WO1995034810A1 - Web monitoring for paper machines - Google Patents
Web monitoring for paper machines Download PDFInfo
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- WO1995034810A1 WO1995034810A1 PCT/GB1995/001222 GB9501222W WO9534810A1 WO 1995034810 A1 WO1995034810 A1 WO 1995034810A1 GB 9501222 W GB9501222 W GB 9501222W WO 9534810 A1 WO9534810 A1 WO 9534810A1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
- G01N21/892—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the flaw, defect or object feature examined
- G01N21/8922—Periodic flaws
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
- G01N33/34—Paper
- G01N33/346—Paper paper sheets
Definitions
- the present invention relates to a method of and apparatus for web monitoring in paper making machines.
- Paper making machines are complicated mechanical systems which are susceptible to a large number of problems, some of which can affect the quality or the consistency of the paper which is being produced.
- a paper machine can be thought of as a gigantic multi-channel tape recorder.
- Their frequencies range from one cycle in about 6 minutes, or 0.003 Hz, up to almost 10,000 Hz.
- Signal averaging is normally used to determine the contribution of the rotation of some roll, wet press felt or impeller either to the variations in the paper web or to the vibration of the end of a press roll.
- Signal averaging also known as signal extraction, is a method for discovering the contribution to some output signal of the cyclic variation associated with a steadily rotating or repeating source.
- a trigger signal in the form of a sharp pulse that indicates the commencement of each new rotation or repetition of the source of possible disturbance.
- sampling of the output signal is immediately commenced at a steady rate many times greater than repetition frequency of the source.
- Each sample is saved digitally in an array. The sampling continues until a further trigger pulse is received. It is then temporarily suspended. This process is repeated, with the difference that as each subsequent set of samples is obtained they are individually added to the values already saved in the array. After 100 or so sets of samples have been summed sampling ceases and each sum saved in the array is divided by the number of sets of samples taken, in order to obtain a time series representing the mean contribution of the input signal to the output.
- Signal averaging works well within its limitations. It is only applicable to periodic inputs for which trigger signals can be obtained. It may be applied to rotating rolls and impellers, when it will give a result corresponding to the sum of the components of the output signal that have frequencies corresponding accurately to multiples of the trigger frequency. It will not detect the faults in the rollers of the bearings used to support the rotating element because these do not give rise to frequencies that are simple multiples of the trigger signal. It may be confused by periodic disturbances having harmonic frequencies that almost match the possible harmonic frequencies of the trigger signal. No statistical test has been devised to show whether or not the averaged signal has been contaminated by such unrelated periodics. It cannot, by its nature, be used to decide whether or not a randomly related signal is affecting another signal.
- Figure 1 shows some examples of the patterns of variation which can occur, as follows :
- machine direction is the direction parallel to movement of the paper web
- cross direction is the perpendicular direction across the paper web.
- One edge of the paper web is normally known as the “front side” (FS)
- BS back side
- FS front side
- BS back side
- Flocculation is the clumping together of the fibres in the diluted pulp from which the paper web is formed; it causes small scale randomly distributed variations in the paper up to 15mm across. (They can be seen in "look through” of any sheet of paper when it is held up against the light.) The importance of floes will be better appreciated when it is realised that floes, rather than paper fibres, can be regarded as the units from which any paper web is constructed. Flocculation is always present to some degree but can be controlled by various means.
- Macro forming faults are random defects, larger than floes, caused by the mechanical disturbance of the pulp as it is being formed into paper. They have not previously been measured or systematically studied.
- Unstable machine direction steaks are thought to arise in the headbox from which the dilute pulp is discharged onto the wire of the paper machine. These take the form of sinuous machine direction lines of high or low basis weight which wander slowly to and fro across the machine. Their width is usually less than 20mm.
- Periodic variations caused by mechanical faults are assigned to one of two classes, dependant on whether their causes are located on the machine or in auxiliary equipment. It is possible to distinguish between these categories because the speed of all paper machines is deliberately altered from time to time. Periodic frequencies that vary with speed are caused by some part of the machine itself. If they remain constant, or vary independently, they are from auxiliary equipment. In either case, a single source of variation might give rise to a several harmonics of its f ndamental. The observed harmonically related components must therefore be examined to detect harmonically related components from a common source, then tabulated with frequency and amplitude. They tend to affect the full width of the web, and to have frequencies in the range 0.2 - 125Hz.
