The present invention relates generally to methods for overcoming the problems associated with web tension and feed rate variations during the unwinding of out-of-round parent rolls. More particularly, the present invention relates to a method for reducing variations associated with unwinding out-of-round parent rolls and the associated web speed tension variations while maximizing operating speed throughout the entire unwinding cycle.
In the papermaking industry, it is generally known that paper to be converted into a consumer product such as paper towels, bath tissue, facial tissue, and the like is initially manufactured and wound into large, round rolls. In many instances, these rolls, commonly known as parent rolls, may be on the order of 10 feet in diameter and 100 inches across and generally comprise a suitable paper that is convolutely wound about a core. Typically, a converting facility will have a sufficient inventory of parent rolls on hand to be able to meet the expected demand for the paper conversion to products such as paper towels and facial tissue as the paper product(s) are being manufactured.
Because of the compressible nature of the paper used to manufacture products like paper towels, bath tissue, facial tissue, and the like, it is quite common for parent rolls to become out-of-round. Not only the soft nature of the paper, but also the physical size of the parent rolls, the length of time during which the parent rolls are stored, how the parent rolls are stored (e.g., on their end or on their side), and the fact that ‘roll grabbers’ used to transport these parent rolls clamp the parent roll generally about the circumference all can contribute to this problem. As a result, by the time many parent rolls are placed on an unwind stand for converting, they have changed from the desired cylindrical shape to an other-than-round (e.g., out-of-round) shape.
In extreme cases, parent rolls can become oblong, assume an ‘egg-like’ shape, or even resemble a flat tire. But, even when the parent roll is only slightly out-of-round, there are considerable problems. In an ideal case, as material is removed from a completely round, convolutely wound parent roll, the feed-rate, web velocity, and tension will generally be consistent. However, process disturbances such as the feed-rate variability, web velocity variability, and tension variability for an out-of-round, convolutely wound parent roll, caused by the shape changes created by the storage and handling of parent rolls, will likely vary the material removal from the ideal web speed of a completely round parent roll depending upon the position and/or radius at the web takeoff point at any moment in time.
If the rotational speed of the parent roll remains substantially constant, the feed-rate, web velocity, and tension of the web material coming off of an out-of-round parent roll will vary during any particular rotational cycle. Naturally, this depends upon the degree to which the parent roll is out-of-round. Since the paper converting equipment downstream of the unwind stand is generally designed to operate based upon the assumption that the feed-rate, web velocity, and tension of web material coming off of a rotating parent roll is generally consistent with the driving speed of the parent roll, web velocity, and/or tension spikes, and/or slackening during the unwinding process can cause significant problems.
While a tension control system is typically associated with the equipment used in a paper converting facility, the rotational speed and the takeoff point radius can be continuously changing in nearly every case. At least to some extent, these process disturbances are unaccounted for by typical tension control systems. It can be dependent upon the degree to which the parent roll is out-of-round and can result in web feed rate variations and corresponding tension spikes and slackening. These problems can be exacerbated by the need for faster unwind speeds to accommodate the need for faster production output.
With an out-of-round parent roll, such process disturbances cause the instantaneous feed-rate, web velocity, and/or tension of the web material to be dependent upon the relationship at any point in time of the radius at the drive point and the radius at the web takeoff point. As previously mentioned, it is known that out-of-round parent rolls may not be perfectly oblong or elliptical but, rather, they may assume a somewhat flattened condition resembling a flat tire, or an oblong or egg-shape, or any other out-of-round shape depending upon many different factors.
Regardless of the exact shape of the parent roll, at least one point in the rotation of the parent roll exists where the feed rate of paper to the line is at a minimum. At this point, the web tension can spike since the feed rate of the web material is at a minimum and is lower than what is expected by the paper converting equipment downstream of the unwind stand. Similarly, there can exist at least one point in the rotation of the parent roll where the feed rate of paper to the line is at a maximum. At this point, the web tension can slacken since the feed rate of the web material can be at a maximum and more than what is expected by the paper converting equipment downstream of the unwind stand. These process disturbances are not conducive to efficiently operating paper converting equipment for manufacturing paper products such as paper towels, bath tissue and the like. A process disturbance, such as a spike in web tension, can even result in a break in the web material requiring a paper converting line to be shut down.
Clearly, there is a need to overcome this problem. Particularly, out-of-round parent rolls create variable web feed rates and corresponding web tension spikes and web tension slackening that have required that the unwind stand and associated paper converting equipment operating downstream thereof be run at a slower speed. In many instances this creates an adverse impact on manufacturing efficiency.
While various efforts have been made in the past to overcome one or more of the foregoing problems with out-of-round parent rolls, there has remained a need to successfully address the problems presented by web feed rate variations and corresponding web tension spikes and web tension slackening.
