WO2010103180A1

WO2010103180A1 - Determining elastic modulus for continuous material web

Info

Publication number: WO2010103180A1
Application number: PCT/FI2010/050175
Authority: WO
Inventors: Markku Haikola; Vesa Kajander
Original assignee: Abb Oy
Priority date: 2009-03-10
Filing date: 2010-03-09
Publication date: 2010-09-16
Also published as: EP2406610A1; BRPI1009433A2; KR20110137313A; CN102348969B; CN102348969A; US20120029844A1

Abstract

A method and equipment for determining elastic modulus for a continuous material web, in which method a continuous material web (4) runs on a roll (2) driven by an electric motor drive. The method comprises the steps of determining material web speed v₂, providing a change in an adjustable characteristic of the continuous material web by the electric motor drive, the characteristic being material web tension T, torque M acting on the material web or material web speed v₂, calculating elastic modulus E on the basis of the determined material web speed v₂ and speed change Δv₂ and torque change ΔM or material web tension change ΔT.

Description

DETERMINING ELASTIC MODULUS FOR CONTINUOUS MATERIAL WEB

BACKGROUND OF THE INVENTION

[0001] The invention relates to the determining of elastic modulus for a continuous material web, particularly a paper web. More specifically, the invention relates to the determining of elastic modulus from a continuous material web while the web is moving in a production machine.

[0002] One of the properties commonly determined for paper, pa- perboard or the like is elastic modulus. Elastic modulus describes the reversibility response of a material subjected to tension, the elastic modulus being determinable as a ratio of tension to the elongation caused by the extension, the extension taking place on a linear area and reversing entirely once the pulling tension is released.

[0003] The elastic modulus of paper, paperboard or the like has an influence on both the runability of the production machine and the quality of the end product. Often the end product is given a specific value or a threshold value, which the elastic modulus is to meet. A low elastic modulus in packing materials, for example, means that the material may tear too easily during packing. Similarly, with regard to paper used for printed matter, runability in printing machines partly depends on elastic modulus.

[0004] Usually elastic modulus is determined with laboratory measurements of finished material. For example, when a paper machine has produced a completed machine roll, a sample is taken from the paper to a laboratory for measurement. The result of the measurement is obtained, at best, after hours from the completion of the machine roll. If the elastic modulus deviates significantly from the target value, an entire machine roll of paper, at worst, may be wasted. Moreover, because of long delays, it is obvious that a quick adjustment of the production process on the basis of laboratory measurements is impossible.

[0005] Proposed methods for on-line measurement of elastic modulus include those in which the measurement sensors do not come into contact with the material web. One of these is a method based on the measurement of changes in web width. The web width measurement and a math- ematic model together allow the tensile strength ratio to be estimated and thus to draw conclusions on the characteristics of the paper during production. [0006] Another known method is to send high-frequency acoustic bursts to the surface of the paper and to observe the correlation between frequency modulation and the elastic modulus of the paper.

[0007] The tensile strength of paper may also be estimated on the basis of fibre orientation.

[0008] All the above methods for determining the elastic modulus or tensile strength of paper require measurement devices specifically devised for this purpose. Other aspects that influence the reliability of the results of acoustic measurements are challenging environment and high web speed. Moreover, an acoustic measurement is taken on a point of the material web and therefore does not necessarily illustrate the properties of the entire material. Mathematical models based on the measurement of web width, in turn, require a comprehensive research material for a reliable model to be obtained.

[0009] US 6993964 discloses a method, in which web speed and tightness are measured at two different web spans, elastic modulus being determined on the basis of these measurement data.

SUMMARY OF THE INVENTION

[0010] An object of the invention is therefore to provide a method, equipment implementing the method, frequency converter and a software product that allow the above problems to be solved. The object of the invention is achieved by a method, equipment, frequency converter and software product characterized by what is stated in the independent claims. The preferred embodiments of the invention are disclosed in the dependent claims.

[0011] The invention is based on the idea of determining elastic modulus for a material and quantities to be derived therefrom by using information obtained from an electric motor drive running the material web. A controlled electric motor drive coupled to a roll produces data on the speed of the web running on the roll and on the torque acting on the web, the elastic modulus being calculated on the basis of these.

[0012] An advantage of the method and arrangement of the invention is simplicity it provides for implementing a measuring arrangement. Elastic modulus may be measured without any measuring devices on the material web. Hence neither installation of measurement devices nor maintenance service thereof is needed. In addition, when sensors and the like installed for the purpose become broken, elastic modulus becomes impossible to determine. [0013] Elastic modulus measured on line may be utilized in various ways during the production process, post-processing as well as in the end product.

