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    • 专利摘要:
    METHOD FOR EARLY ADVISING BURST DETECTION AND EVALUATING PROTECTION MANAGEMENT. The invention configures the application of different combinations of aspects of monitoring and data processing as a means to develop an early warning shake system. Setting up a shake warning system early warning can be as simple as not using alarm settings to develop an alarm strategy from different trend conditions, such as general RMS, selected vibration frequencies, tilt analysis and wavelet analysis . A higher level of alarm is provided using an integrated approach with time to consider both the intensity of the alarm variable and duration. Combining these different aspects with a predictive model incorporates operational process conditions to improve the sensitivity of the alarm for early detection and reduce false positives. Finally, combining the different alarm aspects with a rule-based decision-making approach, such as confusing logic, allows for alarm based on qualitative analysis of different data flows. For example, the combination of general RMS, frequency band and slope analysis trend data to apply confusing logic to develop if - (...) relationships.
    公开号:BR112014003564B1
    申请号:R112014003564-4
    申请日:2012-10-11
    公开日:2021-02-02
    发明作者:William A. Von Drasek；Gary S. Furman Jr.；Sammy Lee Archer
    申请人:Nalco Company；
    IPC主号:
    专利说明:

    Cross-referencing related orders None. Federally sponsored research or development statement Not applicable. Fundamentals of the Invention
    [001] The present invention relates to methods, compositions and apparatus for detecting and preventing chatter in scraping blades in a Yankee dryer. As described at least in US Patents 7,691,236, 7,850,823, 5,571,382, 5,187,219, 5,179,150, 5,123,152, 4,320,582 and 3,061,944, in the process of making tissue paper, a sheet paper is dried in a heated drying cylinder, called a Yankee or Yankee dryer. Adhesive materials are often used to coat the Yankee's surface to help the wet sheet adhere to the dryer. This improves heat transfer, allowing for more efficient drying of the sheet. Most importantly, these adhesives provide the adhesion required to give good cracking of the dry leaf. Creping is the process of impacting the sheet on a hard blade (called a scraper blade), thereby compressing the sheet in the direction of the machine, creating a folded sheet structure. Creping breaks a large number of fiber-to-fiber bonds in the sheet, imparting the qualities of volume, stretch, absorbance and softness that are characteristic of tissue paper. The amount of adhesion provided by the coating adhesive plays a significant role in the development of these tissue paper properties.
    [002] In addition, the present invention covers the detection and prevention of chatter blades to clean residual coating from the Yankee surface as well as cutting scraper blade used during maintenance operations on the creping scraper blade. The present invention focuses on the creping operation, but the extension of the methodology for the cleaning and cutting blade applies equally.
    [003] The Yankee's coating also serves to protect the Yankee and the creping blade surfaces from excessive wear. In this role, the coating agents provide improved functioning of the tissue paper machine. As the scraper blades wear out, they must be replaced with new ones. The process of changing the blades represents a significant source of downtime for the tissue paper machine, or lost production, because the creped product cannot be produced when the blade is being changed. Release agents, typically hydrocarbon oils, are used in association with the coating polymers. These agents assist in the uniform release of the tissue paper web in the creping blades, and also lubricate and protect the blade from excessive wear.
    [004] The appropriate and sustained interaction between the Yankee lining and the creping scraper blade is critical for both the development of the property of the sheet and the operation of the machine. In normal operations, the tip of the creping scraper blade passes the coating on the dryer surface and experiences minimal off-plane movement. However, if the amplitude of the movement outside the plane becomes high enough, the creping scraper blade will oscillate above and below the leaf, leading to the development of chatter that appears as defects in the transverse direction (CD). Defects in the sheet from the chatter will appear as multiple holes in the CD or develop a loop appearance. Coating defects can show long marks on the CD that are visible when viewed with a strobe light. Under severe vibration circumstances, the scraper blade will penetrate through the Yankee lining making direct contact with the dryer surface. If this occurs, potential damage to the dryer surface with the appearance of horizontal grooves on the metal surface can result. Once the dryer surface becomes damaged, it can only be repaired by taking the machine out of production and rectifying the dryer surface again. The new grinding is an expensive operation, due to production losses and the cost of the procedure, as well as the degradation of the dryer's service life due to the reduction in wall thickness that negatively affects the pressure rating of the vessel. Thus, it is imperative for manufacturers to closely monitor the process and identify when chatter is present.
    [005] Excessive vibration in the creping scraper blade, leading to vibration conditions, can originate from mechanical and operational or process conditions. Examples of sources of mechanical vibration include press rollers, pumps, felts, Yankee cylinder bearings, etc., as well as deformation of the dryer circularity caused by non-thermal uniformities. Once a source of mechanical vibration is identified, maintenance intervention to correct the problem often requires stopping the equipment resulting in loss of production. Conversely, operating practices or process conditions inducing excessive vibration can include sheet moisture levels, coating chemistry, machine speed, base weight, supply, unloading pressure and blade loading, etc. can be attended to without interrupting production.
