Abb Automation Gmbh

Abb Schweiz Ag

Abb Industrial Systems, Inc.

Abb Inc.

Other

Process Automation Business Inc.

Abb Technology Ag

Shih-Chin Chen

Peter Quang Tran

Andreas Zehnpfund

Jonas Berggren

Ake Arvid Hellstrom

Timothy F Murphy

Chang Yuan Liu

Ravi Subbarayan

Balaji Sr

Abhay Anand

ChangYuan Liu

Mike Butynski

John Schroeder

Donald Iii Stanley

Changyuan Liu

A system, method, and apparatus is provided for production processes to coordinate the utilization of the operational zone for process variables and automate the execution of the target settings to maximize the production goals without requiring human intervention.

Method and apparatus for coordinating the utilization of operational zones to achieve production goals

A method for detecting a deflection between a source module and a detection module in a scanning apparatus and configured as a sensor pair for scanning transmission measurement of sheet material being transported in a machine direction through a sensing gap formed between the source module and the detection module. The source module is arranged on a first side of the sensing gap and emits a sensing radiation or sensing energy radiation towards the sensing gap, and the detection module is arranged on a second side of the sensing gap opposite to the first side and detects the radiation from the source module and transmitted through the sensing gap. The method includes: attaching a removable blocking device to the detection module; and performing a partially-blocked scanning process during which the source module and the detection module are jointly moved in a cross direction of the scanning apparatus.

Method for detecting a deflection, scanning apparatus, and use of a blocking device for detecting a deflection

CD variations and/or MD variations in scan measurements are determined from spectral components of power spectra of scan measurements taken using two or more scanning speeds. Dominant spectral components having the same spatial frequencies identify CD variations and dominant spectral components having the same temporal frequencies identify MD variations. Dominant spectral components are extracted from a noisy power spectrum (PS) by sorting all spectral components into an ordered PS. A first polynomial representing background noise of the ordered PS is used to set a first threshold. Spectral components of the ordered PS that exceed the first threshold are removed to form a noise PS. A second polynomial representing the noise PS is used to set a second threshold. Spectral components of the PS that exceed the second threshold are identified as dominant spectral components of the PS.

Determination of CD and/or MD variations from scanning measurements of a sheet of material

A method and apparatus for generating a comprehensive response model for a sheet forming machine are provided. A finite number of critical points and a response type are used to create a continuous response profile for each actuator zone. The continuous response profile for each actuator zone is discretized into a discrete response profile based on the resolution appropriate for an application. A multi-zone response model for each pair of actuator set and sheet property profile is created from the discretized response profile of the actuator zones in the actuator set. The comprehensive response model for a multivariable sheet-forming machine is created from a collection of multi-zone response models for multiple pairs of actuator sets and sheet property profiles.

Method and apparatus for creating a comprehensive response model for a sheet forming machine

A method and apparatus for creating a generalized response model for a sheet forming machine are provided. Sheet property profiles are measured while the setpoint of an actuator is changed. A response (or change) profile of the sheet property resulting from a setpoint change is calculated. A finite set of critical points are selected from the property response profile. Using the selected critical points, the property response profile is classified in one of a finite number of response types. Under each of the response types, the property response profile is fitted with a plurality of continuous functions associated therewith. These continuous functions are combined to form the response model that minimizes the deviation between the property response and the fitted combination of continuous functions.

Method and apparatus for creating a generalized response model for a sheet forming machine

A controller to provide base level fiber orientation control of a paper web. The controller achieves one or more indices that are derived from the online measurements of a fiber orientation sensor of the fiber ratio and the fiber angle. The indices are used for control of the sheet forming processes. The controller may be implemented by a single or multi stage fuzzy controller or the combination of fuzzy controllers with non-fuzzy logic controllers.

On-line fiber orientation closed-loop control

Headbox transient responses for sheet weight and moisture are modeled as a combination of two sets of time constants and dead time delays. One set represents a shorter delay with faster response dynamics, the fast mode weight and moisture responses, and the other models the longer delay with slower dynamics, the slow mode weight and moisture responses. A weight and/or moisture transient model is then formed for headbox changes by combining the fast mode weight and moisture responses and the slow mode weight and moisture responses. Stock weight and moisture dynamic and delay time models are determined for operation of stock flow of the paper making machine and the stock flow is controlled in accordance with the stock weight and/or moisture models and the headbox weight transient and/or moisture transient model to compensate for weight and moisture changes in a web of paper being manufacture which weight and moisture changes result from headbox changes.

Modeling and control of sheet weight and moisture for paper machine transition

The CD profile of a web of material being produced is monitored and controlled to update CD control settings on-line so that changes in the operation of a machine manufacturing the web can be corrected before significant profile deviations from a desired CD profile target result. Detected variances in the profile that satisfy a search criteria initiate searches for improved CD control settings. The CD control of the present application recognizes CD actuator mapping misalignments, determines improved CD control settings and applies the improved CD control settings to fine tune a CD controller and thereby improve upon or correct mapping misalignments. The CD control of the present application also recognizes non-smoothness of the setpoints of the CD actuators and controls the smoothness of the setpoints. Recognition and correction of either CD actuator mapping misalignments or CD actuator setpoint smoothness or both can be performed by the automated optimization of the present application.