BRIEF DISCLOSURE OF THE FIGURES

[0014] In the following the invention will be described in greater detail with reference to preferred embodiments and the accompanying drawings, in which:

Figure 1 is a schematic view of a material web controlled by an electric motor drive; and

Figure 2 is an example of a tension-elongation curve.

DETAILED DISCLOSURE OF THE INVENTION

[0015] Figure 1 is a schematic view of a continuous material web in a manufacturing machine for the material in question. An example of this is a paper web in a paper machine. Figure 1 shows how the paper web 4 travels on three rolls 1 , 2, 3. The figure illustrates, by way of example, how roll 2 is controlled by electric motor drives consisting of an electric motor 5 and a frequency converter or a similar device 6 feeding the motor. The shaft of the motor 5 is coupled via a gearbox 7 to the roll axis for rotating the roll in a desired manner. It is to be noted that a gearbox is not necessary, which allows the motor shaft to be coupled directly to the roll. The motor may be an electric motor of any type, such as an induction motor or a synchronous motor. Figure 1 does not show the electric motor drives of the other rolls.

[0016] Motors rotating the rolls may be controlled in various ways by modern frequency converters or similar control means. The control may be carried out as a speed control, for example, while maintaining the web under a desired tension. The control is typically carried out in a situation where one of the motors produces a desired web speed and motors connected to this via the paper web are controlled by torque control to achieve and maintain a desired tension. There is a linear correlation between the torque and the web tension, because the force acting on the web width is web tension, the torque in turn being the product of the roll radius and the web force.

[0017] In a situation where the material web travels between two holding rolls in a static state, a relative elongation between rolls 1 and 2 of Figure 1 may be determined by the following equation: V₂ - V₁ ε = (1) vl

[0018] In a static state, change ZIv₂ in speed v₂ causes a change in elongation:

As = ^ , (2)

^V2 when V₇ is a constant and essentially equal to v₂.

[0019] Since the ratio of tension to elongation is essentially linear on small elongations and small changes in elongation, the Hooke's law may be applied:

σ = Eε , (3)

which defines tension σas the product of elastic modulus E and elongation ε . On the other hand, tension may be determined as a ratio of web force to a web surface area perpendicular to the force:

F_ σ = (4)

^~A

Equation (4) may further lead to:

F T σ = — = -, (5)

Ih h

since surface area A is the product of paper web height h , i.e. thickness, and width / and web tension T is the ratio of web force F to web width / .

[0020] The following notation may be obtained from equations (3) and (5):

h and further: AT

EAε = (7) h

Equation (7) is valid, because the ratio of changes in tension to those in elongation is linear when the changes are small.

[0021] By inserting equation (2) to equation (7) we obtain

E^ = ^ . (8)

With roll radius r and possible gearbox transmission ratio i taken into account, change zlM in torque M of the motor may be expressed as follows:

.. . AFr 2ATIr ,_Q

ZlM₂ = — = — _: — , (9)

from which the change in tension may then be calculated as follows:

AT (10)

2lr

[0022] Further, elastic modulus E is solved from equation (8) and equation (10) is inserted into this solution:

E = ^ΔTv2 = ^ΔM2iv2 (11) hAv₂ hΔv₂2lr '

from which we see that the value of the elastic modulus may be determined using the torque change, web speed and web speed change, and known parameters. The torque change, web speed and web speed change are obtained directly from the frequency converter, which controls the motor coupled to the roll. Similarly, gearbox transmission ratio i and roll radius r in equation (11) may be stored in the memory of the frequency converter or the like. Paper web thickness h and width / may vary, and these values may be stored either on the basis of measurements made during use or as known parameters. [0023] In accordance with the invention, material web speed v₂ is determined and a change into an adjustable property of the material web is introduced by the electric motor drive. These adjustable properties include material web tension, torque acting on the material web and material web speed.

[0024] Further in accordance with the invention, elastic modulus is calculated on the basis of the determined material web speed and the speed change as well as on the basis of the torque change or a change in the material web tension. In the above equations the material web speed was changed. This kind of change may be implemented directly by instructing the motor to change the web speed. This change in the web speed influences the torque on the roll, as expressed in the equations. It is to be noted that the acting torque may be considered to be either a torque acting on the material web or a torque caused by the material web on the roll. Although interpreted differently, these torques are, however, equal in magnitude.

