Dynamic Sheet Manufacturing via Weight Feedback Control
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Solution Overview
Problem
Existing sheet manufacturing apparatuses, particularly those using the wet-type method, face challenges with large size, high water consumption, and energy-intensive drying processes, as well as difficulties in responding to temporary changes in paper supply, which affect grammage and sheet quality.
Innovation Solution
A sheet manufacturing apparatus that includes a supplying unit, a detection unit to monitor the weight of the material, and a defibrating unit, which adjusts the supply interval and amount of material based on real-time weight detection to mitigate changes in grammage, thereby improving sheet quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the supply amount of material is increased to respond to temporary changes (overlapped sending), then the productivity is improved, but the manufacturing precision of grammage deteriorates
Solution Approach 1:
The control unit receives weight information from the detection unit and dynamically adjusts the supply interval of subsequent materials based on the detected weight deviation. This closed-loop feedback mechanism allows the system to respond to temporary supply changes (overlapped or unloaded sending) while automatically correcting grammage variations, thus resolving the contradiction between maintaining productivity and ensuring manufacturing precision
Solution Approach 2:
The supply interval is made dynamic rather than fixed. The control unit adjusts the supply interval in real-time based on detected weight variations, allowing the system to adapt to temporary supply changes. This dynamic adjustment enables the system to maintain grammage precision without sacrificing overall productivity, as the supply rate is optimized continuously based on actual conditions
2Manufacturing precision
If the supply interval is increased to reduce grammage changes, then the manufacturing precision is improved, but the productivity deteriorates
Solution Approach 1:
The supply interval is made dynamic rather than fixed. The control unit adjusts the supply interval in real-time based on detected weight variations, allowing the system to adapt to temporary supply changes. This dynamic adjustment enables the system to maintain grammage precision without sacrificing overall productivity, as the supply rate is optimized continuously based on actual conditions
Solution Approach 2:
The system changes the supply interval parameter dynamically based on detected weight information. When overlapped sending is detected, the supply interval is increased temporarily to prevent excessive grammage, then returned to normal. This parameter adjustment allows the system to maintain precision during critical moments while preserving overall productivity through rapid adaptation
Data Source
AI summary
There is provided a sheet manufacturing apparatus, including: a supplying unit configured to supply a cut-form material including fibers; a detection unit configured to detect information related to a weight of the material which is processed to be supplied by the supplying unit; a defibrating unit configured to defibrate the material; and a forming unit configured to form a sheet by using at least a part of a defibrated material defibrated by the defibrating unit, in which a supply interval of at least one material among a plurality of materials to be supplied later increases in a case where the weight of the material which is supplied at a unit time is heavy rather than in a case where the weight is light.