Abstract: An intelligent wireless cross direction (CD) actuator includes a wireless radio transceiver, a controller and a memory section. The wireless radio transceiver is used for transmitting and receiving control and functional information to and from other intelligent wireless CD actuators. The controller is used for processing the received control and functional information and for outputting a control signal to an electrical or mechanical device based upon the received control and functional information. Control and functional information, the output signal, a unique communications identifier for each of the other intelligent wireless CD actuators, and its own unique communications identifier are stored in the memory section. Each actuator is assigned a unique identification. The unique identifier is used to route information to and from other intelligent wireless CD actuator. Each wireless CD actuator is capable of communication with all other intelligent wireless CD actuators within an actuator network.

Abstract: A system for creating three dimensional products is provided. The system has a plurality of subsystems, with each subsystem configured to print one layer of N1 of a plurality of layers making up a three dimensional product, where N1 is greater than 1 and to change the layer being printed on receipt of a change instruction. In the event that one of the subsystems fails, the system configures at least one of the remaining subsystems to synchronously change to print the layer of the failed subsystem without requiring transfer of data relating the respective layer to the said at least one remaining subsystems. When a subsystem is changed to printing a different layer, the system is arranged to reconfigure the subsystem to be capable of printing N2 of the plurality of layers, where N1 and N2 are the same number of layers.

Abstract: A method and an apparatus for identifying mapping of a paper machine by means of a mapping test. The invention comprises forming a mapping model which takes the linear and non-linear shrinkage of a paper web into account. The mapping test result is analyzed to form a non-linear shrinkage profile and a linear mapping error from it. The linear error and the non-linear shrinkage profile thus obtained are used in the mapping model.

Abstract: A method for managing recipes in a semiconductor manufacturing process which includes resolving a recipe to provide a resolved recipe using a configuration for a current context and rendering the recipe to provide a rendered recipe. The rendered recipe corresponds to a format suitable for consumption by an equipment interface of the semiconductor manufacturing process.

Abstract: An improved field maintenance tool is provided. The tool is operable with process communication loops in accordance with a plurality of process industry standard protocols. Aspects of the invention include hardware features such as an infrared port; removable memory module; and an expansion memory module. Additional aspects of the invention include protocol-specific diagnostic methods executable with the improved field maintenance tool.

Abstract: A system that executes a process, the system including a plurality of subsystems, each of which performs a stage of the process, each of the subsystems configured to perform one of a first subset of N1 of the stages, where N1 is greater than 1 and to change the stage of the subset being performed on receipt of a change instruction; wherein, in the event that one of the subsystems fails, at least one of the remaining subsystems synchronously changes to performing the respective stage of the failed subsystem without requiring transfer of data relating the respective stage to the said at least one remaining subsystems, and when a subsystem changes to performing a different stage, the system reconfigures the subsystem to be capable of performing a second subset N2 of the stages where N1 and N2 have the same number of stages.

Abstract: Paper quality is controlled in the production of a paper web, where paper stock is fed from the headbox of the paper machine onto the wire section, whereby the paper stock is formed into a paper web. The headbox flow rate and consistency are measured from the paper stock fed into the headbox, and the water quantities removed on the wire section during the formation of the paper web are measured on the wire section. In the method, a filler distribution model is established, into which data on the wire section geometry, measured headbox flow rate and consistency and on the water quantities removed on the wire section are entered, and the model is used for establishing an estimate of the filler distribution, and the running values of the paper machine are adjusted on the basis of the estimated filler distribution.

Abstract: A system and method for analyzing and controlling various parameters of a paper machine in its operation, in particular in the forming section of the paper machine, including but not limited to characteristics relating to foil blades wherein the activity and drainage characteristics associated with the blades, along with other parameters like sheet activity, sheet and fabric acceleration, sheet and fabric deflection, moisture profiles, and drainage, can be substantially separately and independently analyzed, established, and controlled, and for representing these parameters, settings, characteristics or configurations of the paper machine operation and the sheet being produced thereon in a diagrammatic manner on a computer screen and printouts or any computer readable medium.

