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image1: With WindPro, manufacturers can view the entire winding process and make real-time adjustments in the torque split between front and rear drums, nip pressure, and paper tension.Image 2:Controlling paper roll density helps prevent quality defects such as wrinkles and tears.
Paper manufacturers are always searching for ways to improve productivity and paper roll quality in their winding applications, which is a large part of the paper making process. To this end they will benefit from a new integrated winder control solution that has been tested and is now being offered by Rockwell Automation. Using this new bundled package, which consists of hardware and software, the paper manufacturers can monitor and control paper roll density and help prevent the typicalquality defects that come into paper manufacturing so often on two drum winders, such as wrinkles and tears. The package is called WindPro.
The WindPro solution includes both advanced visualisation hardware and software, with the objective of providing real-time winder control and monitoring all at one location in the plant. With this solution, manufacturers can view the entire winding process and as a resultof the real-time picture, they can adjust the torque split between front and rear drums, as needed. They can also adjust nip pressure and paper tension to help ensure the proper roll density. In addition to these monitoring and adjusting operations, WindPro can incorporate windermachine logic, such as roll handling and safety gate control, into its system.
How it improves quality
WindPro gives, in effect,a window into the process that paper manufacturers have not had untilnow, and once they have this information, it allows them to make adjustments that will reduce troublesome defects, which amounts to improving paper quality. “In paper winding applications, maintaining optimum torque and tension helps reduce roll defects, helping paper manufacturers take advantage of advanced automation technology to achieve their paper quality and throughput objectives,” said John MacDonald, who is commercial marketing manager of Rockwell Automation’s Global Drive Systems. “WindPro provides a real-time view of the process and the abilityto make immediate changes as the paper is wound,” he says. Catching defects early in the process helps eliminate costly scrap.
The WindPro solution is also something of a historian as well. It also collectsand stores machine production information from each wind for easier diagnostics and troubleshooting. The historical trending analysis helpsmanufacturers identify quality issues and maintain the machine setupparameters for optimum production and repeatability. It also has the capability of storing “recipes” so that setup time between rolls and different grades of paper can be minimised. WindPro is a part of Rockwell Automation’s PaperPro integrated solution, which is a series of product and service offerings designed specifically for the pulp and paperindustry. However, unlike traditional standalone solutions that require separate proprietary systems, WindPro integrates into the entire production process of the paper manufacturing plant in order to increaseefficiency and ease of use.
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