Yankee Dryer Coating Regulation via Predictive Natural Transfer
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Solution Overview
Problem
Conventional methods for adjusting adhesive coating feed rates on Yankee dryers in creped product manufacturing are labor-intensive and not instantaneous, relying on assumptions and offline analysis, making real-time prediction and correction of natural coating transfer difficult due to the dynamic nature of the manufacturing process.
Innovation Solution
A system employing online measurement devices and predictive algorithms, combined with software and hardware, to continuously monitor machine conditions and predict natural coating transfer in real-time, enabling real-time regulation of adhesive coating application based on current machine speed and stock flow, with options for manual or automatic corrective actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional offline analysis and manual adjustment methods are used to control adhesive coating feed rate, then labor intensity and time consumption increase, but measurement and control capability is insufficient for real-time dynamic conditions
Solution Approach 1:
The patent replaces manual mechanical sampling and laboratory analysis with automated optical sensors and computational algorithms. Online sensors continuously monitor stock characteristics (turbidity, color, composition) and use predictive algorithms to estimate natural coating transfer in real-time, eliminating the time delay inherent in conventional offline methods while improving measurement precision.
Solution Approach 2:
The system enables self-service by automatically measuring stock properties, predicting coating transfer behavior, and generating adjustment recommendations without requiring manual sampling or laboratory analysis. The predictive algorithm continuously processes sensor data to provide real-time estimates of natural coating transfer, allowing the system to self-regulate based on actual process conditions.
2Productivity
If real-time online monitoring and predictive algorithms are implemented, then measurement precision and response time improve, but device complexity increases
Solution Approach 1:
The patent achieves productivity improvement without excessive complexity by making the online sensing system multi-functional. The same optical sensors used for process monitoring also provide data for predictive coating transfer estimation. The control system integrates multiple functions (measurement, prediction, recommendation generation) into a single unified platform, reducing overall system complexity while enabling real-time regulation.
Solution Approach 2:
The patent introduces an intermediary predictive algorithm that bridges the gap between simple sensor measurements and complex coating behavior prediction. Rather than directly measuring difficult-to-obtain coating properties, the system uses easily measurable stock characteristics (turbidity, color, composition) as intermediaries to infer natural coating transfer behavior, simplifying the measurement system while maintaining prediction accuracy.
3Measurement precision
If manual sampling and offline laboratory analysis are used to determine stock characteristics, then equipment complexity is reduced, but measurement precision and timeliness deteriorate
Solution Approach 1:
The patent replaces manual mechanical sampling and laboratory analysis equipment with automated online optical sensors. These sensors continuously measure stock characteristics (turbidity, color, composition) directly in the process stream, providing both higher measurement precision and immediate results without the complexity of laboratory infrastructure, sampling protocols, and manual analysis procedures.
Data Source
AI summary
A method is provided for decision support in regulating an adhesive coating applied to Yankee dryers. Online sensors are configured to continuously measure stock characteristics, and additional sensors provide actual stock flow rate and machine speed. A controller predicts potential natural coating application from a fibrous sheet generated from the stock to the Yankee dryer surface, substantially in real time, based on the measured characteristics and sensed actual machine values. An output signal may be provided to a display unit, wherein an optimal adhesive coating feed rate may be determined and displayed for operator decision support. The controller may in an automatic mode be configured to regulate the adhesive coating feed rate based on a comparison of one or more determined optimal values associated with respective actual values. The method may include identifying fiber source changes in real time, and predicting a natural coating potential based partly on predetermined correlations.