While it is known to manufacture products from a web material such as paper towels, bath tissue, facial tissue, and the like, it has remained to provide methods for reducing feed rate variations in the web material when unwinding a parent roll. Embodiments of the present disclosure described in detail herein provide methods having improved features which result in multiple advantages including enhanced reliability and lower manufacturing costs. Such methods not only overcome problems with currently utilized conventional manufacturing operations, but they also make it possible to minimize wasted materials and resources associated with such manufacturing operations. In certain embodiments, the described method can reduce the effects of process disturbances emanating from misshapen parent rolls being unwound for downstream converting.
Generally, the method for reducing the effects of variations in an unwinding, convolutely wound roll of web material, said unwinding being modifiable by an actuator, utilizes the steps of: a. selecting a reference objective relating to a downstream operation, b. choosing at least one feedback device correlated to the reference objective; c. collecting process data from the at least one feedback device at different positions within a time-varying operation cycle for at least one operation cycle at a learning speed; d. calculating an error as the difference between the collected process data from step (c) and a reference signal related to the selected reference objective; e. generating a correction signal based upon the calculated error from step (d); and, f. applying the correction signal to the actuator during a succeeding time-varying operation cycle.
In the manufacture of web material products including paper products such as paper towels, bath tissue, facial tissue, and the like, the web material which is to be converted into such products is initially manufactured and convolutely wound into large parent rolls and placed on unwind stands. The embodiments described in detail below provide exemplary, non-limiting examples of methods for reducing the effects of process disturbances such as feed-rate, web velocity, and/or tension in a web material due to variations in the parent roll when unwinding the parent roll for use in a downstream converting operation. In particular, the embodiments described below provide exemplary, non-limiting methods which take into account any out-of-round variations (or characteristics) of the parent roll and make appropriate adjustments to reduce web feed rate, web velocity, and/or tension variations.
By way of example only, an unwind profile of an out-of-round parent roll may have an exemplary process feedback signal vs. time profile as shown in
With regard to these non-limiting examples, the described method makes it possible to effectively and efficiently operate an unwind stand as part of a paper converting operation at maximum operating speed without encountering any significant and/or damaging process disturbances (e.g., deviations in the web feed rate, web velocity, and/or tension, and the like) of the web material as it leaves an out-of-round (e.g., misshapen) parent roll at the web takeoff point.
In the description herein, the out-of-round parent roll can be considered to be generally elliptical in shape and can be contrasted with a perfectly round parent roll. However, any observations, descriptions, illustrations and/or calculations are merely illustrative in nature and are to be considered non-limiting because parent rolls that are out-of round can take virtually any shape depending upon a wide variety of factors. However, the method disclosed and claimed herein is fully capable of reducing feed rate variations in a web material as it is being unwound from a parent roll regardless of the actual cross-sectional shape of the circumference of the parent roll as the parent roll rotates about its longitudinal axis.
Further, while the invention is described in connection with web substrates such as paper, it will be understood and appreciated that it is highly beneficial for use with any web material or any convolutely wound material to be unwound from a roll since the problem of reducing disturbances in a web material induced by variations in a parent roll is not limited to paper substrates. In every instance, one of skill in the art will clearly recognize that it would be highly desirable to maintain a constant or nearly constant feed rate and/or tension of a web coming off of a rotating parent roll to avoid web tensions spikes or slackening.
Returning again to
Referring to
Alternatively, if the selected reference objective 20 would require the measurement of web speed 34 to correlate to the selected reference objective 20, one of skill in the art would be able to utilize any form of web speed 34 measurement devices. Contact encoders and non-contact web speed 34 sensors are examples of appropriately selected feedback devices 30 that correlate to the desired reference objective (the measurement of web speed 34). It should be understood that non-contact web speed 34 sensors are preferred, as they do not rely on friction between the web and the measurement device to provide an accurate measurement, and there is no wear on manufacturing equipment due to contact with the web. When using non-contact web speed 34 sensors, one of skill in the art would recognize that laser Doppler velocimeters such as the Beta Lasermike (Dayton, Ohio) and LED based optical sensors are suitable such as the COVIDIS manufactured by the Intaction group of Fraba (Hamilton, N.J.).
In this regard, it should be recognized that the selected reference objective 20 could incorporate the use of an actuator feedback device 36 that compares an observed signal to a reference signal. Exemplary actuator feedback devices 36 can be either linear or rotary. One of skill in the art will recognize these actuator feedback devices 36 as encoders and resolvers.
Yet still, the desired reference objective could incorporate the use of servo drives 38. Servo drives 38 can be used for the determination of position and speed errors. Servo drives 38 suitable for use with the present method include, but are not limited to, electronic (e.g., most typical), hydraulic, and pneumatic.
In an exemplary non-limiting embodiment, an actuator suitable for driving (i.e., rotating, unwinding, etc.) a parent roll in accordance with the present method can comprise a servo motor-driven belt in contact with the outer surface of the parent roll. A servo motor can be operatively associated with the belt in any conventional manner as a part of the drive system for controlling the driving speed of the belt. Alternatively, an actuator for driving the parent roll could consist of a center spindle operatively associated with a belt drive and servo motor.
