Sensing Roll Nip Pressure Monitoring via Segmented Sensors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The papermaking process faces challenges in monitoring and maintaining uniform nip pressure across various stages, which affects the quality of the paper produced.
Innovation Solution
A system comprising a sensing roll with sensors positioned at axially spaced-apart locations and an application station with a rotating applicator rod, generating sensor signals as the sensors move through the nips. A processor processes these signals to determine the specific sensor and identify tracking segments, associating the signals with these segments for data analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are used to monitor nip pressure at different axial locations, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The sensing roll is divided into multiple axial segments with sensors positioned at specific locations (e.g., 12 sensors at 30-degree intervals). This segmentation allows comprehensive monitoring of nip pressure across different axial positions, improving measurement precision while maintaining manageable system complexity through modular sensor placement.
Solution Approach 2:
The sensing roll acts as an intermediary element between the applicator rod and the paper web. It indirectly measures nip pressure through sensors that detect forces transmitted through the roll structure, avoiding direct measurement complexity while achieving accurate pressure monitoring at multiple locations.
2Manufacturing precision
If real-time monitoring of applicator rod position is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Sensors on the sensing roll provide real-time feedback about nip pressure conditions to the control system. This feedback enables dynamic adjustment of applicator rod position and pressure to maintain uniform nip force across the web width, improving manufacturing precision through closed-loop control.
Solution Approach 2:
Complex mechanical position measurement systems are replaced with sensors that detect nip pressure forces. The sensing roll converts mechanical pressure into electrical signals that can be processed by the control system, simplifying the monitoring mechanism while maintaining precision.
3Manufacturing precision
If uniform nip pressure is maintained across the web width, then paper quality is improved, but energy consumption increases
Solution Approach 1:
The applicator rod and sensing roll system operates dynamically with adjustable pressure distribution. The system can adapt nip pressure levels in real-time based on web characteristics and process conditions, maintaining quality uniformity while optimizing energy consumption through dynamic rather than static pressure application.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A Sensor signal is generated from a plurality of sensors located on a sensing roll, wherein each sensor enters a nip between the sensing roll and a rotating component during each rotation of the sensing roll. A rotating applicator rod forms forming a second nip with the sensing roll such that each sensor enters the second nip during each rotation of the sensing roil and each sensor generates a sensor signal upon entering the second nip. A periodically occurring starting reference is generated associated with each rotation of the applicator rod and the signal generated by each sensor is received so that a particular one of the sensors which generated the signal is determined and one of a plurality of tracking segments is identified. The signal is stored to associate the sensor signal with the identified one tracking segment.