This application claims priority on Finnish Application No. 20031440, Filed Oct. 3, 2003, the disclosure of which is incorporated by reference herein.
Not applicable.
The invention relates to a measurement method and a measurement apparatus in a paper or paperboard machine.
In modern paper machines it is necessary to measure characteristic variables both from the paper and the parts and partial processes of the machine itself to monitor the quality of the paper to be manufactured and the different parts of the paper machine, as well as to ensure the operation of the machine. On the basis of these variables it is possible to control the machine and its parts to ensure uniform quality of the produced paper.
One factor affecting the quality of paper are the numerous roll nips formed in the paper machine by two rolls rotating against each other, through which nips the paper web to be formed travels at different stages of papermaking. Such nips exist for example in presses, calenders, reel-ups, coating stations and slitter-winders. The nip force prevailing in the nip in the axial direction of the rolls, i.e. the linear load that presses the paper web or another medium traveling through the nip substantially affects the quality of the paper to be produced. To make the paper uniform in quality within its entire width, it is of primary importance to measure the linear load profile prevailing in the nip, so that the process can be adjusted to attain the desired quality for the end product.
U.S. Pat. No. 5,048,353 discloses a method for measuring the nip profile of a reeling nip, in which a strip containing piezoelectric measurement elements, or separate piezoelectric measurement elements are attached on the surface of a reeling cylinder extending in the form of a spiral extending from one end of the cylinder to another. On the basis of the pressure message given by the elements it is possible to determine the nip pressure profile prevailing in the nip in the axial direction of the cylinders. In U.S. Pat. No. 5,562,027 the piezoelectric measurement elements are placed on the surface of the roll in one or several rows in parallel to the shaft of the roll. U.S. Pat. No. 5,383,371 discloses placing a film-like piezoelectric measurement element or measurement elements underneath or inside the roll coating in one row in parallel to the shaft of the roll. A problem with film-like piezoelectric sensors is that their measurement accuracy is poor, because they are sensitive to temperature, which causes creeping of the signals given by said sensors. When using point-like sensors that are attached on the surface of the roll, problems are caused by the fact that the sensors leave marks on the paper. Furthermore, it is difficult to attach them.
Furthermore, in the measurement of the linear load profile, it is known to measure the pressure prevailing in the nip by means of strain-gauge sensors placed on the surface of the roll. One problem of this method is for example the difficulty of installing the sensors.
Thus, it is an aim of the present invention to attain a measurement method in a paper or paperboard machine that eliminates the above-described problems and makes it possible to conduct measurements in the paper or paperboard machine reliably without leaving marks in the paper to be produced. Furthermore, it is an aim of the invention to provide an apparatus implementing the aforementioned method.
The measurement method is intended to be used in numerous locations in the paper or paperboard machine or in the finishing apparatus for paper or paperboard, when the aim is to measure linear load, linear load profile, temperature, moisture content and tension. Possible targets of application include for example measurement of the nip profile of the roll nip and numerous other targets that will be discussed later.
The invention is based on the idea that in the manufacture or finishing of paper or paperboard web the properties of the partial processes or parts of the paper or paperboard machine are measured during the run of the paper or paperboard machine or finishing device by means of measurement sensors attached to an element in a paper or paperboard machine or finishing device. The measurement sensors are substantially capacitive measurement sensors.
The measurement sensors are composed of at least one capacitor that is formed of two conductive material surfaces, for example metal films having an insulating material between them. When for example a radial force is exerted on an element in the paper and paperboard machine, the distance between the surfaces changes, which causes a change of capacitance between the surfaces, on the basis of which it is possible to determine the linear load exerted on the element. In the measurement of the change in capacitance it is possible to use for example a capacitive half-bridge coupling and measurement of the bridge can be made by means of alternating voltage.
