Method of operating a corrugator, corrugator, and computer program product
By utilizing paper data to adjust corrugator operating parameters based on individual paper roll characteristics, the method optimizes corrugated board web production, enhancing quality and reducing waste.
Patent Information
- Application Number
- JP2025501570
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-09-14
- Filing Date
- 2023-09-12
- Publication Date
- 2025-09-25
AI Technical Summary
Existing corrugator operations fail to account for the individual characteristics of each paper roll, leading to suboptimal production of corrugated board webs and increased economic viability due to the production of defective products.
The method utilizes paper data, including individual paper parameters of each roll, to adjust operating parameters of the corrugator proactively, ensuring that the production process is tailored to the specific properties of each paper roll, using feedforward control to optimize the production process.
This approach allows for the production of high-quality corrugated board webs by compensating for variations in paper properties, enabling the use of paper rolls with larger tolerances and reducing waste, thus improving efficiency and cost-effectiveness.
Smart Images

Figure 2025531644000001_ABST
Abstract
Description
[Technical Field]
[0001] The present invention relates to a method of operating a corrugator, a corrugator, a computer program product, and a paper roll.
[0002] Corrugators are used to produce corrugated board webs. In this case, the corrugator is supplied with several paper webs in the form of paper rolls. The paper rolls are unwound using the respective unwinders of the corrugator, and the resulting paper webs are connected to one another by several processing units to form the corrugated board web. In this case, for example, one of the paper webs is corrugated using a corrugating roller and then glued to two non-corrugated paper webs. Multi-layer corrugated board webs with several corrugated paper webs are also possible. Finally, the finished corrugated board web is optionally further processed using the corrugator, i.e., cut into individual sections and, if necessary, further slits and / or grooves are applied.
[0003] The quality of the corrugated board web produced depends on the corresponding selection of values for the operating parameters of the corrugator during operation (i.e., during the production of the corrugated board web), on the one hand, and on the other hand, on the properties of the paper web from which the corrugated board web is produced. The operating parameters are adjusted, for example, manually by an operator during the operation of the corrugator, or automatically in response to measurements by sensors immediately before each processing unit (in-line measurements). In this way, changes in the ambient conditions and the properties of the paper web can be accommodated. For example, temperature and moisture controllers for adapting the temperature and moisture of each paper web can be considered part of the corrugator's control system, immediately before the respective processing unit, in order to influence the processing result of this processing unit as optimally as possible.
[0004] U.S. Patent No. 11,162,226 B2 describes a method for conditioning a paper web with a liquid film to obtain a specific moisture content. The conditioning relies on a hygroexpansivitaetsattribut that is measured for or assigned to the paper web. The measurement of the hygroexpansivitaetsattribut is based on a subsequent measurement of the shape of the finished corrugated web, from which the hygroexpansivitaetsattribut is calculated, thereby allowing similar paper webs to be assigned the same hygroexpansivitaetsattribut. Therefore, the assignment of the hygroexpansivitaetsattribut is also based on the fact that similar paper webs can generally be assigned the same hygroexpansivitaetsattribut.
[0005] See also U.S. Pat. No. 10,095,206, EP 3392649, EP 3369564, EP 2572038, EP 2406616, EP 2391505, EP 1902833, EP 0936059, DE 102017219064, DE 102015206650, CN 107458032, CN 107631684, CN 112644092, CN Utility Model No. 207105756, CN Utility Model No. 210553357.
[0006] Against this background, the object of the present invention is to improve the production of corrugated board webs, for which a suitable method for operating a corrugator, a corresponding corrugator, a computer program product, and an advantageous paper roll should be provided.
[0007] According to the present invention, the above-mentioned problem is solved by a method having the features of claim 1, a corrugator having the features of claim 13, a computer program product having the features of claim 14, and a paper roll having the features of claim 15. Advantageous configurations, developments, and variations are the subject of the dependent claims. Statements relating to the method also apply to the corrugator, the computer program product, and the paper roll, and vice versa. Insofar as method steps are described below, advantageous embodiments of the corrugator result from it being designed to perform one or more of these steps (in particular by means of a control unit of the corrugator). Similarly, advantageous embodiments of the computer program product result from the computer program product comprising commands which, when executed by the corrugator, cause the corrugator to perform one or more of these steps.
[0008] The basic idea of the present invention is to utilize paper data, especially in the corrugator, and to feed (and also transmit) these paper data to the corrugated board layers.
[0009] The method is used in the operation of a corrugator. Corrugators are also used to produce corrugated fiberboard webs and, for this purpose, have a number of adjustable operating parameters. The operating parameters are adjusted by selecting and setting values for the operating parameters. The operating parameters control the behavior of one or more of the corrugator's processing units. Examples of processing units include unwinders, splicers, printers, single facers, bridges, preheaters, gluers, double facers, drying sections, cutting units, slitter units, and groover units. However, the details of the processing units are not important here. Examples of operating parameters include conveying speed, tensile stress, ink volume, corrugation roller temperature, glue volume, dampening solution volume, drying temperature, and notch and / or groove position. The details of the processing parameters are also not important here.
[0010] Within the scope of this method, a number of paper rolls, each containing one (i.e., at least one) paper web made from the paper from which the corrugated board web is produced, are fed to the corrugator. In other words, the corrugator is fed with a number of paper rolls during operation. In this specification, and generally, "a number" is understood to mean "one or more" or "at least one." Each paper roll is formed, in particular, by a paper web and a sleeve (also called a bushing) around which the paper web is wound, and the paper web is unwound by an unwinder from the corrugator to produce the corrugated board web and appropriately connected to other paper webs on other paper rolls. Each paper web is made from or consists of paper. The converting units then process the paper web according to operating parameters, i.e., each operating parameter is assigned to at least one of the converting units and determines its behavior during operation and thus the processing of the paper web by this converting unit.
[0011] Corrugators are supplied with multiple paper rolls in two ways: on the one hand, multiple paper rolls are supplied to the corrugated web, and the paper rolls are connected to each other in different layers of the corrugated web, i.e., multiple paper rolls in different layers are supplied more or less simultaneously; on the other hand, in order to achieve continuous operation, multiple paper rolls are supplied to the corrugated web sequentially, i.e., a new paper roll is supplied after one is used up, i.e., multiple paper rolls are supplied to the same layer.
