more measuring devices include a plurality of weighing gauges disposed on the legs of the winch, on the support bearings of the main roller, on the journal of the main roller, or a combination thereof, wherein the legs of the winch are disposed between the base plate of the winch and the operating base plate, and the winch is supported on the operating base plate.

[0182] The thirty-third aspect of this disclosure may include the thirty-second aspect, wherein a plurality of weighing gauges may be disposed on the legs of the rope winch closest to the pulping system or may be disposed on all legs of the rope winch.

[0183] The thirty-fourth aspect of this disclosure may include any one of the thirty-second or thirty-third aspects, wherein each of the plurality of weighing gauges is operable to measure the relative weight of the tail and generate a weight signal indicating the relative weight of the tail. When executed, machine-readable and executable instructions may enable the winch system to automatically: receive weight signals from the plurality of weighing gauges; determine the relative weight of the tail based on the weight signals; and adjust the tail extraction rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on the relative weight of the tail.

[0184] The thirty-fifth aspect of this disclosure may include any one of the first to thirty-fourth aspects, wherein one or more measuring devices may include an ammeter and a speed sensor operatively coupled to the traction drive and communicatively coupled to the control system. When executed, instrument-readable and executable instructions may cause the winch system to automatically: receive an ampere signal from the ammeter indicating the current consumed by the traction drive; receive a speed signal from the speed sensor indicating the rotational speed of the traction drive; determine the size or weight of the tail section based on the ampere signal and the speed signal; and adjust the tail section extraction rate, the direction of the traction drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on the size or weight of the tail section.

[0185] The thirty-sixth aspect of this disclosure relates to a method for operating a winch for removing solid debris from a pulping system. The method includes removing a tail portion of solid debris from a pulping vessel of the pulping system using the winch. The winch includes a pulling mechanism, a pulling drive, a riding roller spaced apart from the pulling mechanism, and a pressure device configured to adjust the pressure exerted by the riding roller on a tail portion disposed between the pulling mechanism and the riding roller. The method may further include determining one or more properties of the tail portion, one or more operating conditions of the winch, one or more operating conditions of the pulping system, or a combination thereof, based on measurements of one or more input variables. The method may also include adjusting the tail portion extraction rate, the direction of the pulling drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, the rotational position of the winch relative to the pulping vessel, or a combination thereof, based on measured input variables.

[0186] The thirty-seventh aspect of this disclosure may include the thirty-sixth aspect, which includes determining one or more attributes of the tail based on one or more input variables, wherein the one or more attributes of the tail may include the thickness of the tail, the length of the tail, the weight of the tail, the density of the tail, the metal content of the tail, the position of the tail in the pulper container, the location of one or more weak points in the tail, the thickness change rate of the tail, the thickness profile of the tail, or one or more combinations thereof.

[0187] The thirty-eighth aspect of this disclosure may include any one of the thirty-sixth or thirty-seventh aspects, including determining one or more operating conditions of the winch based on one or more input variables, wherein the one or more operating conditions of the winch may include the winch's pulling rate, the winch's pulling direction, the winch's slippage condition, the tail breakage condition, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, the proximity of the riding roller to the pulling mechanism, or one or more combinations thereof.

[0188] The thirty-ninth aspect of this disclosure may include any one of the thirty-six to thirty-eight aspects, including determining one or more operating conditions of the pulping system based on one or more input variables, wherein the one or more operating conditions of the pulping system may include the production rate of the pulping system, the consistency of the pulp in the pulping vessel, the pulp level in the pulping vessel, the ratio of recycled paper to virgin paper in the pulping system, the temperature of the pulp, the speed of the supply conveyor, or one or more combinations thereof.

[0189] The fortieth aspect of this disclosure may include any one of the thirty-sixth to thirty-ninth aspects, including adjusting the extraction rate of the tail from the pulper container, wherein the puller driver may be a variable speed driver and adjusting the extraction rate of the tail includes adjusting the rotational speed of the puller driver, or the puller driver may be a constant speed driver and adjusting the extraction rate of the tail may include adjusting the switching time of the main roller driver.