[0025] As stated above, an induced change in speed caused a change in torque. These changes and the parameters involved in the web speed and drive allow the magnitude of the elastic modulus to be calculated.

[0026] Similarly, the torque or tension subjected to the material web by the roll may also be changed. This change in turn inevitably causes a change to the corresponding roll. Equation (11) shows the elastic modulus as a function of both a tension change zlTand a torque change AM . Use of tension change is preferred for example when the tension of a tension-adjusted material web is changed in order to calculate elastic modulus. In that case the original web speed, change in the web speed caused by a change in tension and a change in tension may be applied to equation (11) to calculate an elastic modulus value by also taking into account the thickness of the material web.

[0027] The term 'speed' as used above refers to the speed of the material web. This speed correlates in a known linear manner with the angular speed of the motor, which means that if desired, motor angular speeds may be applied instead of web speeds. Modern frequency converters are able to internally determine the magnitude of the torque produced by the motor or that of the torque subjected to the motor as well as the web or angular speed. As stated above, the determining of web tension is based on the determining of torque, and therefore all quantities to be determined in the method of the invention are directly known to the control unit of the frequency converter. These quantities may be conveyed as such to a separate computation unit and from there to a higher level control system, such as an automation system controlling the drives. The frequency converter itself may also be arranged to carry out the necessary calculations for determining elastic modulus. In these cases the frequency converter transmits the calculated elastic modulus value to the higher level.

[0028] In the above, the equipment driving the roll has been specifically referred to as a combination of a frequency converter and an induction motor or a synchronous motor. A corresponding functionality for implementing the method of the invention may also be provided by a direct-current motor and equipment driving the motor.

[0029] Determining elastic modulus in accordance with the invention may be carried out at specific timed intervals when the material web is in a static state. It is also conceivable to determine elastic modulus on a continuous basis by providing the roll performing the determining with a slight variation in the speed instruction, for example. For accuracy of the elastic modulus determination, it is important that the roll at which the elastic modulus is determined is a holding roll. This means that the surface speed and the web speed of the roll must correspond to one another as precisely as possible to prevent the material web from sliding on the roll.

[0030] The method of the invention allows the point of operation of the material web to be evaluated on the basis of elastic modulus. Elastic modulus is an angular coefficient of a tension-elongation curve that may be formed for the material, as shown in Figure 2. Within a range of low elongation values, the angular coefficient of the material is relatively high. As the angular coefficient becomes smaller, an identical change in the tension of the material web, i.e. the web force, increases elongation. When the web force is further increased, a breaking point of the material web is achieved, i.e. the break resistance of the material has been exceeded. Before this point the angular coefficient of the curve, i.e. its elastic modulus, is small, the method of the invention thus allowing to deduce situations where the tension of the material web threatens to break the web. This information may be directly applied to the adjustment of the web by lowering the tension instruction, or the like, when the angular coefficient is significantly small.

[0031] Typical situations of manufacturing paper or a similar material take place in a linear tension-elongation curve area, where the magnitude of the elastic modulus to be calculated by the method does not vary essen- tially. When decrease in the elastic modulus is observed, the tension of the material has changed essentially while quality has remained the same. This allows to improve the runability and diagnostics of a machine for manufacturing paper, or the like.

[0032] Further, elastic modulus determined according to the method of the invention during the material production provides added value when reasons for web breaks are to be diagnosed. Unexpected variations in elastic modulus of the material may cause problems in material runability when standard quality material would be driven on the linear tension-elongation curve area. Recording the elastic modulus values determined according to the invention enables to detect correlations even to process disturbances at the upstream end of the production machine. In particular, if the elastic modulus shows cyclically varying changes, it is possible to locate problems in the operation of the production machine on the basis of the cycle.

[0033] Elastic modulus values determined by the method of the invention, or deviations from elastic modulus values considered as normal, may be indicated on a completed machine roll either by a marking on the edge of the finished material or by using electric recording means. These markings allow material defined as reject to be removed from devices where the material is to be processed further.

[0034] The equipment of the invention comprises means for determining the speed of the material web, an electric motor drive of the equipment being arranged to provide a change in an adjustable property of the continuous material web, the property being material web tension, torque acting on the material web or material web speed. The equipment is further arranged to calculate elastic modulus on the basis of the determined material web speed and a change in speed and a change in torque or a change in the material web tension. These means may be implemented by an electric motor drive, the electric motor drive having computing capacity for carrying out the necessary computations and readable memory for taking into account the necessary parameters in the computations. The computing capacity may also reside in a control system, which may receive measurement data from the process and data produced by the frequency converter.