[0012] Each paper roll is characterized by a number of paper parameters, each of which has a distinct value for each paper roll, thereby characterizing each paper roll individually based on the value of the respective paper parameter. Strictly speaking, the paper of each paper roll is characterized by a number of paper parameters, each of which has a distinct value for each paper roll, thereby characterizing each paper roll individually based on the value of the respective paper parameter. Thus, although the paper parameters individually characterize the paper of each paper roll, even if, for brevity, the following sometimes refers only to the paper roll, in this case, it specifically refers to the paper of the paper roll. The values of the paper parameters of a single paper roll are also referred to as "paper data" and together form a data set for this paper roll. Each paper parameter directly or indirectly represents one or more characteristics of the paper of the paper roll, thereby different values mean or imply correspondingly different characteristics. In this case, the term "paper parameter" is particularly broadly interpreted to refer not only to the physical, mechanical, and chemical properties of the paper itself, but also to any information that allows characterization of the paper, such as the place of production, production time, storage period, or operating parameters of the paper machine during production. In suitable embodiments, the paper data are average values, or position and / or time resolved values (e.g., moisture resolved position along the length and width of the paper web), or a combination thereof. Exactly which paper parameters are used is for the time being secondary; what is important here is that a value of the paper parameter exists individually for each of the paper rolls. For example, the paper parameter may be the paper fiber orientation of the paper roll, with associated values a for the first paper roll, b for the second paper roll, and c for the third paper roll.
[0013] Thus, although the values of the paper parameters are different for each paper roll (or, more precisely, for each paper roll), this does not exclude the possibility that two paper rolls do not have the same value for a particular paper parameter. However, the paper of two paper rolls usually differs in one or more of the paper parameters due to their production, storage, transportation, etc., and therefore has different properties. This individuality of the paper rolls is taken into account during the operation of the corrugator, and thus during the processing of the paper rolls, and is utilized to optimize the production of the corrugated board web. For this purpose, the operating parameters of the corrugator are adjusted according to the values of the paper parameters (i.e., according to the paper data), thereby individually adapting the production of the corrugated board web to each paper roll (i.e., the paper) being processed at a given time. In other words, since the paper properties usually differ for each paper roll (or even along a single paper roll), the operation of the corrugator is adapted accordingly to each used paper roll, preferably repeatedly and / or continuously. In this case, the paper data is not detected for the first time at the corrugator or only at the corrugator, but is already detected in advance, particularly remotely and independently from the corrugator. The paper data preferably includes the paper production process and / or the history of the paper roll, and thus the paper data is, so to speak, a resume of the paper roll. In particular, the paper data does not necessarily include only paper parameters that can be detected inline in the corrugator, but preferably also includes paper parameters that, in principle, are completely inaccessible to detection in the corrugator, such as papermaking process parameters. The method presented herein is therefore correspondingly dynamic in that the individual characteristics of the paper roll are taken into account. The above also applies to the simultaneous processing of multiple paper rolls, and therefore the paper data of the paper rolls are then jointly utilized to adjust the operating parameters. The paper parameters themselves, and therefore the entire paper data, can be static, i.e., constant for the entire paper roll, or dynamic, i.e., changing along the paper of the paper roll, so that, for example, the parameter profile changes depending on the portion of the paper web that is currently being unwound.Combinations are also possible, whereby one or more paper parameters are static and one or more other paper parameters are dynamic.
[0014] Here, without limiting generality, it is assumed that there are multiple paper rolls, each with multiple paper parameters, and that multiple operating parameters are adjusted depending on the paper parameters, which is also preferred in principle.
[0015] Here, the paper parameters of each paper roll are advantageously used to adjust the operating parameters of the corrugator, and therefore, in particular, to directly adjust the operating parameters and, therefore, to control the corrugator. This contrasts with the aforementioned U.S. Pat. No. 11,162,226, in which a hygroscopic swelling attribute is first assigned to each paper roll based on a comparison with other paper rolls, and then the adjustments within the corrugator are set based on this. That is, there, the operating parameters are not adjusted according to the specific characteristics of each paper roll. Furthermore, there, the assignment is performed using a purely data-based model, which is correlated between multiple corrugators from different cardboard manufacturers, essentially cross-checking the operating parameters of the corrugators. However, in this case, similar or even invariant paper data is assumed (e.g., from the same manufacturer or the same production slot). In other words, while the approach of U.S. Pat. No. 11,162,226 aims to utilize data from different corrugators, the present invention utilizes paper data from (multiple) paper rolls, usually with different paper properties, possibly for a single corrugator.
[0016] Generally, specific paper parameters of a paper roll outside the corrugator have not been used to control the corrugator, even though these parameters must be known. Focusing solely on the corrugated board layer itself, this is not even immediately necessary, since feedback control is also possible, reacting by readjusting operating parameters based on the corrugated board web being produced. However, such reactions, and therefore necessarily subsequent adaptations, inevitably lead to the production of defective or at least suboptimal products, thereby reducing the economic viability of the corrugator. In contrast, the corrugator presented here advantageously has a shortened control system because it utilizes paper parameters for control. Because the values of the paper parameters are known, particularly in the early stages of operation, especially before the paper roll has even been processed, the control system reacts accordingly and proactively to possible changes in the paper parameters. Therefore, the control system here is particularly feedforward control. In contrast, in feedback control, as already explained, the manufactured output product (corrugated board web) is inspected and then the operating parameters are retroactively controlled accordingly, i.e. the output product provides the input signal for the control system, whereas in feedforward control as described and advantageously used herein, the input product (paper roll) provides the input signal for the control system in order to control the operating parameters (strictly speaking, closed loop control) to obtain a particular output product.
[0017] Preferably, the values of the used paper parameters of a single paper roll are aggregated as much as possible, i.e., received by the corrugator from as few different sources as possible and preferably only from a single source, and therefore as a cohesive data set as much as possible. Thus, the paper data is preferably not delivered at different points in the corrugator and / or at different times, but is instead collected in a single data set and / or at a single time. Optionally, even the paper data of multiple paper rolls is aggregated in a similar manner, and aggregated in such a way that individual values can be assigned to a single paper roll, preferably by the ID of each paper roll.
