Abstract: A method and a system of industrial data communication with dedicated physical isolation are provided that, the data collector and the physical isolator cooperate with each other. The data collector collects the data of each nodes of an enterprise by the intranet or by the wired and wireless communication module. The data is converted into encrypted messages under a protocol. The physical isolator secondarily encrypts the data and uploads the standardized data to a cloud platform via the internet. The data is exchanged between the data collector and the physical isolator by a dedicated data channel. The data transmitted in the dedicated data channel is encrypted by an algorithm, and is transmitted in a form of encrypted messages. Two ports of the dedicated data channel can only transmit the data in the form of encrypted messages. The dedicated data channel uses specific communication media, and forms physical isolation directly.

Abstract: A method and a system of industrial data communication with dedicated physical isolation are provided that, the data collector and the physical isolator cooperate with each other. The data collector collects the data of each nodes of an enterprise by the intranet or by the wired and wireless communication module. The data is converted into encrypted messages under a protocol. The physical isolator secondarily encrypts the data and uploads the standardized data to a cloud platform via the internet. The data is exchanged between the data collector and the physical isolator by a dedicated data channel. The data transmitted in the dedicated data channel is encrypted by an algorithm, and is transmitted in a form of encrypted messages. Two ports of the dedicated data channel can only transmit the data in the form of encrypted messages. The dedicated data channel uses specific communication media, and forms physical isolation directly.

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 method includes obtaining a reference tracking performance ratio and a disturbance rejection performance ratio associated with a model predictive control (MPC) controller. The method also includes filtering an output target signal for the controller using a first filter based on the reference tracking performance ratio. The method further includes filtering a feedback signal for the controller using a second filter based on the disturbance rejection performance ratio. The filters can provide two degrees of freedom for tuning reference tracking and disturbance rejection operations of the controller. The reference tracking operation of the controller and the disturbance rejection operation of the controller can be independently tunable. The reference tracking performance ratio can control how aggressively the controller responds to a change in the output target signal. The disturbance rejection performance ratio can control how aggressively the controller responds to a disturbance in the feedback signal.

Abstract: A method includes designing probing signals for testing an alignment of actuators in a web manufacturing or processing system with measurements of a web of material being manufactured or processed by the system. The method also includes providing the probing signals during alignment testing to identify the alignment of the actuators with the measurements of the web. Designing the probing signals includes designing the probing signals based on both spatial and dynamic characteristics of the web manufacturing or processing system.

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 method includes obtaining a reference tracking performance ratio and a disturbance rejection performance ratio associated with a model predictive control (MPC) controller. The method also includes filtering an output target signal for the controller using a first filter based on the reference tracking performance ratio. The method further includes filtering a feedback signal for the controller using a second filter based on the disturbance rejection performance ratio. The filters can provide two degrees of freedom for tuning reference tracking and disturbance rejection operations of the controller. The reference tracking operation of the controller and the disturbance rejection operation of the controller can be independently tunable. The reference tracking performance ratio can control how aggressively the controller responds to a change in the output target signal. The disturbance rejection performance ratio can control how aggressively the controller responds to a disturbance in the feedback signal.

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 method includes identifying an initial solution to a quadratic programming (QP) problem associated with a process. The method also includes performing an iterative procedure having one or more iterations. Each iteration includes determining whether any constraint associated with the process is violated in the solution. Each iteration also includes selecting a violated constraint, determining a step direction and a step length associated with the selected violated constraint, and updating the solution based on the step direction and the step length. Determining the step direction and the step length includes using a Schur complement based on an active set of constraints associated with the solution. The Schur complement is nonsingular during all iterations of the iterative procedure except when the active set is empty.

Abstract: A method includes identifying an initial solution to a quadratic programming (QP) problem associated with a process. The method also includes performing an iterative procedure having one or more iterations. Each iteration includes determining whether any constraint associated with the process is violated in the solution. Each iteration also includes selecting a violated constraint, determining a step direction and a step length associated with the selected violated constraint, and updating the solution based on the step direction and the step length. Determining the step direction and the step length includes using a Schur complement based on an active set of constraints associated with the solution. The Schur complement is nonsingular during all iterations of the iterative procedure except when the active set is empty.

Abstract: A method includes designing probing signals for testing an alignment of actuators in a web manufacturing or processing system with measurements of a web of material being manufactured or processed by the system. The method also includes providing the probing signals during alignment testing to identify the alignment of the actuators with the measurements of the web. Designing the probing signals includes designing the probing signals based on both spatial and dynamic characteristics of the web manufacturing or processing system.

Abstract: Alignment is a critical component for modeling a cross-directional (CD) papermaking process. It specifies the spatial relationship between individual CD actuators to paper quality measurements. Misalignment can occur unexpectedly due to sheet wander or CD shrinkage variation. In certain applications and circumstances, a misalignment of one third (?) actuator zone width can result in significant paper quality degradation. Detecting a misalignment and identifying CD alignment in closed loop are highly demanded in paper mills but these are nontrivial problems. A technique for maintaining proper CD alignment in sheetmaking systems entails monitoring the alignment online, triggering closed loop identification if misalignment is detected, and then deploying the new alignment. No personnel intervention is required.

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: Alignment is a critical component for modeling a cross-directional (CD) papermaking process. It specifies the spatial relationship between individual CD actuators to paper quality measurements. Misalignment can occur unexpectedly due to sheet wander or CD shrinkage variation. In certain applications and circumstances, a misalignment of one third (?) actuator zone width can result in significant paper quality degradation. Detecting a misalignment and identifying CD alignment in closed loop are highly demanded in paper mills but these are nontrivial problems. A technique for maintaining proper CD alignment in sheetmaking systems entails monitoring the alignment online, triggering closed loop identification if misalignment is detected, and then deploying the new alignment. No personnel intervention is required.