Fiber Orientation Control via Edge Flow Simulation
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Solution Overview
Problem
Existing paper machines face challenges in accurately controlling fiber orientation, which affects the dimensional stability and strength of paper, as prior methods lack a quantitative approach to adjust edge flow and slice lip openings effectively.
Innovation Solution
A fiber orientation control method and apparatus that uses a simulation system to measure and adjust fiber orientation by manipulating slice bolts, edge flow valves, and side bleed valves, based on mathematical models and real-time data comparison to converge the actual fiber orientation profile to an ideal profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fiber orientation control methods are used, then basic fiber orientation control is achieved, but manufacturing precision is insufficient due to lack of quantitative adjustment data
Solution Approach 1:
The patent performs simulation calculations beforehand to establish the relationship between control parameters (edge flow rate, slice lip opening) and fiber orientation angles. This preliminary action provides quantitative data that guides actual control operations, eliminating the need for trial-and-error adjustments and enabling precise control from the start.
Solution Approach 2:
The patent implements a feedback mechanism where the actual fiber orientation angle is measured, compared with the target angle, and the difference is used to adjust control parameters. The simulation-based quantitative relationships enable accurate calculation of required parameter adjustments, ensuring the fiber orientation converges to the target value with high precision.
2Productivity
If trial-and-error adjustment method is used, then basic control functionality is maintained, but productivity is reduced due to repeated adjustments and extended control time
Solution Approach 1:
The simulation calculations are performed in advance to establish quantitative adjustment guidelines. This preliminary action eliminates the need for repeated trial-and-error adjustments during actual operation, significantly reducing control time and improving productivity while maintaining accurate fiber orientation control.
Solution Approach 2:
The system uses the established quantitative relationships to automatically determine the required adjustment amounts based on measured deviations. This self-service capability eliminates manual trial-and-error processes, enabling the control system to autonomously achieve target fiber orientation quickly and efficiently.
3Manufacturing precision
If quantitative control method is implemented, then manufacturing precision is improved, but device complexity increases due to simulation system and measurement devices
Solution Approach 1:
The patent creates a virtual copy of the paper making process through simulation calculations. This virtual model replicates the relationship between control parameters and fiber orientation, enabling precise control without requiring complex physical measurement and adjustment systems. The simulation model serves as a digital twin that simplifies the overall control architecture.
Data Source
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AI summary
A method includes steps of: expressing changes of velocity components of a paper material at an exit of a slice lip by using a mathematical model, wherein the changes of velocity components are caused by manipulating an edge flow adjustment means (or a side bleed adjustment means) of a headbox when supplying the paper material on a wire; without changing a velocity component of a flow of the paper material in the mathematical model, setting the mathematical model based on an assumption in which a velocity component orthogonally crossing a flow direction of the paper material is proportionally changed by changes of an edge flow (or a side bleed) of a certain response width from the exit of the slice lip; and conducting a forecasting calculation of changes of a fiber orientation profile in a cross direction by using the mathematical model.