[0018] The present invention utilizes the consideration that the paper characteristics of a paper roll are primarily determined by its manufacture and may then further change during its production (transportation, storage, etc.). Then, when the paper rolls are actually fed into a corrugator and processed there, the values of the paper parameters of each paper roll will change depending on the paper roll's individual history, so that essentially no two paper rolls are exactly the same. By treating different paper rolls approximately equally before processing, it is essentially possible to keep the characteristics of these paper rolls as similar as possible, so that processing with the same operating parameters allows for acceptable variations in the quality of the corrugated web. In fact, this may be sufficient in many cases, but in any case, certain tolerances must be observed when producing the paper.
[0019] The present invention thus further opens up the possibilities offered by actually taking into account the paper properties of each paper roll individually, thereby compensating for even small differences by adjusting the operating parameters accordingly, so that a corrugated board web of maximum quality can be produced from a paper roll with the specified properties. Therefore, another advantage of the method described here is that paper rolls can be produced with relatively large tolerances, since any deviations from ideally defined paper parameter values are optimally compensated for during corrugator operation. This allows paper, and paper rolls in general, to be produced more simply and cost-effectively. Furthermore, in this case, even paper rolls that would previously have been rejected due to their high number of defects can be used. Therefore, it is also possible to use paper rolls that are not normally intended for the production of corrugated board, since the paper data is known and, by using it, basically any desired paper roll can be optimally and systematically used for the production of corrugated board. Finally, this allows paper, and paper rolls in general, to be produced or procured more cost-effectively, with corresponding advantages for the corrugated board web.
[0020] Thus, the individual characteristics of the paper of the paper roll are advantageously utilized here to optimize the process control of the corrugator. In other words, the individual characteristics of the paper roll are used to control the corrugator, whereby the operation of the corrugator depends on the individual values of the paper parameters of each paper roll. Therefore, the corrugator is controlled separately for each roll. This presupposes, in particular, that the paper data of each paper roll is known and available as early as possible, preferably before the paper roll is processed, and therefore is not determined by the corresponding sensor only immediately before the respective processing station. Preferably, the paper data is already known before the paper of the paper roll is fed to the corrugator. Alternatively or additionally, the values of the paper parameters of each paper roll are measured using appropriate sensors in the corrugator, but in this case not immediately before or even after each processing unit, but already when the paper roll is unwound at the unwinder or immediately thereafter, i.e., before the paper web is processed in a processing unit (e.g., printer, single facer, preheater, gluer). The method presented here therefore differs from in-line measurements precisely in that the paper data is provided to the paper roll prospectively and is also specifically utilized, rather than afterwards when it is needed, thereby avoiding suboptimal or rejected products.
[0021] One advantage, in particular, is that the paper data can be used, and is purposefully used, to validate, calibrate, or test sensors on the corrugator. The value of a paper parameter is then sensed by the sensor on the corrugator and compared with the value stored in the paper data for this paper parameter. Based on this, at least the above-mentioned action options of validating, calibrating, and testing the sensor are performed. For example, a moisture sensor on the corrugator can be calibrated and / or correlated with the paper parameter "moisture" from the paper data of the paper roll.
[0022] Another advantage is that, in particular, the energy requirement for producing a corrugated web from each paper roll (i.e., for processing the paper roll) can be determined using the paper data, preferably the temperature and moisture of the paper. Thus, in an expedient embodiment, the energy requirement, which indicates how much energy is required to produce a corrugated web from the paper roll, is determined based on the paper data of the paper roll.
[0023] Preferably, the values of the operating parameters are selected based on rules that link the values of the paper parameters to values of the operating parameters in such a way that the quality measure of the corrugated board web is changed, in particular improved, in particular maximized. The quality measure is essentially arbitrary; examples of suitable quality measures are the degree of curvature of the corrugated board web, also known as "camber," or the percentage of rejects, i.e., the percentage of the corrugated board web that cannot be used as intended due to manufacturing defects. Other suitable quality measures are strength values of the corrugated board web, in particular edge crush resistance (e.g., according to the ECT = Edge Crush Test), flat crush resistance (e.g., according to the FCT = Flat Crush Test), etc., and generally any corrugated board properties. It is also advantageous to combine several quality measures. The rules are trained in a suitable embodiment, i.e., generated in advance by a learning method in which the quality measure is measured as a function of the paper parameter and the operating parameter. The rules are then derived from this function. Various techniques are suitable for the learning method, the details of which are not important for the present purpose.
[0024] Here, the operating parameters are advantageously adjusted not only indirectly but also directly depending on the values of the paper parameters. In this case, the previously described rules are functions in which the paper parameters are input parameters and the corresponding operating parameters are output parameters. The values of the paper parameters are directly converted by the corrugator into appropriate values of the operating parameters according to rules, in particular predefined rules, and these values are then adjusted. Preferably, no intermediate parameter determination is performed. This contrasts with the aforementioned U.S. Pat. No. 11,162,226, in which, for a given paper web, the hygroscopic swelling properties are first determined and then appropriate operating parameters for adjusting the paper web are obtained based on this. This is unnecessary here, since the rules directly link the paper parameters to the operating parameters, thereby eliminating corresponding calculations and pre-examinations. This is based, inter alia, on the recognition that it is not important to know correlations or causal relationships, but rather that it is sufficient to empirically determine the rules in advance by corresponding experiments, learning methods, and / or big data techniques. In this respect, the rules themselves are also not necessarily known and are a kind of black box that simply outputs corresponding values of operating parameters for given paper data. For example, the rules are implemented, for example, by neural networks or in virtual sensors. Basically, various solutions that achieve similar or similar results in different ways are conceivable and suitable.
[0025] The specific paper parameters utilized are not particularly important at this stage, and become less important as the number of paper parameters increases. Accordingly, it is preferable to use at least 10, and in particular at least 100, paper parameters. The total amount of paper data is revealed, inter alia, by the number of values stored for each paper parameter. Static paper parameters contain only a single value (e.g., linear meters on a paper roll, production date, or average value of a dynamic paper parameter), whereas dynamic paper parameters contain a large number of values (e.g., moisture as a function of the width and length of a paper roll), which, inter alia, depends on the value density / sampling rate (e.g., 1 / cm) and typically ranges from 1,000 to 1,000,000 or more. Paper parameters do not necessarily have to have a directly discernible causal relationship with the quality measure of the corrugated web. Knowing the relationship is not particularly important, especially with the big data techniques mentioned above. However, some paper parameters typically have a greater impact on the quality of the corrugated web than others, and are therefore preferably used, especially when only a small number of paper parameters (i.e., at most 10) are used. Therefore, in a suitable embodiment, one or more of the paper parameters are selected from the following paper parameters: paper fiber orientation of the paper roll, breaking stress of the paper of the paper roll.
