U.S. patent number 3,886,036 [Application Number 05/471,228] was granted by the patent office on 1975-05-27 for method of controlling a drier limited paper machine.
This patent grant is currently assigned to Measurex Corporation. Invention is credited to Erik B. Dahlin.
United States Patent |
3,886,036 |
Dahlin |
May 27, 1975 |
Method of controlling a drier limited paper machine
Abstract
A method of paper machine drier limited control wherein grade
changes are executed in a continuous feedback manner. One control
loop drives conditioned weight from one value to another value via
action on stock flow while a second control loop maintains moisture
at a constant value via action on master speed. The conditioned
weight and moisture control loops are coordinated so that a control
action in one loop will not upset the controlled variable in the
other loop. The change in conditioned weight is also coordinated
with a corresponding change in the headbox slice opening. Changes
in master speed necessary to maintain a constant moisture content
are fed forward to a headbox jet-to-wire ratio control loop so that
the headbox head may be adjusted for speed changes to keep the
jet-to-wire ratio constant. An additional coupling is made between
the jet-to-wire ratio control loop and the slice opening so that
the fiber concentration of the jet is not thrown out of control by
head changes and the rotational velocity of the rectifier rollers
is controlled to eliminate pressure differentials at the slice.
Inventors: |
Dahlin; Erik B. (Saratoga,
CA) |
Assignee: |
Measurex Corporation
(Cupertino, CA)
|
Family
ID: |
26927392 |
Appl.
No.: |
05/471,228 |
Filed: |
May 20, 1974 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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233937 |
Mar 13, 1972 |
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Current U.S.
Class: |
162/198;
162/DIG.6; 162/252; 162/253; 162/256; 162/258; 162/259;
162/263 |
Current CPC
Class: |
D21G
9/0027 (20130101); D21G 9/0036 (20130101); Y10S
162/06 (20130101) |
Current International
Class: |
D21G
9/00 (20060101); D21f 001/08 (); D21f 007/00 ();
D21f 009/00 () |
Field of
Search: |
;162/198,263,252,253,254,259,256,258,342,DIG.6 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Bashore; S. Leon
Assistant Examiner: Alvo; M. Steven
Attorney, Agent or Firm: Flehr, Hohback, Test, Albritton
& Herbert
Parent Case Text
This is a continuation of application Ser. No. 233,937 filed Mar.
13, 1972, and now abandoned.
Claims
I claim:
1. In a method of controlling a paper machine having a pulp stream
flow feeding into a headbox and controlled by a pulp stream valve
to thereby control total head, T.sub.H, said headbox being provided
with rectifier rollers and a slice that permits pulp to jet onto a
moving wire to form a paper sheet and from which the water passing
through is collected, mixed with stock from a stock flow line
controlled by a stock flow valve and supplied to the pulp stream,
said sheet then being passed at a characteristic master speed
through a drier section to which steam is supplied in a dryer
limited mode, the steps comprising: scanning said sheet after the
dryer section and determining a value related to the moisture of
said sheet, comparing said measured value with a target value for
said moisture content, and utilizing the moisture error signal
therefrom to manipulate at substantially every scan said master
speed so that said moisture content is maintained within
specifications; determining a value related to conditioned weight
of said sheet, comparing said measured value with a target value
for said conditioned weight, and utilizing the error signal
therefrom to manipulate said stock flow valve so that conditioned
weight remains within specifications; cross-coupling conditioned
weight error signals to master speed and to said moisture error
signal so that changes in conditioned weight error signals will not
upset moisture, crosscoupling said moisture error signal to said
stock flow so that changes in moisutre error signal will not upset
conditioned weight; coupling said moisture error signal modified by
said crosscoupled weight error signals to a control loop wherein
the total headbox head, T.sub.H, is controlled by manipulating said
pulp stream valve, said coupling being such that the jet-to-wire
ratio remains constant; coupling said headbox head control loop
with said headbox slice such that said slice will be adjusted in
response to jet velocity changes to keep the pulp fiber
concentration for the sheet constant; detecting the rotational
velocity of said rectifier rollers; supplying said detected
velocity to a rectifier roller compensation signal generator;
generating a rectifier roller compensating signal based on the
detected roller velocity such that said compensating signal
eliminates pressure differentials at the slice caused by the
rotational velocity of said rollers when said compensating signal
is supplied to said headbox head control loop; and supplying said
rectifier roller compensating signal to said headbox head control
loop.
