Abstract: Registration and inspection systems and methods for use on a winder are disclosed. The systems and methods include scanning a region proximate a winding module with one or more sensors to determine a product defect. The product defect is then associated with a winding process parameter, such as percent roll build information or the identity of the particular sensor to first detect the defect. The winding process parameter is used to classify the defect into one or more defect profiles. The defect profiles can be based at least in part on segmenting the roll build of a web onto a winding module into a plurality of inspection windows and segmenting a plurality of sensors into a plurality of inspection sensor segments.

Abstract: A controller for a motor is configured to rotate a roll of material. The controller includes a drive speed regulator configured to generate an initial torque command based on a difference between a speed setpoint and a measured drive speed of the motor. The controller also includes an observer module configured to estimate a density error of the roll of material. The initial torque command is adjusted based on the density error to obtain a total torque command. The controller also includes a torque regulator configured to control the motor based on the total torque command.

Abstract: A system and process is described for producing spirally wound products. According to the process of the present disclosure, two or more webs are conveyed together in a superimposed relationship. The webs are then separated such that one web goes to a first winding module while a second web goes to a second winding module, etc. In this manner, at least two spirally wound products can be produced simultaneously. The process and system of the present disclosure are particularly well suited for processing tissue webs, such as paper towels and bath tissue. The process of the present disclosure can effectively at least double throughput on existing winding systems.

Abstract: Registration and inspection systems and methods for use on a winder are disclosed. The systems and methods include scanning a region proximate a winding module with one or more sensors to determine a product defect. The product defect is then associated with a winding process parameter, such as percent roll build information or the identity of the particular sensor to first detect the defect. The winding process parameter is used to classify the defect into one or more defect profiles. The defect profiles can be based at least in part on segmenting the roll build of a web onto a winding module into a plurality of inspection windows and segmenting a plurality of sensors into a plurality of inspection sensor segments.

Abstract: Registration and inspection systems and methods for use on a winder are disclosed. The systems and methods include scanning a region proximate a winding module with one or more sensors to determine a product defect. The product defect is then associated with a winding process parameter, such as percent roll build information or the identity of the particular sensor to first detect the defect. The winding process parameter is used to classify the defect into one or more defect profiles. The defect profiles can be based at least in part on segmenting the roll build of a web onto a winding module into a plurality of inspection windows and segmenting a plurality of sensors into a plurality of inspection sensor segments.

Abstract: A controller for a motor is configured to rotate a roll of material. The controller includes a drive speed regulator configured to generate an initial torque command based on a difference between a speed setpoint and a measured drive speed of the motor. The controller also includes an observer module configured to estimate a density error of the roll of material. The initial torque command is adjusted based on the density error to obtain a total torque command. The controller also includes a torque regulator configured to control the motor based on the total torque command.

Abstract: A system and process is described for producing spirally wound products. According to the process of the present disclosure, two or more webs are conveyed together in a superimposed relationship. The webs are then separated such that one web goes to a first winding module while a second web goes to a second winding module, etc. In this manner, at least two spirally wound products can be produced simultaneously. The process and system of the present disclosure are particularly well suited for processing tissue webs, such as paper towels and bath tissue. The process of the present disclosure can effectively at least double throughput on existing winding systems.

Abstract: Registration and inspection systems and methods for use on a winder are disclosed. The systems and methods include scanning a region proximate a winding module with one or more sensors to determine a product defect. The product defect is then associated with a winding process parameter, such as percent roll build information or the identity of the particular sensor to first detect the defect. The winding process parameter is used to classify the defect into one or more defect profiles. The defect profiles can be based at least in part on segmenting the roll build of a web onto a winding module into a plurality of inspection windows and segmenting a plurality of sensors into a plurality of inspection sensor segments.