Abstract: Techniques are described for inspecting a web and controlling subsequent conversion of the web into one or more products. A system, for example, includes an imaging device, an analysis computer and a conversion control system. The imaging device images a sequential portion of a web to provide digital information. The analysis computer processes the digital information with an initial algorithm to identify regions on the web containing anomalies. The conversion control system selects one of a plurality of converting sites to convert the web into a product, and analyzes at least a portion of the digital information with at least one subsequent algorithm to determine which anomalies represent actual defects in the web for the products.

Abstract: A method of controlling tension in a material handling process. An error signal of the process is determined. The velocity analog value of the material is determined and an instantaneous integral gain is then determined according to the velocity analog value. A proportional gain is determined. A first material parameter threshold value is determined. A first material parameter analog value is measured. The output of a controller is then adjusted according to the error signal, the instantaneous integral gain, and the proportional gain. The adjustment of a process output according to the instantaneous integral gain is controlled according to the relative values of the first material parameter threshold value and the first material parameter analog value.

Abstract: The invention relates to a method for adjusting the degree of engagement of a tool (6, 7) disposed on the outer radius of at least one associated rotating roll (4, 5) with a web of material (1) running past it. The aim of the invention is to improve the method so that the degree of engagement of the tool can be adjusted without loss of time and without producing any scraps. To this end, for adjusting the degree of engagement of the tool (6, 7) with the web of material (1), first several different degrees of engagement are electronically defined by means of different peripheral speeds of the tool (6, 7) so as to be retrievable. Once an adjuster (13) is activated, the change to another defined degree of engagement takes place during operation precisely when the tool (6, 7) engages with the web so that the new degree of engagement is carried out when the tool (6, 7) engages with the web of material (1) for the next time.

Abstract: A system and/or method for cutting designs of text and/or shapes out of sheet material, such as paper, vellum, and other materials used in, for example, the scrapbooking and card making industries.

Abstract: A method of adjusting a process output in a material handling process. The velocity analog value of the material is determined and an instantaneous integral gain is then determined according to the velocity analog value. The output of a controller is then adjusted according to the instantaneous integral gain.

Abstract: A process for achieving décor on surface elements (1) which comprises a decorative upper layer (2) and a supporting core (5). A selected main décor is entered via a terminal, the selected décor emanating from the group consisting of; an archetype digitized via digital camera or scanner and a digitized décor from a database. The dimensions of the surface to be covered by surface elements (1) and the desired dimension of the décor is entered into the terminal. Support programs is then used for calculating the segmentation of the main décor to cover more than one surface element. The result of the selections and calculations is visualized via the terminal.

Abstract: A method of dynamically controlling the tension of a moving web material. A web material is transported with an apparatus. A modulus-of-elasticity-analog value is determined for the web material. The modulus-of-elasticity-analog value is used to adjust an instantaneous gain of the web control system. The instantaneous gain is used in the control calculation of the control system. The control calculation is used to control the speed of a web handling drive. Controlling the speed of at least one appropriate web handling drive controls the tension of the web.

Abstract: Web tension in web material passing through a web transport system is determined in real time using position sensors coupled to driven rollers that define a beginning and an end of a tension zone. The position sensors on the rollers provide information related to the amount of strained web material that has been added and subtracted from the web material present in the tension zone. The amount of web material added to, subtracted from and present in the tension zone in a sample time period is then converted to an unstrained amount of web material that when combined provides an estimate for the present amount of unstrained web material present in the tension zone. Because the length of the tension zone is both fixed and known, the tension in the web material is determined from the present amount of unstrained web material in the tension zone.

Abstract: A feedback controlled tension applying system includes a corrugated fin processing device that processes a fin material in continuous sheet form while applying a tension to the fin material. A tension applying device applies the tension to the fin material. An encoder measures a moving amount of the fin material, and a control device that feedback-controls the tension applying device based on a measurement result of the encoder so that the moving length amount per predetermined time of the material becomes a set value that is set in advance.