Description
BACKGROUND OF THE INVENTION
The present invention relates to the digital control of paper
making machines. More particularly it relates to a feedback control
system for changing the grade of paper and an improved method of
controlling a paper machine headbox.
The process of paper making utilizes logs as the basic raw
material. The logs have their bark removed, are cut into chips, and
then are converted to pulp. Pulp to be used for white paper is then
bleached whereas unbleached pulp may be used for such products as
paper bags. After bleaching, pulp streams of different compositions
and properties are blended together to produce a sheet with the
desired properties. The blended stream is then sent to refiners
which consist of counter rotating disks or cones between whose
surfaces the pulp slurry is pumped. The refiner disks cut the
fibers and rupture the outer cell walls to expose the softer inner
materials. This increases the surface area of the pulp and to some
degree the strength of the paper product.
The product from the refiner, called stock, is then mixed with
white water and passed through a stream flow valve into a headbox.
The headbox transforms the incoming flow of pulp into a wide jet
stream about one inch deep. This is done by allowing the water to
escape or jet from the bottom of the headbox through a long narrow
opening called the "slice". The jet discharges on top of and
parallel with a moving wire screen, often called a fourdrinier wire
(hereafter called the wire). The speed of the jet and wire are
controlled to run at nearly the same velocity. However, a slight
differential in the two speeds causes a certain amount of fiber
orientation and thus improves the paper quality. Thus, it is
critically important to control the jet speed to wire speed ratio
(hereafter called jet-to-wire ratio). Water passes through the wire
but leaves the majority of the fiber behind as a wet web. The water
that passes through the wire is called white water and is collected
and again mixed with the stock flow as mentioned earlier. The next
step in the process is that of pressing water out of the web. In
this way the solids content is increased from about 20% to about
40%. Following pressing, the sheet passes through a steam heated
dryer section from which the sheet emerges at about 95% solids. In
other words, the moisture content is a critical parameter with
small deviations around 5% making considerable differences in both
the properties of the paper product and the economies of
production. Thus, moisture content must be carefully
controlled.
The paper sheet passes from the dryer section to a "calendar stack"
where the thickness uniformity is improved and a surface finish is
imparted to the paper. Finally, the paper is wound on a reel.
Paper making machines start with the headbox and end with the reel.
They are very expensive and to be economical must be run as
continuously as possible. As with other expensive production
equipment, unscheduled down time or slow downs on the paper machine
are very costly. In maximizing the output of a paper machine, one
significant area ripe for improvement is in time lost in changing
the grade of the paper. Grade here refers to the basis or
conditioned weight of the paper being made where conditioned weight
and basis weight are two very similar ways of describing the weight
of fiber content per unit area of paper produced. Due to pulp input
limitations, grade changes usually require commensurate speed
changes as well as changes in many other variables. Because of this
complexity, reducing the unproductive time in a grade change is a
formidable task and requires a very sophisticated control scheme
that includes special headbox controls not heretofore available.
The present invention fills this gap in paper machine control.
The application of process control techniques to paper making has
been going on for some time now. These techniques have developed
from a point where human operators were watching meters and
adjusting valves through analog feedback control to the present.
Recently digital feedback control has replaced analog control for
many applications. The process of replacing analog control with
digital control started in situations where the control schemes
were relatively simple and the advantages quite clear.
Progressively more difficult applications were switched over from
analog to digital control. The present invention is directed at two
complex and interrelated problems that have not been solved - grade
change and headbox control.
In the past the general approach for handling grade changes was to
move the actual process variables such as machine speed, stock
flow, headbox head, and steam along complex trajectories that were
predetermined from process models. The procedure started with the
development of accurate process variable trajectories using data
logging, curve fitting and similar techniques. When a grade change
was required, the machine was taken off control and the various
process variables were carefully moved from their initial set point
to their final set point along the previously determined
trajectories. After the process variables reached their final
values, the machine was brought back on control and good paper
again made. Because little or no feedback information is used in
controlling the change, this approach just described is called open
loop grade change control.