[0190] The forty-first aspect of this disclosure may include any one of the thirty-sixth to fortieth aspects, including measuring the torque on the traction machine drive, the torque on the traction machine mechanism, the riding roller or the riding roller drive torque, or a combination thereof; and identifying a slip condition of the winch based on the measurement of the torque on the traction machine drive, the torque on the traction machine mechanism, the riding roller or the riding roller drive or both, wherein a slip condition refers to a condition in which the tail slips on the traction machine mechanism, the riding roller or both and further operation of the traction machine mechanism does not pull the tail out of the pulper container.

[0191] The forty-second aspect of this disclosure may include the forty-first aspect, further comprising generating a slip alarm indicating the slip condition of the winch in response to identifying the slip condition of the winch, adjusting the pull-out rate of the tail, adjusting the direction of the puller drive, adjusting the pressure of the pressure device, adjusting the torque on the riding roller, adjusting the speed of the riding roller, or a combination thereof, to correct the slip condition of the winch.

[0192] The forty-third aspect of this disclosure may include any one of the thirty-six to forty-two aspects, including measuring the torque on the puller drive, the torque on the puller mechanism, the riding roller or the riding roller drive torque, or a combination thereof; identifying a tail breakage condition of the winch based on the measurement of the torque on the puller drive, the torque on the puller mechanism, the riding roller or the riding roller drive, or both, wherein a tail breakage condition refers to a condition where the tail breaks off and falls back into the pulper container; and in response to identifying the tail breakage condition of the winch, generating a tail breakage alarm indicating the tail breakage condition, adjusting the tail extraction rate, adjusting the direction of the puller drive, adjusting the pressure of the pressure device, adjusting the torque on the riding roller, adjusting the speed of the riding roller, or a combination thereof, to correct the tail breakage condition of the winch.

[0193] The forty-fourth aspect of this disclosure may include any one of the thirty-sixth to forty-third aspects, wherein one or more input variables may include the amount of current consumed by the traction machine driver and the rotational speed of the traction machine driver, and the method may include: measuring the amount of current consumed by the main roller driver and the rotational speed of the main roller driver; determining the relative size or relative weight of the tail section based on the current consumed by the main roller driver and the rotational speed of the main roller driver; and adjusting the tail section extraction rate, the direction of the traction machine driver, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof based on the relative size or relative weight of the tail section.

[0194] The forty-fifth aspect of this disclosure may include any one of the thirty-sixth to forty-fourth aspects, wherein one or more input variables may include the frequency, amplitude, or both of the vibration caused by the oscillation of the tail relative to the winch, and the method may include measuring the frequency, amplitude, or both of the oscillation of the tail using a vibration sensor; determining the relative size or relative weight of the tail based on the frequency, amplitude, or both of the vibration caused by the oscillation of the tail; and adjusting the tail extraction rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof based on the determined tail size.

[0195] The forty-sixth aspect of this disclosure may include any one of the thirty-sixth to forty-fifth aspects, wherein one or more input variables may include the position of the riding roller relative to the traction mechanism, and the method may include measuring the position of the riding roller relative to the traction mechanism, wherein the position of the riding roller relative to the traction mechanism indicates the thickness of the tail; and adjusting the tail extraction rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof based on the position of the riding roller relative to the traction mechanism.

[0196] The forty-seventh aspect of this disclosure may include the forty-sixth aspect, wherein one or more input variables may further include the pressure of the pressure device, and the method may further include adjusting the pressure of the pressure device; measuring the position of the riding roller relative to the traction mechanism for each pressure during adjusting the pressure of the pressure device; determining the relative density of the tail based on the pressure and position of the riding roller relative to the traction mechanism; and adjusting the tail extraction rate, the direction of the traction machine drive, the pressure of the pressure device, the torque of the riding roller, the speed of the riding roller, or a combination thereof based on the determination of the relative density of the tail.