Abstract: A system and method is provided for analyzing data obtained during manufacture of a web of paper or paperboard on a machine. The system comprises a computer including a database module, a statistical analysis module, and a processor for executing the modules. The database module contains measurements of quality parameters obtained from the web during manufacture. The statistical analysis module is executed by the processor to analyze the measurement data and estimate a target shift in at least one quality parameter that could be made if the controllable variations were removed. The target shift can be transformed into an economic amount (i.e., dollar value) by the statistical analysis module to assist the mill operator with making well informed, economic based decisions. The system further includes a diagnostic module capable of automatically identifying machine parameters that correlate to quality parameters that caused the web to fall outside the desired quality specifications.

Abstract: A fully-integrated computer-aided method for sizing and building paper reels from which a plurality of smaller rolls of paper are created. Data pertaining to the measurements of paper reels and the rolls to be built therefrom is entered into a computer programmed with electronic spreadsheet software, which stores, validates and computes measurement values so that the diameter of the paper reel from which the smaller paper reels are being built is of the correct size to minimize waste.

Abstract: This invention pertains to processing continuous webs such as paper, film, composites, and the like, in dynamic continuous processing operations. More particularly, it relates to accumulating limited lengths of such continuous webs and to controlling tension in such continuous webs during the processing operation. Both tension control and limited accumulations are achieved in festoon systems by connecting corresponding movably mounted festoon rolls to an actuator, sensing parameters such as position, tension, velocity, and acceleration related to the web and the festoon, and providing active force commands, in response to the sensed variables, to cause translational movement, generally including a target acceleration, in the movably mounted festoon rolls to control tension in the web while providing limited accumulation of a length of the web. The festoon control system can be used to attenuate tension disturbances, in the alternative to create controlled tension disturbances.

Abstract: A control and/or regulating system of a machine for making a fibrous web, such as a paper and/or cardboard web, is provided. The system includes a plurality of actuators, each assigned to at least one final control element, for varying certain properties of the fibrous web to be made. The actuators form intelligent participants in a decentralized communications hardware structure in which they are coupled to one another via a closed pipeline ring and/or a local area network.

Abstract: A method of controlling tension in a material handling process. An error signal of the process is determined. The velocity analog value of the material is determined and an instantaneous integral gain is then determined according to the velocity analog value. A proportional gain is determined. The output of a controller is then adjusted according to the error signal, the instantaneous integral gain, and the proportional gain.

Abstract: The present invention provides a method of manufacturing an item. The method includes providing a pattern building program to a client, wherein the client is to build a pattern using the program. The method also includes manufacturing the item based on the pattern. Preferably, the item is one of a textile, a tile, a wallpaper, or a carpet.

Abstract: Combined information exchanges systems and methods suitable for use in connection with a manufacturing production line constructing a composite product. Some of the disclosed combined systems and methods include relating inspection data, such as product (or process) attribute data, to data from other manufacturing-related systems. Also disclosed are combined systems and methods for linking product (or process) attribute data obtained during the manufacturing process with one or more data sources including raw material data, process setting data, product quality data, and/or productivity data. Also disclosed are combined systems and methods for identifying manufacturing set point changes and automatically implementing such changes and automated web steering changes based on data from one or more inspection systems.

Abstract: Systems and methods for guiding one or more web components in connection with a web converting manufacturing process such as that used for manufacturing disposable absorbent garments. Some of the disclosed embodiments include relating inspection data, such as product (or process) attribute data, to data from other manufacturing-related systems. Also disclosed are systems and methods for linking product (or process) attribute data obtained during the manufacturing process with one or more data sources including raw material data, process setting data, product quality data, and/or productivity data. Also disclosed are systems and methods for identifying manufacturing set point changes and automatically implementing such changes and automated web steering changes based on data from one or more inspection systems.