    [006] Regardless of the source, excessive vibration experienced by the scraper blade can lead to vibration conditions affecting product quality, machine operation, and asset value. Operators will often depend on audible sound changes or visual inspection (quality of the Yankee dryer sheet or surface) as the first indication that chatter is present. However, this approach is subjective and unreliable, often resulting in detection of chatter after the condition has become severe, thereby generating more difficult corrective action steps. To improve detection reliability and sensitivity for detection of chatter, condition monitoring technology (CM) using piezoelectric sensor (s) and / or micro-phone sensor (s) can be used. CM has a long history in the paper industry, but mainly for its use in bearing monitoring on rotating components. Examples of use of CM in the creping scraper blade are limited and in these cases the measurement analysis is done after traditional CM methods based on the level of the sensor signal that exceeds an alarm limit. In this approach, the state of the system is assessed from the sensor signal trend. A flat trend is considered a normal condition whereas an upward slope trend indicates a wear condition, and a step change is considered a component failure. The dynamics of the Yankee dryer operation can produce large variations in the sensor signal, without reaching a vibration condition. As a result, data analysis becomes more complex compared to conventional CM based on wear and failure detection levels.
    [007] Previous attempts to address this problem include: Aurelio Alessadrini and Piero Pagani, Chatter Marks: Orgin, Evolution and Influence of the Creping Doctors, Ind. Carta vol. 41, no. 4, June 2003, pp 120-129, S. Archer, V. Grigoriev, G. Furman, L. Bonday, and W. Su, Chatter and Soft Tissue Production: Process Driven Mechansims. Tissue World Americas. Feb-Mar 2009, pp 33-35, S. Zhang, J. Mathew, L. Ma, Y. Sun, and A. Mathew, Statistical condition monitoring based on vibration signals, Proceedings VETOMAC-3 & ACISM-2004, pp. 1238-1243, New Delhi, India, M. Fugate, H. Sohn, and C. Farrar, Vibration-based damage detection using statistical process control. Mechanical Systems and Signal Processing, Vol. 15, Issue 4, July 2001, pp 707-721, H. Sohn, C. Farrar, Damage diagnosis using time series analysis of vibration signals, Smart Materials and Strucures, Vol 10, 2001, pp . 446451, A. Heng, S. Zhang, A. Tan, and J. Mathew, Rotating machinery prognostics: State of the art, challenges and opportunities. Mechanical Systems and Signal Processing, 23, 2009, pp. 724-739, A, Messaoud, C. Weihs, and F. Hering, Detection of chatter vibration in a drilling process using multivariate control charts, Computational Statistics & Data Analysis, Vol. 52, 2008, 3208-3219, AA, Junior, FC Lobato de Almeida, Automatic faults diagnosis by application of neural network system and condition-based monitoring using vibration signals. Proceedings of the 2008 IAJC- IJME International Conference, ISBM 978-1-60643-379-9, and AG Rehorn, J. Jiang, P. Orban, State-of-the-art methods and results in tool condition monitoring: review, Int J Adv. Manuf Technol, 26, 2005, pp. 693-710. Unfortunately, so far, none of these attempts satisfactorily addresses the problems caused by scraping on scraper blades.
    [008] Thus, there is a clear need and usefulness for methods, compositions and apparatus for the detection and prevention of chatter on scraper blades. The technique described in this section is not intended to constitute an admission that any patent, publication or other information referenced here is "prior art" with respect to this invention, unless specifically designated as such. In addition, this section should not be interpreted to mean that a survey has been carried out or that no other pertinent information as defined in 37 CFR § 1.56 (a) exists. Brief Summary of the Invention
    [009] At least one embodiment of the invention is directed to a method of detecting and treating the shaking blade vibration of the Yankee dryer used in creping, cleaning and / or cutting operations. The method comprises the steps of: for a period of time, with a sensor built and arranged to measure the frequencies and amplitudes of vibrations on a scraper blade when it forms crepe on a paper product, measure the frequencies and amplitudes of vibrations indexed by time, collect measurements in a time waveform, convert waveform into a fast Fourier transform having a frequency spectrum which includes different vibration bands, correlate characteristics of vibration bands with acceptable performance properties of the scraper blade and define a baseline of acceptable vibration bands, predict, from the correlated characteristics, the degree of deviation from the baseline of acceptable vibration band bands associated with scraper blade shake, and send, when a data point in a vibration band exceeds the degree of deviation, that excessive chatter has occurred.
    [010] The sensor can be an accelerometer and / or a piezoelectric accelerometer. The measurements can be analyzed and modeled by a data processing device built and arranged to use a process selected from the group consisting of: RMS data trend, neural network techniques, multiple regression analysis, AR, ARMAX, partial least squares and any combination thereof. At least one of the correlations can be determined by comparing the characteristics of the vibration bands with the age of the blade. Measurements can be analyzed and modeled by a data processing device built and arranged to use RMS data trends and where the determination is made at least in part by noting that the slope in a sawtooth-shaped vibration band continuously increases over time with the same blade and becomes discontinuous when the blade is changed.
    [011] The method may further comprise the step of defining a deviation from the baseline due to chatter only occurring when a deviation exceeds the mean and standard deviation from the baseline due to both an increase in magnitude and a duration of that increase. greater than the average duration of all data peaks in the waveform. The method may further comprise the steps of predetermining the slope at which the blade is too old to be desired for use and replacing the blade when a slope manifests itself in the waveform.
