Real time regulation of yankee dryer coating based on predicted natural coating transfer
A method is provided for decision support in regulating an adhesive coating applied to Yankee dryers. Online sensors are configured to continuously measure stock characteristics, and additional sensors provide actual stock flow rate and machine speed. A controller predicts potential natural coating application from a fibrous sheet generated from the stock to the Yankee dryer surface, substantially in real time, based on the measured characteristics and sensed actual machine values. An output signal may be provided to a display unit, wherein an optimal adhesive coating feed rate may be determined and displayed for operator decision support. The controller may in an automatic mode be configured to regulate the adhesive coating feed rate based on a comparison of one or more determined optimal values associated with respective actual values. The method may include identifying fiber source changes in real time, and predicting a natural coating potential based partly on predetermined correlations.
1. An adhesive coating control system for Yankee dryers, the adhesive coating control system comprising:
an adhesive coating application unit configured to apply an adhesive coating to a surface of the Yankee dryer, the adhesive coating comprising an adhesive aid and a release aid;
one or more online sensors configured to continuously measure a plurality of characteristics corresponding to a stock comprising one or more fiber sources from which a fibrous sheet is generated and transferred to engage the surface of the Yankee dryer, said one or more online sensors comprising a turbidity sensor, a conductivity sensor and a pH sensor;
said one or more online sensors configured to continuously sense actual machine control values comprising a stock flow rate and a machine speed; and
a controller configured to
generate a value for total suspended solids associated with the stock flow based on predetermined correlations with at least a measured turbidity value;
generate a value for total dissolved solids associated with the stock flow based on predetermined correlations with at least a measured conductivity value;
predict a natural coating potential to be applied from the sheet to the surface of the Yankee dryer, substantially in real time, based at least in part on the measured characteristics and the sensed actual machine control values,
wherein the natural coating potential to be applied from the one or more fiber sources to the surface of the Yankee dryer, substantially in real time, is based at least in part on the generated values for total suspended solids and total dissolved solids; and
generate an output signal corresponding at least in part to the predicted natural coating potential.
2. The adhesive coating control system of claim 1 , wherein the controller is further configured to determine an optimal adhesive coating feed rate for projection upon the surface of the Yankee dryer, based at least in part on the predicted natural coating potential, and
wherein the generated output signal corresponds to the optimal adhesive coating feed rate.
3. The adhesive coating control system of claim 2 , further comprising a display unit configured to receive the generated output signal and to display the optimal adhesive coating feed rate on the display unit.
4. The adhesive coating control system of claim 2 , wherein the controller is configured to automatically control the adhesive coating feed rate based on a comparison of the determined optimal value with an actual adhesive coating feed rate.
5. The adhesive coating control system of claim 4 , wherein the controller is configured to identify changes from a first group of one or more fiber sources to a second group of one or more fiber sources, and to predict a natural coating potential to be applied from the second fiber source to a surface of the Yankee dryer, substantially in real time, based at least in part on predetermined correlations for the second group of one or more fiber sources.
6. The adhesive coating control system of claim 5 , wherein the first and second groups of one or more fiber sources comprise respective first and second ratios of the same one or more combined fiber sources,
the system further comprising a data storage functionally linked to the controller, the data storage comprising known or extrapolated collective correlations for the first and second ratios of fiber sources with respect to the measured operating characteristics.