- Events are bursts of variation caused by intermittent faults. They may have durations from less than 0.01 second up to 30 seconds or more.
- sampling means for repeatedly or continuously sampling variations in a characteristic of the web (4) at each of a plurality of inspection locations (18,20,22,24) spaced apart across the web to produce a corresponding plurality of raw data signals;
- the invention further extends to a paper making machine having apparatus for analysing variations in the moving paper web, as well as a method of analysing variations in the moving paper web of a paper making machine.
- the web to be sampled may be dry or wet paper, coated or uncoated, or may be some other material.
- the invention may also be generalised for use on other types of moving webs, such as textile webs or webs carrying printed material. It could also be used to monitor webs of other materials, such as plastics or sheet steel.
- one of the main purposes of monitoring a paper machine is to detect and if possible to diagnose causes of variations affecting the paper web. Rather than attempt to monitor all the possible sources of disturbance, the present invention aims to monitor the paper web and to detect and automatically characterise the variations present in the paper so that their sources can readily be identified.
- the system is permanently installed on a paper machine.
- optical detectors are used to sense the variations occurring in the paper as it is made. Their design facilitates the complex task of classification, allowing local variations to be separated from those that extend across the web. The signals from these detectors pass through a number of stages of digital processing and analysis, and the disturbances present are then assigned to one of a number of classes. Some of these classes of variation can be readily distinguished by the patterns of variation that they cause in the paper web (see the examples illustrated in Figure 1) .
- the results from the monitoring system preferably take the form of tables in which the faults currently present in the paper are listed by category together with details of their frequency and intensity. Graphs showing how particular types of variation have changed with time can be prepared from archived results and plotted to order.
- some embodiments of the invention incorporate transducers which can be connected to suspected sources of disturbance on the paper making machine (or on the equivalent machine where the web is not of paper) .
- means are provided to compare the outputs of the transducers on the machine with the sensors on the web, so that the identity or possible identity of the two signals can be statistically tested.
- the preferred embodiment of the web monitor system of the present invention is capable of measuring not only the intensity of variation caused by floes but also their size and size distribution.
- the preferred embodiment is also capable of detecting and measuring unstable machine direction streaks. These have not previously been measured by an on-machine device, although they have been studied in laboratories.
- the preferred embodiment of the present invention can separate them rather easily from other disturbances. Such streaks contribute significantly to the look-through of paper seen against the light, and they are therefore of commercial if not of practical significance.
- the preferred embodiment can also detect macroforming faults, periodic variations caused by mechanical faults and slow, often random variations in the consistency of the dilute pulp from which the paper web is formed. It is also capable of detecting temporary increases of variation caused by intermittent faults with durations from less than 0.01 second up to 30 seconds or more.
- the events can be classified by frequency and duration, and either logged in a two-way table or individually time stamped and saved in the form of time tracers for subsequence examination.
- the preferred embodiment concentrates particularly on detecting basis weight variation, but is also capable of detecting and distinguishing press-roll vibration from calender stack vibration. Both of these cause thickness rather than weight variations.
- the monitor does not scan the web in the cross direction. Instead, there are a plurality of detectors which are stationary and which are spaced across the web in the cross direction.
- the system classifies faults by their cross direction width, and either by their machine direction duration or by their frequency. It also classifies according to whether they occur continuously or intermittently.
- the system then preferably includes means for suggesting the probable location of the cause, thus providing the engineers with the information that they need to locate it accurately. Means may be provided for comparing the suspected source with the variation in the web, and for calculating the probability that the cause has been correctly identified.
- the system includes means for determining whether the source of the variation measured in the paper web is on the paper machine itself, or whether it is caused by auxiliary equipment.
- Means for determining the probable rotation speed of the mechanical component responsible may also be provided.
- an interleaving method is preferably used.
- the signals from a first plurality of detectors are summed, and the signals from a second plurality of detectors are also summed.
- the first plurality is interleaved with the second plurality in the cross direction. Then, the signal representative of the sum of the first plurality may be subtracted from the signal representative of the sum of the second plurality.
- first plurality of detectors which are adjacent to the front side of the web, and a second plurality which are adjacent to the back side.