There are, however, several drawbacks to the open loop approach. To
start with, severe process transients may develop if the process
variable trajectories are not accurate. Thus considerable effort
must be put into the development of process models. But even after
the investment is made to get good models, there are still
problems. In particular, all models depend on some assumptions. As
long as the assumptions are realistic, they cause no great harm.
But all too often conditions change so that one or more of the
assumptions are no longer valid. For example, pulp from a different
tank may be introduced while a grade change is taking place. Unless
the pulp from the new tank has nearly the same properties as that
from the old tank, the assumptions may be far off. And, pulp often
varies considerably from tank to tank due to such things as the use
of a different kind of wood or a different percentage of used
paper. Thus, the projected variable trajectories may be thrown far
off due to no greater disturbance than a change in pulp
characteristics.
As a result of these possiblilities, the grade change must be made
very slowly to allow time for human intervention. Otherwise there
is a risk of having to abort midway through a grade change or even
a risk of sheet break. Since all of these alternatives are quite
expensive in production time lost, an improved method of changing
grade is needed.
Furthermore, the open loop schemes usually require very expensive
instrumentation. For example, they require a control valve in the
white water line and a flow meter in either the stream flow line or
the white water line. Since these lines are on the order of 30
inches in diameter, the instrumentation therefor is very
expensive.
Since a grade change requires a movement of the headbox parameters,
coordination of grade change with headbox control is critical. In
particular, the jet-to-wire ratio and headbox fiber concentration
must be accurately controlled, both during grade change and during
normal regulatory operation. The prior art schemes have done poorly
in this regard.
Thus it is an object of this invention to provide a faster method
of implementing grade changes.
Another object of the invention is to provide a method of grade
change control that reduces the risk of sheet breaks.
Still another object of the invention is to provide a method of
grade change control that greatly reduces the required investment
in instrumentation.
Another object of the invention is to provide a method of grade
change capable of immediately adjusting to a change in pulp.
Another object of the invention is to provide an improved method of
grade change control that accurately coordinates grade change and
headbox control.
Another object of the invention is to provide a headbox control
method that accounts for the impact of rectifier rollers.
Another object of the invention is to provide a manual speed feed
forward without upsetting moisture or conditioned weight.
Finally, it is an object of this invention to control grade changes
by moving the condition weight of the paper from one value to
another while maintaining moisture content constant by adjusting
stock flow, speed, jet-to-wire ratio, and headbox fiber
concentration.
SUMMARY OF THE INVENTION
The present invention broadly achieves the foregoing objectives of
paper machine control by first determining the actual scan average
value of moisture, comparing this value with a moisture target
value, and utilizing the error signal therefrom to manipulate
master speed so that moisture content is maintained within
specifications. Similarly the actual scan average value of
conditioned weight is compared with a conditioned weight target,
and the error signal therefrom is utilized to manipulate stock flow
such that conditioned weight remains within specifications.
Crosscoupling is provided between conditioned weight error signals
and master speed so that changes in the error signal will not upset
moisture. Likewise crosscoupling is provided between moisture error
signals and stock flow so that changes in the moisture error
signals will not upset conditioned weight. The moisture error
signal modified by the crosscoupling signal is coupled to the
headbox control loop wherein the total headbox head is controlled
by manipulating stream flow where the objective is to maintain a
constant jet-to-wire ratio. Finally the headbox head control loop
is coupled to the headbox slice such that changes in the head do
not affect the pulp fiber concentration of the paper sheet.
According to another aspect of the invention, an automatic grade
change is achieved by ramping the targets of the control system
parameters from their pre-grade change value to their respective
new grade change values such that master speed target is moved no
faster than some predetermined rate. In the nondryer limited mode,
steam to the dryer section is also ramped along a predetermined
trajectory.
BRIEF DESCRIPTION OF THE DRAWING
A preferred embodiment of the invention will now be explained in
detail in conjunction with the drawing wherein:
FIG. 1 is a schematic showing the interaction between a
conventional paper machine and applicant's invention.
FIG. 2 is a partial perspective view of a paper machine sheet
scanner that may be used for detecting average values of
conditioned weight and moisture.
FIG. 3A is the first part of a systems diagram of a control scheme
for a paper machine according to the present invention.