[0035] The invention may be implemented into existing systems or by using separate elements and devices in a centralized or distributed manner. Existing devices, such as electric motor drives, typically comprise a processor and a memory that may be utilized to implement the functionality of the embodiments of the invention. Hence all changes and configurations needed for implementing the embodiments of the invention, may be performed by software routines, which in turn may be implemented as added or updated software routines. If the functionality of the invention is implemented by software, the software may be provided as a computer program product comprising a computer program code which, when run on a computer, causes the computer, or similar equipment, to perform the functionality of the invention as described above. The computer program code may be stored on a computer readable medium, such as a suitable memory means, e.g. a flash memory or on a disc memory, from which it is readable to the unit or units executing the program code. In addition, the program code may be loaded to the unit or units executing the program code through a suitable data network and it may replace or update a possibly existing program code.

[0036] A person skilled in the art will find it obvious that as technology advances the basic idea of the invention may be implemented in various ways. The invention and its embodiments are therefore not restricted to the above examples but may vary within the scope of the claims.

Claims

1. A method for determining elastic modulus for a continuous material web, in which method the continuous material web (4) runs on a roll (2) controlled by an electric motor drive, characterized in that the method comprises the steps of determining material web speed v₂ , providing an adjustable characteristic of the continuous material web with a change by the electric motor drive, the characteristic being material web tension T , torque M acting on the material web or material web speed ^₂ , calculating elastic modulus Eon the basis of the determined material web speed v₂ and speed change Av₂ and torque change AM or change in material web tension AT .

2. A method according to claim ^ characterized by using the electric motor drive to provide a change in material web speed v₂, determining the motor torque before and after the change in speed to provide torque change AM , and calculating elastic modulus Eon the basis of material web speed v₂, and the provided material web speed change Av₂ and motor torque change AM caused by the material web speed change.

3. A method according to claim 1, characterized by using the electric motor drive to provide a change in material web tension T , determining material web speed change Av₂ caused by material web tension change AT , and calculating elastic modulus Eon the basis of material web speed v₂ and the provided change in material web tension AT and the motor speed change Av₂ caused by the change in the material web tension.

4. A method according to claim 1, characterized by using the electric motor drive to provide a change in torque M acting on the material web; determining material web speed change Av₂ caused by torque change AM , and calculating elastic modulus Eon the basis of material web speed v₂ and the provided material web torque change AM , and the motor speed change Av₂ caused by the change in the material web torque.

5. A method according to any one of preceding claims 1 to 4, characterized in that the material web speed and the torque acting on the material web are determined in the electric motor drive.

6. A method according to any one of preceding claims 1 to 5, characterized in that the method further comprises the steps of comparing the magnitudes of elastic modulus values determined by different measurements, and reducing the material web tension, when a decrease in elastic modulus is observed.

7. A method according to any one of preceding claims 1 to 6, characterized in that the elastic modulus is determined in the electric drive.

8. A method according to any one of preceding claims 1 to 6, characterized in that the electric motor drive transmits data needed for determining the elastic modulus to a higher level, where the elastic modulus is determined.

9. A method according to any one of preceding claims 1 to 8, characterized in that the calculation of the elastic modulus further includes the use of web thickness, web width and the radius of the roll to be driven, and gear transmission ratio, if any, between the electric motor and the roll.

10. A method according to any one of preceding claims 1 to 9, characterized in that the motor in the electric motor drive is an alternating current motor or a direct current motor.

11. Equipment for determining elastic modulus for a continuous material web, the material web running on a roll arranged to be driven by an electric motor drive, characterized in that the equipment comprises means for determining the speed of the material web; and the electric motor drive is arranged to provide a change in an adjustable characteristic of the continuous material web, the characteristic being material web tension, torque acting on the material web or material web speed, the equipment being configured to calculate the elastic modulus on the basis of the determined material web speed and a change in the speed and a change in torque or a change in material web tension.

12. Equipment according to claim 11 , c h a r a c t e r i z e d in that the motor in the electric motor drive is an alternating current motor or a direct current motor.

13. A frequency converter arranged as a part of the electric motor drive used in the method according to any one of preceding claims 1 to 10 to control a roll on which a continuous web runs, the frequency converter being configured to be driven so as to provide a change in an adjustable characteristic of the material web and to calculate elastic modulus.

14. A computer program product comprising a computer program code which, when run on a computer, causes the computer to perform the steps of the method according to any one of claims 1 to 9.