Rewinding Machine Tension Control via Load Cell Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rewinding machines lack adaptive control of slip during the winding cycle, leading to excessive loss of bulk and creping in tissue paper production, as they do not maintain optimal tension throughout the process, especially during acceleration and deceleration phases.
Innovation Solution
The implementation of a rewinding machine with load cells to detect tension and a control unit that adjusts the speed difference between winding and unwinding motors to maintain a desired tension, allowing for adaptive control of slip based on real-time tension data and specific parameters like grammage and creping percentage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the speed difference (slip) between winding and unwinding motors is increased to maintain tension during high-speed operation, then the web material tension is sufficient to prevent vibration and oscillation, but the creping loss increases due to excessive tensile force
Solution Approach 1:
The patent implements dynamic adjustment of the slip between winding and unwinding motors based on real-time web material tension feedback from load cells. The control unit continuously modulates the speed difference to maintain optimal tension throughout the winding cycle, including during acceleration and deceleration phases, thereby preventing creping loss at high speeds while avoiding excessive tension that would flatten the cellulose fibers
Solution Approach 2:
The system uses load cells to detect web material tension in real-time and feeds this information back to the control unit, which adjusts the motor speeds accordingly. This closed-loop control ensures that the slip is optimized for each moment of the winding cycle, maintaining sufficient tension to prevent vibration and oscillation without causing excessive creping loss
2Shape
If the grammage of the cellulose ply on the Yankee roller is reduced to increase creping ratio, then the creping percentage increases, but the production of the tissue paper machine decreases
Solution Approach 1:
The patent optimizes the web material tension parameters throughout the winding cycle to minimize creping loss. By maintaining precise tension control during acceleration and deceleration phases, the system reduces the need to over-compensate with higher initial creping ratios, thereby preserving production efficiency while achieving the desired final creping specifications
3Device complexity
If existing rewinding machines operate without adaptive slip control, then the device complexity is lower, but the loss of bulk and creping increases during acceleration and deceleration phases
Solution Approach 1:
The patent introduces load cells and a control unit that continuously monitors web material tension and adjusts motor speeds in real-time. This feedback mechanism enables adaptive slip control during acceleration and deceleration phases, minimizing bulk loss and creping reduction without requiring overly complex external systems
Solution Approach 2:
The control unit automatically modulates the slip between winding and unwinding motors based on real-time tension feedback, enabling the system to self-adjust and optimize performance without external intervention. This maintains minimal bulk loss and creping preservation through autonomous control
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
This solution minimizes the loss of bulk and creping by maintaining optimal tension, reducing production losses and improving the efficiency of tissue paper production, allowing for higher production rates and reduced material loss.
Implementation Method 1
at least one load sensor associated with at least one guide roller, which is adapted to detect a parameter proportional to the tension of the web material
Data Source
AI summary
The rewinding machine (1) includes: a winding station (3) with winding members (5, 7) operated by winding motors (8.1, 8.2); an unwinder (31.1, 31.2) with an unwinding member (35.1, 35.2) operated by at least one unwinding motor (38.1, 38.2); a guide roller (43.1, 43.2) along a feed path (P) of the web material (N, N2). There is associated with the guide roller (43.1,43.2) at least one load sensor (42.1, 42.2), adapted to detect a parameter proportional to the tension of the web material (N; N2) guided around the guide roller (43.1,43.2). There is also provided a control unit (71) adapted to modulate a difference in speed between the winding members (5, 7) and the unwinding member (35.1,35.2) as a function of a signal corning from the load sensor (42.1,42.2).