FIG. 3B is the second part of 3A. Taken together FIGS. 3A and 3B
are one complete figure.
FIG. 4 is a schematic showing automatic grade change control.
According to one aspect of the invention, control is concentrated
on two parameters - conditioned weight and moisture content. The
control objective is to maintain moisture at a constant value and
either keep conditioned weight constant or cause it to move on a
particular trajectory depending on whether operation is in a
regulatory or grade change mode. Steam in the dryer section is
maintained constant at its maximum value. Thus, the process is
called dryer limited. Control is achieved under these conditions by
manipulating speed and stock flow. But the movement of speed and
stock must be synchronized so that both the moisture and
conditioned weight requirements are met simultaneously. This is
accomplished by decoupling speed changes from conditioned weight
changes. That is, adjustments in speed to compensate for a moisture
error are not allowed to upset conditioned weight. Likewise
adjustments in stock flow are not allowed to upset moisture. By
upset is meant that in theory changes in one parameter will have no
impact whatsoever on the other. In practice there probably is some
disturbance but it is lost in the noise of the measuring gauges.
Furthermore, this is achieved in spite of strong process coupling
between these variables.
As an aid in understanding the invention, the paper making process
and a control system therefor are briefly described with the aid of
FIG. 1. A more elaborate description is provided in U.S. Pat. No.
3,757,122 issued Sept. 4, 1973 and entitled "Basis Weight Gauging
Apparatus, System and Method Using a Digital Count". Referring now
to FIG. 1, raw stock is supplied to paper machine 2 via stock valve
3 and line 3A. White water from collection reservoir 4 is drained
via line 4a, mixed with raw stock and supplied through stream valve
5 and fan pump 6 to head box 7. The pulp and white water mixture
jets from head box 7 through slice 8 on top of and parallel with
wire 9. Water passes through wire 9 and is collected by reservoir
4. However, the majority of fiber is left behind to form a wet web
10. After leaving wire 9, web 10 is passed through press 11
consisting of a plurality of rollers 12 which removes much of the
water from web 10 and essentially converts it to a sheet of wet
paper. Thereafter the paper sheet passes into a dryer section 14
consisting of a plurality of rollers 15 through which steam is
supplied via steam control valve 16. The steam heats the rollers
and consequently evaporates much of the water in the paper sheet so
that the paper emerging from dryer section 14 has the desired
moisture content. The paper passes dryer section 14 to a calender
stack 17. Thereafter the sheet passes through scanner 18 and is
wound on reel 19.
Scanner 18 is shown in more detail in FIG. 2. Referring now to FIG.
2, scanner 18 consists generally of a frame 150 having a pair of
spaced upper and lower parallel beams 152 and 154 that extend
laterally across the sheet of paper 10 being produced by paper
machine 11. Upper and lower heads 156 and 158 contain sensors and
are moveably mounted to frame 150 and are adapted to scan the
entire width of the paper sheet which passes through a gap 160
between the two heads. Within the heads are conditioned weight and
moisture sensors which may be of conventional design well known in
the art or as described in application, Ser. No. 861,588, filed
Sept. 29, 1969 and now U.S. Pat. No. 3,641,349 issued Feb. 8, 1972,
entitled Apparatus for Measuring the Amount of Substance that is
Associated with a Base Material and Method Therefore. This
application is assigned to the assignee of the present invention.
As the heads traverse the paper sheet, both conditioned weight and
moisture are continuously measured and supplied to the rest of the
system.
In particular, signals indicative of conditioned weight and
moisture are supplied via data channel 24 to production log station
25 that includes a digital processor 27 having an I/O device 29 and
a digital output terminal 29a attached thereto. I/O device 29
provides communication interface between processor 27 and operators
while digital output terminals 29 a provides real time information
in digital format on the measurements being made.
Output signals from processor 27 are supplied via data channel 31
to consoles 37 and 39 that may contain various displays and input
command devices as shown and described in more detail in the above
referenced application.
Referring now to FIG. 3, the conditioned weight signal from
conditioned weight sensor 20 in scanner heads 156 and 158 is
supplied through data interrupt 21 to scan average processor 22.
Since the control method is usually implemented with a digital
computer, data interrupt would commonly be a program controllable
connection to sensor 20, and the various signals would be in
digital form. Scan average processor 22 determines the average
value of conditioned weight across an entire scan of scanner 18.