- Figure 1 illustrates examples of patterns of variation that can occur in paper webs
- FIG. 2 shows the components of a web monitoring system embodying the present invention
- Figure 3a is a front elevation of one embodiment of suitable lookers that can be used with the system of Figure 2;
- Figure 3b is a side elevation of the lookers of Figure 3a;
- FIG. 4 illustrates various fibre optic combinations
- Figure 5 shows an alternative embodiment of the lookers of Figures 3a and 3b
- Figure 6 shows how the looker modules of Figure 5 can be positioned across the web
- Figure 7 shows possible DSP mulitiplexed inputs
- Figure 8 shows possible measuring stations for a large monitoring system
- Figure 9 shows four exemplary inspection areas
- Figure 10 shows various patterns of variation in the paper web that can be recognised using the inspection areas of Figure 9;
- Figures 11 to 13 show further possible arrangements of inspection areas;
- Figure 14 is a model illustrating the transfer function
- Figure 15 is a model corresponding to that of Figure 14, but for a paper machine
- Figure 16 is a more detailed model corresponding to the model of Figure 15;
- Figure 17 shows schematically the calculations that may be carried out in one preferred embodiment of the invention (without using dual channel spectral analysis) ;
- Figure 18 shows calculations that may be carried out in an embodiment using dual channel spectrum analysis.
- FIG. 2 shows, very schematically, the main features of a web monitoring system according to a preferred embodiment of the present invention.
- the paper machine is indicated schematically by the dotted line 2.
- the system itself consists of two or more lookers 6, 8, one of which is located over the front side and one over the back side of the paper web 4 near the end of the drier section (not shown) .
- Signals from the lookers are fed to a cabinet 10 close to the machine 2 which contains a power supply for the lookers, a PC board (PCI) , and a digital signal processing (DSP) board.
- PCI communicates with a further PC 12 (PC2) , located in the machine control room which is schematically indicated by the dotted lines 14.
- PC2 serves as an operator console.
- PCI has, in addition, facilities to take in signals corresponding to variations from suspected sources of disturbance at the wet end or elsewhere on the machine, as an aid to diagnosis. These signals are derived from portable transducers (not shown) .
- the lookers 6,8 convert variations of reflectance or opacity to optical signals that are transmitted to the cabinet 10. Here they are converted to electrical signals which are sampled by the DSP board.
- the use of two lookers allows variations extending the full width of the web to be distinguished from local variations.
- the lookers each input a similar area of the web.
- the computer PCI supervises and controls the activities of the lookers and the DSP board, under the direction of PC2 12. In particular, it selects two or four optical signals to be read by the DSP board, and down-loads to the DSP board the code used for their analysis.
- the DSP board checks the validity of the looker signals, then carries out the preliminary analysis. Typically, two signals are sampled for a period of about 30 minutes. Large numbers of FFTs (Fast Fourier Transforms) are calculated. At the end of the sampling period the FFTs are averaged, further processed by PCI, and sent to PC2.
- FFTs Fast Fourier Transforms
- the computer PC2 12 completes the analysis of the data from PCI, and outputs the results to a VDU or printer (not shown) . It accepts instructions from the operator about the type of analysis that is required, and sends appropriate instructions to PCI. Also it is responsible for archiving the results on hard disk and for preparing summaries of past results. Computer PC2 may host an expert system to help operators locate sources of disturbance.
- the exact design of the lookers 6,8 is to some extent arbitrary: all that is required is a design which will allow detection of variations in light transmitted or reflected by the moving paper web.
- One specific exemplary embodiment (not currently the preferred embodiment) is illustrated in Figures 3a and 3b.
- the lookers may be sensitive to any appropriate characteristic of the web, such as moisture content or colour.
- the lookers may be replaced with devices for measuring the electrical conductivity of the web, for example by the use of contact pads.
- the basic principle in the preferred embodiment is to illuminate brightly an area of the web and focus its image on the ends of fibre optics arranged in a long row across the web, (and therefore perpendicular to the direction of motion of the paper web) .
- the light from bunches of these fibre optics is directed onto photodetectors (preferably photodiodes) (not shown) to obtain electrical signals corresponding to the variations in the paper web.
- photodetectors preferably photodiodes
- each fibre optic The area viewed by each fibre optic is 0.8 - 1.3mm diameter, so that small scale variations can be detected if necessary.
- the paper web moves at about 10, OOOmm/second; the looker signals must be sampled at about 10kHz to record such small scale variation.
- the overall width of web that can be viewed by each looker is about 260mm. To allow variations extending across the full width of the web be distinguished, two lookers are installed, one near each edge of the paper.
- the internal construction of the lookers is modular.