[0026] In a suitable embodiment, two paper rolls fed to the corrugator for simultaneous processing are selected so that they do not differ from each other by more than a maximum value in at least one of the paper parameters. In other words, the two paper rolls processed simultaneously are as similar as possible. Selecting paper rolls that are as identical as possible simplifies the adjustment of the operating parameters depending on the value of the paper parameter. This is particularly advantageous with respect to moisture. Thus, in a suitable embodiment, one of the paper parameters is the paper moisture of each paper roll. In this case, the two paper rolls (fed to the corrugator for simultaneous processing) are also selected so that their moisture does not differ from each other by more than a maximum value, in particular 2% (relative to each other). In other words, paper rolls with moisture as similar as possible are selected. In this case, the two paper rolls are processed simultaneously, in particular to form different layers of the corrugated board web, preferably the two outer layers of the corrugated board web, i.e., the upper and lower sides. This is based on the idea that if the moisture deviation is too large, i.e., if the deviation is greater than the maximum value, the production of the corrugated board web may become impossible, or at least may not be of sufficient quality. Here, advantageously, the paper parameters are accessible, so that, as mentioned above, it is possible to select the paper rolls precisely so that they are optimally matched to one another, in particular with regard to the respective moisture content of the paper.
[0027] Particularly preferably, at least one of the paper parameters is a dynamic paper parameter, the value of which is shown as a function of the width and / or length of the paper web of the paper roll. In contrast, static paper parameters exhibit the same value along the entire paper web. Suitable dynamic paper parameters are fiber orientation as a function of the width and / or length of the paper web, temperature as a function of the width and / or length of the paper web, for example in the form of a "heat map" showing the temperature at each point on the paper web, and moisture as a function of the width and / or length of the paper web, for example in the form of a "moisture map." Dynamic paper parameters are distinctive in that they may exhibit different values at different points on the paper web and thus represent the non-uniformity of the paper roll. The use of one or more dynamic paper parameters provides a detailed picture of the paper roll, which can be advantageously used when adjusting the operating parameters. The operating parameters are then dynamically adjusted accordingly.
[0028] It is also expedient to use papermaking process parameters, i.e., process parameters used during the production of the paper of each paper roll itself. Papermaking process parameters are not the direct, immediate properties of the paper (moisture, fiber orientation, length, width, etc.), but rather parameters of the paper production, and therefore are only indirect or indirect paper parameters. In a suitable embodiment, the paper parameters accordingly include a number of papermaking process parameters used during the production of the paper roll. Papermaking process parameters are, in particular, operating parameters of the paper machine for producing the paper roll and / or for producing the paper of the paper roll. Using the papermaking process parameters, it is expedient to detect a correlation between the production of the cardboard and the production of the paper used therein, which may not be discernible with direct paper parameters. Therefore, subsequent determination of other paper parameters, such as breaking stress and fiber orientation, temperature, moisture, etc., may become unnecessary in some cases, and thus in advantageous embodiments, these may even be omitted completely or partially. In this case, the recognition that the production of the paper roll ultimately has a decisive influence on these properties and that its production is also decisively influenced by the papermaking process parameters is utilized. They are therefore advantageously used directly to adjust the operating parameters of the corrugator.
[0029] Suitable paper parameters are listed below in particular: a) Characteristics of the paper roll - (Exact) Sleeve Outer Diameter - (Accurate) linear meter on paper roll -Splicing position of paper roll b) Paper production process - Production date -Manufacturer name -Manufacturing location -Manufacturing date -Storage period -Storage conditions (e.g. humidity and / or ambient temperature) -Transportation time -Transport conditions (humidity and / or temperature of the surrounding environment, etc.) c) Basic characteristics of paper -Moisture / moisture content -Mass per unit area -Thickness -ash -Fiber orientation (including fiber orientation angle) d) Tensile properties of paper - Breaking force -Tearing length -Elongation at break - Elastic modulus e) Paper surface / printability characteristics -Smoothness, e.g. according to Bekk) - roughness, e.g. according to Bendtsen - breathability, e.g. according to Bendtsen / Gurley f) Characteristics of corrugated board (especially characteristics of base paper) -Flat crush resistance (e.g. CMT = Conchoramedium Test, FCT = Flat Crush Test, etc.) -Short span compressive strength (e.g. SCT = Short span compressive strength test)
[0030] It should be understood that the above list provides preferred paper parameters but is not exhaustive. Although it is already advantageous to use only a portion of the paper parameters mentioned above, it is expedient to use as many paper parameters as possible.
[0031] Regardless of whether the paper parameters are static or dynamic, paper parameters that change as little as possible or not at all during the life of the paper roll, i.e., until the paper roll is processed in the corrugator, are particularly suitable. For example, the temperature of the paper roll is less suitable (but not entirely unsuitable) since it typically changes during transport from the paper mill to the corrugator. Moisture is less of a concern compared to temperature, but it also generally changes over time. In contrast, fiber direction (and sometimes even as a dynamic paper parameter as a function of width and length) is particularly suitable since it does not change.
[0032] The detection of the values of the paper parameters does not necessarily have to be a component of the method for operating a corrugator described herein. Purposefully, at least one, and preferably all, of the values of the paper parameters of each paper roll are provided in advance, i.e., before the paper roll is fed to the corrugator. Therefore, the values of the paper parameters are known before the paper roll is loaded into the corrugator, and therefore only need to be transmitted to the corrugator to adjust the operating parameters. This allows for uninterrupted and fully automatic operation.
[0033] Suitably, the values of the paper parameters of each paper roll are already determined during its production, in particular in the case of the above-mentioned papermaking process parameters. Alternatively or additionally, the values of the paper parameters of each paper roll are determined after its production, in particular by laboratory tests. In general, it is advantageous if at least some of the paper parameters are further determined already during production or immediately after production, in particular by the manufacturer of the paper roll itself, and subsequently transmitted to the corrugator by being appropriately stored, for example, on a data carrier.
