Optimal Roll in a Paper Machine Reel
Develop an improved nip loading (pli) curve for a Horizontal Rail Reel
(Pope Reel) to wind parent rolls with improved bulk uniformity, and
with a greater bulk.
METHOD OF SOLUTION
- For reels
equipped with PLC based nip control, compute and apply
improved psi curves.
- For older
reels, design and implement PLC based nip control.
- Analyze the current state by
computing the nip pli and relating it to the current bulk profile.
- Create a new nip pli curve
using the above information, and past experience.
- Convert this new pli curve
to psi curve for the secondary arm loading cylinders, along with
appropriate back pressure.
Analyses the current loading scheme to develop the line load
in the nip against the drum.
Computes the loading pressure in the loading cylinder to create the
desired nip line load.
MEASURE OF SUCCESS
drawing of the reel.
used nip control method, and loading curve.
bulk profile in the wound reel.
data: product variability from top to bottom, slab wastage.
- The bulk
profile in the new reels would be fairly flat except near the core and
- The bulk in
the new reels would be higher.
- Slab waste
would be reduced, and there would be an increased utilization of the
converting winders should pick up speed, and run steadily.
through-dry (TD) process, the above method increased the throughput by
as much as 5%.
light-dry-crepe (LDC) process, the speed of the winders in converting
increased by about 50 fpm.
- In heavy-wet-crepe
(HWC) process, perf breaks and wrap-ups were reduced.