- Four lamps 16, arranged in a row illuminate four separate areas of the web 18,20,22,24. Each area is viewed by one of four simple lenses 26,28,30,32 that focuses an image of part of the web area onto a group of fibre optics 34,36,38,40.
- the arrangement of the optical fibres in each group is similar. Each group is arranged in a row and the individual rows are aligned so they form the single long row referred to above.
- the spacing d of the pairs of fibres shown in Figure 4A should be chosen to be wider than the floes and streaks to be detected.
- d an initial test should be carried out.
- the value of d should initially be chosen to be small, and it should gradually be increased until the coherence between the signals from the two bundles selected falls to a low steady value.
- the numbers of inspection areas are limited to two per looker module, except when a measure of floe or streak width is required.
- the looker modules are restricted to two or four across the width of the paper web. With this arrangement it is feasible to use one dedicated photodiode with its own fibre optic bundle for each inspection area. Although this makes the separation of different patterns of variation in the paper web less sharp, it leads to considerable simplification both of the monitoring system and the subsequent DSP calculations. It also has the advantage that the signals from each area can if necessary be individually corrected for the non-linearity of the relationship between basis weight and optical signal.
- the ideal looker would be designed to take into account the particular patterns of variation in the web for which it was intended, and to give sharp separations or patterns having different CD widths.
- the characteristics for the patterns are not accurately known in advance and may change with time, it is preferable to chose a general purpose looker design that can readily be modified.
- the preferred system can be specified very simply by the spacing of the pairs of inspection areas seen by each module, together with the spacing of the looker modules.
- Figure 5 shows two views of a basic module designed to observe reflectance variation at two small areas 42,44 of the web 4.
- the web is illuminated in this case by means of a remote light source (not shown) and fibre optic light guide 46.
- the light collected from each inspection area is conducted by further small light guides 48,50 to remotely sited photodiodes.
- the web 4 might be illuminated from below in order to sense variations in light transmission.
- each light guide leads to a separate photo detector.
- This provides an electrical signal which may then be sent by multiplexers ( Figure 7) to one of four delta-sig a converters at the input to a DSP board.
- the DSP board may then be used to add or subtract the signals before they are further analysed.
- FIG 6 shows four of the modules illustrated in Figure 5, designated with reference numerals 52, 54, 56, 58, arranged across a paper web 4, two near the FS and two near the BS.
- Each module 52, 54, 56, 58 outputs two optical signals designated A or B to a group of multiplexers 53, 55, 57, 59 feeding the DSP system analogue to digital converters (see Figure 7) .
- the multiplexer 53 receives signals from the lookers 54, 58; and the other multiplexers likewise receive signals from two separate lookers.
- the multiplexers could also accept signals from other measuring stations along the length of the paper machine.
- Signals IA and IB may be added or subtracted and the result compared with a sum or difference of 3A and 3B.
- the differences (1A-1B) and (3A-3B) gives two independent measures of floe and streak intensity at the BS of the machine, the effects other CD variation being eliminated.
- (1A+1B-3A-3B) gives a measure of the intensities of macroforming faults extending between lookers 1 and 3 at the BS of the web, with CD barring eliminated but with some contribution from floes and streaks.
- the signals 2A, 2B, 4A and 4B may be compared to obtain information about the similar variations at the FS of the machine.
- Signals IA, 2A, 3A 4A may be combined and compared.
- two channel spectral analysis of the sums (1A+3A) and (2A+4A) allows the variations extending across the full width of the paper web to be distinguished from those that extend less far, even if there are phase lags between the variations affecting the FS and BS of the web.
- Figure 8 shows a possible arrangement of lookers and other transducers throughout a paper machine. Such an arrangement can be built around a single 4-input DSP board fed by 8-way multiplexers. Some local multiplexers are also needed where there are several transducers at one measuring station. It might also be helpful to duplicate the DSP board and its multiplexers, but neither amendment causes undue difficulty.
- a monitoring system would be able constantly to examine the variations in the paper as it is made and to identify many individual sources of variation.
- the addition of a gloss monitoring station allows thickness and roughness variations, often caused by wet press vibration, to be sensed.
- the monitoring of press rotation would allow the causes of such roughness variation to be pinpointed.
- the combination of gloss and wet press monitoring allows sound judgements to be made on the wet press faults present.
- the press roll and press felt rotations should be used to generate trigger signals (one pulse per rotation) . Signal averaging or dual channel spectral analysis may then be used to determine the contribution of each rotating element to the variation of gloss or, if appropriate, the vibration that can be observed by transducers mounted on the press roll bearings.