[0034] It is advantageous to update one or more paper parameters based on paper data that represent the history of the paper roll, in particular up to its actual processing in the corrugator. In this case, the paper data includes, on the one hand, one or more paper parameters that change over time (e.g., temperature or moisture), and additionally further logistics data (e.g., storage, transportation, and / or tracking data, such as transportation time, transportation conditions, storage period, supplementary temperature, etc.). Paper parameters that change over time may, for example, undergo changes during or after the production of the paper roll, before its removal from the paper mill, and also due to the storage and transportation of the paper roll. These changes are then traced using the logistics data, and the paper parameters are then updated (i.e., recalculated), preferably just before or during processing in the corrugator. In a suitable embodiment, temperature and moisture loggers are transported on a truck together with the paper roll, and in this case, the initial paper parameters, temperature and moisture from the paper mill, are updated, e.g., enhanced, using the recorded data of the temperature and moisture loggers and corrected using suitable models (temperature distribution calculations and diffusion equations).
[0035] The corrugator preferably has a data interface via which values of the paper parameters of each paper roll are transmitted to the corrugator. The values are transmitted before, during, and / or after loading the corrugator, preferably before the paper roll is unwound for processing. However, to adjust the operating parameters assigned to a processing station, it is generally sufficient to transmit immediately before each processing station at least the values specifically required for processing the paper web entering that processing station. However, in the sense of the preferred predictive approach, all values are preferably transmitted together as a single, aggregated data set via the data interface and are then immediately available.
[0036] In a particularly preferred embodiment, each paper roll is assigned a data carrier on which individual values of paper parameters for the paper of each paper roll are stored. Thus, each data carrier is assigned to exactly one paper roll and, in particular, contains only the paper data of a single paper roll. The data carrier is preferably read by the corrugator to adjust the operating parameters depending on the paper parameters. For this purpose, the corrugator has a suitable reader. The reader is, in particular, part of the data interface already mentioned. The data carrier is suitably a code, for example, a QR code or a barcode, a transponder, for example, an RFID tag or an NFC tag, or a volatile or non-volatile memory, for example, a floppy disk, a CD, or a flash memory. Thus, the reader is, for example, a scanner, a receiving unit with an antenna, a drive, a USB port, etc. The data carrier enables an offline solution in which the values of the paper parameters are transmitted to the corrugator to receive the data sets for each paper roll without connecting to the Internet or another network.
[0037] The data carrier is attached to the paper roll or is provided separately from the paper roll. According to one embodiment, the data carrier is a label or a kind of data sheet for the paper roll, also called a "roll tag." Furthermore, the data carrier can advantageously be sent together with the paper roll. Therefore, in an advantageous embodiment, the data carrier is attached to the paper roll, for example, glued or printed directly on the paper web of the paper roll or on the packaging of the paper roll, for example on the paper or sleeve. This makes the allocation and handling of the data sets particularly uncomplicated. For example, the data carrier is a code attached to the paper roll and read by a reader thereof when loading the corrugator.
[0038] It is generally conceivable that a paper roll is used several times (e.g., three times), i.e., it is not necessarily completely used up after being fed into the corrugator, but is only partially used, and then removed from the corrugator again and stored. If necessary, the partially used paper roll is then fed again to the corrugator at a later time. Therefore, the data carrier is preferably designed to be reliably connected to the paper roll even if the paper roll is fed into or removed from the corrugator several times. In a suitable embodiment, the data carrier is detachable for this purpose, being removed when the paper roll is fed and reattached to the paper roll during removal and subsequent storage. In another suitable embodiment, the data carrier is attached to the paper roll so that it does not need to be removed, i.e., it remains on the paper roll when the paper roll is processed in the corrugator. Expediently, the data carrier is attached centrally for this purpose, in particular on or in the sleeve of the paper roll. Contactless or electronically readable data carriers, such as RFID and NFC tags, are particularly suitable for this purpose. Overall, this ensures that the paper parameters remain available over the entire service life of the paper roll, even if it is used several times. The remarks regarding the data carrier apply equally to the already mentioned ID, which will be explained in more detail below.
[0039] Updating paper parameters is particularly advantageous when a paper roll is used multiple times. For this purpose, in a suitable embodiment, one or more paper parameters of a paper roll are updated when the paper roll is only partially used and removed from the corrugator for later use, particularly when it is temporarily stored away from the corrugator, for example, in a roll warehouse. The update can either change existing paper parameters or add new paper parameters. For example, it is expedient to update the paper length, i.e., to store the remaining paper length, the diameter of the paper roll, and basically all properties of the paper roll that change during processing in the corrugator. A suitable paper parameter that can be added in some cases is the unwinding direction, i.e., the direction in which the paper roll was unwound during processing (especially in the case of paper for corrugating a cardboard web). In a particularly advantageous embodiment, one or more operating parameters of the corrugator used to process the paper roll are stored when the paper parameters are updated, so that the operating parameters last used for this paper roll are accessible and available as soon as the paper roll is used again. Once the operating parameters are selected, they are, so to speak, inherited. Alternatively or additionally, it is also stored which other paper rolls the paper roll has been processed with, and optionally under which operating parameters. In this way, advantageously, operating parameters are learned that are particularly advantageous for working with such or similar paper rolls (e.g. from the same batch). The updating is carried out in particular by means of a writer on the corrugator. Optionally, the reader and writer are combined into a writer-reader.
[0040] Alternatively or in addition to the above-mentioned offline solutions, online solutions, such as cloud solutions, are also fundamentally advantageous. Such online solutions have the particular advantage that, for example, paper parameters can be determined by laboratory tests in parallel (i.e., simultaneously) with the transport of the paper rolls, and then the paper parameters can be transmitted online. In a suitable embodiment, at least some (one or more), in particular all, of the paper rolls have, in particular, individual IDs (also called identifiers or identification marks), which are stored together with the paper data of each paper roll in a database, for example, a data lake. In a suitable embodiment, the database is part of the cloud. The IDs are used to assign specific paper rolls to paper data, which are then detected and / or stored independently of the paper rolls. The use of IDs to assign paper rolls to one data set among multiple aggregated data sets has already been outlined above. In a suitable embodiment, the database is designed separately from the corrugator and is connected to the corrugator for data transmission, for example, via the Internet or another network. A design in which the database is part of the corrugator is also suitable. The database is connected to only one corrugator or, alternatively, to multiple corrugators. The corrugator requests the paper data for each paper roll from the database based on its ID. As soon as the corrugator receives the values, it adjusts its operating parameters accordingly. Essentially, the rules used in this case are also stored in the database, and these rules can directly transmit the relevant values of the operating parameters when the corrugator requests a specific ID. Therefore, even in the case of an online solution, the paper parameters are directly used to control the corrugator, and the ID is merely a pointer to the database to request the corresponding data set, which is not directly attached to the paper roll itself. Instead, the ID is attached to the paper roll, and accordingly, the same explanation regarding the data carrier also applies to the ID.