Abstract: A system (30) and method for determining stock consistency and for using consistency as a process variable to control some aspect of operation of a refiner (32) used to refine stock. The system includes at least one sensor (70 or 180) from which some refiner characteristic is obtained that is used by a processor (38) in determining consistency. The method uses the characteristic, such as temperature or pressure inside the refiner or in a refining zone (304) of the refiner, along with at least one other refiner parameter in determining consistency. A controller (274) uses the consistency determined in controlling some aspect of refiner operation. In one preferred controller, consistency is compared with a consistency setpoint and adjustments are made to try to converge consistency with the setpoint. The controller can be paused to accommodate other changes made to refiner operation and released when steady state refiner operation is achieved.

Abstract: A feedback controlled tension applying system includes a corrugated fin processing device that processes a fin material in continuous sheet form while applying a tension to the fin material, a tension applying device that applies the tension to the fin material, an encoder that measures a moving amount of the fin material, and a control device that feedback-controls the tension applying device based on a measurement result of the encoder so that the moving length amount per predetermined time of the material becomes a set value that is set in advance.

Abstract: A state information system for acquiring measured values of chemical and/or physical variables during the production, processing or finishing of a material, in particular in the case of a printing material web in a web-fed press, includes at least one sensor for recording the chemical and/or physical variables, the state information system being provided on or in the material such that the operating process carried out with the material remains unaffected by it.

Abstract: Cigarettes are manufactured using modified automated cigarette making apparatus. Those cigarettes possess smokable rods having paper wrapping materials having additive materials applied thereto as patterns. The additive materials, which can have the forms of liquid or paste formulations, are applied to a continuous paper web on the cigarette making apparatus. The formulation is applied to the paper web using application apparatus possessing rollers, and one of those rollers has a series of pockets in its roll face to receive additive formulation from a reservoir and to define the pattern of the formulation on the paper. A modified figure rail assembly and garniture entrance cone provide air flow toward the paper web being advanced through the garniture region of the cigarette making apparatus.

Abstract: A system and method for trim optimization comprising a database. The database comprises information concerning widths of specific machines of manufacturers, widths of the orders and remaining space required to be filled on the machines at a given time. The database further comprises specifications of products to be manufactured on the specific machines and specifications of the orders.

Abstract: A method of controlling a converting line having a rewinder, accumulator, and downstream equipment includes: providing upper and lower target limits for the accumulator level; determining the slowest maximum speed of the downstream equipment; determining the fastest minimum speed of the downstream equipment; monitoring the speed of the rewinder and the actual level of the accumulator; generating a master speed reference value to control the downstream equipment which: (i) corresponds to said slowest maximum speed of the downstream equipment if the actual accumulator level is greater than the upper target limit; or (ii) corresponds to the fastest minimum speed of the downstream equipment if the actual accumulator level is less than the lower target limit; or (iii) is based on the actual production speed of the rewinder if the actual accumulator level is less than the upper target limit and greater than the lower target limit for the accumulator.

Abstract: A method of detecting streaks in a web of, for example, moving paper which may be moisture, basis weight or caliper. A cross-direction profile is sensed and a moving average computed and then using minimum thresholds for the variation of the streak value from the average and its width in profile data boxes, the streak is detected.

Abstract: The invention relates to a device and a method for detecting, identifying and relocating defects in a material strip of great length. In order to enable defects to be relocated reliably and quickly with relatively little effort, the material strip is checked for defects, and position indicators are applied to the material strip continuously over its length. In the event of a defect being observed, an associated defect position indicator is stored, and during the subsequent relocation of a defect, a current starting position indicator is established, and the material strip is moved over a conveying length which is calculated from the established starting position indicator and the stored defect position indicator.

Abstract: The invention relates to a method for adjusting the degree of engagement of a tool (6, 7) disposed on the outer radius of at least one associated rotating roll (4, 5) with a web of material (1) running past it. The aim of the invention is to improve the method so that the degree of engagement of the tool can be adjusted without loss of time and without producing any scraps. To this end, for adjusting the degree of engagement of the tool (6, 7) with the web of material (1), first several different degrees of engagement are electronically defined by means of different peripheral speeds of the tool (6, 7) so as to be retrievable. Once an adjuster (13) is activated, the change to another defined degree of engagement takes place during operation precisely when the tool (6, 7) engages with the web so that the new degree of engagement is carried out when the tool (6, 7) engages with the web of material (1) for the next time.