The capacitance of a plate capacitor can be determined by means of the following formula:
Thus, the change in the capacitance can be caused by a change in any factor. Thus, by means of the change in the capacitance caused by the change in the distance S between the metal surfaces it is possible to determine the force exerted on the films, i.e. the tension of the web or wire or for example the nip pressure between the rolls, and on the basis of the change in the capacitance caused by the change in the permittivity it is possible to determine the moisture content or temperature of the material, for example the roll coating. On the basis of the change in capacitance caused by a change in the effective surface area A between the film-like metal surfaces it is possible to determine the shearing force. The effective surface area A between the films can change for example so that the conductive films are placed in the roll coating, and they are capable of moving with respect to each other. The measurement method can be implemented for example for the measurement of both in the travel direction and cross-direction of the paper web effecting local elongations exerted on the paper web in the nip, thus making it possible to recognize local flaws in the paper or paperboard web or reasons for a web break. The measurement of the shear force can be applied especially for monitoring the condition of roll coatings. Thus, on the basis of the change in the shear force it is possible to detect permanent shift of the conductive films with respect to each other, which results for example from the loosening of the roll coating or a part of it, wherein the manufacturing process can be stopped before the coating or a part of it becomes permanently detached. The insulating material has a crucial significance in the measurement of different variables. By selecting suitable materials as insulating materials, it is possible to measure the desired property at a given time. For example for the measurement of the moisture content of the roll coating a hygroscopic insulating material is selected, which material absorbs moisture, thus creating a change in permittivity, which can be seen in the capacitance.
To implement the invention it is possible to apply several different measurement sensor structures. The sensor can, for example be integrated in the coating of an element in a paper or paperboard machine, such as a roll, a coating blade or the like, in such a manner that insulating material used in the coating is used as an insulating substance and the conductive surfaces of the capacitors are metal films evaporated or glued on the layers of the coating. It is also possible to form the sensor with its conductive surfaces and insulating substances into a strip-like or net-like structure or to form individual point sensors that are placed inside the coating. Such a structure integrated in the coating is simple and easy to install in the element in connection with the coating process. Furthermore, it is affordable and durable, and does not cause marks in the paper to be manufactured. It is also possible to use the frame parts of the element, such as the shell of the roll as the conductive surface of the sensor.
It is also an advantage of the measurement solution according to the invention that by using the capacitive measurement method it is possible to easily protect the measurement sensors and conductors from electrical disturbances. Other advantages of the measurement method include good resolution and good tolerance to disturbances. Furthermore, it is possible to modify the measurement method and apparatus according to the object of measurement in question by selecting the sensor material, i.e. the insulation and the conductive layers so that they are suitable for each object of measurement and coating. By means of the bridge coupling it is possible to improve the stability and temperature compensation of the sensor. In addition, it is easy to manufacture the sensors in different sizes and shapes depending on the object of measurement and the property to be measured.
Another advantage of the invention is that it enables reliable measurement of the cross-profile of nip pressure profiles of an element equipped with a sensor and the nips, for example roll nips of another machine element pressed against the same in the machine direction.
When a measurement sensor integrated in the roll coating is used, the measurement sensors are attached to the roll at the manufacturing stage of the roll, and it is dependent on the property to be measured where the roll containing the measurement sensors is positioned in the paper machine. By means of a roll equipped with sensors it is possible to measure the force or linear load profile between said roll and another, structural element extending longitudinally in the lateral direction of the paper machine and being pressed against the roll. During the measurement there may be a moving paper web or another medium between the roll equipped with sensors and the structural element pressed against the same. The roll equipped with sensors is thus suitable for measurement of total linear load and/or nip pressure profile of roll nips formed by rolls in different parts of the paper or paperboard machine, wherein the nip is formed for example by a roll equipped with sensors and another roll, for example the roll of a press, a calender, a reel-up or a slitter winder, and the paper web travels through the nip. The roll equipped with sensors is also suitable for measurement of linear load profiles of backing rolls in coating stations, and blade and rod load profiles of the coating blades and coating rods in coating devices, wherein the coating blade or rod is pressed against the roll equipped with sensors. In the paper machine it is also possible to measure the loads of doctor blades in different locations by means of the roll equipped with sensors according to the invention.
Furthermore, the roll equipped with sensors according to the invention is suitable for example for measurement of the temperature distribution of coatings on calender rolls, as well as for example for the measurement of the moisture content of the coating on a polyurethane-coated roll.
In a corresponding manner it is possible to place measurement sensors in other longitudinal elements in the lateral direction of the web in the paper or paperboard machine or finishing apparatus, for paper, such as doctor blades, or coating blades or rods. It is also possible to place measurement sensors in an endless element moving in the travel direction of the web and forming a closed loop, such as a wire, a felt, or a belt of an extended nip calender. Furthermore, it is possible to place measurement sensors in an element substantially narrower than the width of the paper or paperboard machine, for example in a texture used in threading or a wheel guiding said texture.
