Cardboard Sheet Warpage Prediction for Fast Control Table Updates
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Solution Overview
Problem
The existing cardboard sheet manufacturing systems face challenges in promptly suppressing warping, leading to sheet damage due to the need for frequent feedback control adjustments with changes in production states, resulting in delayed warping suppression.
Innovation Solution
A cardboard sheet manufacturing system that includes a production state information acquisition unit, operation state information acquisition unit, control table storage unit, control value output unit, control unit, warping state information acquisition unit, information editing unit, prediction model calculation unit, and control table update unit, which allows for the exclusion of transient operation state information and defects to update target control values precisely, enabling rapid warping suppression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If feedback control is performed frequently to adapt to production state changes, then warping suppression accuracy is improved, but response time deteriorates
Solution Approach 1:
The system performs preliminary actions by storing multiple pre-calculated control value sets in advance for different production states. When a production state change is detected, the system immediately retrieves and applies the corresponding pre-prepared control values, eliminating the need for real-time calculation and achieving both high accuracy and fast response.
Solution Approach 2:
The system dynamically switches between different control value sets based on detected production state changes. The control values are not fixed but are selected and adjusted dynamically according to the current production state, allowing the system to adapt quickly to changing conditions while maintaining optimal warping suppression performance.
2Adaptability or versatility
If matrix control with pre-control tables is used to set initial control values, then adaptability to production states is improved, but control precision deteriorates
Solution Approach 1:
The system incorporates feedback mechanisms where the actual warping state is measured and used to adjust the control values. The warping detection unit continuously monitors the cardboard sheet warping state, and this feedback information is used to fine-tune the control values applied to the preheater, ensuring both adaptability to different production states and high precision in warping suppression.
Data Source
AI summary
A cardboard sheet manufacturing system includes an information editing unit storing production state information, operation state information, and warping state information as acquisition information in a storage unit, the information editing unit deleting, in a case where the stored acquisition information includes prescribed information to be deleted, the information to be deleted from the storage unit and outputting the acquisition information stored in the storage unit as editing information. The system also includes an editing information storage unit storing the editing information output from the information editing unit, a prediction model calculation unit calculating a prediction model of the warping state based on the editing information stored in the editing information storage unit; and a control table update unit updating a target value of a control value of a control element in the cardboard sheet manufacturing apparatus, based on the prediction model.