Abstract: A method includes obtaining a model associated with a model-based controller in an industrial process having multiple actuator arrays and performing temporal tuning of the controller. The temporal tuning includes adjusting one or more parameters of a multivariable filter used to smooth reference trajectories of actuator profiles of the actuator arrays. The temporal tuning could also include obtaining one or more uncertainty specifications for one or more temporal parameters of the model, obtaining one or more overshoot limits for the actuator profiles, identifying a minimum bound for profile trajectory tuning parameters, and identifying one or more of the profile trajectory tuning parameters that minimize one or more measurement settling times without exceeding the one or more overshoot limits. The controller could be configured to use the adjusted parameter(s) during control of the industrial process such that the adjusting of the parameter(s) alters operation of the controller and the industrial process.

Abstract: Sheetmaking cross-directional (CD) control requires a sophisticated model-based controller whose operation requires an accurate model of process behavior, but due to the complexity of the process, identifying these process models is challenging. Current techniques rely on open-loop process experimentation. Using non-causal scalar transfer functions for the steady-state CD process model and controller model avoid the problem of large dimensions associated with the CD process. These non-causal transfer functions can be represented by causal transfer functions that are equivalent to the non-causal ones in the sense of the output spectrum. A closed-loop optimal input design framework is proposed based on these causal equivalent models. CD actuators have responses in both sides along the cross direction which can be viewed as a non-causal behavior.

Abstract: A method includes executing a control algorithm for an industrial process using a controller objective function, where the industrial process is associated with at least one controlled variable. The method also includes executing an optimization algorithm for the industrial process using an extended version of the controller objective function. The extended version of the controller objective function includes one or more additional terms added to the controller objective function, and one or more results of the optimization algorithm are provided to the control algorithm. The method further includes, based on tracking errors associated with the at least one controlled variable, adjusting at least one adaptive weight parameter in the extended version of the controller objective function. The at least one adaptive weight parameter is associated with at least one of the one or more additional terms.

Abstract: Automated parameter tuning techniques for cross-directional model predictive control for paper-making under user-specified parametric uncertainties to reduce variability of the actuator and measurement profiles in the spatial domain is proposed. Decoupling properties of the spatial and temporal frequency components permit separate controller design and parameter tuning. CD-MPC design that explicitly accounts for parametric model uncertainty while finding MPC cost function weighing matrices that prevent actuator picketing and guarantee robust stability of the spatial CD profile. Picketing refers to periodic variation patterns in the actuator array.

Abstract: Controlling a multiple-array, sheetmaking cross-directional process with a multivariable model predictive controller (MPC) employs a cost function incorporating a prediction horizon. The MPC provides a measurement profile target reference trajectory over the prediction horizon of the MPC cost function. Improved CD-MPC performance is achieved by employing a measurement profile target reference trajectory over the prediction horizon in the MPC cost function. A series of target profiles creates a reference trajectory to bring the cross-direction measurements smoothly from their current profile to the final target. By carefully designing the reference trajectory, the CD-MPC exhibits a good measurement response without aggressive control action. The current measurement target profile can be filtered through a first order plus deadtime process at each controller update and repeating the filter operation once for each step of the MPC prediction horizon generates a full reference trajectory for the profile.

Abstract: A method includes generating a model associated with cross-directional fiber orientation of a web, which includes identifying spatial frequency characteristics of a fiber orientation (FO) process. The method also includes providing the model for control of the FO process. Generating the model could include performing a spatial impulse test of the FO process, and long wavelength responses of the FO process can be identified by performing a spatial long wavelength test of the FO process or by retrieving information from a historical database. Actuator edge padding can be applied to the model in order to generate a controller model. A controller can be used to control the process based on the controller model. At least one parameter of the controller model can be dynamically adjusted during operation of the controller. The controller can change average fiber orientation angle profiles and twist profiles by only adjusting slice lip actuators in a headbox.

Abstract: A scanning measurement system includes independently driven, self-aligning, dual-sided heads. The system is configured to perform a method that includes receiving information associated with a discrepancy in a desired cross direction alignment of a first sensor head and a second sensor head that are disposed on opposite sides of a web of material and that are configured to move in a cross direction relative to the web. The method also includes adjusting a velocity of at least one of the sensor heads based on the received information to improve the cross direction alignment of the first sensor head and the second sensor head.

Abstract: Non-contacting caliper measurements of free standing sheets such as porous polymer and paper detect mid-IR interferometric fringes created by the reflection of light from the top and bottom surfaces of the sheet. The technique includes directing a laser beam at a selected angle of incidence onto a single spot on the exposed outer surface wherein the laser beam comprises radiation having a wavelength in the 3-50 micron range and scanning the laser beam through a selected angle range as the laser beam is directed onto the exposed outer surface and measuring the intensity of an interference pattern that forms from the superposition of radiation that is reflected from the exposed outer surface and from the inner surface. Thickness can be extracted from the fringe separation in the interference pattern. Rotating and focusing elements ensure that the spot position on the sheet remains the same while varying the incident angle.

Abstract: On-line detection of mesophase particles employs a laser diode light source to illuminate a target area with a pulsed laser linearly or circularly polarized probe beam. Analysis of images determines extent of presence the birefringent mesophase particles, which are precursors to coking in catalytic hydrocracking processes. The inherently polarized low-coherence, unfocused but sufficiently collimated, pulsed laser beam yield sharp imaging with high depth of field of very small mesophase particles that are present in a moving, dark reactor liquid environment.