An element, such as a beam or a rotating or non-rotating roll extending longitudinally in the lateral direction of the web produced in a paper or paperboard machine is also especially suitable for the measurement of the tension of a paper or paperboard web and/or a texture, such as a wire or felt in a paper or paperboard machine. Thus, the web or the texture is conveyed over the element equipped with measurement sensors in such a manner that the web or the texture touches said element and the tension and/or tension profile of the web or texture is measured.
In the following, the invention will be described in more detail with reference to the appended drawings.
The sensor 1 is composed of an insulating film 3 on both sides of which a conductive film, such as a metal film 4 is attached by means of glueing, painting or evaporating. The conductive film can be for example a copper film or it can be made of conductive polymer. The insulating film 3 is typically made of plastic, and it is selected according to the variable to be measured by means of the sensor. It is also possible to select one of the coating materials used in the roll as an insulating film. The sensor can be easily manufactured in connection with the coating of the roll by evaporating, painting or glueing two metal films between the coating layers in such a manner that the sensor is formed. The sensor 1 can also be manufactured beforehand either by printed-circuit technology or by evaporating, or by attaching the metal film in some other way on both surfaces of the insulating material, and attaching the thus formed sensor between the coating layers of the roll when coating the roll. Thus, it is also possible to select one of the materials used in the roll coating as an insulating material. The sensor can also have a perforated or net-like structure, wherein it is possible to affect the elastic properties of the sensor in such a manner that the sensors inside the roll coating do not affect the behavior of the coating during pressing, for example in nip contact. Preferably the metal films of the sensor are as thin as possible and the insulating layer therebetween is of the same material as the roll coating.
The use of a capacitive bridge coupling requires two identical sensors attached to the roll 2.
The sensors 1 can also be formed of separate fragments. Thus, they can be formed of separate insulating fragments metallized on both sides, for example of substantially square-shaped insulating fragments. Such a structure is shown in
The size of individual sensors is determined on the basis of the property to be measured. If an individual sensor or sensors forming the sensor pair have a large surface area, i.e. they extend in the machine direction over the nip width, they measure force, i.e. the total linear load prevailing in the nip. The linear load is typically indicated as a force prevailing in the direction of the loading, i.e. in this case in the machine direction, divided with the nip width (extension in the cross-machine direction), and the unit used for the same is typically kN/m. If, on the other hand, the sensor or sensors have a small surface area, they measure pressure, and thus it is possible to determine the pressure profile of the nip in the machine direction. By means of the invention it is also possible to simultaneously measure both the total linear load prevailing in the nip and the nip pressure profile, wherein a measurement method is utilized in which two sensor-conductor combinations are installed around the roll in a spiral-like manner according to
The roll coating wears when the roll is used in a paper or paperboard machine or in a finishing apparatus for paper or paperboard. The effect of the wearing of the roll coating on the sensor signal is corrected by means of a mathematical model.
If desired, the above-described technique necessary for the electrification and processing of the measurement data can be positioned entirely outside the roll 2, wherein the variable measured by the sensors is transmitted as an electric signal outside the roll for example by means of slide rings. Preferably a major part of the electronics is positioned at the end of the roll 2, close to the roll shaft, wherein wireless data transmission can be utilized. Thus, a transmitter, for example a telemetry transmitter is positioned for example at the end of the roll for transmitting the measurement data for example by means of an inductive link to a telemetry receiver positioned close to the roll.
The voltage required by the sensors can be produced in many different ways, for example by conveying it to the roll by means of an inductive coupling or a slide conductor positioned for example at the end of the roll. It is also possible to integrate an accumulator or a battery in the measurement apparatus or for example at the end of the roll, which accumulator or battery can be loaded during maintenance of the machine when the roll is stopped. The invention is not intended to be limited to the embodiments presented above as examples, but the invention is intended to be applied widely within the scope of the inventive idea as defined in the appended claims. Capacitive sensors can be used analogously in all structures extending in the cross-machine direction that are subjected to forces resulting from the process. The sensors can also be integrated in elements moving in the machine direction, such as belts or wires, for example in belts of a shoe calender. In static elements that do not move in accordance with the web speed separate sensors are advantageously used, if the aim is to measure loading at different points in the cross-machine direction, such as doctor blades.
Number | Date | Country | Kind |
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20031440 | Oct 2003 | FI | national |