Suction Roll Adjustment via Image Analysis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for adjusting suction rolls in paper machines are inefficient and rely heavily on manual, visually-based adjustments, leading to suboptimal positioning of sealing strips and edge deckles, which can result in reduced dry content of the paper web and increased energy consumption due to incorrect positioning.
Innovation Solution
A method and apparatus utilizing image and video recording, combined with a computing unit and display, to determine the actual position of non-visible components like sealing strips and edge deckles through image analysis, and superimpose their positions onto a display, enabling precise and reproducible adjustments using augmented reality techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual adjustment of sealing strips is performed, then operator experience and visual estimation are used, but positioning precision is insufficient leading to reduced dry content
Solution Approach 1:
The patent replaces manual visual adjustment with an optical measurement system consisting of a camera and computing unit that automatically detects and displays the position of sealing strips and edge deckles, eliminating the need for operator experience and visual estimation while achieving precise positioning
Solution Approach 2:
The patent creates a visual copy of the suction roll components by recording images and videos with a camera, then processing these images to generate a display showing the actual positions of sealing strips and edge deckles, allowing operators to see component positions that are not directly visible on the actual machine
2Ease of operation
If conventional adjustment methods are used, then operator experience is required, but adjustment time and complexity increase
Solution Approach 1:
The system performs automatic detection and calculation of component positions through image processing algorithms, eliminating the need for operator experience and manual measurement, making the adjustment process accessible to operators of any skill level while reducing adjustment time
Solution Approach 2:
The patent implements a feedback mechanism by displaying the detected positions of sealing strips and edge deckles on a screen, allowing operators to immediately see the current configuration and make precise adjustments based on visual feedback rather than trial and error
3Reliability
If edge deckles extend too far into the paper web, then vacuum is lost at the edge, but adjustment precision is insufficient to prevent this
Solution Approach 1:
The patent replaces manual estimation of edge deckle position with automated optical detection that precisely measures the position relative to the paper web, enabling accurate positioning that maintains vacuum at the edge without requiring operator experience
Data Source
AI summary
A method and an apparatus for adjusting a suction roll. The method includes: recording images and/or videos of the exterior of the roll and transmitting the recording to a computing unit; determining the actual values of the position of the sealing strips and/or edge deckles and/or other, non-visible components by the computing unit through image analysis of the image and/or video recording of the exterior of the roll and/or by acquiring values from an embedded sensor system; and displaying the determined actual values by superimposing the position of the non-visible components on a display with the image and/or video recording.