Abstract: The energy efficiency of a throughdrying papermaking process is improved by recycling exhaust gas from one or more throughdryers prior to throughdrying to profile the consistency of the web.

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: The present invention solves the quality control problems that exist in manufacturing equipment for sheet form products, that is, although the position correspondence between actuators and measuring points has been measured and switched for every raw material recipe, it takes a lot of time and effort and if the position correspondence shifts during machine operation, the position correspondence must be measured again by measuring step responses. According to the present invention, the position correspondence, interference width, and process gain of a process model are modified so that the deviation between the process model and the measured profile is minimized by inputting the manipulated variable of the actuators to the process model. This position correspondence is also set to a cross direction controller that outputs the manipulated variable.

Abstract: An improved intrinsically safe field maintenance tool is provided. The tool is operable with process communication loops in accordance with a plurality of process industry standard protocols. Aspects of the invention include hardware features such as an infrared port; removable memory module; and an expansion memory module. Additional aspects of the invention include protocol-specific diagnostic methods executable with the improved intrinsically safe field maintenance tool.

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 method and an apparatus for adjusting a chemical dosage of a pulp processing stage. The method comprises measuring a change in a variable in dependence on the chemical dosage and the chemical dosage to be added, and determining a model describing the change in the variable as a function of the chemical dosage. A performance index is determined for the new model to be compared with the performance index of certain previously determined models. The model that produced the best performance index is put to use.

Abstract: A web making machine is monitored to identify at least one cross-machine direction (CD) actuator that is developing local mapping problems. The identified CD actuator and a segment of surrounding actuators are probed to determine a performance curve for the actuator. The center of an insensitivity region of the performance curve is selected as an optimal mapping alignment setting for the identified actuator with the setting for the actuator being updated. Global smoothing may also be accomplished by probing a global smoothness factor to generate a corresponding performance curve that is then similarly used to select an optimal value for the smoothness factor.

Abstract: A process for coordinated control of machine direction MD and cross direction CD actuators in a sheetmaking machine for manufacturing a sheet of material is disclosed. The process involves measuring a plurality of sheet properties at regular intervals to collect sheet measurement data. The sheet measurement data is manipulated to establish a plurality of sheet property measurement arrays, which are then mapped to a common resolution. The common resolution sheet property measurement arrays are concatenated into one larger one-dimensional common resolution measurement array. The common resolution measurement array and an array of past changes in actuator set point are used as inputs to a paper machine process model state observer to generate the estimated current internal state of the sheet manufacturing process. A plurality of future-sheet property target arrays are concatenated into one target array.

Abstract: The present invention provides a method for controlling a process by inputting a deviation between setpoint and process variables to a controller to calculate a controlled/manipulated variable, and then inputting the controlled/manipulated variable to the process, wherein conditions for the process variable to settle within a finite length of time are determined from the final-value theorem, the transfer function of the controller is derived from the conditions, and the value of or change in the controlled/manipulated variable with which to control the process is calculated using the transfer function. With this control method and apparatus for the method, it is possible to allow even a process with a long dead time and a large time constant to settle within a short length of time.

Abstract: The present invention solves the quality control problems that exist in manufacturing equipment for sheet form products, that is, although the position correspondence between actuators and measuring points has been measured and switched for every raw material recipe, it takes a lot of time and effort and if the position correspondence shifts during machine operation, the position correspondence must be measured again by measuring step responses.

Abstract: A method and an apparatus for controlling a moisture profile of a paper web, in which the moisture profile of the paper web prior to drying is measured. The measurement is carried out with a measuring device, which measures a cross-direction profile of the web substantially simultaneously. On the basis of the measurement, the moisture profile of the paper web is controlled prior to drying the paper web.

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: A feed velocity of a control axis and acceleration thereof do not exceed a maximum feed velocity and a maximum acceleration defined in mechanical specifications even if a radial operation is carried out for the purpose of a cut-in or escape operation in a contour describing control. A radial permissible maximum velocity (Vnp) and a radial permissible maximum acceleration (&agr;np) in a contour describing control using a circular interpolation is set separately from a setting value of a maximum feed velocity (Vm) of a control axis and that of a maximum acceleration (&agr;m) thereof set as mechanical specifications, and when a command of the circular interpolation is given, limitations are given to a radial velocity (Vn) and acceleration (&agr;n) so that the radial velocity (Vn) and acceleration (&agr;n) do not exceed the radial permissible maximum velocity (Vnp) and permissible maximum acceleration (&agr;np).