    [012] At least one of the correlations can be determined by comparing the characteristics of the vibration bands with a selected factor of: tracking flange, balance, dryer lubricity, dust levels, humidity levels, temperature, perceived age, degree , supply composition, coating chemistry, cleaning blade status (on or off), machine speed, external source vibrations, external pressure sources and any combination thereof. The range of characteristics of the vibration bands caused by the factor can be so wide that the sensor must be able to detect frequency bandwidth covering four orders of magnitude. In at least one modality the sensor only measures vibrations of the scraper blade indirectly because it is attached not to the blade itself, but to a blade holder which is attached to and provides more rigid support to the blade, but which does not dampen vibration to a extent that an accurate measurement cannot be taken. Measurements can be taken synchronously and / or asynchronously. The output can be an alarm.
    [013] Additional features and benefits are described here and will be apparent from the following Detailed Description. Description of Drawings
    [014] FIG. 1 illustrates a side view of an embodiment of the invention using an accelerometer sensor measuring the operation of a scraper blade.
    [015] FIG. 2 illustrates a perspective view of an embodiment of the invention using two accelerometer sensors to measure the operation of a scraper blade.
    [016] FIG. 3A is a graph of an RMS trend of an accelerometer using the invention.
    [017] FIG. 3B is a graph of an expanded view of an accelerometer RMS trend using the invention.
    [018] FIG. 4 is a graph of an RMS trend including an alarm setpoint for an accelerometer using the invention.
    [019] FIG. 5 is a graph of an alarm integrated in time and accumulated alarm of RMS data from an accelerometer using the invention.
    [020] FIG. 6 is a graph of RMS residuals from a predictive model using data obtained from an accelerometer using the invention.
    [021] FIG. 7 is a group of graphs that show the advantage of predictive modeling to detect early chatter and to prevent false positive alarms.
    [022] FIG. 8 is a graph of estimated vibration frequency for different shake mark spacing in a Yankee dryer.
    [023] FIG. 9 is a trend graph of an integrated frequency band (15 20 kHz) with and without visible vibration in the coating.
    [024] FIG. 10A is the raw sensor data for a Yankee cylinder revolution from an accelerometer using the invention.
    [025] FIG. 10B is a fast Fourier transform (FFT) of the data in FIG. 10A.
    [026] FIG. 10C is a wavelet analysis of the recorded accelerometer time waveform signal of FIG. 10 A displayed as a scaled graph.
    [027] FIG. 10D is an expanded view of the waveform of FIG. 10A showing only the 0.225 to 0.272 second zone.
    [028] FIG. 10E is an expanded view of the scaled graph in FIG. 10C showing only the 0.23 to 0.264 second zone.
    [029] FIG. 11 is a graph of slope analysis of RMS trend data.
    [030] Detailed Description of the Invention
    [031] The following definitions are provided to determine how the terms used in this application and, in particular as the claims, are interpreted. The organization of the definitions is for convenience only and is not intended to limit any of the definitions to any particular category.
    [032] "Bevel" or "bevel surface" as used here refers to the portion of the blade that forms the surface between the guide edge of the blade and the end side of the blade and is typically the "working surface" of the blade.
    [033] “Volume” means the inverse of the density of a tissue paper web and is usually expressed in units of cm3 / g. It is another important part of real and perceived performance of tissue paper wefts. Bulk improvements usually add to the absorbent, tissue-type perception. A portion of the volume of a tissue paper weave is checked by creping.
    [034] "Transverse Direction of the Machine" or "CD" means the direction perpendicular to the direction of the machine in the same plane as the fibrous structure and / or the fibrous structure product comprising the fibrous structure.
    [035] “Scraper blade” means a blade that is arranged on other equipment, so that the scraper blade can help remove material from that equipment that is on it. Scraper blades are generally used in many different industries for many different purposes such as, for example, their use to help remove material from equipment during a process. Examples of materials include, but are not limited to, tissue paper webs, paper webs, glue, residual build-up, pitch and combinations thereof. Examples of equipment include, but are not limited to, drums, plates, Yankee dryers, and rollers. Scraper blades are commonly used in papermaking, non-woven fabrication, the tobacco industry, and in printing, coating and adhesive processes. In certain cases, scraper blades are referred to by names that reflect at least one of the purposes for which the blade is being used.
    [036] "Fiber" means an elongated particle having an apparent length greatly exceeding its apparent width. More specifically, and as used here, the fiber refers to those fibers suitable for a papermaking process.
    [037] “Highly polished” means a surface that has been processed by a sequential progression from relatively rough to fine grain with proper lubrication and is highly planar and substantially free from defects. This sequential progression will be referred to here as a “step polishing process”.
    [038] "Machine Direction" or "MD" means the direction parallel to the flow of the fibrous structure through the paper-making machine and / or product manufacturing equipment.
    [039] “Paper product” means any products formed from a fibrous structure, traditionally, but not necessarily, comprising cellulose fibers. In one embodiment, the paper products of the present invention include paper tissue paper towels. Non-limiting examples of paper tissue paper towels include paper towels, facial tissue, bath tissue, table napkins and the like.
    [040] “Sheet control” as used here, refers to the absence of vibrations, turbulence, edge turning, flickering, or waviness of the web that results in a loss of control at higher speeds.
    [041] "Softness" means the tactile sensation perceived by the consumer as he / she holds a particular product, rubs it on his / her skin, or kneads it inside his hand. This tactile sensation is provided by a combination of several physical properties. One of the most important physical properties related to softness is generally considered by those skilled in the art to be the rigidity of the paper web from which the product is made. Rigidity, in turn, is generally considered to be directly dependent on the weft resistance.