- wet end transducers can be added, temporarily or permanently, to allow comparisons of variations in the approach flow system with those in the paper, thus confirming the conclusions reached by examining the data from the web monitoring stations. They are not seen as an essential part of the system.
- the lookers may be positioned to receive signals from any required areas of the moving paper web. Typically, the lookers will be placed in a line, across the paper web, although that is not essential. In some embodiments (as discussed further below) it may be desirable to use a rectangular group of looker modules. It is of course obvious that signals from two inspection areas which are aligned in the machine direction will give rise to signals which come from the same area of the web, but with a time delay between them.
- a single CD row of inspection areas can provide all the necessary information: this can be achieved by means of a multiplexer and DSP board, as previously discussed. Nevertheless, it may sometimes be convenient to use a rectangular arrangement of four inspection areas, since this allows the separation and direct measurement of flocculation from other patterns of variation by rather simple means.
- the separation of patterns is brought about in two stages. Firstly, by adding or subtracting the signals from suitably selected inspection areas, resultant signals are obtained in which the effects of certain patterns or variation are either diminished or totally eliminated. For example the difference between the signals from two areas one inch (2.5cm) apart in the cross direction will not be affected by barring that extends uniformly across the web.
- the power spectra of these manipulated signals are calculated and subtracted one from another, with the application of suitable weighting, to obtain estimates of power spectra of individual patterns of variation.
- the first step is at least partly achieved by optically summing the signals from different inspection areas 18, 20, 22, 24 using groups of optical fibres.
- each inspection area produces its own signal
- both the first step and the second step are carried out digitally.
- this method works only if the patterns in the web differ significantly in at least one dimension. It depends on some prior knowledge of the nature and typical dimensions of such patterns to be expected in the web. On the whole they are similar in all paper machines, but if necessary can be checked so that suitable spacings of the inspection areas can be selected. This is within the capability of a person skilled in the art.
- the separation of patterns by use of lookers is dependent on the assumption that certain patterns, such as barring, are strictly aligned with the cross direction. While this is so for CD distances of 300mm or so, it may not be so for the full 5000mm width of a typical paper machine. To deal with this difficulty, dual channel spectral analysis must be used.
- the CD widths of lookers are desirably therefore restricted to 300mm or so.
- signals representing variations on a paper machine must first be filtered (smoothed) in order to remove irrelevant high frequencies that would otherwise cause "aliasing” and thus confuse the subsequent analysis.
- the filtered signals may then be sampled (digitised) to obtain a sequence of values, known as a "time series", suitable for analysis by a computer.
- sampling may be carried out either at constant distances along the moving web or at constant increments of time. This choice depends on whether the speed of the paper machine varies appreciably with time and if so, on whether the variations to be studied are thought to be caused by faults in the machine itself rather than in off-machine equipment.
- the function of a looker is to produce output signals corresponding to variation present in the moving paper web. By careful choice of the parts of the web seen by the looker, its response to different patterns may be varied. Sequences of output signals can thus be provided that correspond to the effects of, for example:
- barring is a term used to refer to any pattern of bands of variation extending uniformly across the web.
- Such signals do not respond identically to individual defects in the web, and so cannot be subtracted to yield the signals corresponding to individual causes of variation. Their statistical properties and their power spectra do however correspond and they can be subtracted to obtain the characteristics of individual types of variation. (To avoid confusion it should be mentioned that the patterns referred to do not include small- scale wire mark and suction roll patterns for which a different approach is necessary.)
- Figure 9 shows four inspection areas, lettered A-D, arranged in a rectangle with its sides aligned with the machine and cross directions (the MD and CD) of the web.
- Figure 10 shows the maximum widths of the floes, unstable MD streaks, and CD bars present in the paper.
- the MD length of the rectangle must be is chosen to exceed the width of any bar, the CD width must exceed the width of any streak, and both must exceed the diameter of any floe.
- cv 2 (single inspection area) cv 2 (F) + cv 2 (S) + cv 2 (P) .. (1)
- the cv 2 of the quantity (A-B-C+D) may be obtained by pooling the light from pairs of fibres or otherwise adding the output signals to obtain signals equivalent to (A+D) and (B+C) , taking their difference and calculating its coefficient of variation. Because the areas A&C, and also B&D, are equally affected by the bars, while the cv 2 is calculated from the differences between these pairs, bars will not contribute to the cv 2 . Similarly, this cv 2 will be unaffected by streaks. It can be shown that:
- the variance is divided by four because four independent measures of flocculation are pooled.
