Corrugator Paper Roll Matching for Stable Cardboard Web Quality
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of corrugated cardboard webs is hindered by variations in the properties of different paper webs, leading to reduced quality and potential waste due to issues like distortion and suboptimal gluing, which existing control methods struggle to address effectively.
Innovation Solution
A method involving 'role matching' or 'role pairing' where paper rolls are intelligently selected and combined based on their paper parameters using an assignment rule, optimized through machine learning, to produce high-quality corrugated cardboard webs by minimizing deviations and optimizing production parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If paper rolls with varying properties are joined together to form corrugated cardboard web, then production flexibility is improved, but quality of the corrugated cardboard web deteriorates due to distortion and suboptimal gluing
Solution Approach 1:
The system performs preliminary measurement of paper web properties (moisture content, thickness, density) before joining operations, and pre-adjusts operating parameters of processing units based on these measurements. This advance preparation ensures that when paper rolls with varying properties are joined, the quality parameters are already optimized, preventing distortion and gluing issues while maintaining production flexibility.
Solution Approach 2:
The corrugator incorporates inline measurement systems that continuously monitor paper web properties during production. These measurements feed back to the control system, which automatically adjusts operating parameters of subsequent processing units. This closed-loop feedback ensures that variations in paper roll properties are compensated in real-time, maintaining consistent corrugated cardboard web quality even when joining different paper rolls.
2Manufacturing precision
If operating parameters are manually adjusted by operator to compensate for varying paper web properties, then quality control is improved, but productivity deteriorates due to time-consuming adjustments
Solution Approach 1:
The corrugator system performs self-adjustment of operating parameters through automated control. The inline measurement systems continuously monitor paper web properties, and the control system automatically modifies processing parameters without operator intervention. This self-service capability maintains high quality control while eliminating time-consuming manual adjustments, thereby preserving productivity.
Solution Approach 2:
The system replaces manual mechanical adjustment with automated electronic control. Instead of operators physically adjusting parameters based on experience, sensors measure paper properties and electronic control systems automatically adjust processing parameters. This substitution of mechanical/manual operations with automated systems maintains quality control while significantly improving production speed.
3Device complexity
If open-loop control is used to adjust operating parameters, then simplicity of control system is maintained, but ability to compensate for varying paper web properties deteriorates
Solution Approach 1:
The corrugator implements closed-loop control by incorporating inline measurement systems that continuously monitor paper web properties during production. These measurements provide feedback to the control system, which automatically adjusts operating parameters based on actual paper conditions. This feedback mechanism significantly improves the ability to compensate for varying paper web properties while adding only moderate complexity through standardized sensor and control components.
Solution Approach 2:
The control system dynamically changes operating parameters (temperature, moisture, speed, tension) based on measured paper web properties. By continuously adapting parameters to match actual paper conditions, the system achieves high compensation capability. The parameter changes are automated through control algorithms that translate sensor measurements into appropriate adjustments, balancing complexity with performance.
Data Source
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.