[0041] A bidirectional interface between the corrugator and the paper machine (or paper mill in general) is also advantageous. In that case, on the one hand, paper data is transmitted to the corrugator via the bidirectional interface in order to control the corrugator as described above. On the other hand, conversely, via the bidirectional interface, cardboard data is transmitted to the paper machine, which is then controlled. In a suitable embodiment, a basically symmetrical relationship is realized in that the cardboard data includes cardboard parameters of the cardboard as well as the paper data, and thus describes the properties of the cardboard. The paper parameters mentioned above in connection with the paper data are also basically suitable as cardboard parameters. Alternatively or additionally, cardboard-specific cardboard parameters, such as, for example, the warp or the quality of the glue, are advantageously used. In that case, the paper machine is controlled using the cardboard data, and the description regarding the control of the corrugator also applies here to the control of the paper machine, in particular, the paper machine being controlled with different operating parameters than the corrugator. One advantage of the two-way interface is that, in particular, any production anomalies or rejects at the corrugator are correlated with the paper data of the paper rolls processed therein and fed back to the paper machine, based on which the paper machine makes appropriate corrections (i.e., appropriately changes its operating parameters) accordingly in order to subsequently produce paper that does not result in the aforementioned production anomalies or rejects, or at least has fewer of them. In other words, the paper machine receives feedback regarding the suitability of the paper produced by the paper machine, and in response to this feedback, the paper machine's operating parameters are optimized with the aim of improving the subsequent production of corrugated board.
[0042] In an expedient embodiment, the corrugator has one or more sensors with which the values of the paper parameters of each paper roll are measured, particularly during operation, while the paper roll is being fed into the corrugator, especially before the paper roll is processed. This is also an online solution. According to this design, processing begins with unwinding from the unwinder of the corrugator and includes, in particular, one or more of the following processing steps: splicing, corrugating (with corrugating rollers), dampening, drying, printing and gluing, and / or connection with another paper web. Knowledge of the actual values of the paper parameters is fundamentally useful for all processing steps, but especially for any processing steps after unwinding or splicing. Therefore, it is sufficient for sensors to be positioned along the paper web downstream of the unwinder or splicer and upstream of each other processing unit. Furthermore, integrating sensors into the unwinder or splicer is also advantageous, so that the values of the paper parameters are measured immediately before, during, or immediately after unwinding / splicing.
[0043] Instead of or in addition to one or more real sensors as described above, in an advantageous embodiment, the corrugator has a virtual sensor, also called a soft sensor. The virtual sensor does not actually perform measurements on the corrugator; instead, paper data, in particular paper parameters detected outside the corrugator (e.g., already during paper production), are supplied to the virtual sensor. Optionally, as described above, one or more paper parameters detected by a real sensor on the corrugator are supplied to the virtual sensor. Since the aforementioned papermaking process parameters cannot be measured on the corrugator itself due to their principle, an embodiment in which these are supplied to the virtual sensor is also particularly advantageous. In that case, the virtual sensor determines operating parameters for the corrugator, in particular from the supplied paper data, and in that sense, converts the aforementioned big data methods and / or the above-mentioned rules into values of the paper parameters in order to assign values of the operating parameters.
[0044] The corrugator according to the invention comprises a control unit designed to carry out the above-mentioned method, in particular to carry out one or more of the above-mentioned steps of the method, for which the control unit controls the processing unit accordingly and thereby adjusts the operating parameters.
[0045] Suitably, the corrugator has a custom-order system, by means of which the adjustment of the operating parameters is planned in advance. This is correspondingly improved by the individual values of the paper parameters being made available for each paper roll. In particular, the custom-order system queries the paper data of each paper roll, for example by means of a reader or ID, and transfers these to the control unit, which then appropriately adjusts the operating parameters and thus the individual processing units, in particular as soon as each paper roll has been processed.
[0046] A computer program product according to the present invention includes commands which, when executed by the corrugator as described above, cause the corrugator to select and adjust operating parameters in the manner described above depending on the values of the respective paper parameters, thereby individually adapting the production of the corrugated board web to the paper of each supplied paper roll. In particular, the above-mentioned rules for assigning values of the operating parameters to values of the paper parameters are also implemented by the computer program product. Suitably, the computer program product includes commands which, when executed by the corrugator, cause the corrugator to implement the above-described order planning system.
[0047] The paper roll according to the present invention is used in particular for producing a corrugated board web and is characterized by a number of paper parameters having individual values, as described above. The paper roll has a data carrier on which the individual values of the paper parameters are stored. The data carrier is designed to be readable by the corrugator in the manner described above, thereby controlling the corrugator, in particular, based on the values of the paper parameters. Alternatively or additionally, the paper roll has an ID for referencing the values of the paper parameters in a database. The ID is designed to function as a pointer for the corrugator to request the values of the paper parameters from the database in the manner described above.
[0048] In the following, exemplary embodiments of the invention will be explained in more detail with reference to the drawings, in which the following are respectively outlined: [Brief explanation of the drawings]
[0049] [Figure 1] FIG. [Figure 2] 2 shows a variant of the corrugator according to FIG. 1;
[0050] 1 and 2 each illustrate a corrugator 2 to illustrate an exemplary embodiment of a method for operating such a corrugator 2. The corrugator 2 is used to produce a corrugated fiberboard web 4 and, to this end, has a number of adjustable operating parameters 6. Herein, and generally, "a number" is understood to mean "one or more" or "at least one." Adjustment of the operating parameters 6 is performed by selecting and setting values for the operating parameters 6. The operating parameters 6 are used to control the behavior of one or more processing units 8 of the corrugator 2. Examples of processing units 8 include an unwinder 10, a splicer, a printer, a single facer, a bridge, a preheater, a gluer, a double facer, a drying section, a cutting unit, a slitter unit, a groover unit, etc.
[0051] Within the scope of the method, a number of paper rolls 12, each having a paper web of paper from which a corrugated board web 4 is produced, are fed to the corrugator 2. Each paper roll 12 is formed by a wound paper web, which is unwound by the unwinder 10 by the corrugator 2 and appropriately connected to other paper webs of other paper rolls 12 in order to produce a corrugated board web 4. The converting unit 8 then processes the paper web in accordance with the operating parameters 6. In the figure, the paths of the paper webs and the corrugated board web 4 through the corrugator 2 are only shown very simply.