- Figures 11-13 show three possible arrangements, each using four groups of inspection areas. The locations within groups are lettered, while the groups are numbered. Inspection areas in similar locations in different groups will be distinguished by subscripts. An example of the use of a specific arrangement to separate the main types of variation now follows.
- the right hand side of the second version of this equation shows how the fibre optics, in the Figure 3 embodiment, should be bunched together and connected to a pair of photodiodes.
- the difference of the photodiode outputs is taken and its cv calculated and multiplied by the square root of 8 to obtain the cv contributed by flocculation.
- the left hand side of the second version shows how, in the Figure 3 embodiment, the fibre optics are to be routed to a pair of photodiodes .
- the cv of the difference of the photodiodes outputs is calculated and squared.
- the variance due to the streaks can then be found from equation (10) , using the flocculation variance from equation (8) .
- the fibre optics bunches used to obtain the cv caused by flocculation may also be used to estimate the variance caused by macroforming faults. With reference to Figure 11, the sum of their outputs has the following variance:
- m'form refers to macroforming faults having CD widths less than the gaps (l s -l c ) wide, between the four groups of inspection areas. Its variance is found by subtracting from the above result the value found for the left hand side of equation (10) .
- the variance associated with barring and other similar patterns extending across the web can be found from the sum of the outputs from the fibre optic bunches used to find the variance of the streaks, as follows:
- the arrangement of Figure 12 shows an alternative to the above arrangement.
- the pairs of A and B areas aligned in the MD can be used to measure flocculation and streaks.
- the functionality is similar to that of the above arrangement.
- the difference between the two sets of fibre bunches in 4B has the following components:
- Power spectra can be calculated either for signals received from one individual inspection area, or more usually from the sum and/or difference of signals from individual areas .
- power spectra representative of a particular individual pattern of variation may be estimated by:
- weights depend upon the particular pattern of variation that is being studied; the weights for specific cases may be extracted from the equations such as those given above.
- Two channel spectral analysis comprises comparing the transfer function and coherence between pairs of signals obtained from different inspection areas.
- Two channel spectral analysis is useful for the separation of variations which extend across the full width of the paper web. These may be caused mainly by faults in the approach flow system, from more localised variations arising mainly at the headbox or in the forming zone (ie. on the wire) . It may also be used for comparison of variations in the web with random disturbances at the wet end of the machine. For this purpose a digital time delay is used to correct for the distance-velocity lag of the paper web.
- Figure 15 shows a model corresponding to the manufacture of the paper web.
- the input x(t) affects all parts of the web to a similar extent except that the time lag to different observation points across the width of the web may differ.
- the complex constants k 1A and k 1B thus imply similar attenuations at observation points A and B, but differing phase shifts.
- the added noise signals e A (t) and e B (t) affecting the two outputs y A and y B have similar statistical properties. Each corresponds to a noise contaminated version of the unknown input x(t) .
- Given y A and y B the problem, which can be solved by two channel spectral analysis, is how to distinguish the systematic variation corresponding to x(t) from the noise.
- the paper web is affected by two types of variation:
- Variations such as head box vibration, or thin stock consistency variation, which affect the full width of the web and therefore cause correlation between the variations detected at, say, the FS and BS.
- Coherence can be used numerically to separate the variations in the FS and BS spectra into spectra of "correlated" and "uncorrelated” parts, corresponding to the above two categories.
- Figure 16 shows a more realistic representation of a paper machine system than Figure 15.
- Periodic variations can be classified dependent on whether or not they vary in frequency as the speed of the paper machine is changed. Also, harmonically related frequencies, probably all caused by the same fault, can be grouped together.
- the digital samples (readings) of that signal must be taken at a frequency that is at least twice the highest frequency present in the analog signals. If any variations with frequencies higher than twice the sample rate are present they must be filtered out before the signals are sampled to avoid misleading results (caused by "aliasing").
- a block of 1024 values may be "decimated" to give 512 values corresponding to half the original sample rate. During decimation, high frequencies that would cause aliasing are removed by digital filtering. After filtering, alternate samples may be omitted without further loss of information. Two blocks of data are therefore used to produce one block of the same length but half the original sample frequency.
- the sampled data are decimated repeatedly to provide data for the calculation of spectra over ten or more frequency ranges.