Abstract: The present invention provides a method for controlling a process by calculating a manipulated variable from a deviation between setpoint and control output variables and then using the manipulated variable, wherein the time-series data of the control output variable is subjected to a frequency analysis, the rate of change in the frequency response amplitude of the control output variable in relation to a control gain ratio is determined, and a control gain is adjusted according to the rate of change and the results of the frequency analysis. With this adaptive control method and apparatus for the method, it is possible to automatically set a control gain according to the condition of disturbance. As a result, optimum control can always be achieved and follow-up capability can be improved for such events as a setpoint change.

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: A controller to provide base level fiber orientation control of a paper web. The controller achieves one or more indices that are derived from the online measurements of a fiber orientation sensor of the fiber ratio and the fiber angle. The indices are used for control of the sheet forming processes. The controller may be implemented by a single or multi stage fuzzy controller or the combination of fuzzy controllers with non-fuzzy logic controllers.

Abstract: A method of carrying out a fiber or paper manufacturing process using a plurality of successive method steps is provided. Defined process steps are carried out by means of predefinable chemical and physical sequences and process optimization is performed, wherein at least those characteristic variables of all the individual method steps which influence the target variables of the respective end product of the method in a significant way are registered on-line to control or optimize the overall process. Characteristic variables are formed both on the basis of the starting materials or raw materials and of the chemicals, auxiliaries and energy supplied in the successive method steps as well as of the materials and emissions to be disposed of.

Abstract: Method for determining an intermediary profile of a metal strip between an upstream and a downstream roll stand in a mill train having at least two roll stands is described intermediary profile (pout) and the final profile (pout) of the metal strip downstream from the downstream roll stand are determined using an analytical model with parameters. The final profile is determined using a final profile model. At least one parameter is modified so that the difference between the final profile, determined using an analytical model, and the final profile, determined using the final profile model, is reduced.

Abstract: An improved measuring system used with a process control system provides substantially real time correction of aliasing effects in a system having moving equipment that exhibits periodic parameters while being monitored. The measuring/control system can be used with a rotating equipment process line, such as used in a paper mill, in which a measurement scanner travels in the cross direction of a moving web of material, while that same moving web of material continues to move in a longitudinal direction (the machine direction) transverse to the cross direction. The measuring/control system begins by acquiring data utilizing a time synchronous monitoring system that produces a count matrix and a measurement matrix of readings from the measurement scanner. After a sufficient number of data samples have been acquired, a correction matrix can be built.

Abstract: The CD profile of a web of material being produced is monitored and controlled to update CD control settings on-line so that changes in the operation of a machine manufacturing the web can be corrected before significant profile deviations from a desired CD profile target result. Detected variances in the profile that satisfy a search criteria initiate searches for improved CD control settings. The CD control of the present application recognizes CD actuator mapping misalignments, determines improved CD control settings and applies the improved CD control settings to fine tune a CD controller and thereby improve upon or correct mapping misalignments. The CD control of the present application also recognizes non-smoothness of the setpoints of the CD actuators and controls the smoothness of the setpoints. Recognition and correction of either CD actuator mapping misalignments or CD actuator setpoint smoothness or both can be performed by the automated optimization of the present application.

Abstract: Apparatus and methods controlling a process producing segments of product wherein a destabilizing event of a particular type periodically destabilizes the process, resulting in product or process deviation from a target parameter associated with a number of segments of the product, from segment number 1 to segment number n. The method associates, with respective ones of the n units of product, deviation amounts corresponding to historical deviation amounts for the respective so-numbered units of product in past occurrences of the particular type destabilizing event, and applying to selected ones of the n segments of product correction factors derived from respective associated historical deviation amounts for the respective units of product, thereby making pro-active adjustments to respective ones of the n units of product, upon occurrence of the destabilizing event. Preferred methods include applying the correction factors to each of the n units of product.