    [042] "Resistance" means the ability of the product, and its constituent wefts, to maintain physical integrity and resist tearing, bursting and shredding under conditions of use.
    [043] “Tissue paper weave”, “paper weave”, “weft”, “sheet of paper”, “tissue paper”, “tissue paper product” and “paper product” are all used in a interchangeable and mean sheets of paper made by a process comprising the steps of forming an aqueous papermaking supply, depositing that supply on a foraminous surface, such as a Fourdrinier wire, and removing a portion of the water from the supply (for example, gravity or vacuum-assisted drainage), forming an embryonic web and in conventional tissue paper preparation processes, transfer the embryonic web from the forming surface to a fabric or felt conveyor and then to the Yankee dryer, or directly to the Yankee dryer of the forming surface. Alternatively in TAD tissue manufacturing processes, the embryonic web can be transferred to another tissue or surface moving at a lower speed than the forming surface. The weft is then transferred to a fabric on which it is air-dried to a typically 10 to 50% dryness, and finally to a Yankee dryer for final drying and creping, after which it is rolled up on a spool.
    [044] "Water Soluble" means materials that are soluble in water up to at least 3% by weight at 25 ° C.
    [045] In the event that the definitions above or a description mentioned elsewhere in this application are inconsistent with a meaning (explicit or implicit) that is commonly used in a dictionary or mentioned in a source incorporated by reference in this application, the terms of the particular application and claims are understood to be interpreted according to the definition or description in this application, and not according to the common definition, dictionary definition or the definition that has been incorporated by reference. In light of the above, in the event that a term can only be understood if it is interpreted by a dictionary, if the term is defined by Kirk-Othmer Encyclopedia of Chemical Technology, 5th Edition, (2005), (published by Wiley, John & Sons, Inc.) this definition will control how the term will be defined in the claims.
    [046] In at least one embodiment of the invention, a method detects the onset of the cracking of the creping scraper blade. This method, by alerting machine operators that blade shake conditions are imminent, allows operators to take corrective actions to avoid malfunctions and prevent damage to the Yankee dryer surface. The method uses signal analysis using at least one piezoelectric accelerometer operated close to the scraper blade holder. In at least one modality the method of analysis differs from conventional CM techniques in using an integrated approach over time. As a first level approach, the signal is tracked based on both intensity above an alarm threshold and duration. This makes it possible to account for strong but short-lived vibration, as well as weaker vibration for long periods. Improved monitoring is described by extending this method to predictive models using process input data, wavelet analysis for high vibration MD regions spatially resolved on the dryer surface, and trend inclination analysis to predict the onset of an invading alarm condition. . In all cases, the Yankee dryer's exposure to excess vibration is accounted for by tracking the integrated value over the accumulated time, thus providing a historical record to assist in scheduling maintenance.
    [047] At least one modality of the method comprises the steps of detecting directly or indirectly the vibration of the creping scraper blade. In at least one embodiment, the sensor technology is robust enough to operate in harsh environmental conditions. Conditions include one or more high levels of dust, high levels of humidity and temperatures> 125 ° C. In addition, geometric constraints around the creping operation may require a compact sensor footprint. In addition, in some circumstances, the sensor must be able to detect a frequency bandwidth covering four orders of magnitude (for example, 10 Hz to 20 kHz).
    [048] In at least one embodiment, the piezoelectric accelerometer used is a typical commercially available shelf sensor that meets these criteria. Industrial accelerometers, such as the SKF model CM2207, are hermetically sealed and hardened with an acceptable footprint (54 x 30 mm) for mounting on or near the creping blade holder. In at least one embodiment, the accelerometer is directly mounted on the creping scraper blade to monitor blade vibration once it is in contact with the Yankee dryer coating and surface. However, direct mounting on the scraper blade presents additional challenges with greater geometric restrictions, higher temperatures and limited blade service life that requires frequent (from a few hours to 24 hours, depending on the blade process and composition) blade changes . Therefore, in at least one mode, the sensor assembly is positioned on the scraper blade holder. This provides an effective alternative since the blade holder is in close proximity and in contact with the scraper blade and is itself stationary.
    [049] An illustration of a possible arrangement for mounting an accelerometer on a scraper holder is shown in FIG. 1. On the blade holder, the scraper support plate provides a flat, rigid surface for mounting the sensor. In at least one embodiment, the method of mounting the sensor is with a threaded hole in the scraper holder and threaded fastener through the center of the accelerometer sensor. The adhesive assembly can still be used, but with the sacrifice of higher frequency detection. Other blade support designs are ladder support and super crepe, as well as all other means known in the art and their equivalents. Regardless of the blade holder design, mounting the sensor close to the scraper blade on a structurally rigid holder with minimal damping is the preferred method. The location of the sensor along the blade support CD is dependent on the operation of the machine. If possible, the sensor should be located within the edge of the sheet and, preferably, multiple sensors are used to monitor different zones on the DC.
    [050] With reference now to FIG. 2 an illustration of an accelerometer assembly inside the sheet is shown from the trend and drive sides in a Yankee dryer. In this case, sensors mounted close to the edge of the leaf on the drive and trend side allow to detect differences in frequencies and amplitudes of vibration between the sides. Therefore, using a minimum of two sensors positioned at equal distances from the edge of the trend and drive side is the preferred approach. In principle, a single sensor could be used, but with the sacrifice of sensitivity and monitoring of variation side-by-side.