[0197] The forty-eighth aspect of this disclosure may include any one of the thirty-sixth to forty-seventh aspects, wherein one or more input variables may include one or more images of the tail, and the method may include capturing one or more images of the tail; processing one or more images to determine one or more properties of the tail; and adjusting the tail extraction rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, the rotational position of the winch relative to the pulping machine container, or a combination thereof, based on the one or more properties of the tail determined from the one or more images.

[0198] The forty-ninth aspect of this disclosure may include any one of the thirty-sixth to forty-eighth aspects, wherein one or more input variables may include one or more images of the tail, and the method may include identifying one or more weak points in the tail from the one or more images; and adjusting the tail extraction rate, the direction of the traction machine driver, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof based on the identification of weak points from the one or more images.

[0199] The fiftieth aspect of this disclosure may include the forty-ninth aspect, wherein identifying one or more weak points in the tail may include processing one or more images of the tail to generate a thickness profile of the tail; and identifying thinner regions of the tail, wherein the thinner regions of the tail indicate weak points in the tail.

[0200] The fifty-first aspect of this disclosure may include any one of aspects forty-eight to fifty, wherein one or more attributes of the tail may include the frequency, amplitude, or both of the oscillation of the tail relative to the winch, and the method may include capturing multiple images of the tail as a function of time with one or more cameras; processing the multiple images to determine the frequency, amplitude, or both of the oscillation of the tail relative to the winch; and adjusting the tail pull-out rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on the frequency, amplitude, or both of the vibrations caused by the oscillation of the tail.

[0201] The fifty-second aspect of this disclosure may include any one of aspects thirty-six to fifty-one, wherein one or more input variables may further include the consistency of the pulp stock in the pulper container, the level of the pulp stock, the temperature of the pulp stock, the production rate of the pulping system, the conveyor speed of the feed conveyor to the pulper container, the torque on the rotor motor of the pulper container, or a combination thereof. The method may also include measuring one or more of the consistency of the pulp stock in the pulper container, the level of the pulp stock, the temperature of the pulp stock, the production rate of the pulping system, the conveyor speed of the feed conveyor to the pulper container, the torque on the rotor motor of the pulper container, or a combination thereof, and adjusting the tail pull-out rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof based on the consistency of the pulp stock in the pulper container, the level of the pulp stock, the temperature of the pulp stock, the production rate of the pulping system, the conveyor speed of the feed conveyor to the pulper container, the torque on the rotor motor of the pulper container, or a combination thereof.

[0202] The fifty-third aspect of this disclosure may include any one of the thirty-sixth to fifty-second aspects, including capturing one or more images of the tail; identifying one or more locations of sudden thickness expansion of the tail from the captured images, wherein the locations of the sudden thickness expansion of the tail include locations along the tail where the tail is at least 20% thicker relative to other adjacent portions of the tail; and adjusting the tail extraction rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on the identification of the locations of sudden thickness expansion from the one or more images.

[0203] The fifty-fourth aspect of this disclosure may include any one of the first to thirty-fifth aspects, wherein, when executed by a processor, machine-readable and executable instructions enable the winch system to automatically capture one or more images of the tail; identify, based on the captured images, one or more locations of sudden thickness expansion of the tail, and wherein the locations of sudden thickness expansion of the tail include locations along the tail where the tail is at least 20% thicker relative to other adjacent portions of the tail; and adjust the tail extraction rate, the direction of the traction machine drive, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, based on the identification of the locations of sudden thickness expansion in the one or more images.

[0204] While various embodiments of the rope winch system have been described herein, it should be understood that each of these embodiments and techniques can be used alone or in combination with one or more embodiments and techniques. It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Therefore, this specification is intended to cover modifications and variations of the various embodiments described herein, provided that such modifications and variations fall within the scope of the appended claims and their equivalents.

