Roll Weighing Control for Uniform Basis Weight in Web Winding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing basis weight monitoring systems are inadequate for coated tissue webs, leading to inefficiencies and waste due to non-uniformity, and there is a need for improved systems that can efficiently monitor and adjust basis weight in real-time.
Innovation Solution
A system and method that utilizes a rotatable reel spool with integrated weighing devices and a controller to continuously monitor and adjust the basis weight of a winding roll, allowing for real-time adjustments to maintain uniformity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional scanners are used to monitor basis weight, then periodic readings can be obtained for untreated webs, but the system becomes unreliable when coating materials are applied to the tissue webs
Solution Approach 1:
The patent replaces optical scanners with a mechanical weighing system. Load cells directly measure the weight of the wound roll, and through calculation based on roll diameter and web length, determine basis weight. This mechanical approach is not affected by coating materials that interfere with optical scanning, providing reliable measurements for both coated and uncoated webs.
Solution Approach 2:
The system uses an intermediary calculation approach rather than direct measurement. Instead of directly scanning the web surface, the system measures the roll weight and diameter, then calculates basis weight using the relationship between these parameters and the web properties. This indirect measurement method bypasses the interference caused by coating materials.
2Loss of information
If scanners are used for basis weight monitoring, then some information can be obtained, but the monitoring efficiency is insufficient and cannot provide continuous feedback
Solution Approach 1:
The weighing system provides continuous monitoring of the wound roll weight throughout the winding process. As the roll accumulates web material, the load cells continuously measure the changing weight, enabling real-time basis weight determination without the periodic sampling limitation of scanners. This continuous action ensures no information is lost and provides constant feedback for process control.
Solution Approach 2:
The system incorporates feedback by continuously measuring roll weight and comparing it against target basis weight parameters. The controller can detect deviations and provide feedback signals to adjust the web making process, ensuring continuous optimization of basis weight uniformity throughout production.
3Device complexity
If the reel spool is fixed in position, then the structure is simple, but the system cannot accommodate the growing roll diameter during winding
Solution Approach 1:
The mounting device transitions from a static fixed position to a dynamic adjustable position. The reel spool mounting is designed to move radially outward as the roll diameter increases during winding. This dynamic adjustment allows the system to accommodate growing rolls without structural failure or measurement error, maintaining adaptability throughout the winding process.
Solution Approach 2:
The mounting structure is segmented into adjustable components rather than a single rigid structure. This allows different parts of the mounting device to move independently to accommodate the expanding roll, with the reel spool position being adjustable relative to the fixed frame structures. The segmentation enables the system to handle varying roll sizes while maintaining structural integrity.
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 and continuous monitoring of basis weight, allowing for proactive adjustments to maintain uniformity and stability, reducing waste and improving product quality.
Implementation Method 1
The weighing devices are configured to weigh the roll of material on the reel spool as the roll of material builds in diameter
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A web winding process is disclosed for controlling one or more characteristics of a web of material being wound into a roll. In one aspect, the system includes a weighing platform that weighs the roll of material as the roll of material is building. From this information, a basis weight characteristic of the web is determined. One or more parameters in the web making process can be controlled in order to ensure that the basis weight characteristic of the web of material stays within preset limits. In this manner, rolls of material can be produced having uniform characteristics and dimensional stability.