Sensing Roll Nip Pressure Monitoring System
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Solution Overview
Problem
Conventional methods for measuring and addressing rotational variability in nip pressure profiles of rolling processes, such as in papermaking, are limited as they require stopping the rolls and cannot account for real-time temperature and speed changes, leading to uneven pressure distribution and potential defects in the paper product.
Innovation Solution
A system with sensors on a sensing roll that collect data on the mating roll's rotational position and pressure variability, generating a synchronized map to correct for rotational variability and maintain uniform pressure, allowing for real-time adjustments and improved paper quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional nip pressure measurement methods are used (stopping rolls and using carbon paper), then the measurement process is simple, but the productivity is reduced due to production stoppage and real-time changes cannot be captured
Solution Approach 1:
The patent replaces conventional mechanical measurement methods (carbon paper impressions requiring roll stoppage) with electronic sensing technology. Sensors mounted on the sensing roll surface electronically detect nip pressure variations during continuous operation, eliminating the need to stop production while capturing real-time pressure data that reflects actual operating conditions including temperature and speed changes.
Solution Approach 2:
The invention enables continuous nip pressure measurement during roll operation. The sensing roll with mounted sensors continuously monitors pressure variations as it rotates with the mating roll, maintaining uninterrupted production while capturing dynamic pressure changes that occur during actual papermaking operations, rather than relying on static measurements taken during stoppage.
2Measurement precision
If conventional measurement methods are used, then the device complexity is low, but the measurement precision is insufficient to detect rotational variability effects
Solution Approach 1:
The patent replaces simple mechanical carbon paper impressions with electronic sensing and digital data processing systems. Multiple sensors mounted on the sensing roll surface electronically detect subtle pressure variations caused by rotational variability, and a computer system processes the resulting digital signals to identify pressure patterns and their causes, providing much higher measurement precision than conventional methods.
Solution Approach 2:
The invention introduces a computer-based data processing system as an intermediary between the sensors and the operator. The computer receives raw pressure data from multiple sensors, processes the signals to remove noise, identifies pressure patterns corresponding to rotational variability, and presents analyzed results to the operator, enabling precise detection of subtle effects that would be impossible to detect with simple mechanical methods.
3Reliability
If real-time monitoring is implemented, then the reliability of pressure control is improved, but the device complexity increases due to additional sensors and processing systems
Solution Approach 1:
The patent implements a feedback control system where sensors continuously monitor nip pressure distribution, the computer analyzes the pressure data to identify deviations from uniform pressure, and the system can signal for corrective adjustments to roll loading or positioning. This closed-loop feedback enables real-time detection and correction of pressure non-uniformities, improving reliability of pressure control despite the added system complexity.
Solution Approach 2:
The invention replaces manual or mechanical pressure adjustment methods with electronic sensing and computer-based control. Electronic sensors provide continuous, precise measurement of pressure distribution, and the computer system processes this data to identify and correct pressure non-uniformities, providing more reliable and consistent pressure control than manual mechanical adjustment methods.
4Manufacturing precision
If rotational variability compensation is implemented, then the manufacturing precision of paper product is improved, but the device complexity increases due to synchronized data collection and processing requirements
Solution Approach 1:
The patent uses feedback from the pressure sensors to identify rotational variability effects on paper quality. The computer system analyzes pressure patterns that correspond to specific roll positions and rotational speeds, determining how rotational variability affects sheet characteristics such as moisture content and caliper uniformity, and provides feedback for correcting these variations to improve manufacturing precision.
Solution Approach 2:
The invention introduces a computer-based analysis system as an intermediary that processes synchronized pressure data from multiple sensors, correlates pressure variations with rotational position and speed, and identifies the specific effects of rotational variability on paper product characteristics. This intermediary processing system enables precise compensation for rotational effects despite the complexity of synchronized measurement and analysis.
Data Source
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Figure 3A~3C
AI summary
Collecting roll data for a sensing roll and mating roll forming a nip includes generating a respective sensor signal from each of a plurality of sensors located at axially spaced-apart locations of the sensing roll, wherein each respective sensor signal is generated when each sensor enters a region of a nip between the sensing roll and the mating roll during each rotation of the sensing roll and receiving the generated signal. Upon receiving the signal, a processor a) determines a particular which of the sensors which generated the signal, b) based upon a rotational position of the mating roll relative to a reference position, determines which one of a plurality of tracking segments associated with the mating roll occurs substantially concurrently with the sensor entering the region of the nip, and c) stores the respective sensor signal to associate the signal with the determined one tracking segment.