[0052] Each paper roll 12 is characterized by a number of paper parameters 14, each having a distinct value for each individual paper roll 12, such that each paper roll 12 is individually characterized based on the values of its paper parameters 14 (also referred to as paper data). Each paper parameter 14 directly or indirectly represents one or more characteristics of the paper of the paper roll 12, such that different values signify or imply correspondingly different characteristics. Typically, two paper rolls 12 differ in one or more of the paper parameters 14 due to their production, storage, transportation, etc. This individuality of the paper rolls 12 is taken into account during processing and utilized to optimize the corrugated web 4. For this purpose, the operating parameters 6 are adjusted according to the values of the paper parameters 14, such that the production of the corrugated web 4 is individually adapted for each paper roll 12. Accordingly, the individual paper data of the paper rolls 12 is used to control the corrugator 2, such that the operation of the corrugator depends on the distinct values of the paper parameters 14 of each paper roll 12. The values of the used paper parameters 14 of a single paper roll 12 are here aggregated as much as possible, ie put together in a data set 16 .
[0053] In the illustrated exemplary embodiment, the values of the operating parameters 6 are selected based on rules 18, which link the values of the paper parameters 14 to the values of the operating parameters 6 in such a way that the quality measure of the corrugated board web 4 is maximized. The rules 18 are, for example, trained, i.e. generated in advance in a learning method in which a relationship between the operating parameters 6 and the paper parameters 14 is detected, in which case the rules 18 are determined directly from these data or indirectly via a function derived from these data.
[0054] Here, the operating parameters 6 are adjusted not only indirectly, but also directly depending on the values of the paper parameters 14. The rules 18 are in this case, for example, functions having the paper parameters 14 as input parameters and, accordingly, the operating parameters 6 as output parameters. The values of the paper parameters 14 are converted by the corrugator 2 according to the rules 18 into appropriate values of the operating parameters 6, which are then also adjusted. Preferably, no determination of any intermediate parameters is made.
[0055] Which specific paper parameters 14 are used is not particularly important for the time being, and becomes less relevant as the number of paper parameters 14 increases. Therefore, here, as many as possible paper parameters 14 are used, for example, at least 10, or even at least 100. However, some paper parameters 14 usually have a greater influence on the quality of the corrugated board web 4 than other paper parameters 14, and therefore are used appropriately in possible embodiments. For example, in this case, one or more of the paper parameters 14 are selected from the following paper parameters 14: paper fiber orientation of the paper roll, paper breaking stress 12 of the paper roll.
[0056] In a possible embodiment, at least one of the paper parameters 14 is a dynamic paper parameter 14, the value of which is shown as a function of the width and / or length of the paper web of the paper roll 12. In contrast, the static paper parameters 14 have the same value along the entire paper web of the paper roll 12. Suitable dynamic paper parameters 14 are moisture and temperature as a function of the width and / or length of the paper web of the paper roll 12.
[0057] Alternatively or additionally, the paper parameters 14 include a number of papermaking process parameters used during the production 20 of the paper for the paper roll 12. The papermaking process parameters are operating parameters of a paper mill's paper machine for producing the paper roll 12, or at least for producing the paper for the paper roll 12.
[0058] In the exemplary embodiment shown here, some or all of the values of the paper parameters 14 for each paper roll 12 are determined in advance, i.e., before the paper roll 12 is fed into the corrugator 2. Thus, the values of the paper parameters 14 are already known before the paper roll 12 is loaded into the corrugator 2, and the operating parameters 6 need only be adjusted by communicating those values to the corrugator 2.
[0059] Furthermore, at least some of the values of the paper parameters 14 of each paper roll 12, in particular the above-mentioned papermaking process parameters, have already been determined during its production 20. Alternatively or additionally, the values of the paper parameters 14 of each paper roll 12 have been determined after its production 20, for example by laboratory tests 22. For example, the paper parameters 14 are determined and stored during or shortly after production 20, possibly by the manufacturer of the paper roll 12 itself.
[0060] In the illustrated exemplary embodiment, the corrugator 2 has a data interface 24, via which the values of the paper parameters 14 of each paper roll 12 are transmitted to the corrugator 2. These values are transmitted before, during and / or after loading of the corrugator 2, for example already before the paper roll 12 has been unwound for processing.
[0061] In the exemplary embodiment of FIG. 1 , each paper roll 12 is assigned a data carrier 26, which stores the individual values of the paper parameters 14 for that paper roll 12. Each data carrier 14 is assigned to exactly one paper roll 12 and contains only the values for that single paper roll 12. The data carrier 26 is read by the corrugator 2 to adjust the operating parameters 6 in response to the paper parameters 14. For this purpose, the corrugator 2 has a suitable reader 28. The data carrier 26 enables an offline solution in which the values of the paper parameters 14 are transmitted to the corrugator 2 without connecting to the Internet or another network to receive the data sets 16 for each paper roll 12. The data carrier 26 can be sent together with the paper roll 12 and is, so to speak, a label or a kind of data sheet for the paper roll 12. In the embodiment shown here, the data carrier 26 is attached to the paper roll 12.
[0062] Instead of or in addition to an offline solution, an online solution is also advantageous. An exemplary embodiment of this is shown in FIG. 2. There, each paper roll 12 has an ID 30, which is stored in a database 32 together with the values of the paper parameters 14 of the paper roll 12. The ID 30 is attached to the paper roll, for example, similar to the data carrier 26 in FIG. 1. The database 32 may be designed separately from the corrugator 2, as shown in FIG. 2, or may be part of it (not shown). The corrugator 2 requests the values of the paper parameters 14 of each paper roll 12 from the database 32 based on its ID 30. As soon as the corrugator 2 receives the values, the operating parameters 6 are adjusted accordingly. Essentially, the rules 18 potentially used here can also be stored in the database 32, and the database can directly transmit the associated values of the operating parameters 6 when the corrugator 2 requests a given ID 30. Therefore, even in the case of an online solution, the paper parameters 14 are used directly to control the corrugator 2, and the ID 30 is merely a virtual placeholder for the paper roll 12 and its paper data to query the associated data set 16.