    [051] In at least one modality, the signal transmission from the sensors mounted next to the creping scraper blade is done through communication with a rigid or wireless wire to a vibration data acquisition unit, for example, the SKF IMX-S multilog online system or any equivalent thereof. The data sent by the sensor can be raw, for example, waveform, or processed by a microprocessor integrated in the sensor or signal transmission line. The data acquisition system processes the sensor data and presents the results and status of the alarm as well as providing a means to reach and retrieve data. In at least one modality, the data acquisition system can monitor other process variables, such as machine speed, and can use a tachometer for synchronous data collection. The data collected from the acquisition system can also be routed via Ethernet or wirelessly to a centralized location (inside a company or outside) where data from various monitoring systems can still be analyzed. Compiling data from multiple locations allows the calculation of aggregate performance properties and relative classifications of blade shake levels.
    [052] Process variables for unit operation of the Yankee dryer are dynamic with timescales ranging from minutes to days. Process variables, such as creping blade age, felt age, grade, supply, coating chemistry, cleaning blade status (on or off), machine speed, etc., all contribute to the signature of vibration observed in the creping scraper. In addition, vibration that originates from other sources, such as a fan pump, Yankee dryer bearings, pressure roller, overhead crane, etc. it can also propagate through the process structure to the creping blade. The aggregation of the vibration sources results in the signature of the general vibration detected by the sensor. For a piezoelectric accelerometer sensor, the monitored vibration signature is a time waveform that can be collected synchronously or asynchronously in relation to the Yankee dryer rotation. Taking a fast Fourier transform (FFT) of the waveform generates a frequency spectrum that provides unique frequencies and / or bands of vibration. Additional data reduction is accomplished by extracting the quadratic mean (RMS) of the spectral density of FFT power to obtain a value of general vibration magnitude and / or bandwidth to tend over time.
    [053] The RMS trend of an accelerometer mounted on the creping blade holder will show natural variations under normal operating conditions because of the process dynamics. The complexity and multiple interactions of different vibration sources makes the identification of specific process variables contributing to a single frequency or vibration band a difficult task. However, some general characteristics, such as blade age, are clearly seen in the RMS trend as a sawtooth pattern. The installation of a new blade will reduce the RMS by improved efficiency (reduced drag) in the color through the coating and in the removal of the sheet. As the blade degrades over time, drag will increase resulting in an increase in RMS. To illustrate this point, FIG. 3 shows an RMS trend for bandwidth data 0 to 10 kHz collected for 11 days. The trend is comprised of a baseline of natural process variation associated with the age of the creping scraper blade, as well as periods where the RMS value peaks in relation to the baseline.
    [054] Different characteristics in FIG. 3 are highlighted and an enlarged area shows the effect of the creping blade age in an RMS trend (vertical markers indicate periods when a blade change has occurred). Periods where peaks in RMS levels can potentially lead to degradation of the coating and / or the dryer surface. The source of vibration associated with these peaks is not always obvious and often requires further investigation of the process and operating conditions (human and mechanical). Degradation of the Yankee lining or dryer surface can occur from a single RMS peak event or a cumulative effect over time. Therefore, minimizing the frequency and breadth of RMS excursions above the natural baseline is a best practice scenario for maintaining asset functioning and protection.
    [055] As a first level for vibration monitoring, the state of vibration of the creping scraper blade is tracked using an alarm based on the mean and standard deviation (o) of the RMS trend data that exclude peak periods and none visible chatter is present in the coating or on the dryer surface. The alarm sensitivity is based on the number selected by the user of standard deviations from the mean. The alarm (real time) is based on the RMS level or RMS level and duration time. For RMS alarms only, an alarm signal (visual, audible or combination) is sent to the operator and stored in a database when the RMS value is greater than the alarm level setting ns. Different alarm states can be selected using various settings. For example, an alarm level 2o can be a warning alarm alert alerting the operator that the RMS value is trending upwards but not yet reaching a critical state. If the RMS value continues to trend upwards after alarm setting 3o then a critical alarm can be sent to the operator. This method of alarming is commonly found in commercial condition monitoring systems used in predictive maintenance or on rotating machinery. In this order, condition monitoring tracks bearings, balance and overall health in the machinery. As the bearings wear, the RMS trend of a sensor (typically an accelerometer mounted next to the bearing of the rotating shaft) will gradually increase indicating that bearing maintenance, such as replacement or lubrication, is necessary. If left unattended, the RMS level would remain at a high level or continue to rise.
    [056] Unlike traditional health monitoring, the dynamics of the creping process can result in large variations in RMS without developing chatter. Therefore, a transient RMS peak above an alarm level does not necessarily guarantee an alarm event. However, as the duration of the RMS value above the alarm setting increases, the likelihood of developing chatter increases. In this alarm mode, the intensity of the alarm signal (alarm *) is a function of both the RMS value> alarm level at (RMS +) and the duration of the RMS + signal remaining above the alarm level. The expression for the alarm signal * is given by Alarm * (RMS, t) = (wRMSRMS +) (wtt) where wRMS and wt are weighting parameters or functions, t is the time above the alarm level and RMS + is the difference between the RMS signal and the alarm value n ^. Tending the alarm signal integrated in time will show variations> 0 for conditions when the RMS level is above the setpoint n ^ and increases with time. This method addresses both high RMS values of short duration and RMS values that remain slightly higher than the alarm level for long periods.
