Suction Roll Contamination Detection via Fluid Flow Measurement
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Solution Overview
Problem
Existing methods for cleaning suction rolls in fibrous web production are inefficient, as they require frequent and unnecessary cleaning, leading to increased costs and personnel outlay, and cannot be performed during ongoing operations.
Innovation Solution
A method and device for determining the contamination level of suction rolls by measuring the flow rate or pressure drop of a fluid through a measuring area of the roll shell, allowing for comparison with reference variables to assess contamination without stopping the machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cleaning is carried out at regular intervals during stoppages, then contamination is avoided, but cleaning costs and personnel outlay increase unnecessarily
Solution Approach 1:
The system continuously monitors the actual contamination level of the suction roll by measuring pressure drop across the roll shell and comparing it with reference values. This feedback mechanism enables dynamic adjustment of cleaning schedules, allowing operators to clean only when contamination reaches critical levels rather than following fixed intervals, thus eliminating unnecessary cleaning time and costs while maintaining reliable operation.
2Reliability
If cleaning is carried out more frequently to avoid contamination, then operational reliability improves, but consumption of cleaning medium increases
Solution Approach 1:
By implementing continuous monitoring of contamination levels through pressure drop measurements and comparison with reference data, the system provides real-time feedback on the actual state of the suction roll. This enables condition-based cleaning decisions, ensuring cleaning medium is applied only when contamination reaches thresholds that affect operation, thereby reducing unnecessary consumption while maintaining operational reliability.
3Productivity
If cleaning is performed during ongoing operations, then productivity is maintained, but complex cleaning mechanisms are required
Solution Approach 1:
The system performs preliminary assessment of contamination levels by measuring pressure drop and comparing with reference values before initiating cleaning. This preliminary action enables planned cleaning during scheduled stoppages at the optimal moment, avoiding the need for complex in-operation cleaning mechanisms while maintaining productivity through informed timing of necessary maintenance activities.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the assessment of suction roll contamination without removing it from the machine, enabling targeted cleaning only when necessary, thus reducing costs and improving operational efficiency.
Implementation Method 1
determining a characteristic variable K, the characteristic variable K consisting of the resultant flow rate with flow at a constant pressure and of the resultant pressure drop during the measurement with a constant flow rate
Implementation Method 2
causing a fluid to flow through a measuring area A of the roll shell, either the pressure or the flow rate of the fluid being kept constant
Data Source
AI summary
A method and a suitable device determine the contamination of a suction roller of a machine for producing a fibrous web, in particular a paper, cardboard, tissue or pulp web. The method includes the steps of: a. flowing a fluid through a measurement area of a roller shell, wherein either the pressure or the throughflow speed of the fluid is kept constant; b. determining a characteristic variable, wherein the characteristic variable includes the resulting throughflow speed in the case of a throughflow at a constant pressure and of the resulting pressure drop in the case of the measurement at a constant throughflow speed; c. providing one or more reference variables; and d. determining a degree of contamination of the suction roller by way of comparison of the characteristic variable with the reference variable or variables.