Claims

1. A rope winch system for removing solid debris from a pulping machine container in a pulping system, the rope winch system comprising: A rope winch, operable to pull the tail end of the solid debris from the pulping machine container, the rope winch comprising: A pulling mechanism, the pulling mechanism including a pulling machine drive operatively coupled to the pulling mechanism, the pulling mechanism operable to engage the tail and pull the tail from the pulper container; Riding roller, which is spaced apart from the traction mechanism; and A pressure device configured to adjust the pressure exerted by the riding roller on the tail portion disposed between the traction mechanism and the riding roller; At least one measuring device operable to measure one or more input variables indicating one or more properties of the tail section, one or more operating conditions of the winch, one or more operating conditions of the pulping system, or combinations thereof, wherein the one or more measuring devices include a position sensor operable to determine the position of the riding roller relative to the traction mechanism; and A control system, comprising a processor, a memory module communicatively connected to the processor, and machine-readable and executable instructions stored on the memory module, wherein: The control system is communicatively connected to the at least one measuring device, and communicatively connected to the traction machine driver, the pressure device, or a combination thereof; and When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: The position sensor is used to measure the position of the riding roller relative to the traction mechanism; The thickness of the tail section is determined based on the position of the riding roller relative to the traction mechanism, as measured by the position sensor; and The tail section's extraction rate, the direction of the traction machine driver, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, are adjusted based on the determination of the tail section's thickness.

2. The system as described in claim 1, characterized in that: The traction machine driver is a variable speed driver; The pulling mechanism driver continuously drives the pulling mechanism during the operation of the rope winch to advance the tail through the rope winch, and does not operate to periodically close and open the pulling mechanism to advance the tail; and The rate at which the tail is drawn out of the pulper container is controlled by changing the speed of the puller driver.

3. The system of claim 1, wherein, The at least one measuring device includes a torque measuring device connected to the traction mechanism, the traction drive, or a transmission system connecting the traction drive to the traction mechanism, and when executed by the processor, the machine-readable and executable instructions cause the winch system to automatically: The torque measuring device is used to measure the torque on the traction machine mechanism; and The tail pull-out rate, the direction of the traction machine driver, the pressure of the pressure device, the torque on the riding roller, or a combination thereof are adjusted based on the measured torque on the traction machine mechanism.

4. The system as described in claim 1, characterized in that, It also includes a riding roller driver operatively coupled to the riding roller, wherein, when executed by the processor, computer-readable and executable instructions cause the winch system to automatically adjust the torque on the riding roller, the speed of the riding roller, or both, based on the measured one or more input variables.

5. The system as described in any one of claims 1-4, characterized in that: The at least one measuring device includes a torque measuring device connected to the traction machine mechanism, a riding roller torque measuring device connected to the riding roller, or both; and When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: The torque on the traction mechanism, the torque on the riding roller, or both are measured using the at least one measuring device. The slippage condition of the winch is identified based on the measured torque on the traction mechanism, the measured torque on the riding roller, or both. as well as In response to identifying a slippage condition in the winch, the system generates a slippage alarm signal indicating the slippage condition of the winch, adjusts the pull-out rate of the tail section, adjusts the direction of the traction machine driver, adjusts the pressure of the pressure device, and adjusts the torque or speed of the riding roller, or a combination thereof.

6. The system as described in any one of claims 1-4, characterized in that: The at least one measuring device includes a torque measuring device connected to the traction machine mechanism, a riding roller torque measuring device connected to the riding roller, or both; and When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: The torque on the traction mechanism, the torque on the riding roller, or both are measured using the at least one measuring device. The tail breakage condition of the winch is identified based on the measured torque on the pulling mechanism, the measured torque on the riding roller, or both; and In response to identifying a tail breakage condition of the winch, the system generates a tail breakage alarm signal indicating the tail breakage condition of the winch, adjusts the tail pull-out rate, adjusts the direction of the traction machine driver, adjusts the pressure of the pressure device, adjusts the torque on the riding roller, adjusts the speed of the riding roller, or a combination thereof.