    [057] The second alarm mode is based on the cumulative effect of alarm * over time and can be trended continuously as well as reported daily, weekly, monthly or annually. The accumulated * Acc alarm is given by
    and represents the total vibration excess to which the Yankee dryer has been exposed over time. Minimizing the frequency, duration and amplitude of the alarm * ACC will reduce Yankee exposure to critical vibration levels, thereby minimizing maintenance and extending the asset's service life. Trending the alarm * ACC is useful for evaluating and predicting different levels of maintenance for the Yankee dryer ranging from simple inspection to surface reconditioning. Accumulated alarm information also helps to identify differences in operating procedures, for example, between worker shifts, grades manufactured, supply, etc., where vibration levels may tend to be abnormally high.
    [058] An example using this alarm strategy for RMS vibration data collected for 11 days is shown in FIG. 4 for a 1.0 minute sample rate. FIG. 4 shows the measured RMS data collected with a 3rd alarm level determined from an independent training data set. The graph shows the historical RMS trend registered with the alarm level 3rd (dashed line). FIG. 5 shows the alarm value * integrated in the resulting time using unit weight values. Under normal operating conditions alarm * = 0.0, since the RMS value is below alarm level 3 °. Also shown in Figure 5 is the accumulated alarm * value to track excess total vibration to which the dryer surface has been exposed over the 11-day period.
    [059] In at least one modality the alarm method still involves a predictive model that reduces or removes the process dynamics contributing to the measured vibration. The benefit of using a predictive model is improved alarm sensitivity and reduced false positive alarms. Numerous model-building techniques, such as neural network (NN), multiple regression, autoregressive (AR), autoregressive movement average with exogenous terms (ARMAX), space-state, partial minimum squares and any combination of them, can be used to develop a predictive model based on waveform, frequency spectrum or RMS trend data. Ideally, model building begins by collecting process damping test data to develop cause-and-effect relationships. However, damping testing is generally restricted to a limited range of process changes to minimize losses in quality and production. To address this issue, data collection for long periods is required to capture process changes to model fit. Alternatively, continuous adjustment (learning) using adaptive algorithms can be used to update the model. Using a predictive model requires process input data that can be collected from the distributed control system or monitored directly with the vibration data acquisition system. In either case, the collected process data is used as a model input.
    [060] An example illustrating an NN model predictive of the RMS trend of FIG. 4 based on a process model with 25 input variables is shown in FIG. 6 as a graph of the residuals (difference between the measured and predicted value). In this example, the age dependence of the creping blade is modeled by applying a transformation to the blade changing data that is reported as the time of the event to force the model to behave similarly. The transformation uses a fixed slope in the mean obtained from RMS trend measurements over the life of a slide. Large residuals represent a process condition not captured by the data in the model construction stage. Large residuals may or may not be a real chatter condition, but they are an indication that excess vibration has spread to the creping scraper blade.
    [061] The advantage of using the predictive model for alarm is shown in FIG. 7 for time-integrated alarm. The enlarged areas show two different cases. The LHS figure shows the predicted (residual) alarm * value appearing before the alarm * value of the data in Figure 4. In this case, the predicted alarm * value occurs almost 60 minutes before the standard alarm * value. The early alarm results from a lower 3rd alarm level. The RHS graph shows only the opposite effect as an alarm * occurring first. In this case, the NN model takes into account the contribution to RMS of the process conditions and reduces or removes the occurrence of a false positive alarm condition.
    [062] In at least one embodiment of the invention, a frequency or vibration band is monitored with an alarm based on simple nG alarm level or time-integrated alarm. Unlike most sources of mechanical vibrations that occur at frequencies <500 Hz, chatter appears at higher frequencies. In the case where chatter is visible on the coating or surface of the dryer an estimate of the frequency range is performed by measuring the space between the chatter marks and knowing the speed of the dryer. As the chatter spacing decreases, the chatter frequency increases as shown in FIG. 8 for a fixed machine speed of 6000 FPM. Even at a 1-inch chatter spacing the estimated vibration frequency at this machine speed is> 1000 Hz. In the development of chatter by the stick-slip mechanisms (S. Archer et. Al., Tissue World Americas 2008) the spread visible shake mark is typically much less than an inch. Therefore, high frequency band monitoring can improve the measurement sensitivity to detect judder. The sensitivity gain is obtained by focusing on smaller spectral regions compared to the general RMS monitoring which can be affected by non-low-frequency chatter events, for example, the fan pump. In addition, changes in a narrow spectral region can be attenuated in the general RMS value because of averaging with the surrounding spectral characteristics.
    [063] Trend data shown in FIG. 9 highlight the difference in data observed for the integrated frequency band (15 to 20 kHz) in conditions with and without vibration. The first section of FIG. 9 shows the integrated frequency trend when no chatter is visibly observed in the coating or on the dryer surface. When visible vibration did not occur in the coating, a step change in the integrated frequency resulted. Monitoring different integrated frequency bands is directly applicable with the simple nG or time-integrated alarm * methods previously discussed.
