Calender Temperature Control via Dual Sensor Feedback
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Solution Overview
Problem
The calendering process often results in inconsistent outcomes despite control of heating means, belt pressure, and contact time, highlighting the need for improved temperature measurement and control to achieve consistent calendering results.
Innovation Solution
Incorporating temperature sensors to measure the outer periphery and fluid temperatures of the roller, with control means adjusting heating means, belt pressure, and contact time based on these measurements, and utilizing a database to store and analyze data for optimal process control, including parameters like material properties and ambient conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are installed to measure outer periphery and fluid temperatures, then temperature measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent implements feedback control by installing temperature sensors to measure the actual temperature of the roller outer periphery and fluid, then using this measured data to adjust the heating means power output. This closed-loop feedback system ensures accurate temperature control while justifying the added device complexity through improved process consistency and quality.
Solution Approach 2:
The patent replaces manual or mechanical temperature estimation methods with electronic temperature sensors and automated control systems. This substitution of mechanical/measured approaches with electronic sensing and digital control enables precise temperature measurement and adjustment, improving measurement precision despite increased device complexity.
2Manufacturing precision
If control means adjust heating means, belt pressure, and contact time based on temperature measurements, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent implements dynamic control by allowing the heating means power, belt pressure, and contact time to be adjusted in real-time based on measured temperature variations. This dynamic adjustment capability enables the system to adapt to changing conditions and maintain precise calendering results, justifying the increased device complexity through improved manufacturing precision.
Solution Approach 2:
The patent changes operational parameters (heating power, belt pressure, contact time) based on measured temperature values. By dynamically adjusting these parameters in response to temperature feedback, the system achieves precise control over the calendering process, with the added complexity justified by the significant improvement in manufacturing precision.
3Reliability
If multiple temperature sensors are used to measure different temperature points, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent segments the temperature measurement system into multiple independent temperature sensors positioned at different locations (roller outer periphery and fluid temperature). This segmentation allows each sensor to independently monitor specific temperature points, improving overall system reliability through redundant measurements while the modular sensor design keeps the added complexity manageable.
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 enables more accurate and consistent calendering processes by directly measuring and controlling critical temperature points, improving the quality of the calendering results through data-driven adjustments.
Implementation Method 1
The heat comes from the heating means which heat the fluid, such as oil or air, whereby the roller is heated by the heated fluid
Implementation Method 2
Direct heating of the roller by for instance radiation takes place particularly in the case of air-filled rollers
Implementation Method 3
at least one first temperature sensor, also referred to below as the first temperature sensor, which measures the temperature at the outer periphery of the roller
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
The invention relates to a calender, comprising a rotatable roller, a belt, co-acting with the roller, with a determined belt pressure, wherein at least one material for feeding through the calender is situated between the roller and the belt for a determined contact time during throughfeed through the calender, heating means for heating the fluid and/or the roller, control means for controlling the heating means and/or the belt pressure and/or the contact time, and at least one first temperature sensor for measuring the temperature of an outer periphery of the roller and at least one second temperature sensor for measuring the temperature of the fluid, wherein the control means are configured to control the heating means and/or the belt pressure and/or the contact time on the basis of the measured outer periphery temperature and the measured fluid temperature. The invention further relates to a set with a plurality of such calenders and a method for controlling such a calender.