7. The system as described in any one of claims 1-4, characterized in that, When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: Adjust the pressure of the pressure device; The position sensor is used to measure the position of the riding roller relative to the traction mechanism at each pressure of the pressure device; The relative density of the tail section is determined based on the pressure of the pressure device and the position of the riding roller relative to the traction mechanism. as well as The extraction rate of the tail, the direction of the traction machine driver, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, are adjusted based on the determination of the relative density of the tail.

8. The system as described in claim 7, characterized in that, When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: A control signal is sent to the pressure device, wherein the control signal indicates the pressure applied by the riding roller against the tail; and The control signal is changed periodically, wherein changing the control signal causes the pressure device to adjust the pressure applied by the riding roller against the tail.

9. The system as described in claim 1, characterized in that, The at least one measuring device further includes a plurality of measuring devices operable to measure a plurality of input variables, wherein, when executed by the processor, the machine-readable and executable instructions also cause the rope winch system to automatically: The plurality of measuring devices are used to measure the plurality of input variables; and The tail pull-out rate, the direction of the traction machine driver, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof are adjusted based on the measured input variables.

10. The system according to any one of claims 1-4, characterized in that: The one or more measuring devices further include a consistency sensor operatively connected to the pulper container, a level sensor operatively connected to the pulper container, a pulper torque sensor connected to the rotor of the pulper container, a temperature sensor operatively connected to the pulper container, a supply conveyor speed sensor connected to the supply conveyor of the pulping system, or a combination thereof. as well as When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: The consistency sensor is used to measure the consistency of the pulp, the level sensor is used to measure the level of the pulp, the torque sensor is used to measure the rotor torque on the rotor of the pulper container, the temperature sensor is used to measure the temperature of the pulp, and the speed of the supply conveyor is used to measure the speed of the supply conveyor, or a combination thereof. as well as The tail pull-out rate, the direction of the traction machine driver, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof are adjusted based on the consistency of the pulp, the level of the pulp, the temperature of the pulp, the torque on the rotor of the pulper container, the speed of the supply conveyor, or a combination thereof.

11. A rope winch system for removing solid debris from a pulping machine container in a pulping system, the rope winch system comprising: A rope winch, operable to pull the tail end of the solid debris from the pulping machine container, the rope winch comprising: A pulling mechanism, the pulling mechanism including a pulling machine drive operatively coupled to the pulling mechanism, the pulling mechanism operable to engage the tail and pull the tail from the pulper container; Riding roller, which is spaced apart from the traction mechanism; and A pressure device configured to adjust the pressure exerted by the riding roller on the tail portion disposed between the traction mechanism and the riding roller; At least one measuring device, operable to measure one or more input variables indicating one or more properties of the tail, one or more operating conditions of the rope winch, one or more operating conditions of the pulping system, or combinations thereof, wherein: The at least one measuring device includes one or more cameras positioned inside the pulper container or above the pulper container, the rope winch, or both; and The one or more cameras are positioned to capture images including at least 50% of the exposed length of the tail, wherein the exposed length of the tail is the length of the tail from the traction mechanism to the point where the tail enters the pulping container; and A control system, comprising a processor, a memory module communicatively connected to the processor, and machine-readable and executable instructions stored on the memory module, wherein: The control system is communicatively connected to the at least one measuring device, and communicatively connected to the traction machine driver, the pressure device, or a combination thereof; and When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: The at least one measuring device is used to measure the one or more input variables, wherein the one or more input variables indicate one or more properties of the tail, one or more operating conditions of the rope winch, one or more operating conditions of the pulping system, or a combination thereof; The tail pull-out rate, the direction of the traction machine driver, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof are adjusted based on the measured one or more input variables. The one or more cameras are used to capture one or more images of the tail, wherein the captured images show at least 50% of the exposed length of the tail; and The captured image is processed to generate a thickness profile as a function of the position along the length of the tail, wherein the thickness profile includes the tail thickness at each position along the length of the tail.

