Tissue Log Measurement Station for Real-Time Quality Control
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Solution Overview
Problem
Existing tissue paper log production methods face challenges in efficiently controlling and adjusting production parameters such as firmness, weight, and embossing depth in real-time, leading to inconsistencies in log quality without significantly slowing down the production line.
Innovation Solution
A method and system that involves randomly selecting logs from the production line for measurement at a dedicated station, allowing for automatic data collection and adjustment of production parameters, including winding tension and embossing settings, to maintain desired quality standards without halting the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If measurements are performed on logs in the production line, then quality control and parameter adjustment are improved, but production line speed is reduced
Solution Approach 1:
The measurement process is extracted from the main production line by diverting selected logs to a separate measurement station. This allows measurements to be performed on diverted logs while the main production line continues operating at full speed with undiverted logs, thereby maintaining productivity while achieving quality control through measurement.
2Manufacturing precision
If production parameters are adjusted in real-time, then log quality consistency is improved, but production line complexity increases
Solution Approach 1:
A feedback system is implemented where measurement results obtained at the measurement station are transmitted to a control unit, which automatically adjusts production parameters (such as winding tension, embossing depth, or winding speed) to maintain desired log quality. This closed-loop feedback mechanism improves quality consistency while keeping the control system integrated and manageable.
3Measurement precision
If logs are diverted to measurement station, then measurement accuracy is improved, but production time is increased
Solution Approach 1:
Instead of measuring every log continuously, the system implements periodic measurement by diverting only selected logs (e.g., at regular intervals or based on specific criteria) to the measurement station. This periodic sampling approach maintains measurement accuracy for quality control while minimizing the time logs spend diverted from the main production line, thereby reducing overall production time loss.
Data Source
AI summary
A line is disclosed for producing logs of web material provided with a system for controlling, in real time, one or more parameters of the logs produced by the line and for facilitating any corrective actions. The line includes a rewinder, a feed path for the logs from the rewinder towards at least one station arranged downstream of the rewinder; and a measurement station. The measurement station includes at least a measurement device for measuring at least one parameter of logs randomly selected from the feed path and held in the measurement station, for example a device for measuring the firmness of the logs. The measurement station further includes first transferring members for transferring selected logs from the feed path to the measurement station, and second transferring members for transferring selected logs from the measurement station to the feed path.