- This transform may be computed by an algorithm known as the Fast Fourier Transform, (FFT) . If an FFT is performed on a sampled signal of 1024 (real) values, it yields 512 complex values in the form of 512 real (cosine) parts and 512 imaginary (sine) parts. This complex spectrum covers the frequency range zero to half the sampling frequency. Each of the 512 complex values is said to occupy a separate "bin” . Ideally, each bin contains components lying solely within a frequency band of width equal to 1/1024th of the sampling frequency. In the analysis of practical data the energy from each component is spread over a number of bins. Such "leakage” is usually controlled by the weighting of the blocks of data and also by adjusting the block means to zero before calculating the transforms.
- FFT Fast Fourier Transform
- the first step is to calculate the power and cross spectra.
- PAB(f) ReA(f)*ReB(f) + ImA(f) *ImB(f) ..(20)
- the relative phase angle Pha(f) may be calculated for each component from the following equation.
- the common variation x(t) may take differing times TA and TB to arrive at the transducers from which yA(t) and yB(t) are obtained. Also, each variation may suffer attenuation to a varying degree.
- the signals may thus be represented by
- yA(t) Al.x(t-TA) + A2.eA(t) ..(24)
- yB(t) Bl.x(t-TB) + B2.eB(t) .. (25)
- Power is an additive quantity. Power spectra from the repeated sampling and FFT calculations on many blocks of date may be summed, term by term, then divided by the number of sums, N, to get the averaged power spectra. In order to obtain reliable spectra to be used in the study of random variations it is essential either to average the individual spectra or to smooth them to remove the statistical variations caused by random disturbances.
- This averaging process may also be applied to the cross power spectra.
- averaging removes from the cross products the contributions of the uncorrelated components eA(t) and eB(t) , leaving only the effects of the common component x(t) . It follows that, provided the common component is not extremely small in the original signals, its relative phase can now be reliably calculated for each bin using equation (23) .
- the spectral function known as coherence may also be calculated from the averaged power and cross spectra. As the averaging proceeds, so the contributions of unrelated components of cross power spectra decay so the equality give in equation (22) no longer holds. This suggests that, for well averaged spectra, it should be possible to use the cross spectra to estimate the contributions to the power spectra of the common components. Coherence provides such an estimate. It is calculated as follows from the ratio of the left and right hand sides of equation (22) .
- Coherence is normally represented by gamma squared. It is function of frequency, and thus may be calculated for each bin for a set of averaged spectra. Otherwise it is similar to r 2 , the square of correlation coefficient.
- variation of the second type is caused by small randomly distributed defects that individually affect only a small part of the width of the web. Such variations would cause signals from the FS and BS lookers to vary independently with var(e) . Denote these signals by eA(t) and eB(t) .
- var(y) [var(yA) * var(yB)] 0 - 5 ..(32)
- the square root of coherence therefore gives the proportion of the variance of the signals (or of their power, in spectral analysis terms) that is caused by variations from the approach flow system.
- the proportion of the variance caused by localised forming faults is the complement, [1 - coherence °- 5 ] .
- Plots of power per octave against the logarithm of frequency may be nested together to show the relative intensities of different types of variation over a wide range of frequencies.
- FIG. 17 and 18 show, by way of example, the way in which the calculations may be carried out in two preferred embodiments of the invention.
- Figure 17 illustrates how the separation of patterns in the web may be achieved without the use of dual channel spectral analysis.
- Figure 18 shows how dual channel spectral analysis may be brought into play, if required.
- the analysis starts by sampling 110 the web at two points, for example 20 mm apart.
- One calculates at 112 the sum and difference signals from the individual sampled signals.
- the power spectra of the sum and differences are separately calculated to give a power spectrum of the difference 116 and a power spectrum of the sum 118.
- the subscript 20 indicates the spacing of the original sample points.
- the web is also sampled 120 at two other points, for example 200 mm apart.
- the sum and difference signals are then calculated at step 122, and the power spectra at 124.
- One thus obtains the power spectrum of the difference 126 and the power spectrum of the sum 128.
- the subscript 200 indicates the spacing of the sampling points.
- step 130 the DIFF 20 and DIFF 200 are subtracted, leaving one with a power spectrum 132 of macro-forming faults.
- the power spectrum of SUM 20 is ignored.
- curve fitting is carried out to the humps of the power spectrum of DIFF 20 at step 136, and depending upon the size of humps one thus obtains details of the flocculation size and intensity 138 and on the unstable streak intensity 140.