    [064] In at least one embodiment of the invention, a means is provided to monitor and alarm the early onset of chatter through waveform analysis of the time waveform. For synchronous data collection, the time waveform represents the measured vibration signal for a full rotation of the Yankee dryer. Taking the continuous wavelet transformation (CWT) of the time waveform sensor data analyzes the vibration intensity and frequency information as a function of time. By knowing the Yankee dryer speed and diameter, a transformation from the time domain to the spatial MD is performed. The MD vibration frequency and intensity are useful for tracking specific special zones to determine the start of potential chatter. For example, the MD can be divided into an n number of zones to tend to an average or cumulative local RMS frequency, band, or value. Alarming using the simple or time-integrated nG approach can then be used to alert operators of potential problems. In particular, the wavelet technique will provide an early alarm condition for cases when chatter is initially developed locally before the formation of a chatter band around the circumference of the dryer.
    [065] An example of using wavelet analysis in time waveform vibration sensor data is shown in FIG. 10. The graph marked FIG. 10 A represents the raw data from the sensor or waveform collected from a sensor mounted on the scraper holder as shown in FIG. 1. Data were collected for 0.64 seconds representing a cylinder revolution. Spectral characteristics and intensity of the FFT analysis (graph marked FIG. 10B) is the integrated result for 0.64 seconds, so the strong frequency bands observed close to 7800 and 11800 Hz represent the accumulated effect. Identifying unique spectral characteristics of FFT is useful in data interpretation, but it lacks temporal information. Waveform waveform analysis addresses this issue by extracting frequency and vibration intensity information at different times. When applying wavelet analysis to the waveform, a scale chart is constructed (marked FIG. 10C) to show the square magnitude of the CWT's complex wavelet coefficients to present the frequency and intensity as a function of time. Expanded views of the waveform (marked FIG. 10D) and scale (marked FIG. 10E) clearly illustrate the correlation between waveform characteristics and spatial vibration frequencies. For example, in the zone between 0.234 and 0.236 according to an intense band of vibration frequencies> 10 kHz is observed. This frequency band appears sporadically throughout the scale, but in this particular time (local), the intensity is maximum indicating localized high frequency vibration.
    [066] In at least one embodiment of the invention, there is a means to monitor the early detection of early chatter by analyzing the slope of the vibration frequency band or RMS trend. A typical feature for RMS trend graphs or selected vibration frequency bands is the age effect of the creping scraper blade. A newly installed blade causes an initial decrease in the RMS trend. As the blade ages and wears out the trend signal will increase over time. Tracking the characteristic features of the trend, such as the slope and marginal slope (2nd derivative), is an indicator of the process state used in the assessment if a potential chatter condition is approaching. FIG. 11 shows variations in the slope of the RMS trend that occurs under “normal” conditions between scraper blade changes. Cases where RMS increases to a higher level than the normal operating baseline are usually preceded by a sharp increase in slope. The slope tracking then provides a means to predict whether the RMS value is moving towards a higher trajectory.
    [067] In at least one embodiment of the invention, the method comprises a simple alert method based on the time-integrated alarm * value that could be color-coded or audible. Color-coded alarm uses a set of colors to indicate the current alarm state, for example, green for normal operation, yellow for approaching shake condition and red for the presence of a potential critical shake condition. In this case, the built-in chatter condition takes into account both low and high RMS values above the alarm level for short and long duration times, respectively.
    [068] Although this invention can be configured in different ways, it is shown in the drawings and described in detail here specific preferred embodiments of the invention. The present disclosure is an example of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. All patents, patent applications, scientific articles and any other material mentioned here are incorporated by reference in their entirety. In addition, the invention encompasses any possible combination of some or all of the various embodiments described here and incorporated here.
    [069] The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many changes and alternatives to a person skilled in the art. All of these alternatives and variations are intended to be included within the scope of the claims where the term "comprising" means "including, but not limited to". Those familiar with the technique may recognize others equivalent to the specific modalities described here whose equivalents are intended to be encompassed by the claims.
    [070] All ranges and parameters disclosed here are understood to encompass any and all sub-ranges comprised therein, and any number between extreme points. For example, a range mentioned from "1 to 10" should be considered to include any and all sub-ranges between (and including) the minimum value of 1 and the maximum value of 10; that is, all sub-bands beginning with a minimum value of 1 or more, (for example 1 to 6.1), and ending with a maximum value of 10 or less (for example 2.3 to 9.4, 3 to 8 , 4 to 7), and finally each number 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 contained within the range.
    [071] This completes the description of the preferred and alternative embodiments of the invention. Those skilled in the art may recognize others equivalent to the specific embodiments described here whose equivalents are intended to be encompassed by the claims appended hereto.
