Corrugator Feedforward Control for Variable Paper Roll Pairing
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Solution Overview
Problem
Existing corrugated board production methods fail to account for the individual properties of paper rolls, leading to suboptimal product quality and increased rejects due to variations in paper properties, which are typically addressed through feedback control systems that react retrospectively to the manufactured output.
Innovation Solution
A feedforward control system that utilizes paper data, including individual paper parameters of each roll, to proactively adjust operating parameters of the corrugated board machine, ensuring optimal production by considering the unique properties of each paper roll before processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If feedback control systems are used to adjust operating parameters based on measurements taken directly in front of each processing unit, then the system can react to changing environmental conditions and varying paper web properties, but the control is retrospective and does not prevent quality deviations from occurring in the first place
Solution Approach 1:
The system performs preliminary action by determining operating parameters for processing units based on paper web properties before the paper web actually enters each processing unit. This feedforward approach uses measured properties (such as moisture content, tensile strength, thickness) to proactively set optimal processing conditions in advance, preventing quality deviations rather than reacting to them after they occur.
Solution Approach 2:
The system implements feedback by using measurements taken from the paper web (moisture content, tensile strength, thickness, etc.) to automatically adjust operating parameters of processing units. The control system continuously monitors paper web properties and uses this feedback information to optimize processing conditions, creating a closed-loop control system that adapts to varying paper qualities.
2Productivity
If manual setting of operating parameters by operators is used, then flexibility in adjustment is maintained, but production efficiency decreases and consistency is compromised
Solution Approach 1:
The system implements self-service by automatically determining optimal operating parameters for processing units based on measured paper web properties without requiring manual operator intervention. The control system autonomously processes measurement data, calculates appropriate parameters, and adjusts processing unit settings automatically, enabling the system to regulate itself based on real-time paper quality conditions.
Solution Approach 2:
The system applies parameter changes by dynamically adjusting operating parameters (such as temperature, speed, tension, moisture content) of processing units based on the specific properties of each paper web batch. Rather than using fixed manual settings, the system continuously modifies parameters to match the actual paper characteristics, optimizing processing conditions for each unique paper roll.
3Reliability
If paper rolls with strict tolerances are used, then product quality is maintained, but material costs increase and availability decreases
Solution Approach 1:
The system enables the use of paper rolls with greater tolerances by dynamically adjusting processing parameters to compensate for variations in paper properties. Instead of requiring tight manufacturing tolerances in the paper rolls themselves, the system modifies operating parameters (temperature, speed, tension, moisture) to accommodate a wider range of paper qualities, thereby reducing material costs and improving availability without sacrificing final product quality.
Data Source
Figure 1
AI summary
The invention relates to a method for producing a corrugated cardboard web (4) by means of a corrugator (2), a plurality of paper rolls (10, 12) being provided, each having a paper web made of paper, the paper rolls (10, 12) each being characterised by a number of paper parameters (16) which have individual values for each of the paper rolls (10, 12) so that each of the paper rolls (10, 12) is individually characterised on the basis of their values for the paper parameters (16), an assignment rule (18) being provided which links the paper parameters (16) of two paper rolls (10, 12) with a quality parameter (20) which results from combining said two paper rolls (10, 12) for producing the corrugated cardboard web (4), a first paper roll (10) and a second paper roll (12) being selected from the paper rolls (10, 12) with the aid of the assignment rule (18) in such a way that the quality parameter (20) is optimised, the corrugated cardboard web (4) being produced by feeding the first and second paper rolls (10, 12) to the corrugator (2) which then connects the paper webs of said first and second paper rolls (10, 12) to one another. The invention also relates to a corrugator (2) and to a computer programme product.