Automated optimization of cross machine direction profile control performance for sheet making processes

Multiple two-dimensional variation patterns are extracted from two-dimensional sheet measurement data of sheet material being manufactured with the variation patterns being classified to identify the causes of the extracted patterns. The extracted two-dimensional variation patterns are identified with the elements or components of the process or machine which caused the patterns. The machine components which cause the variation patterns can then be adjusted and/or controlled so that the patterns can be reduced or substantially eliminated in sheets of material produced by the machine. In addition to adjustment and/or control of the process or machine producing the sheet of material, the extracted variation patterns can be used as new representations of sheet quality, process or machine quality and the patterns will provide more in-depth understanding for operators of the machine.

Method for extracting and classifying sheet variation patterns from two-dimensional sheet measurements

A plurality of random probing sequences are used to perturb a corresponding plurality of cross-machine direction (CD) actuators of a web manufacturing machine. The web of sheet material is measured as the CD actuators are perturbed. The global process machine direction (MD) dynamics is estimated and a CD response is estimated for each of the plurality of CD actuators using the plurality of random probing sequences, measurements of the web of sheet material and the estimated global process MD dynamics. The estimated global process MD dynamics and the estimated CD responses form 2D responses for the plurality of CD actuators. To refine the 2D responses, the estimates of global process MD dynamics, and CD responses for each of the plurality of CD actuators are iterated. The actuator dynamics of the plurality of CD actuators may also be estimated and used in the estimates of the global process MD dynamics of the plurality of CD actuators and CD responses for each of the plurality of CD actuators. Variations that are not associated with actuator responses are removed from the estimated CD responses, for example by filtering. The estimated CD responses may be further refined by selecting one of the CD responses as a reference response. All remaining CD responses are shifted into alignment with the reference response to determine relative CD response locations and to define a group of overlapping CD responses. Using iterative techniques, a mean response is determined from a group of overlapping CD responses and variation bounds are set above and below the mean response. A family of probable CD responses are generated within the variation bounds and a most probable response is selected from the family of probable responses for each CD actuator response. The CD response for each CD actuator is replaced with the most probable response shifted by an appropriate amount for each CD actuator and multiplied by an optimal gain.

Methods for modeling two-dimensional responses of cross-machine direction actuators in sheet-forming processes

A new two-dimensional (2D) variation modeling and control technique for a machine producing a web of material, such as paper, uses functional transformation with basis functions which are wavelets, preferably wavelets derived from and closely resembling the responses generated by actuation of cross direction (CD) actuators of the machine. By using the disclosed functional transformation together with carefully selected basis functions, memory and real-time processing requirements are substantially reduced so that practical controls can be readily implemented. In addition, the functional transformation technique of the present application expands conventional CD correction to also correct for a portion of the residual variations which, until now, have remained uncorrected. The new 2D profile is treated as the superposition of two main components: a pure machine direction (MD) variation component and a two-dimensional sheet variation component. The pure MD variation is identical to the conventional MD variation; however, the two-dimensional sheet variation represents the evolution of a sheet property being measured in both a temporal direction (TD) and a spatial direction (SD), i.e. it includes both the traditional pure CD profile and a portion of the residual variation. The TD is aligned with the MD and the SD is perpendicular to the TD or is aligned with the CD. The new 2D variation is controlled by a new 2D control arrangement which includes an optimal predictive SD controller and a model based TD controller to quickly achieve 2D web uniformity.

Two-dimensional web property variation modeling and control

Sensors are spaced along an extended process from its beginning end to its finishing end. Each sensor is associated with a parallel inferential control loop (PICL) and generates an actual measurement signal for a portion of the process. Each PICL includes a process model emulating the sensed portion of the process with the process models being cascaded from the beginning end through and including the finishing end. Each PICL generates a loop control signal corresponding to its sensed portion of process with the loop control signals from the PICLs being summed to generate a total control signal which controls a control element at the beginning end of the process and also is received by the first or most up-stream process model. The process models produce expected measurement signals which are combined with the actual measurement signals to determine difference signals for each PICL which includes a reset model emulating the sensed portion of the process. Each reset model receives a reset input signal from a preceding PICL and generates a reset output signal to decouple control of preceding PICLs from the PICL receiving the reset input signal. One or more of the PICLs can be disabled provided its deviation signal and setpoint signal are nullified, its reset output signal is routed to be the reset input signal for the succeeding PICL and any setpoint signal for the loop is converted and transferred from the disabled loop to a preceding loop.

Method and apparatus for controlling an extended process

A standard control signal for a web forming machine is temporarily interrupted and replaced by a perturbing signal or signgals which are applied to one, a grouping, or all of a series of actuation cells of the web forming machine. One or more actuation cells are driven with an alternating perturbing signal(s) which generate a corresponding action in the actuation cell(s). The perturbing signal(s) alternates from a neutral position of the cell and is selected to minimize means effects over any given period of time. The effects of the alternating signal(s) on the web appear within the area of the web which is affected by the actuation cell(s) such that the mapping and the response of the actuation cell(s) can be determined by monitoring that poriton of the web which is formed while the alternating signal(s) is applied to the actuation cell(s). The mapping(s) and/or response(s) of the actuation cell(s) are obtained by correlating the perturbing signal(s) and a web property signal or profile signal obtained by monitoring the web formed by the machine. The perturbing signal(s) is defined by a pseudo-random binary sequence with multiple signals being selected to be statistically independent of one another. To ensure that the web is not perturbed beyond defined specifications, the perturbing signal preferably is gradually increased in amplitude and is terminated individually for each actuation cell upon reaching a usable amplitude.

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Dublin, OH, United States of America

Shih-Chin Chen