When data interrupt 21 is figuratively closed, the scan average
signal is compared at summing unit 23 with a target conditioned
weight signal supplied via data path 24 (FIG. 1). The resulting
error signal is supplied to conditioned weight control function 26
which generates the primary command signal for adjusting stock flow
controller 30 such that conditioned weight is kept on target.
Conditioned weight control function 26 is a well known relationship
that takes the following form: ##EQU1## Where: .DELTA.SF = change
in stock flow
.DELTA.CWE = change in conditioned weight error signal
n = Integer(.delta..sub.b /.delta..sub.s)
.delta..sub.6 = transport delay between stock valve and reel
.delta..sub.s = time between control actions
K.sub.1 = gain constant
Z = z transform
a.sub.1,a.sub. 2 = constants
b.sub.1, b.sub.2 = constants
The moisture signal generated by the moisture sensor in heads 156
and 158 and converted to digital form is shown figuratively as
originating at point 32. This signal is supplied via data interrupt
33 to scan average processor 34. The scan average signal is
supplied to summing unit 36 where it is compared with a moisture
target signal 35. The resulting error signal is supplied to
moisture control function 38 which generates the primary command
signal for adjusting the paper machine master speed such that
moisture is kept on target. By master speed is meant the speed at
which sheet 10 passes through the paper machine. This control
function is well known and takes the following form: ##EQU2##
Where: .DELTA.MS = change in paper machine master speed
.DELTA.MOI E = change in moisture error signal
K.sub.2 = gain constant
c.sub.1 ,c.sub.2 = constants
d.sub.1 ,d.sub.2 = constants
The command signal from moisture control function 38 is supplied to
summing unit 40 where it is combined with a conditioned weight
decoupling signal.
This signal is generated by conditioned weight decoupling function
42 from the conditioned weight error signal supplied via data path
44. Functionally, the decoupling signal compensates for any impact
that a change in conditioned weight may have on moisture, and
thereby makes it possible to take control action on conditioned
weight without having to worry about upsetting moisture control.
Mathematically decoupling function 42 takes the following form:
##EQU3## Where: K.sub.3 = gain constant
e.sub.1 ,e.sub.2 = constants
f.sub.1 ,f.sub.2 = constants
The output of summing unit 40 is supplied to a conventional clamp
function 46 which restricts the permissible change in master speed
to predetermined magnitudes. The output of clamp 46 is supplied to
ramp function 48 which specifies the maximum single step at which
the speed control equipment should be driven and the time
separation between those steps. Together, clamp 46 and ramper 48
protect the sensitive and expensive speed drive mechanism from
excessive control action.
The output of ramper 48 is supplied via transport delay 50 to
master speed controller 52. Delay 50 is necessary to synchronize
the impact of a change in speed with a change in stock flow as seen
at the scanner. Since the propagation time through the process is
less for a control action on speed than for a control action on
stock, an artificial delay must be added in the speed control path
to make sure that the impact of speed and stock flow changes reach
the scanner at the same time. Master speed controller 52 translates
the command signal from delay 50 into the appropriate hardware
action so that the paper machine master speed is changed
accordingly.
To achieve decoupling between a control action on speed and
conditioned weight, the output of ramper 48 is supplied not only to
master speed controller 52 but also to master speed to stock flow
feed forward control function 54 via data path 56. This function
supplies an output command signal to summing unit 28 that adjusts
stock flow so that conditioned weight will not be affected by an
adjustment of master speed. Mathematically, decoupling function 54
takes the following form: ##EQU4## Where: K.sub.4 = gain
constant
This system, called a decoupled dryer limited controller, provides
total noninteractive control. That is, moisutre target adjustments
can be made without upsetting conditioned weight, and conditioned
weight target adjustments can be made without upsetting
moisture.
Stock flow controller 30 and master speed controller 52 may be
direct digital control units or analog controllers whose set points
are controlled by the command signals supplied thereto.
In the regulatory mode, it is sometimes undesirable to change speed
frequently because the speed drives tend to wear. In this case,
control action on speed is restricted to 1 in N scans. However,
control action on stock flow need not be and is not restricted.