Abstract: A method of controlling tension in a material handling process. An error signal of the process is determined. The velocity analog value of the material is determined and an instantaneous integral gain is then determined according to the velocity analog value. A proportional gain is determined. The output of a controller is then adjusted according to the error signal, the instantaneous integral gain, and the proportional gain.

Abstract: a control system of a factory automation facility for a seatbelt retractor assembly comprising a factory automation facility and a control portion for controlling the operating of all parts in the factory automation facility, integrally, to enable the mass-production of a seatbelt retractor assembly, in which the factory automation facility comprises a webbing throwing-in portion for throwing-in a webbing of a strip type thereinto by a first webbing supplying portion; first and second webbing position determining devices for guiding the webbing to pass through the hole of a retractor spool, a webbing withdrawing portion including a second webbing supplying portion and a case to withdraw the webbing and store it for a while, first and second part supplying portions for assembling a tongue, a guide ring and a ring mount on the withdrawn webbing, a stopper fixing portion including a third webbing supplying portion for carrying the webbing to a webbing folding portion, upper and lower stopper suppliers for supply

Abstract: A system of detecting and adjusting the normal force exerted by a web material around the circumferential surface of a cylinder is provided. Sensors associated with the cylinder surface are wired to a processor that compares detected normal web forces with a set value. An actuation device is activated by the processor to adjust the normal force exerted by the web by, e.g., adjusting the tension in the web material. A positioning device that preferably translates a web-wound spool is also provided as an option for the actuation device.

Abstract: Systems and methods for guiding one or more web components in connection with a web converting manufacturing process such as that used for manufacturing disposable absorbent garments. Some of the disclosed embodiments include relating inspection data, such as product (or process) attribute data, to data from other manufacturing-related systems. Also disclosed are systems and methods for linking product (or process) attribute data obtained during the manufacturing process with one or more data sources including raw material data, process setting data, product quality data, and/or productivity data. Also disclosed are systems and methods for identifying manufacturing set point changes and automatically implementing such changes and automated web steering changes based on data from one or more inspection systems.

Abstract: A system, method and article of manufacture are provided for monitoring and optimizing utility usage in an entity. Utility usage is collected for one or more utility resources in an entity. The utility usage for the entity is then aggregated. Utility utilization in the entity is monitored and utility usage of the one or more devices is selectively limited to optimize utility usage.

Abstract: A fully-integrated computer-aided method for sizing and building paper reels from which a plurality of smaller rolls of paper are created.

Abstract: Headbox transient responses for sheet weight and moisture are modeled as a combination of two sets of time constants and dead time delays. One set represents a shorter delay with faster response dynamics, the fast mode weight and moisture responses, and the other models the longer delay with slower dynamics, the slow mode weight and moisture responses. A weight and/or moisture transient model is then formed for headbox changes by combining the fast mode weight and moisture responses and the slow mode weight and moisture responses. Stock weight and moisture dynamic and delay time models are determined for operation of stock flow of the paper making machine and the stock flow is controlled in accordance with the stock weight and/or moisture models and the headbox weight transient and/or moisture transient model to compensate for weight and moisture changes in a web of paper being manufacture which weight and moisture changes result from headbox changes.

Abstract: The present invention provides a process and means for identifying opportunities for improvement in assembly line production that overcomes the problem of overlooking opportunities for improvement. Six sigma techniques are used to identify these opportunities. The process includes collecting time data accurately representing operations in an assembly line; conducting a capability analysis of the data collected to identify opportunities for improving operations; identifying changes in operations based on this analysis; and implementing such changes into operations to produce improved assembly line performance. Capability analysis of the data using statistical techniques is a more rigorous and thorough approach than traditional assembly line optimization techniques. The present invention targets opportunities for improvement that would otherwise be overlooked.

