Paper Machine Formation Sensing for Real-Time Variability Tracking
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Solution Overview
Problem
Existing paper machines face delays in identifying the precise location of variability introduction due to continuous changes in machine variables, leading to waste and out-of-specification products during grade changes, with limited real-time monitoring capabilities for multi-layer sheet formation.
Innovation Solution
A formation detection system with two or more sensors and a control system that matches formation data from different locations along the paper machine to identify and compensate for negative changes in real-time, monitoring each stage from the wet end to the reel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional scanners are used to monitor paper formation, then the system can detect formation changes, but the precise location of the impact is not known due to lag and continuous variable changes
Solution Approach 1:
The paper machine is divided into multiple monitoring sections, each with its own scanner. This segmentation allows each section to be independently monitored for formation changes, enabling precise location identification without the lag associated with centralized scanning. The wire is divided into multiple zones along its length, with dedicated sensors for each zone.
Solution Approach 2:
Forming boards are positioned in advance to control and direct stock flow before it reaches the wire. By preparing the forming board position beforehand, the system can prevent formation issues rather than merely detecting them after they occur, eliminating the need for reactive correction and reducing time lag.
2Manufacturing precision
If changes are made to the paper machine based on dry end test results, then the paper quality can be adjusted, but there is a delay causing additional waste and extended grade changes
Solution Approach 1:
The system implements real-time feedback by continuously monitoring formation at the wire using multiple scanners positioned along the wire's length. This immediate feedback allows operators to detect and correct formation issues as they occur, eliminating the delay between dry end testing and machine adjustment. The feedback loop enables continuous optimization without stopping production.
Solution Approach 2:
By monitoring formation at the wire before the stock reaches the dry end, the system allows for preliminary adjustments to be made to the paper machine. This prevents quality issues from developing in the first place, eliminating the need for corrective actions after production has already occurred and reducing waste.
3Measurement precision
If multiple scanners are positioned along the wire, then the precise location of formation issues can be identified, but the device complexity increases
Solution Approach 1:
Each scanner positioned along the wire serves multiple functions: it monitors formation quality, identifies the precise location of issues, and provides feedback for control adjustments. This multi-functionality reduces the need for separate dedicated components for each function, thereby managing complexity while achieving high measurement precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables real-time identification and compensation for formation issues across the paper machine, reducing waste and improving product quality by pinpointing the responsible section for changes, thus enhancing production efficiency and consistency.
Implementation Method 1
one of the one or more sensors is located substantially planar with a wire of a paper machine and proximate to a slice opening so that the one of the one or more sensors is adjacent to a cut through so that the one of the one or more sensors is capable of measuring stock above the wire and removed water below the wire
Implementation Method 2
one or more lights that illuminate a location of interest so that the one or more sensors can monitor the location of interest
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A formation detection system comprising: (a) one or more sensors and (b) one or more lights that illuminate a location of interest so that the one or more sensors can monitor the location of interest; wherein one of the one or more sensors are located substantially planar with a wire of a paper machine and proximate to a slice opening so that the one of the one or more sensors is adjacent to a cut through so that the one of the one or more sensors is capable of measuring stock above the wire and removed water below the wire, and wherein the one of the one or more sensors is capable of measuring a distance between an impingement location of a stock jet and the wire from a forming board.