Abstract: A method includes obtaining information identifying (i) uncertainties associated with multiple time-domain parameters of a model and (ii) time-domain performance specifications for a model-based industrial process controller. The model mathematically represents a MIMO industrial process. The method also includes generating multiple tuning parameters for the controller based on the uncertainties and the time-domain performance specifications. The tuning parameters include vectors of tuning parameters associated with the controller, and each vector includes values associated with different outputs of the industrial process. The time-domain parameters could include a process gain, a time constant, and a time delay for each input-output pair of the model. The time-domain performance specifications could include requirements related to worst-case overshoots, settling times, and total variations. The uncertainties could be specified as intervals in which the time-domain parameters lie.

Abstract: Continuous on-line thin film measurements employ a sensor having a spectrometer for interferometric measurements and a stack of single channel detectors for adsorption measurements. The stack is separated from the spectrometer, which analyzes radiation that emerges (transmitted pass or reflected from) the film, whereas the stack analyzes radiation that has passed through the film multiple times. The spectrometer is (i) positioned directly opposite the source of radiation so that it detects transmitted radiation or (ii) disposed on the same side of the film as is the source of radiation so that the spectrometer detects radiation that is specularly reflected from the film. The sensor includes a broadband radiation source emitting visible to far infrared light which propagates through a measurement cell defined by reflective surfaces exhibiting Lambertian-type scattering. The sensor is capable of measuring thin plastic films with thicknesses down to 1 micron or less.

Abstract: On-line detection of mesophase particles employs a laser diode light source to illuminate a target area with a pulsed laser linearly or circularly polarized probe beam. Analysis of images determines extent of presence the birefringent mesophase particles, which are precursors to coking in catalytic hydrocracking processes. The inherently polarized low-coherence, unfocused but sufficiently collimated, pulsed laser beam yield sharp imaging with high depth of field of very small mesophase particles that are present in a moving, dark reactor liquid environment.

Abstract: An environmental control system (ECS) includes a controller; and a mode selector in communication with the controller and configured to select at least one of a plurality of modes. The mode is based on one of: number of occupants in an environment; activity of the occupants in the environment; destination of the environment; and performance of an engine that moves the environment. The controller is configured to change an ECS load on the system based upon the selected mode.

Abstract: Near infrared moisture sensors using stable holmium oxide glass calibration standards that simulate different moistures levels in paper obviates problems associated with glass encased paper samples. Holmium oxide glass has a strong absorption at 1.93 microns which is close to absorption by paper. Standards can have varying thicknesses to simulate different moisture levels. Didymium glass can also be used with holmium oxide glass. The moisture sensor operates at reference and measurement infrared regions of 1.94 microns and 1.8 microns, respectively.

Abstract: An environmental control system (ECS) includes a controller; and a mode selector in communication with the controller and configured to select at least one of a plurality of modes. The mode is based on one of: number of occupants in an environment; activity of the occupants in the environment; destination of the environment; and performance of an engine that moves the environment. The controller is configured to change an ECS load on the system based upon the selected mode.

Abstract: An apparatus includes a chassis configured to move back and forth along multiple rails. The apparatus also includes electrical contacts configured to form electrical connections to the rails. The apparatus further includes a power converter/conditioner configured to receive power from the rails via the electrical contacts and to convert the power into a different form and/or condition the power. In addition, the apparatus includes one or more sensors configured to measure at least one characteristic of a material, where the one or more sensors are configured to operate using the power from the power converter/conditioner. The electrical contacts could touch the rails and receive the power directly from the rails. The electrical contacts could also touch rail contacts and receive the power indirectly from the rails via the rail contacts.

Abstract: An apparatus includes a cable track configured to be coupled to a moveable object and to be pushed and pulled by the movable object without buckling. The cable track is also configured to transport at least one signal or material to or from the moveable object. The cable track has a curved profile. A cross-section of the cable track showing a height, a width, and a thickness of the cable track can have a “(” shape. The cable track can be configured to be bent in order to create a “U” bend in the cable track, and the cable track can be configured to be pushed and pulled without buckling to change a location of the “U” bend along the cable track. The cable track can be configured to change shape repeatedly between a “J” shape and a “U” shape.

Abstract: A gap and displacement magnetic sensor system for scanner heads in paper machines or other systems includes a multiple-sensor assembly. The multiple-sensor assembly includes multiple magnetic field orientation sensors configured to capture measurements of a magnetic field in order to identify (i) a displacement of first and second scanning sensor heads in a first direction, and (ii) a gap separation of the first and second scanning sensor heads in a second direction, and (iii) a displacement of the first and second scanning sensor heads in a third direction. At least one of the magnetic field orientation sensors is disposed offset from a centerline of the magnetic field such that an output from the at least one magnetic field orientation sensor indicates a combination of the gap separation and the displacement in either the first direction or the third direction.

Abstract: Augmented reality techniques for monitoring and controlling continuous sheetmaking systems superimpose real-time sheet quality measurements onto images of the sheet and/or machine during production. A portable, hand-held computer device that is equipped with a camera, such as a tablet or smartphone, enables an operator to direct the device at the sheet along specific locations of the papermaking machine and view an indication of one or more quality measurements that are superimposed over the image of the paper. The operator can assess and resolve problems associated with the sheet being produced and/or machine.

Abstract: Product packaging technique including the conversion of paperboard into boxes and packages in a process that includes layout optimization of printing plates and takes into account vendor specifications, box order types, and printing machine constraints.