Abstract: The present invention includes processes for making fibers, which processes include an extrusion step wherein molten polymers are extruded through an extrusion die, thereby forming at least one extruded filament; and an orientation step, wherein the filament is drawn to align the molecules of the filament, and wherein multivariate data analysis techniques are used to analyze data regarding various process variables and, optionally, process variables are adjusted in response to the multivariate data analysis.

Abstract: The present invention is characterized in that in a simulation for predicting a steam pressure setpoint after grade change, an initial moisture percentage is evaluated from differences between bone-dry basis weights and between machine speeds before and after grade change; the bone-dry coated weight of a size is evaluated from the flow rate and concentration thereof; and then the dryer inlet moisture percentage of a web after a size press is calculated from the coated weight. Thus, the invention intends to improve the quality of products through precise dryer control, as well as reduce the time required for grade change, by precisely predicting the web's initial moisture percentage at the dryer inlet after grade change and precisely and quickly controlling dryer steam pressure during grade change.

Abstract: In a production operation for producing rolls of tissue or towel from a parent roll including a converting line provided with a rewinder, an accumulator and downstream processing equipment, a method of controlling the converting line includes: (a) providing an upper target limit for the inventory level of the accumulator; (b) providing a lower target limit for the inventory level of the accumulator; (c) determining the slowest maximum speed of the downstream equipment; (d) determining the fastest minimum speed of the downstream equipment; (e) monitoring the average production speed of the rewinder; (f) monitoring the actual inventory level of the accumulator; (g) generating a master speed reference value which: (i) corresponds to said slowest maximum speed of the downstream equipment if the actual inventory level of said accumulator is greater than about the upper target limit for the inventory level of the accumulator; or (ii) corresponds to the fastest minimum speed of the downstream equipment if the actual

Abstract: A Kalman filter algorithm is used for estimation in a feedback control system for a moving web. Matrices of the Kalman filter algorithm are solved with reduced computational complexity. One of the matrices is solved as a diagonal matrix for both state prediction and covariance and another matrix for gain is solved merely as a vector.

Abstract: A method for measuring the quality properties of paper and/or board on moving webs is disclosed. The present invention utilizes a staged evaluation method in which the basic properties of the paper or board and further properties are determined via multi-stage modeling.

Abstract: This invention pertains to processing continuous webs such as paper, film, composites, and the like, in dynamic continuous processing operations. More particularly, it relates to accumulating limited lengths of such continuous webs and to controlling tension in such continuous webs during the processing operation. Both tension control and limited accumulations are achieved in a festoon system by connecting a corresponding festoon to actuator or the like, sensing variables such as position, tension, velocity, and acceleration parameters related to the web and the festoon, and providing active force commands, in response to the sensed variables, to cause translational movement, generally including a target acceleration, in the upper festoon rolls to control tension disturbances in the web while providing limited accumulation of a length of the web. In some applications of the invention, the festoon control system is used to attenuate tension disturbances.

Abstract: A system of providing fast machine direction (MD) and cross direction (CD) basis weight adjustments using a simultaneous multi-point water weight sensor which provides independent MD and CD measurements is described. The water weight sensor is placed under the wire of the sheetmaking machine and provides fast wet end water weight measurements which are converted into predicted dry end basis weight information and used to control operating variables of machine elements in the sheetmaking machine to compensate for high frequency process variations. MD wet end measurements are used to control operating variables of machine elements that influence the MD dry end basis weight and CD wet end measurements are used to control operating variables of machine elements that influence CD dry end basis weight.

Abstract: The present invention provides a method and apparatus for monitoring a UV curing lamp system to determine whether a UV-curable material passing through the curing lamp system is being properly cured. A thermal sensor is disposed to measure the temperature of gas being exhausted from a center tube of the UV curing lamp system. The center tube typically has nitrogen gas pumped into it to purge air from the center tube. The UV-curable material passes through the center tube. If a defect exists in the center tube, or if insufficient UV radiation is reaching the UV-curable material, the temperature of the gas stream exhausted from the center tube will drop. The temperature of the gas is compared to first and second threshold values, respectively, to determine whether a defect in the center tube exists or whether insufficient radiation is reaching the UV-curable material, respectively.

