Sensing Roll Nip Pressure Monitoring via Axial Sensor Segmentation
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Solution Overview
Problem
In the papermaking process, there is a need to monitor and maintain uniform nip pressure across rolls to ensure consistent quality of the paper product, as variations in pressure can lead to poor quality paper due to differences in liquid removal and material distribution across the web.
Innovation Solution
A system comprising a sensing roll with axially spaced sensors that generate signals as they enter the nip region, a processor to identify which sensor generated each signal, and a method to associate these signals with tracking segments based on a periodically occurring reference, allowing for the determination of pressure profiles across the roll and continuous band, enabling real-time monitoring and adjustment of nip pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are used to measure nip pressure at different locations, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The sensing roll is divided into multiple axially spaced sensor locations, with each sensor measuring pressure at a specific segment of the roll. This segmentation allows comprehensive pressure profiling across the nip region while keeping each individual sensor simple and manageable.
Solution Approach 2:
A processor acts as an intermediary that receives signals from multiple sensors, identifies which sensor generated each signal, and associates signals with tracking segments. This intermediary component coordinates the complex sensor array, making the system manageable and the data interpretable.
2Manufacturing precision
If real-time monitoring of nip pressure is implemented, then manufacturing precision is improved, but use of energy increases
Solution Approach 1:
The sensors continuously monitor nip pressure as the sensing roll rotates through the nip region, providing ongoing real-time data. This continuous measurement ensures consistent paper quality by detecting and enabling correction of pressure variations throughout the production cycle.
Solution Approach 2:
The system provides feedback by measuring actual nip pressure conditions and making this information available for process adjustment. The processor analyzes sensor signals and can trigger adjustments to rolling mill duties or other process parameters to maintain optimal pressure conditions.
3Measurement precision
If sensors are positioned at axially spaced locations on the sensing roll, then measurement precision is improved, but difficulty of detecting and measuring increases
Solution Approach 1:
The system establishes tracking segments and sensor identification protocols before measurement begins. Each sensor's position and measurement timing are pre-configured and tracked, allowing the processor to correctly identify which sensor generated each signal and associate it with the appropriate tracking segment.
Solution Approach 2:
The system dynamically tracks the rotation of the sensing roll and the position of each sensor as it enters and exits the nip region. By monitoring the dynamic timing and position of each sensor signal relative to roll rotation, the system correctly attributes measurements to specific sensors and locations.
Data Source
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AI summary
Collecting data includes generating a sensor signal from each of a plurality of sensors located on a sensing roll, wherein each signal is generated when each sensor enters a region of a nip between the sensing roll and mating roll during each rotation of the sensing roll; wherein a web of material travels through the nip and a continuous band contacts a region of the web of material upstream from or at the nip. A periodically occurring starting reference is generated associated with each rotation of the continuous band and the signal generated by each sensor is received so that the one of the plurality of sensors which generated this signal is determined and one of a plurality of tracking segments associated with the continuous band is identified. The signal is stored to associate the respective sensor signal with the identified one tracking segment.