Accelerometer Angular Position Detection for Rotating Roll Noise Reduction
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Solution Overview
Problem
Existing industrial roll sensing systems are prone to false readings due to signal noise, particularly when using trigger signals to determine the angular position of sensors embedded in polymeric covers, which can lead to inaccuracies in pressure and position information.
Innovation Solution
A method utilizing an accelerometer attached to the roll to detect signals and establish the angular position by setting pre-trigger and trigger thresholds, ensuring accurate triggering and reducing noise-induced errors, implemented through a controller and computer program product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a trigger signal is used to determine the angular position of sensors on a rotating roll, then the system can provide position information for pressure sensors, but false readings occur due to signal noise
Solution Approach 1:
The system performs preliminary action by detecting a pre-trigger threshold signal before the main trigger event. This preliminary detection allows the system to prepare and filter signals in advance, distinguishing true trigger events from noise by establishing a known temporal sequence: pre-trigger signal first, then main trigger signal. This resolves the contradiction by improving reliability through preliminary signal validation while maintaining measurement precision through accurate trigger detection.
Solution Approach 2:
The system implements feedback by continuously monitoring accelerometer signals and comparing them against threshold criteria. The controller uses feedback from the pre-trigger detection to validate subsequent trigger signals, creating a closed-loop verification process. This feedback mechanism filters out false positives caused by noise while maintaining accurate angular position measurement, resolving the reliability-precision contradiction.
2Loss of information
If sensors are embedded in the polymeric cover of the roll, then pressure information can be collected across the web sheet, but signal noise causes false readings
Solution Approach 1:
The accelerometer serves as an intermediary device that provides a reference signal for validating sensor readings. By measuring roll position independently of the pressure sensors, the accelerometer creates a reference framework against which pressure sensor triggers can be validated. This intermediary measurement system resolves the contradiction by providing a noise-resistant position reference that validates the completeness of pressure information while filtering false readings.
Solution Approach 2:
The system replaces direct mechanical contact-based triggering with an accelerometer-based optical/electronic detection system. Instead of relying solely on mechanical pressure sensor triggers that are susceptible to noise, the system uses accelerometer measurements of roll motion to establish a more reliable trigger reference. This substitution reduces noise-induced false readings while maintaining complete pressure and position information collection.
3Adaptability or versatility
If the roll operates in demanding environments with high dynamic loads and temperatures, then the roll can perform required papermaking functions, but sensor signals become noisy and unreliable
Solution Approach 1:
The system performs preliminary signal validation by detecting pre-trigger threshold signals before processing main sensor data. This preliminary action allows the system to establish a valid measurement window in advance, filtering out noise generated by harsh environmental conditions. The pre-trigger detection creates a temporal marker that validates subsequent sensor readings, maintaining signal reliability while preserving the roll's operational capability in demanding environments.
Solution Approach 2:
The system uses feedback from accelerometer measurements to continuously validate sensor signal reliability. By comparing sensor triggers against the accelerometer-derived position reference, the system creates a feedback loop that identifies and rejects noise-corrupted signals. This feedback mechanism maintains signal reliability in harsh environments while allowing the roll to operate at full capability across varying temperatures and dynamic loads.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures precise determination of the roll's angular position, reducing false positives and enhancing the accuracy of sensor data collection, particularly in environments with multiple nips and complex pressure profiles.
Implementation Method 1
detecting signals generated by an accelerometer attached to an end of a rotating roll
Data Source
AI summary
A method of determining the angular position of a roll includes: (a) detecting signals generated by an accelerometer attached to an end of a rotating roll; (b) determining whether a signal generated in step (a) has reached a pre-trigger threshold, and repeating step (a) if the signal has not reached the pre-trigger threshold; (c) if the signal is determined in step (b) to have reached the pre-trigger threshold, detecting a subsequent signal generated by the accelerometer; (d) determining whether the signal detected in step (c) has reached a trigger threshold, and repeating step (c) if the signal has not reached the trigger threshold; and (e) if the signal has reached the trigger threshold, establishing the angular position of the roll based on the signal that has reached the trigger threshold.