Abstract: To correct delayed transmission of instructions associated with increased communication load on a communications line, so as to safely and reliably control a working robot, a system for controlling an operation unit performing a plurality of operations is configured to include a working robot and a controlling personal computer transmitting in operation a command via a wireless LAN and a wired LAN to control an operation. The controlling personal computer detects the load of a communication between the working robot and the controlling personal computer and limits a predetermined one of the plurality of operations depending on the detection result.

Abstract: A roll sensing system for measuring the pressure distribution and nip width in a nip roll press. The sensing system comprises a strip having sensors thereon, the strip being placed in a nip press, for sensing the pressure at several locations therealong. At one end of the strip lies electronics associated with the sensors. The electronics communicate with an optional multiplexer and a bidirectional transmitter for signal transmission to an external signal conditioner and an external computer. The computer determines pressure values and nip width values at various locations along the strip, and communicates with a display which provides a visual, graphical and/or numerical data to the operator. Optionally, a control system can be in communication with the transmitter or the computer to initiate crown corrections in response to pressure or nip width readings.

Abstract: This invention pertains to processing continuous webs such as paper, film, composites, and the like, in dynamic continuous processing operations. More particularly, it relates to accumulating limited lengths of such continuous webs and to controlling tension in such continuous webs during the processing operation. Both tension control and limited accumulations are achieved in a festoon system by connecting a corresponding festoon to actuator or the like, sensing variables such as position, tension, velocity, and acceleration parameters related to the web and the festoon, and providing active force commands, in response to the sensed variables, to cause translational movement, generally including a target acceleration, in the upper festoon rolls to control tension disturbances in the web while providing limited accumulation of a length of the web. In some applications of the invention, the festoon control system is used to attenuate tension disturbances.

Abstract: The present invention relates to a method and system for optimizing trim from a sheet product.

Abstract: The invention relates to method for identifying plural relations in a sheet manufacturing process. Sheet properties are deduced from a response in a pseudo-property profile to a cyclic stimulation. A pseudo-property profile is calculated using a phase lag equal to half the stimulation cycle time, with and without stimulation. The properties of the sheet are deduced from the difference between an excited pseudo-property profile and a reference pseudo-property profile.

Abstract: An apparatus for forming a surface structure. The apparatus forms a skin to a single-sided die by applying gas pressure to a skin preform placed between the die and a cap that confines the gas against the skin preform. The apparatus also has a dispensing apparatus that is movable in relation to the surface of the skin/die. In one embodiment the dispensing apparatus is a heated nozzle on a crane arm that has five axis of movement with respect to the surface of the die. The nozzle dispenses fluid plastic, for example, in a selected pattern and at a selected height on the skin.

Abstract: This invention pertains to processing continuous webs such as paper, film, composites, and the like, in dynamic continuous processing operations. More particularly, it relates to controlling tension in such continuous webs during the processing operation. Tension is controlled in a dancer control system by connecting a corresponding dancer roll to an actuator apparatus or the like, sensing variables such as position, tension, velocity, and acceleration parameters related to the web and the dancer roll, and providing active force commands, in response to the sensed variables, to cause translational movement, generally including a target acceleration, in the dancer roll to control tension disturbances in the web. In some applications of the invention, the dancer control system is used to attenuate tension disturbances. In other applications of the invention, the dancer control system is used to create tension disturbances.

Abstract: A system and method for incorporating, in the production of a continuous stream of images, by an image transfer device upon a moving web, post-production operations upon the web at various locations. Locations of a web, having a plurality of images placed thereon, output from an image transfer device are tracked. Specific operations at various locations upon the web are performed by a post-production device as the web passes through it. The web is directed from the image transfer device to the post-production device. In response to the tracking of locations upon the web, the point when a location has entered the post-production device is determined. In response to this determination, the post-production device is commanded to perform its specific operation at a connect location.