Wireless Reel Weight Verification for Basis Weight Calibration
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Solution Overview
Problem
Current papermaking processes rely on online measurements for basis weight, which are estimates and lack real-time verification, leading to potential inaccuracies in controlling the sheetmaking process and producing substandard material.
Innovation Solution
A wireless technique for measuring the actual gross weight of the sheet material on a reel using load cells and RFID tags, providing real-time weight readings for dynamic verification and adjustment of operating parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If online measurements are used to estimate basis weight, then real-time monitoring is achieved, but measurement precision is insufficient
Solution Approach 1:
The patent replaces the mechanical/scanning measurement system with a wireless sensor system that uses electromagnetic fields to measure roll weight. Load cells with wireless transmitters directly measure the weight of the paper roll on the reel, substituting the indirect scanning method with a direct mechanical weight measurement that is then transmitted wirelessly for real-time monitoring.
2Reliability
If scanning sensors are used to measure basis weight after the dryer section, then continuous measurement is achieved, but the measurements remain estimates without verification
Solution Approach 1:
The patent introduces an intermediary wireless measurement system that acts as a mediator between the papermaking process and the control system. Load cells with wireless transmitters provide intermediate weight measurements that verify and correct the basis weight estimates from scanning sensors, improving reliability without requiring complete system replacement.
3Measurement precision
If actual roll weight measurement is implemented, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the weight measurement function from the complex scanning sensor system and places it on the reel assembly itself. By integrating load cells directly into the reel structure that supports the paper roll, the measurement capability is separated from the main papermaking line complexity, providing accurate weight measurement through a dedicated, simplified subsystem.
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
Enables fast and accurate verification of online weight measurements, allowing for immediate adjustments to the sheetmaking process, reducing substandard material production and ensuring consistent quality.
Implementation Method 1
comprises a sensor configured to sense a force produced by the roll of material when lifted
Data Source
AI summary
Wireless technique of measuring the gross weight of sheet material on a finished reel spool generates real time weight readings. An apparatus for determining the gross weight of sheet material on a roll includes: a spool that is equipped with an RFID tag to identify its tare weight and/or its spool identification number wherein the spool is configured to wind the sheet of material; means for lifting a roll of material that is wound on the spool and comprises a sensor configured to sense a force produced by the roll of material when lifted and transmitting wireless signals that include information representative of the force produced by the roll; and means for calculating the gross weight of the sheet of material wound on the roll. The actual weight measurements achieve fast dynamic correlations to the online weight measurements. Operating parameters of actuators and sensors can be adjusted following verification.