Abstract: A process device couples to a process control loop. The process device receives process signals. A memory in the process device contains a nominal parameter value and a rule. Computing circuitry calculates a statistical parameter of the process signal and operates on the statistical parameter and the stored nominal value based upon the stored rule and responsively provides an event output based upon the operation. Output circuitry provides an output in response to the event output. The statistical parameter can be used in statistical process control systems.

Abstract: Streak defects in web structures are characterized by electronically obtaining a plurality of results of a plurality of tests of a web structure, electronically determining a location of and/or a quantification of one or more streak defects based on the plurality of results, and electronically characterizing the streak defect(s) as being static or stochastic based on the plurality of results.

Abstract: The present invention is directed to improving the accuracy with which a stationary array sensor provides cross directional measurements by providing an offset compensation to the stationary array sensor using the output of a scanning sensor associated with the manufacturing process. Exemplary embodiments correlate outputs from the stationary sensor array and the scanning array using a data reconciliation process. For example, a practical, real time data reconciliation of measurements from the scanning sensor and measurements from the stationary array sensor is achieved by computing offsets using a bank of Kalman filters to correlate outputs from the two sensors for each measurement zone, wherein each filter possesses a relatively simple computational structure. The Kalman filters can fuse the outputs from the stationary array sensor and the scanning sensor to track, and compensate, drift of the stationary array sensor.

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 and an apparatus for identifying mapping of a paper machine by means of a mapping test. The invention comprises forming a mapping model which takes the linear and non-linear shrinkage of a paper web into account. The mapping test result is analyzed to form a non-linear shrinkage profile and a linear mapping error from it. The linear error and the non-linear shrinkage profile thus obtained are used in the mapping model.

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 sample collecting device takes samples from the white water drained from the web through the wire in the wire part, at a number of points in the cross direction of the web. An analyzer analyses the samples and forms a retention profile for controlling the paper machine. The device for measurement and regulation of the retention profile comprises means for measurement of the retention profile across the web width from different points of width of the web. The headbox comprises ducts passing to different points of width of the headbox to pass a flow of liquid containing a retention agent in the headbox into connection with the stock flow to regulate the retention profile across the web width. The ducts have valves which are regulated on the basis of the retention profile data for regulating the retention agent into duct flow.

Abstract: Method for influencing relevant quality parameters of a rolling strip, particularly the profile or flatness of the rolling strip, in a roll stand with rolls, by adjusting the crownings of the rolls, i.e., the surface geometry of the rolls in the longitudinal direction of the rolls, wherein the crowning of the rolls is adjusted by an adjustable cooling of the rolls or of their surfaces in longitudinal direction of the rolls. The cooling of the rolls is adjusted by a controller (1) as a function of the actual value (pactual) of the crowning and a predetermined setpoint value (psetpoint) of the crowning.

Abstract: This invention relates to a novel on-line pulp digester control system. More particularly, this invention pertains to a novel control system which employs real time measurements from ion mobility spectrometry to automatically rapidly and continuously determine the physical and chemical characteristics of wood chip feedstock being fed into a pulp digester and thereby maximize process efficiencies, minimize chemical and energy consumption and improve product uniformity.

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: Multiple two-dimensional variation patterns are extracted from two-dimensional sheet measurement data of sheet material being manufactured with the variation patterns being classified to identify the causes of the extracted patterns. The extracted two-dimensional variation patterns are identified with the elements or components of the process or machine which caused the patterns. The machine components which cause the variation patterns can then be adjusted and/or controlled so that the patterns can be reduced or substantially eliminated in sheets of material produced by the machine. In addition to adjustment and/or control of the process or machine producing the sheet of material, the extracted variation patterns can be used as new representations of sheet quality, process or machine quality and the patterns will provide more in-depth understanding for operators of the machine.