Because of this difference, conditioned weight decoupling function
42 must either be deactivated or restricted to operate only when
control action on speed is permissible. This restriction is
symbolized by switch or data interrupt 53 which is closed every N
scans. Of course, the function of switch 53 may be accomplished by
a programming routine.
According to another aspect of the invention, control is performed
on the headbox where the jet-to-wire ratio and the pulp fiber
concentration are the dependent control variables. The jet-to-wire
ratio is the ratio of the water velocity coming out of the headbox
slice to the velocity of the fourdrinier wire. In controlling this
variable, the jet velocity coming from the headbox slice is
controlled by manipulating the head in the headbox. By head is
meant the total pressure on the fluid at the slice location. This
pressure is determined from the height of the pulp-water column and
the air pressure over the liquid surface.
In controlling the jet-to-wire ratio, it is convenient to use
cascaded control. That is, fluctuations in total head pressure are
regulated by an analog controller acting on stream flow and the
controller set point is determined by the basic control scheme.
The basic control scheme for jet-to-wire ratio utilizes four
independent variables. The first is a change in the master speed
command signal supplied to master speed controller 52 from delay
50. Clearly, any change in this command signal will cause a change
in the wire speed, and without a compensating change in jet
velocity the jet-to-wire ratio would be altered. To handle this
problem the output of transport delay 50 is supplied through manual
disconnect 57 and data interrupt 58 to jet-to-wire ratio controller
60. Manual disconnect 57 enables the operator to disconnect links
in the controlling program, such as the link between master speed
and the headbox, at his discretion. Data interrupt 58 again
illustrates the requirement that speed changes be initiated only
every N scans.
The second input variable to be accounted for is the jet-to-wire
ratio target which is supplied to controller 60 from manual entry
station 64. Manual entry station 64 is a general purpose data entry
and data display panel where various control variables may be
entered, modified or displayed.
The third independent variable to be accounted for is wire speed.
This variable must be considered in addition to master speed since
the operator can change the draw, that is, the velocity difference
between two sections of the paper machine, at his discretion. It is
important that the operator be able to adjust the draw to minimize
the chance of a paper sheet break. But if a change in draw is made
between the master speed section and the wire, it will cause a
change in wire speed, and any change in wire speed impacts the
jet-to-wire ratio Consequently, the wire speed is measured by wire
speed sensor 65 whose output signal is supplied directly to
jet-to-wire ratio controller 60.
The jet-to-wire ratio controller 60 transfer function is derived in
the following manner. First the jet-to-wire ratio is defined as:
##EQU5## Where: J = jet-to-wire ratio
V.sub.j = jet velocity of the stock from the slice
V.sub.w = wire velocity
From classical fluid mechanics theory it can be shown that:
V.sub.j =.sqroot.2gH (6)
Where
g = acceleration due to gravity
H = total headbox head
To accommodate master speed changes, a new variable V.sub.c is
defined as:
V.sub.c = V.sub.w + V.sub.m (7)
Where:
V.sub.m = change in master speed
By substituting equations (6) and (7) into (5), and solving for H,
one gets: ##EQU6## From equation (8) the target for the total head
controller is defined as: ##EQU7## and ##EQU8## Where: H.sub.F =
previously determined target for total head control
The output of jet-to-wire ratio controller 60 is defined by
equation (9).
The fourth independent variable that must be accounted for is the
rectifier roller velocity. Rectifier rollers in the headbox modify
the flow pattern in the headbox and generate a pressure
differential at the slice opening that can be positive or negative.
The rectifier roller velocity is detected by detector 66 and is
supplied to rectifier compensator function 68 which generates an
output signal of the following form:
H.sub.e = H.sub.e.sup.nom + c.sub.1 (V.sub.e -V.sub.e.sup.nom)
(10)
Where:
H.sub.e = head loss due to rectifier roller speed
H.sub.e.sup.nom = nominal head loss due to rectifier roller
speed
c.sub.1 = constant
V.sub.e = measured rectifier roller speed
V.sub.e.sup.nom = nominal rectifier roller speed
This signal is summed with the output of jet-to-wire ratio
controller 60 at summing unit 70 so that the actual target signal
for the headbox controller is: ##EQU9## If the rectifier rollers
are creating a positive pressure differential at the slice opening,
then the output signal from rectifier roller compensator 68 will
subtract from the output of controller 60, and vice versa.