[0063] In the exemplary embodiment of FIG. 1 , the corrugator 2 has one or more sensors 34 by means of which some values of the paper parameters 14 of each paper roll 12 are measured during operation. In this case, this paper roll 12 has already been introduced into the corrugator 2. This is also an online solution. The process essentially begins with unwinding from the unwinder 10 and includes all subsequent processing steps. Essentially, knowing the actual values of the paper parameters 14 is useful for all processing steps, but especially for any processing steps after unwinding or splicing. Therefore, unlike in FIG. 1 , it is sufficient for the sensors 34 to be positioned along the paper web downstream of the unwinder 10 or splicer and upstream of each other processing unit 8. The solution using one or more sensors 34 is also applicable to the exemplary embodiment of FIG. 2 .
[0064] Each corrugator 2 further comprises a control unit 36 designed to implement the above-described method. The control unit 36 controls the converting units 8 accordingly and adjusts the operating parameters 6 accordingly. Furthermore, the corrugator 2 of FIG. 2 also comprises a custom-order system 38, by means of which the adjustment of the operating parameters 6 is planned in advance. The custom-order system 38, for example, uses the ID 30 of each paper roll 12 to query the values of the paper parameters 14 of each paper roll 12 from the database 32 used, as shown in FIG. 2, and transfers them to the control unit 36, which then adjusts the operating parameters 6 and thus the individual operating units 8 as soon as each paper roll 12 is processed. A custom-order system 38 is also possible in the embodiment according to FIG. 1.
[0065] Each of the corrugators 2 shown here also executes a computer program product including commands for operation that causes the corrugator 2 to select and adjust the operating parameters 6 in the manner described above in response to the values of the respective paper parameters 14 as described above, thereby individually adapting the production of the corrugated board web 2 to each of the supplied paper rolls 12.
[0066] Individual aspects described or illustrated in connection with only one of the exemplary embodiments may also be applied to other exemplary embodiments, essentially independently of other concepts included in that exemplary embodiment. [Explanation of symbols]
[0067] 2 Corrugator 4 Cardboard 6 Operating parameters 8 Processing Unit 10 Unwinder 12 paper rolls 14 Paper parameters 16 datasets 18 rules 20. (Paper roll) manufacturing 22 Laboratory Testing 24 Data Interface 26 Data Carrier 28 Reader 30 ID 32 databases 34 Sensors 36 Control Unit 38 Order Planning System
Claims
1. A method of operating a corrugator (2), comprising: - said corrugator (2) is used to produce a corrugated board web (4) and to this end has a number of adjustable operating parameters (6); - said corrugator (2) is supplied with a number of paper rolls (12) each containing a paper web made from the paper from which said corrugated board web (4) is produced; - each of said paper rolls (12) is characterized by a number of paper parameters (14) having individual values for each of said paper rolls (12), whereby each of said paper rolls (12) is individually characterized based on said values of said paper parameters (14) of said paper roll; - the operating parameters (6) are adjusted depending on the values of the paper parameters (14), whereby the production of the corrugated board web (4) is individually adapted to the respective supplied paper roll (12).
2. the values of the operating parameters (6) are selected based on rules (18), which rules link the values of the paper parameters (14) to values of the operating parameters (6) such that a quality measure of the corrugated board web (4) is influenced, in particular improved, in particular maximized; The method of claim 1.
3. The one or more of the paper parameters (14) are selected from the following paper parameters (14): fiber orientation of the paper of the paper roll (12), breaking stress of the paper of the paper roll (12), 3. The method according to claim 1 or 2.
4. One of the paper parameters (14) is the paper moisture content of each paper roll (12); the two paper rolls (12) fed to the corrugator (2) for simultaneous processing are selected such that the moisture contents of the two paper rolls do not differ from each other by more than a maximum value; The method according to any one of claims 1 to 3.
5. At least one of the paper parameters (14) is a dynamic paper parameter (14), the value of which is expressed as a function of the width and / or length of the paper web of the paper roll (12). The method according to any one of claims 1 to 4.
6. The paper parameters (14) include a number of papermaking process parameters used during the production (20) of the paper for each paper roll (12); The method according to any one of claims 1 to 5.
7. the value of the paper parameter (14) of the paper of each paper roll (12) is detected before the paper roll (12) is fed to the corrugator (2); The method according to any one of claims 1 to 6.
8. The corrugator (2) has a data interface (24), and values of paper parameters (14) of the paper of each paper roll (12) are transmitted to the corrugator (2) via the data interface. The method according to any one of claims 1 to 7.
9. Each paper roll (12) is assigned a data carrier (26) on which individual values of the paper parameters (14) of the paper of each paper roll (12) are stored, The data carrier (26) is read in particular by the corrugator (2), The method according to any one of claims 1 to 8.
10. The data carrier (26) is attached to the paper roll (12).
10. The method of claim 9.
11. At least some of the paper rolls (12), in particular all of the paper rolls (12), have an ID (30), said ID being stored in a database (32) together with the values of the paper parameters (14) of the paper of each of the paper rolls (12), The corrugator (2) requests the values of the paper parameters (14) of the paper of each of the paper rolls (12) from the database (32) based on the ID (30) of each of the paper rolls; The method according to any one of claims 1 to 10.
12. the corrugator (2) has one or more sensors (34) for measuring the value of the paper parameter (14) of the paper of each paper roll (12) while the paper roll is being fed into the corrugator (2); The method according to any one of claims 1 to 11.
13. A corrugator (2) having a control unit (36) designed to carry out the method according to any one of claims 1 to 12.
14. 13. A computer program product comprising commands which, when executed by a corrugator (2), cause the corrugator (2) to select and adjust operating parameters (6) in accordance with values of respective paper parameters (14) in a method according to any one of claims 1 to 12, thereby individually adapting the production of the corrugated board web (4) to the paper of the respective supplied paper rolls (12).
15. - characterized by a number of paper parameters (6) with distinct values, - a data carrier (26) on which the individual values of the paper parameters (14) are stored, the data carrier being designed to be readable by the corrugator (2) in a method according to any one of claims 1 to 12, and / or A paper roll (12) having an ID (30) for referencing values of said paper parameters (14) in a database (32), said ID (30) being designed to request values of said paper parameters (14) from said database (32) based on said ID (30) by a corrugator (2) in a method according to any one of claims 1 to 12.
Citation Information
Patent Citations
Paper-specific moisture control in advancing paper webs.
JP2022536194A