Abstract: The present invention provides a method for controlling a process by inputting a deviation between setpoint and process variables to a controller to calculate a controlled/manipulated variable, and then inputting the controlled/manipulated variable to the process, wherein conditions for the process variable to settle within a finite length of time are determined from the final-value theorem, the transfer function of the controller is derived from the conditions, and the value of or change in the controlled/manipulated variable with which to control the process is calculated using the transfer function.

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: A paper machine for making a fiber web includes an approach flow system with a plurality of control modules. Each control module controls one of a plurality of adjustable input parameters. A wet end receives a fiber suspension from the approach flow system, and includes a headbox which discharges a fiber suspension with a known cross sectional profile onto a wire. A press section, forming section and drying section are used to press form and dry the fiber web, respectively. A plurality of sensors are respectively positioned in association with the approach flow system, wet end, press section, forming section and/or drying section. Each sensor is configured to sense a physical characteristic of the fiber suspension or fiber web and provide an output signal indicative thereof. A chemistry process controller is coupled with each sensor and each control module within the approach flow system to define a closed loop control system. The chemistry process controller controls operation of each control module.

Abstract: Regulation method in a paper machine for controlling the variation of the basis weight of a paper web in the machine direction in which the basis weight profile of the web is measured by means of a measurement device and a basis weight regulation system receives a signal of the measurement of the basis weight from the measurement device and generates a regulation signal for controlling the flow of thick stock passed into a short circulation circuit in the paper machine by a basis weight valve and/or a regulation pump. The variation of the basis weight in the machine direction in the paper machine is controlled, besides by the short circulation circuit of regulation, also by a substantially faster second circuit of regulation which comprises one or more actuators for controlling the flow rate of the dilution water flow in the dilution profiling system of the headbox and/or the consistency of the dilution water flow across the entire width of the paper web.

Abstract: A plurality of random probing sequences are used to perturb a corresponding plurality of cross-machine direction (CD) actuators of a web manufacturing machine. The web of sheet material is measured as the CD actuators are perturbed. The global process machine direction (MD) dynamics is estimated and a CD response is estimated for each of the plurality of CD actuators using the plurality of random probing sequences, measurements of the web of sheet material and the estimated global process MD dynamics. The estimated global process MD dynamics and the estimated CD responses form 2D responses for the plurality of CD actuators. To refine the 2D responses, the estimates of global process MD dynamics, and CD responses for each of the plurality of CD actuators are iterated. The actuator dynamics of the plurality of CD actuators may also be estimated and used in the estimates of the global process MD dynamics of the plurality of CD actuators and CD responses for each of the plurality of CD actuators.

Abstract: Method and apparatus for controlling moving paper web during manufacture or subsequent processing, wherein a web elongation profile and a moisture profile are measured. The web elongation is governed by at least two CD moisture actuators, which are situated at different stages in the web manufacturing process or subsequent processing. Means for measuring the web elongation profile and the moisture profile are situated after the CD actuators.

Abstract: A method for controlling the properties of a sheet of material to be manufactured on a sheet making machine using a network of intelligent actuators distributed across and down the length of the paper machine. The method includes the steps of measuring and acquiring properties data about the sheet of material and communicating the measured properties data as the data becomes available to the actuators that control the properties of the sheet of material. A control action for each actuator is calculated and implemented using a control model of each actuator's influence on the properties of the sheet so as to minimize the variation of the measured properties data from a desired target. The control action made at an actuator and the predicted changes in the measured properties based on the control model are also communicated to all the actuators.

Abstract: System and method for producing paper are provided. The system controls formation of wet stock comprising fibers on a moving water permeable wire of a de-watering machine that has a refiner that is subject to a variable load and a headbox having at least one slice, wherein each slice has an aperture through which wet stock is discharged at a stock jet speed onto the wire that is moving at a wire speed. A sheet of wet stock moving a speed develops on the wire.

Abstract: The order of optical conditions and mask conditions necessary required in a photolithography process to be varied is designated so as to minimize the number of recalculations for a transmission cross-coefficient and a Fourier transform of a mask. The conditions are systemically varied and Fourier transforms of the mask and the transmission cross-coefficients are tabulated. With the resultant tables, the parametric analysis for calculating the light intensity distribution is performed.