Single Facer Vibration Control for Stable Nip Pressure
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Solution Overview
Problem
The existing gap adjusting mechanisms in single facers for producing corrugated paperboard fail to stably apply nip pressure due to vibration-induced fluctuations, affecting the thickness combination of corrugated and linerboards.
Innovation Solution
A single facer with a movable supporting mechanism, a restricting mechanism, and a motor control system that reduces vibration in processing rolls to set a stable gap between corrugating and processing rolls, ensuring consistent nip pressure through first and second control processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the gap adjusting mechanism uses motor control based on gap detection signals, then the gap between rolls can be adjusted, but the nip pressure becomes unstable due to vibration-induced signal fluctuations
Solution Approach 1:
The system performs preliminary action by detecting vibration of the processing roll and adjusting the gap between the processing roll and corrugating roll before the vibration significantly affects the nip pressure. The control section detects vibration through gap detection signals and proactively adjusts the gap to prevent unstable nip pressure, rather than reacting after the problem occurs.
Solution Approach 2:
The system implements feedback control by continuously monitoring the gap detection signal to detect processing roll vibration, then using this information to adjust the gap between the processing roll and corrugating roll. The control section compares the detected vibration with a predetermined threshold and adjusts the gap accordingly, creating a closed-loop control system that maintains stable nip pressure despite vibration.
2Productivity
If the processing roll periodically contacts corrugating roll ridges during rotation, then corrugated medium can be formed, but vibration occurs in the processing roll
Solution Approach 1:
The system converts the harmful vibration caused by periodic ridge contact into a useful signal for control. The vibration, which normally disrupts nip pressure stability, is detected through gap detection signals and used as feedback to adjust the gap between the processing roll and corrugating roll. This transforms the harmful vibration into a basis for maintaining stable operation.
Solution Approach 2:
The system changes the gap parameter between the processing roll and corrugating roll in response to detected vibration. By dynamically adjusting this gap based on vibration detection, the system maintains optimal nip pressure despite the periodic contact that causes vibration during corrugated medium formation.
3Extent of automation
If gap detection signal is used for motor control, then gap adjustment is automated, but the signal fluctuates continuously due to vibration
Solution Approach 1:
The control section performs preliminary analysis of the gap detection signal to distinguish between normal signal variations and vibration-induced fluctuations. By detecting vibration patterns before they significantly affect control accuracy, the system can adjust the gap proactively while maintaining automated control based on the gap detection signal.
Solution Approach 2:
The system uses feedback control to process the gap detection signal, comparing it with predetermined thresholds and adjusting the gap accordingly. This feedback mechanism filters out noise and vibration-induced fluctuations, allowing automated motor control to operate reliably despite signal instability caused by processing roll vibration.
Data Source
AI summary
A single facer comprises: a swingable frame supporting a press roll in such a manner as to allow a gap between one of a pair of corrugating rolls and the press roll to be changed; an adjusting screw contactable with a contact member coupled to the swingable frame; an encoder for detecting vibration of the press roll occurring during formation of a corrugated medium by the pair of corrugating rolls; and a control section for controlling drive of a motor for displacing the adjusting screw. The control section is configured to execute a first control processing of driving the motor until a magnitude of the vibration is reduced to a given value.