Industrial Roll Sensor Arrays for Accurate Pressure Profiles
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Solution Overview
Problem
Industrial rolls in papermaking processes face challenges in accurately measuring pressure profiles due to overlapping sensor signals, especially in wide nip or multiple nip applications, leading to erroneous measurements.
Innovation Solution
The implementation of a sensing system with multiple sets of sensors arranged in helical configurations and connected by separate signal carrying members, allowing for selective monitoring by a signal processing unit to prevent signal overlap and ensure accurate data collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are arranged in a single helical configuration and connected by a single signal carrying member, then the sensing system can provide comprehensive pressure profile data, but sensor signals overlap in wide nip or multiple nip applications leading to erroneous measurements
Solution Approach 1:
The sensor array is divided into multiple independent sets (first set, second set, etc.), with each set arranged in its own helical configuration and connected by separate signal carrying members. This segmentation prevents signal overlap because only one sensor from each set is active at any given time, even in wide nip or multiple nip applications. The segmentation principle directly resolves the contradiction by maintaining measurement precision while eliminating the reliability issue caused by overlapping signals.
2Device complexity
If a single signal carrying member connects all sensors serially, then the device structure is simplified, but signal overlap occurs when multiple sensors are simultaneously positioned in nips
Solution Approach 1:
The single signal carrying member is segmented into multiple separate signal carrying members, each dedicated to a specific sensor set. This increases device complexity slightly but eliminates signal overlap entirely, as each signal carrying member transports signals from its own set independently. The segmentation ensures that even though more components are used, measurement precision is maintained or improved because overlapping signals no longer corrupt the data.
3Measurement precision
If sensors are densely arranged to capture detailed pressure profiles, then measurement coverage is improved, but the likelihood of signal overlap increases in wide nip applications
Solution Approach 1:
The dense sensor array is segmented into multiple sets with different helical configurations. Each set can maintain high sensor density for detailed pressure profile capture, but because the sets are independent and only one sensor per set is active at a time, signal overlap interference is eliminated. This segmentation allows the system to achieve both high measurement precision and freedom from harmful signal overlap effects.
Solution Approach 2:
The multiple sensor sets operate in a periodic manner, with each set being activated sequentially as the roll rotates. This periodic activation ensures that even though sensors are densely arranged, only one sensor from each set contributes to the measurement at any moment, preventing signal overlap. The periodic action principle maintains high measurement precision while avoiding the harmful effects of simultaneous signal generation from multiple sensors.
Data Source
AI summary
An industrial roll includes: a substantially cylindrical core having an outer surface; a polymeric cover circumferentially overlying the core outer surface; and a sensing system. The sensing system includes: a first signal carrying member serially connecting a first set of sensors; a second signal carrying member serially connecting a second set of sensors; and a signal processing unit operatively associated with the first and second signal carrying members and configured to selectively monitor the signals provided by the first and second set of sensors.