The output signal from summing unit 70 is supplied to sample and
hold device 74. This device, in effect, holds the output of summing
unit 70 and supplies it to analog controller 76 which operates on
stream flow valve 80 to maintain the total head on target. In so
doing, the actual head as detected by head sensor 78 is compared
with the total head target, T.sub.H. Any difference therebetween
causes control action on stream flow valve 80 to reduce the
difference. A separate control loop exists for controlling the air
pressure over the liquid in the headbox. Thus clearly it would also
be possible to tie into this loop to aid in controlling the jet
velocity. However, controlling the stream flow valve is believed to
be a superior scheme.
As can be seen from equation (11), the set point for controller 76
will be changed by either a change in J or in V.sub.c. Any wire
speed change resulting from a master speed change, .DELTA.V.sub.m,
will have been accompanied by a feedforward to stock flow via
master speed to stock feedforward function 54. Consequently, if the
slice area A.sub.j remains constant, then the headbox consistency
C.sub.h will remain constant. Thus any wire speed change due to a
change in master speed need not be accompanied by control action on
the slice to keep C.sub.h constant.
If, however, a change in wire speed occurs that is not due to a
change in master speed, the head set point, T.sub.h, will also
change to maintain a constant jet-to-wire ratio. But this will
cause a change in the flow rate, F.sub.j, from the slice. Since the
changed flow rate is not accompanied by a corresponding change in
fiber supplied to the headbox, it is necessary to change the slice
opening so that the flow rate is returned to its previous value.
Headbox consistency C.sub.h is thereby maintained at a constant
value. Quantitatively the relationships are derived as follows:
The flow at the slice F.sub.j is defined as:
F.sub.j = A.sub.j V.sub.j (12)
Where:
A.sub.j = slice area
V.sub.j = slice exit velocity
The dry weight at the reel is given by: ##EQU10## Where: Ch = head
consistency in %
r = the fraction of fiber retained on the wire
.delta. = the density of the fiber
W = the width at the slice
Re = the number of square feet per ream
.alpha. = the shrinkage factor, i.e., width at reel/width at
slice
From equations (5), (12), (13) it follows that: ##EQU11##
differentiating equation (14) ##EQU12## where Ch is computed from
equation 13 and .DELTA.Ch is the desired change in consistency
entered from manual entry station 64. The relationship of equation
(15) is implemented by slice control unit 98.
To decouple headbox consistency from changes in jet-to-wire ratio
target or wire speed changes, feedforward is utilized. The output
of jet-to-wire ratio control unit 60 is supplied via data path 84
through delay 86 to headbox head to slice feedforward functional
unit 88. Analytically the feedforward relationship is derived as
follows:
Since conditioned weight is constant, F.sub.j is required to remain
constant. Thus by differentiating equation (12) it follows
that:
A.sub.j .DELTA.V.sub.j + V.sub.j .DELTA.A.sub.j = 0 (16)
From equation (6) it follows that: ##EQU13## Combining equation (5,
), (16) and (17) one gets the correct relationship for unit 88:
##EQU14##
For changes in master speed, the headbox head to slice feedforward
is disabled since any change in master speed is synchronized with a
stock flow change via master speed to stock flow feedforward unit
54. Thus, fiber concentration is maintained at a constant value
without adjusting the slice opening.
A manual speed feedforward feature is supplied from manual entry
station 64 via data path 59 to summing junction 40. The purpose of
this function is to make a speed change without upsetting
conditioned weight or moisture. This capability is particularly
useful since speed changes are made quite frequently by the
operator. By coupling the speed change through summing unit 40, the
impact on conditioned weight thereby is minimized due to the
crosscoupling via master speed to stock flow and via the
jet-to-wire ratio and fiber concentration crosscoupling.