12. The system as claimed in claim 11, characterized in that, It also includes a riding roller driver operatively coupled to the riding roller, wherein, when executed by the processor, computer-readable and executable instructions cause the winch system to automatically adjust the torque on the riding roller, the speed of the riding roller, or both, based on the measured one or more input variables.

13. The system as described in claim 11, characterized in that, When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: The rate of change of the tail thickness at each location along the exposed length of the tail is determined based on the thickness profile. Identify one or more locations along the exposed length of the tail where the magnitude of the rate of change of thickness of the tail exceeds a thickness rate of change threshold; and The extraction rate of the tail, the direction of the traction machine driver, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, are adjusted based on the identification of the location where the magnitude of the rate of change of the tail exceeds the thickness rate of change threshold.

14. The system as claimed in claim 11, characterized in that, When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: Capture one or more images of the tail; Weak points in the tail are identified based on captured images and the locations of these weak points, wherein the weak points include locations along the tail where the tail is at least 10% thinner relative to other adjacent portions of the tail; and The tail pull-out rate, the direction of the traction machine driver, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof are adjusted based on the identification of the weak points in the one or more images.

15. The system as described in claim 14, characterized in that, When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: Process one or more images of the tail to generate a thickness profile of the tail; and Identify thinner regions in the tail section, which indicate weak points in the tail section.

16. The system as claimed in claim 11, characterized in that, When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: Capture one or more images of the tail; Identify one or more locations of sudden thickness expansion of the tail portion based on the captured image, wherein the locations of the sudden thickness expansion of the tail portion include locations along the tail portion where the tail portion is at least 20% thicker relative to other adjacent portions of the tail portion; and The tail pull-out rate, the direction of the traction machine driver, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, are adjusted based on the identification of the location of the sudden expansion of the thickness in the one or more images.

17. The system as described in any one of claims 11-16, characterized in that, When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: One or more cameras are used to capture multiple images of the tail as a function of time; Process the plurality of images to determine the frequency, amplitude, or both of the oscillation of the tail relative to the winch; and The extraction rate of the tail, the direction of the traction machine driver, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, are adjusted based on the frequency, amplitude, or both of the oscillation of the tail.

18. The system as claimed in claim 17, characterized in that, When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: For each of the multiple images of the tail captured by the camera, determine the position of a reference point on the width of the tail; A dataset is generated for the plurality of images of the tail, the dataset including the position of the reference point on the width of the tail as a function of time; as well as The dataset is processed using a Fast Fourier Transform (FFT) algorithm to generate the frequency and amplitude characterizing the oscillations of the tail relative to the winch.

19. The system as claimed in claim 18, characterized in that, When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: One or more correlations are formed that associate the frequency and amplitude characteristics of the tail oscillation relative to the winch with one or more attributes of the tail, one or more operating conditions of the winch, one or more operating conditions of the pulper container, or a combination thereof. One or more attributes of the tail, one or more operating conditions of the rope winch, one or more operating conditions of the pulper container, or a combination thereof, are determined based on the one or more correlations mentioned above. as well as The tail pull-out rate, the direction of the traction machine driver, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof, are adjusted based on one or more attributes of the tail determined according to one or more correlations, one or more operating conditions of the rope winch, one or more operating conditions of the pulping machine container, or a combination thereof.

20. The system as claimed in any one of claims 11-16, characterized in that: The traction machine driver is a variable speed driver; The pulling mechanism driver continuously drives the pulling mechanism during the operation of the rope winch to advance the tail through the rope winch, and does not operate to periodically close and open the pulling mechanism to advance the tail; and The rate at which the tail is drawn out of the pulper container is controlled by changing the speed of the puller driver.