Returning again to
In any regard, the method provides for collection of data from the selected feedback device 40 to be first collected from the selected feedback device 30 at different rotational positions within the revolution of the parent roll for at least one ‘operation cycle’ at the desired learning speed. For most operations, an operation cycle would be the first complete revolution of the unwinding paper web after it has reached a steady-state speed.
One of skill in the art will recognize that an ‘operation cycle’ should provide for sufficient machine operation to characterize a periodic disturbance caused by variations in the parent roll over time (also referred to herein as a ‘time-varying operation cycle’). This can provide the ability to correlate the pattern of disturbances (if any) to the position within the unwinding cycle. In most instances of conventional web unwinding operations, this could provide for the collection of data over the first complete rotation of the parent roll during an unwind operation. However, the described method envisions that one or more rotations of the material feed roll can also provide sufficient machine operation (i.e., ‘operation cycles’) to characterize a periodic disturbance caused by the variations in the parent roll (time-varying operation cycles). It should also be recognized that the unwinding operation cycle can change duration continuously in time throughout the manufacturing operation as material is removed from the parent roll. Additionally, it is envisioned that the operation cycle can include all or any part of the 360 machine degrees of a typical machine cycle. It is preferred that an operation cycle include 360 machine degrees. However, in some circumstances it may be feasible to use only 45 machine degrees, or 90 machine degrees, or 180 machine degrees, or 270 machine degrees of a machine cycle.
By way of non-limiting examples, one of skill in the art would recognize that the determination of an operation cycle for a non-center driven unwinding process can utilize an encoder disposed upon a moving core. In such a system, the position of the load in revolutions (or radians) can be used directly. Alternatively, an encoder can be disposed upon the motor driving the center of the parent roll. Here, one of skill in the art can calculate position of the load in revolutions (or radians) through a known mechanical transmission ratio. Preferably, an operation cycle can be determined by one of skill in the art by registering a virtual axis based on registration input from a sensor that sees a signal once per revolution of the parent roll, looking at the parent roll, or the shaft connected to the parent roll. In other words, disturbances caused by variations in the parent roll can vary over time so it can be useful to map a disturbance to a position within the operation cycle over time as the length of the operation cycle changes over time. This can provide continuous mapping of the circumferential position of the parent roll to the virtual axis even as the parent roll decreases in diameter and the mapping varies over time. An algorithm suitable for the latter example of an operation cycle is described in U.S. Pat. No. 8,244,393. Such a process will likely wait for convergence of a virtual axis to an error less than a desired threshold before collecting any process data.
Returning again to
Returning again to
Next, optionally, the calculated error signal 60 can be filtered 70 for the purpose of removing any operational noise generated during the collection of data from the feedback device step 40. One skilled in the art of signal processing will recognize that an exemplary, but non-limiting filter can be a zero lag Gaussian low pass digital filter with a typical filter having a cutoff frequency of 0.1. Other filters that could be used include a Butterworth or Chebyshev low pass filter. These exemplary filter options smooth the estimated error signal over the operation cycle so that eventual transformation to an actuator command does not inject measurement noise into the system.
Again referencing
Now referring back to
If it is determined that the error signal between the reference objective and feedback is within a specified and/or desired range of limits, as described infra, then the process can be stopped. These limits could include, but not be limited to, independent maximum and minimum errors or thresholds describing variability such as error variance, error standard deviation, or root mean square (RMS) error. In this instance, it may be prudent for one of skill in the art to continue monitoring 110 the signal from the feedback device 40 to ensure that the feedback signal 20 remains within the desired range of limits of the selected reference objective. If it has been determined by one of skill in the art that the process error signal has grown out of a selected tolerance for the desired range of limits while running at production speed, additional data can be collected from the feedback device 40 and the process described herein can be repeated and/or resumed as required.
As will be appreciated, the method described herein can also utilize any conventional logic device (e.g., an ASIC (Application Specific Integrated Circuit), FPGA (Field Programmable Gate Array) or another similar device in conjunction with a PLC (Programmable Logic Controller), computer, automation controller, or other logic device) to assist with the high speed receiving and processing of data. Further, the PLC system can apply the total correction factor 90 to determine and implement an appropriate operation cycle adjustment by undergoing a suitable initialization, data collection, data processing and control signal output routine.
From the foregoing, it will clearly be appreciated that the method presented by the present disclosure can reduce variations in the feed rate, and hence variations in tension in a web material when unwinding a parent roll having disturbances caused by variations therein to transport the convolutely wound web material away from the parent roll at a web takeoff point.
Referring again to
Any dimensions and/or values disclosed herein are not to be understood as being strictly limited to the exact dimensions and/or numerical values recited. Instead, unless otherwise specified, each such dimension and/or value is intended to mean both the recited dimension and/or value and a functionally equivalent range surrounding that dimension or value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
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