- the ⁇ power spectra of DIFF 200 and SUM 200 are subtracted to give a power spectrum 144 representative of bars (periodics) , low frequency faults from the wet end, and faults extending partway across the web.
- curve fitting is carried out on this power spectrum, and spikes and humps separated out. This provides data on spikes 148, low frequency wet end faults 150 and other faults of intermediate frequency 152.
- the analysis starts at step 210 by sampling the web at two separate points, preferably at the front side and at the back side. Dual channel spectrum analysis 220 is then carried out on the individual sampled signals. From that analysis one obtains two-power spectra: a power spectrum 222 of the variations extending across the full width of the web; and a power spectrum 221 of local variations such as flocculation, streaks, macro-forming faults, and faults which are wider than macro-forming faults but which do not extend across the full width of the web.
- step 224 curve fitting is applied to the power spectrum 222, to separate the spikes. This provides information on periodics 226. Once the spikes have been separated, the humps in the power spectrum may be separated as well, at step 228, providing information on medium and low frequency variations from the wet end, along with front side/back side phase difference information.
- the distance in the cross direction between the samples may be determined by trial and error.
- the 20 mm spacing suggested at step 110 is determined experimentally, according to the particular paper machine in question and the effects one is looking for. The skilled man will appreciate that the spacing can be determined experimentally by calculating the cross correlation between the signals.
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU25718/95A AU2571895A (en) | 1994-06-14 | 1995-05-26 | Web monitoring for paper machines |
DE69528649T DE69528649D1 (en) | 1994-06-14 | 1995-05-26 | RAILWAY MONITORING FOR PAPER MACHINES |
AT95920156T ATE226723T1 (en) | 1994-06-14 | 1995-05-26 | WEB MONITORING FOR PAPER MACHINES |
EP95920156A EP0765474B1 (en) | 1994-06-14 | 1995-05-26 | Web monitoring for paper machines |
US08/750,500 US5745365A (en) | 1994-06-14 | 1995-05-26 | Web monitoring for paper machines |
FI965009A FI965009A (en) | 1994-06-14 | 1996-12-13 | Path monitoring for paper machines |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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GB9411908.8 | 1994-06-14 | ||
GB9411908A GB9411908D0 (en) | 1994-06-14 | 1994-06-14 | Web monitoring for paper machines |
Publications (1)
Publication Number | Publication Date |
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WO1995034810A1 true WO1995034810A1 (en) | 1995-12-21 |
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ID=10756708
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/GB1995/001222 WO1995034810A1 (en) | 1994-06-14 | 1995-05-26 | Web monitoring for paper machines |
Country Status (9)
Country | Link |
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US (1) | US5745365A (en) |
EP (1) | EP0765474B1 (en) |
AT (1) | ATE226723T1 (en) |
AU (1) | AU2571895A (en) |
CA (1) | CA2190853A1 (en) |
DE (1) | DE69528649D1 (en) |
FI (1) | FI965009A (en) |
GB (1) | GB9411908D0 (en) |
WO (1) | WO1995034810A1 (en) |
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- 1995-05-26 DE DE69528649T patent/DE69528649D1/en not_active Expired - Lifetime
- 1995-05-26 US US08/750,500 patent/US5745365A/en not_active Expired - Fee Related
- 1995-05-26 EP EP95920156A patent/EP0765474B1/en not_active Expired - Lifetime
- 1995-05-26 AT AT95920156T patent/ATE226723T1/en not_active IP Right Cessation
- 1995-05-26 WO PCT/GB1995/001222 patent/WO1995034810A1/en active IP Right Grant
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WO2000008462A1 (en) * | 1998-08-06 | 2000-02-17 | Scapa Group Plc | Method and apparatus for monitoring water balance in a papermachine |
GB2341232A (en) * | 1998-09-07 | 2000-03-08 | Charlier Jean Ray | Rate of change monitoring system |
Also Published As
Publication number | Publication date |
---|---|
FI965009A0 (en) | 1996-12-13 |
DE69528649D1 (en) | 2002-11-28 |
EP0765474A1 (en) | 1997-04-02 |
CA2190853A1 (en) | 1995-12-21 |
EP0765474B1 (en) | 2002-10-23 |
GB9411908D0 (en) | 1994-08-03 |
ATE226723T1 (en) | 2002-11-15 |
AU2571895A (en) | 1996-01-05 |
FI965009A (en) | 1996-12-16 |
US5745365A (en) | 1998-04-28 |
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