    权利要求:
    Claims (20)
    [0001]
    1. Method to detect and treat vibration from Yankee dryer scraper blades used in the creping process, cleaning or cutting operations, the method CHARACTERIZED by the fact that it comprises the steps of: for a period of time, with a sensor built and arranged to measure the frequencies and amplitudes of vibrations on a scraper blade when it forms a crepe on a paper product, measure the frequencies and amplitudes of time-indexed vibrations, collect the measurements in a time waveform, convert the waveform using a fast Fourier transform, the converted waveform having a frequency spectrum which includes distinct vibration bands, correlate characteristics of the vibration bands with performance properties of the scraper blade to produce correlated vibration bands, define (i) acceptable performance properties of the scraper blade and (ii) a baseline of acceptable vibration bands based on the correlated vibration bands and acceptable performance properties of the scraper blade; predict, from the correlated characteristics, the degree of deviation from the baseline of acceptable vibration bands associated with the vibration of the scraper blade, predict, from the correlated characteristics, the duration of deviation from the baseline of acceptable vibration bands associated with the scraper blade shake, send, when a data point on a correlated vibration band indicates that excessive scraper blade shake has occurred based on the predicted degree and duration of deviation from the acceptable vibration bands, and perform a or more corrective actions to deal with excessive scraping of the scraper blade, the one or more corrective actions being from the group, consisting of: installing a new scraper blade, reconditioning a surface, replacing a bearing, and lubricating a bearing.
    [0002]
    2. Method, according to claim 1, CHARACTERIZED by the fact that the sensor is an accelerometer.
    [0003]
    3. Method, according to claim 1, CHARACTERIZED by the fact that the sensor is a piezoelectric accelerometer.
    [0004]
    4. Method, according to claim 1, CHARACTERIZED by the fact that the measurements are analyzed and modeled by a data processing device built and arranged to use a process selected from the group consisting of: RMS data trend, neural network, multiple regression analysis, AR, ARMAX, partial least squares and any combination thereof.
    [0005]
    5. Method, according to claim 1, CHARACTERIZED by the fact that at least one of the correlations is determined by comparing the characteristics of the vibration bands with the age of the blade.
    [0006]
    6. Method, according to claim 5, CHARACTERIZED by the fact that the measurements are analyzed and modeled by a data processing device built and arranged to use RMS data trends and where the determination is made at least in part noting that the slope in a sawtooth-shaped vibration band continuously increases over time with the same blade and becomes discontinuous when the blade is changed.
    [0007]
    7. Method, according to claim 6, CHARACTERIZED by the fact that it further comprises the step of defining that a deviation from the baseline due to chatter only occurs when a deviation exceeds the mean and the standard deviation from the baseline due to both to an increase in magnitude for a duration of that increase greater than the average duration of all data peaks in the waveform.
    [0008]
    8. Method according to claim 6, CHARACTERIZED by the fact that it further comprises the steps of predetermining the slope at which the blade is too old to be desired for use and replacing the blade when that slope manifests itself in the waveform.
    [0009]
    9. Method, according to claim 1, CHARACTERIZED by the fact that at least one of the correlations is determined by comparing characteristics of the vibration bands with a selected factor of: tracking bearing, balance, dryer lubricity, dust levels, humidity levels, temperature, perceived age, grade, supply composition, coating chemistry, cleaning blade status (on or off), machine speed, external source vibrations, external pressure sources and any combination thereof.
    [0010]
    10. Method, according to claim 1, CHARACTERIZED by the fact that the range of characteristics of the vibration bands caused by the factor is so wide that the sensor must be able to detect frequency bandwidth covering four orders of magnitude.
    [0011]
    11. Method, according to claim 1, CHARACTERIZED by the fact that the sensor measures only the vibrations of the scraper blade because it is attached not to the blade itself, but to a blade holder that is attached to and provides more rigid support to the blade, but which does not dampen vibration to such an extent that an accurate measurement cannot be taken.
    [0012]
    12. Method, according to claim 1, CHARACTERIZED by the fact that the measurements are taken synchronously.
    [0013]
    13. Method, according to claim 1, CHARACTERIZED by the fact that the measurements are taken asynchronously.
    [0014]
    14. Method, according to claim 1, CHARACTERIZED by the fact that the output is an alarm.
    [0015]
    15. Method according to claim 1, CHARACTERIZED by the fact that it further comprises determining a trend of the frequency spectrum over time, in which the baseline of acceptable vibration bands comprises an alarm level at which the trend is compared.
    [0016]
    16. Method according to claim 15, CHARACTERIZED by the fact that it further comprises determining the trend slope over time, determining marginal slope over time, and predicting a start of a trend deviation above the alarm level based on slope and marginal trend slope.
    [0017]
    17. Method, according to claim 16, CHARACTERIZED by the fact that: sending, when a data point in a vibration band exceeds the degree, and the duration of the excessive deviation shake that has occurred comprises displaying an alarm signal based comparison of trend and alarm level.
    [0018]
    18. Method according to claim 17, CHARACTERIZED by the fact that it displays an alarm signal which comprises displaying a coded alarm signal to indicate a current alarm state, comprising: provided that the trend is within the acceptable deviation baseline, displaying a first alarm signal, on the condition that the start of a trend deviation above the alarm level is predicted, displaying a second alarm signal, and on the condition that the trend is above the alarm signal. alarm, displaying a third alarm signal.
    [0019]
    19. Method, according to claim 15, CHARACTERIZED by the fact that the trend value represents a measure of one of: (i) general vibration magnitude, or (ii) vibration magnitude of a frequency bandwidth.
    [0020]
    20. Method, according to claim 1, CHARACTERIZED by the fact that the one or more corrective actions are performed by a system operator.
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    法律状态:
    2018-03-27| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-08-06| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-12-01| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-02-02| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 11/10/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US13/277,545|US9404895B2|2011-10-20|2011-10-20|Method for early warning chatter detection and asset protection management|
    US13/277,545|2011-10-20|
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