Embedded Pressure Sensors for Industrial Roll Nip Width Sensing
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Solution Overview
Problem
Existing papermaking roll systems cannot accurately measure the nip width, which is crucial for understanding pressure profiles and maintaining paper quality, as they only measure contact stress without interrupting the process.
Innovation Solution
A method and system using pressure sensors embedded in the roll to determine nip width by calculating partial nip width based on pressure signals and applying a preselected multiplier, allowing for continuous measurement without process interruption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pressure sensors are embedded in the roll to measure nip width, then measurement precision is improved, but device complexity increases
Solution Approach 1:
Pressure sensors are embedded within the roll structure itself, nesting the measurement devices inside the existing roll. This allows the sensors to be positioned directly in the nip zone without adding external complexity, enabling precise nip width measurement while maintaining a compact integrated design
Solution Approach 2:
The patent replaces traditional mechanical measurement methods (such as physical gauges or contact-based measurement systems) with electronic pressure sensors that provide continuous digital signals. This substitution enables more precise measurements and facilitates data processing while reducing mechanical complexity
2Productivity
If continuous measurement is implemented without process interruption, then productivity is improved, but measurement precision may deteriorate
Solution Approach 1:
The pressure sensors are designed to operate continuously as the roll rotates, providing uninterrupted nip width measurements throughout the papermaking process. The sensors remain active during normal operation, enabling real-time monitoring without requiring process stoppages or interruptions
Solution Approach 2:
The system incorporates feedback mechanisms where pressure sensor signals are continuously processed and used to monitor nip width variations. This feedback loop allows for real-time detection of changes in linear load and stiffness, maintaining measurement precision through continuous data validation and processing
3Measurement precision
If multiple pressure sensors are used to determine nip width, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The measurement system is segmented into multiple pressure sensors positioned at different locations on the roll. Each sensor provides localized pressure data, and by combining these segmented measurements, the system achieves comprehensive nip width determination with improved precision while allowing for targeted sensor placement to optimize cost-effectiveness
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 precise measurement of nip width, facilitating the identification of changes in linear load and stiffness, improving paper sheet densification and dewatering control, and aiding in sensor calibration.
Implementation Method 1
a plurality of pressure sensors mounted in the roll; positioning the industrial roll in contact with the mating structure to form a nip; rotating the industrial roll; receiving pressure signals from the plurality of pressure sensors
Data Source
Figure 1~1A
Figure 2
Figure 3
AI summary
A method of determining the width of a nip formed by an industrial roll and a mating structure includes the steps of: providing an industrial roll having a cylindrical core and a polymeric cover surrounding the core, the industrial roll further comprising a plurality of pressure sensors mounted in the roll (optionally distributed in a helical pattern on the roll about a longitudinal axis of the roll); positioning the industrial roll in contact with the mating structure to form a nip; rotating the industrial roll; receiving pressure signals from the plurality of pressure sensors at a controller; and in the controller, utilizing the pressure signals from the pressure sensors to determine the width of the nip at locations on the roll associated with the pressure sensors.