Another aspect of the invention is the automatic control of grade
change. The objective of automatic grade change control is to drive
the paper machine from one conditioned weight to another while
either holding moisture constant or moving it only slightly. On
occasion a grade change may require that both conditioned weight
and moisture be moved significantly. As mentioned in the background
of the invention, the old approach to grade change was to directly
move the process control variables from one set point to another
very slowly along some predetermined trajectory. The present
invention in contrast moves the targets of the control system. This
distinction, of moving the control system targets rather than the
actual process control variables, is significant in that the former
approach allows the sophisticated control system to remain in
operation and effect a speedy and smooth grade change. In
initiating a grade change, it would be desirable to change the
control targets instantaneously from their initial value to their
final value. However as mentioned previously, such action would
destroy the sensitive drive mechanisms on most machines. To avoid
this problem, the present invention moves the master speed target
on a ramp whose slope may be any value up to a predetermined
maximum above which the speed drive would be damaged. As an aid in
conceptualizing automatic grade change, it is useful to refer to
FIG. 4. There it can be seen that grade change involves three basic
levels. The first is level 170 which consists of the paper machine
and its associated control parameters such as the stock valve, the
stream flow valve, slice opening, master speed control, and steam
among others. The second level is the control system 172 as was
described in detail in connection with FIG. 3. The third level is
ramp selection and movement 174.
As can be seen, the first step is to select a new grade change.
This may be done by entering a code number on manual entry station
64 in FIG. 3. By so doing, a new set of grade data which includes
conditioned weight, headbox consistency, steam pressure and
moisture targets are automatically fetched from a table.
The new targets for moisture and conditioned weight in turn define
the nominal target values for jet-to-wire ratio, master speed,
slice opening, and stock flow. The targets for these control
parameters are then moved from their original value to their new
value.
As described earlier, the movement of master speed must be
restricted below some maximum rate. But below this level it may be
moved as desired. If grade change is to be made as quickly as
possible, the movement of conditioned weight target is made as a
step function and control of the master speed done via ramper 48
and clamp 46 in FIG. 3. All other targets are also moved as a step.
If, however, a slower grade change is desired, then the conditioned
weight target may be moved on a ramp having the desired slope.
Typically several ramping routines are available in storage, and
the operator may select one. When a slower than maximum grade
change is selected, the other control targets such as moisture and
headbox consistency are usually, but not necessarily, moved in one
step.
The movement of the control targets in turn causes the process
variables to be changed as described in connection with FIG. 3. For
example, control on speed and stock flow from moisture and
conditioned weight scan average are accomplished just as in the
case of drier limited control. However, the restrictions on
regulatory movement of master speed are now removed. That is, for
switches 33 and 53, N is set equal to 1.
In FIG. 3, the grade change is illustrated by select grade change
target 100 and select grade change ramps 102. The ramped
conditioned weight signal is supplied via data path 105 and switch
107 to summing unit 23 where it is a command on the basis weight
target.
During a grade change, the fiber concentration in the headbox must
also be moved to a new value in accordance with the new conditioned
weight. Accordingly, the slice opening target value is ramped in
conjunction with the conditioned weight. This operation is
illustrated as conditioned weight to slice feedforward function
106, the output of which is supplied via data path 94 to summing
unit 90. The stepped or ramped moisture target is supplied via data
path 103 to summing unit 40, and the stepped or ramped jet-to-wire
ratio target is supplied via data path 104 to jet-to-wire ratio
controller 60.
If the paper machine is operating in a dryer limited mode when the
grade change is initiated, there will be no command signal to
steam. If, however, the paper machine is not operating in a dryer
limited mode when the grade change is initiated, i.e., steam to the
dryer section is less than maximum, then the set point for steam is
moved on a ramp in conjunction with the target for the conditioned
weight. The steam pressure set point is moved from its pregrade
change value to a nominal value for the new grade. Thus, in the non
dryer limited mode, when a grade change is initiated, a final set
point value for steam is fetched from a table, and an appropriate
ramp function is selected to move the steam target from its
pregrarde change value to its post grade change value. This step is
illustrated at 108. The steam set point is then ramped at 110.
Sample and hold device 112 converts the output of ramper 110 to a
target command signal for steam value controller 114. Because of
the problems mentioned earlier in connection with moving set points
in a grade change, steam pressure and speed will not end up at
precisely the right point. However, they will be very close, and
the feedback mechanisms of the dryer limited system will quickly
adjust speed to the right value.
While the invention has been described with reference to a
particular embodiment, it will be understood that the invention is
limited only by the appended claims.
* * * * *