21. The system as claimed in any one of claims 11-16, characterized in that: The one or more measuring devices further include a consistency sensor operatively connected to the pulper container, a level sensor operatively connected to the pulper container, a pulper torque sensor connected to the rotor of the pulper container, a temperature sensor operatively connected to the pulper container, a supply conveyor speed sensor connected to the supply conveyor of the pulping system, or a combination thereof. as well as When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: The consistency of the pulp is measured using the consistency sensor, the level of the pulp is measured using the level sensor, the rotor torque on the rotor of the pulper container is measured using the pulper torque sensor, the temperature of the pulp is measured using the temperature sensor, and the speed of the supply conveyor is measured using the supply conveyor speed sensor, or a combination thereof. as well as The tail pull-out rate, the direction of the traction machine driver, the pressure of the pressure device, the torque on the riding roller, the speed of the riding roller, or a combination thereof are adjusted based on the consistency of the pulp, the level of the pulp, the temperature of the pulp, the torque on the rotor of the pulper container, the speed of the supply conveyor, or a combination thereof.

22. A rope winch system for removing solid debris from a pulping vessel of a pulping system, the rope winch system comprising: A rope winch, operable to pull the tail end of the solid debris from the pulping machine container, the rope winch comprising: A pulling mechanism, the pulling mechanism including a pulling machine drive operatively coupled to the pulling mechanism, the pulling mechanism operable to engage the tail and pull the tail from the pulper container; A riding roller, the riding roller including a riding roller driver operatively coupled to the riding roller, wherein the riding roller is spaced apart from the traction mechanism; and A pressure device configured to adjust the pressure exerted by the riding roller on the tail portion disposed between the traction mechanism and the riding roller; At least one measuring device, operable to measure one or more input variables indicating one or more attributes of the tail section, one or more operating conditions of the winch, one or more operating conditions of the pulping system, or combinations thereof, the at least one measuring device including a torque measuring device coupled to the traction mechanism, a riding roller torque measuring device coupled to the riding roller, or both; and A control system, comprising a processor, a memory module communicatively connected to the processor, and machine-readable and executable instructions stored on the memory module, wherein: The control system is communicatively connected to the at least one measuring device, and communicatively connected to the traction machine driver, the riding roller driver, the pressure device, or a combination thereof; When executed by the processor, the machine-readable and executable instructions cause the rope winch system to automatically: The torque on the traction mechanism, the torque on the riding roller, or both are measured using the at least one measuring device. The slippage condition of the winch is identified based on the measured torque on the pulling mechanism, the measured torque on the riding roller, or both; and In response to identifying a slippage condition in the winch, the system generates a slippage alarm signal indicating the slippage condition of the winch, adjusts the pull-out rate of the tail section, adjusts the direction of the traction machine driver, adjusts the pressure of the pressure device, and adjusts the torque or speed of the riding roller, or a combination thereof.

23. The system of claim 22, wherein, When executed by the processor, computer-readable and executable instructions cause the winch system to automatically adjust the torque on the riding roller, the speed of the riding roller, or both, based on the measured one or more input variables.

24. The system as described in claim 22, characterized in that: The traction machine driver is a variable speed driver; The pulling mechanism driver continuously drives the pulling mechanism during the operation of the rope winch to advance the tail through the rope winch, and does not operate to periodically close and open the pulling mechanism to advance the tail; and The rate at which the tail is drawn out of the pulper container is controlled by changing the speed of the puller driver.

25. The system as described in claim 22, characterized in that, When executed by the processor, the machine-readable and executable instructions also cause the rope winch system to automatically: The tail breakage condition of the winch is identified based on the measured torque on the pulling mechanism, the measured torque on the riding roller, or both; and In response to identifying a tail breakage condition of the winch, the system generates a tail breakage alarm signal indicating the tail breakage condition of the winch, adjusts the tail pull-out rate, adjusts the direction of the traction machine driver, adjusts the pressure of the pressure device, adjusts the torque on the riding roller, adjusts the speed of the riding roller, or a combination thereof.

Images