Reel Hardness Profile Control via Linear Measuring Head
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Solution Overview
Problem
Current methods for controlling the reeling profile of material web reels, particularly in material web machines, are inadequate in ensuring even CD-directional profiles, leading to issues like track breaks and operational disturbances during unwinding, due to limitations in measuring and controlling the tightness and hardness profiles, resulting in suboptimal reel quality and increased labor costs for handling defects.
Innovation Solution
A method and system that utilize profiling devices and measuring technologies to adjust and control the CD-directional profiles of the material web reel by using data from reeling nip and reel measurements, incorporating profiling devices such as humidifiers, dryers, and track strain organs, and employing a linear measuring head with a power cylinder for precise measurements, allowing for real-time adjustments to maintain even profiles and reduce defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional reeling control methods are used, then the reeling process is simple to operate, but the CD-directional profile uniformity deteriorates
Solution Approach 1:
The system performs preliminary measurements of the CD-directional profile during the reeling process using a measuring device that scans the reel surface. Based on these measurements, the control system calculates required adjustments and pre-adjusts the profiling devices (such as calendar rollers or web tensioning devices) before the uniformity defect fully develops, preventing the problem rather than correcting it afterward.
Solution Approach 2:
The invention implements a closed-loop feedback system where the measuring device continuously monitors the CD-directional profile of the reeled material web. The measured data is fed back to the control system, which automatically adjusts the profiling devices to maintain uniform profile characteristics, creating a self-correcting system that improves precision through continuous monitoring and adjustment.
2Manufacturing precision
If profiling devices are added to control CD-directional profiles, then profile uniformity improves, but device complexity increases
Solution Approach 1:
The control system is designed to perform multiple functions: it controls the profiling devices for CD-directional profile adjustment, operates the measuring device, processes the measurement data, and coordinates with the reeling control. This multi-functional integration reduces the need for separate dedicated systems for each function, thereby limiting the increase in overall device complexity while achieving improved profile uniformity.
Solution Approach 2:
The invention introduces a control system as an intermediary that mediates between the measuring device and the profiling devices. Rather than requiring direct complex mechanical linkages between sensors and actuators, the control system serves as an intelligent intermediary that processes information and generates appropriate control signals, simplifying the physical system architecture while achieving precise profile control.
3Manufacturing precision
If real-time measurements are performed during reeling, then reel quality improves, but measurement and control complexity increases
Solution Approach 1:
The invention replaces complex mechanical measurement systems with non-contact or minimal-contact measurement methods. For example, optical sensors or capacitive sensors are used to measure the CD-directional profile without requiring physical contact with the moving web, thereby reducing mechanical complexity while enabling real-time measurements that improve reel quality through continuous monitoring.
Data Source
AI summary
A method and a system to control a reeling profile of a material web reel (30), when, in the forming of a material web reel (30), a web is reeled around a reeling core and when in an adjustment of CD-directional profiles of the web reel, profiling devices (8) have been applied. For adjusting quality profiles and reeling profiles of the web, profiling devices are managed with the help of profile measurings of the roller nip and/or of the profile measurings of the reel (30), which are obtained from the reel-up (2). A measuring device (40) for a measuring of a CD-directional hardness profile of the fiber web reel includes a measuring head (43), which is connected with a loading means (41, 42), which loads the measuring head against the fiber web reel. The motion course of the measuring head is linear.