Single Sensor Web Tension and Caliper Measurement
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Solution Overview
Problem
Current methods for measuring and controlling paper roll runnability are costly, complex, and inadequate in predicting mechanical properties, leading to poor end product quality and sheet breaks due to uneven web tension and caliper profiles.
Innovation Solution
A single sensor system that alternates between measuring web tension and caliper across a moving web, using a scanning frame with support structures to provide accurate and cost-effective data for improved roll quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple separate sensors are used to measure both tension and caliper, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines tension measurement and caliper measurement into a single integrated sensor system. The sensor head includes both a load cell for tension measurement and caliper measurement capabilities, allowing both parameters to be measured simultaneously at the same location across the web. This merging eliminates the need for separate sensor systems while maintaining measurement precision for both tension and caliper profiles.
Solution Approach 2:
The sensor system is designed with multi-functionality to perform both tension measurement and caliper measurement using a single device. The sensor can alternate between measuring tension in the machine direction and caliper across the cross direction, providing universal measurement capabilities that reduce device complexity while maintaining the precision of both measurement functions.
2Manufacturing precision
If continuous measurement of both tension and caliper is performed, then manufacturing precision is improved, but use of energy and data processing requirements increase
Solution Approach 1:
The sensor system implements periodic measurement cycles, alternating between tension measurement mode and caliper measurement mode. Rather than continuously measuring both parameters simultaneously, the sensor performs tension measurements at one location and caliper measurements at the same location at different times in a periodic sequence. This approach maintains the precision needed for roll building while reducing the continuous energy consumption and data processing burden compared to simultaneous continuous measurement of both parameters.
Data Source
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AI summary
A system for measuring both caliper and tension of a web such as paper wound into a roll (10) . The system may include a standard caliper sensor whose air supply is selectively modified to allow for both the measurement of caliper and tension of the web. In another embodiment two similar or identical measurement devices are installed in tandem where one device measures tension without pinching the sheet and the other device measures caliper. The sensor may include two sheet guides (70, 72) for providing support for tension measurement or one or both sheet guides can be eliminated by support from machinery rolls.