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Paper machine applications and controls

Improve speed and accuracy of cross- and machine-direction variables


ABB´s Paper Machine Control Software uses model-based algorithms to improve the speed and accuracy of cross- and machine-direction variables, resulting in greater product uniformity, minimized process upsets, and efficient raw material usage. ABB Control Software solutions are part of a complete, integrated quality control system. 

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Multivariable CD (MCD) control
Cross direction controls
Machine direction controls
Optimizing controls
Multivariable CD (MCD) Control is built upon ABB’s many years of technology leadership in the area of CD controls. The MCD application simultaneously optimizes and balances multiple paper quality CD profiles, while coordinating the contributions of multiple sets of CD actuators within their operational limits.

Some examples include:
  • Minimizing energy consumption when the increased application of an actuator carries a penalty of increased energy demand; for example, the coordination of a rewet shower and a steambox can result in reducing the consumption of both steam and water.
  • Achieving the optimum balance between competing quality objectives; for example, the application of both slice actuators and dilution actuators on a machine to balance the objectives of a uniform weight profile and a uniform fiber orientation profile.
  • Reducing expensive coating additives (used to improve gloss) and improve reel building by optimizing MD and CD gloss, moisture and caliper, simultaneously on a supercalender.
  • Faster recovery from process upsets by reducing the machine-direction variation that results from independent control of multiple actuator sets.
    MCD achieves these goals by coordinating multiple sets of CD actuators used for controlling multiple profiles of sheet properties. It delivers the most effective results by empowering operators to set the best balance among the objectives using a simple and intuitive operator interface.

Data


  • MCD control can be applied to either QCS800xA or QCS450 with QCS LAN, and the 800xA (QC Aspects) user environment.
  • The user interfaces for MCD control are fully integrated with the ABB 800xA Aspect System.
  • MCD control is implemented in a separate dedicated server called MCD Connectivity Server. The specifications for this server are the same as for an 800xA Connectivity Server.
  • Each MCD Control supports up to five input profiles and five output arrays. One large MCD application can also be broken down in a number of smaller MCD controllers for practical purposes. For example, one 5x5 MCD product license can be operated as one 2x2 and one 3x3 MCD controllers.
  • To ensure quick delivery and startup, ABB offers a full range of installation and commissioning services. These include outlining customer specifications, installation support, ensuring optimal performance, and expert project management. 
ABB's cross-direction controls provide superior CD control in all types of mills. These controls use time-based measurements to take faster control actions for more aggressive and effective cross-directional control. A completely open solution, ABB CD controls are completely upgradeable and are designed to be integrated into your mill's IT infrastructure.

ABB's array of CD controls gives you ultimate control over the quality and uniformity of your product - and ultimately ensures customer satisfaction now and into the future. 

Cross-Direction Controls include:
  • Basis Weight Controls
  • Moisture Controls
  • Smart Caliper Controls
  • Coat Weight Controls
  • Finishing Controls
  • LV CD Controls

Data


Weight Control
ABB Weight Control calculates control actions for slice actuators, such as ABB Linear Steppers, to optimize the weight profile. Advanced control strategies work together with algorithms to minimize weight variations under all operating conditions. 

Moisture Controls
ABB Moisture Control calculates control actions for CD actuators, including the full range of ABB Moisture Actuators, to optimize the moisture profile. By combining advanced control strategies and high performance algorithms, moisture variations are minimized, no matter what the operating conditions.

Caliper Control
ABB Caliper Control optimizes the caliper profile using advanced control actions for calendar stack actuators such as the ABB Smart Calender Profiler. By utilizing both advanced control strategies and high-performance algorithms, ABB Caliper Control minimizes caliper variations under any operating conditions. 

Coat Weight Controls
ABB Coat Weight Controls improve the appearance and printing characteristics of your product, while enhancing runnability in printing and converting operations. Accurate and consistent control of coating applications enables papermakers to reduce rejects and downgrades while conserving raw materials and energy. 

This control ensures an optimum, smooth coat weight profile by precisely positioning the coater blade. This control works in concert with ABB's measurements and profilers to reduce variation and enhance the overall quality of your finished product. 

Finishing Controls
ABB finishing control algorithms simultaneously and safely minimize cross-direction variability by adjusting the setpoints of actuators such as the ABB Finishing Profiler. Finishing controls also maximize production and eliminate sheet delamination or blackening, and individual steam flows compensate for changes in speed, production, stack temperature and other stack parameters. 

LV CD Control
ABB LV CD Control automatically optimizes control performance without manual intervention and interruption of the CD control system. It provides your operators with hands-free automation and long-term persistent, optimal performance. This advanced feature enhances ABB's CD Control system by providing superior results, increasing operating efficiency and providing an excellent return on your investment. 

These controls use model-based algorithms to improve the speed and accuracy of machine direction variables, resulting in greater product uniformity, minimized process upsets, and efficient raw material usage. ABB's machine-direction controls are part of a complete, integrated quality control solution.

ABB controls are the fastest and most accurate in the industry using an advanced, time-based Kalman filtering technique for process scanning measurement. This technique extracts precise MD information from scanning online sensors housed in ABB's scanner. Since ABB scanners never leave the sheet, ABB MD controls receive accurate and continuous online product information for better overall performance.

Machine Direction Controls include:

  • Weight Controls
  • Moisture Controls
  • Ash Controls
  • Opacity Controls
  • Coat Weight Controls
  • Automatic Grade Controls
  • Color Controls
  • Automatic Shade Change Controls

Data


Weight Control
Weight Control calculates control actions for slice actuators, such as ABB Linear Steppers, to optimize the weight profile. Advanced control strategies work together with algorithms to minimize weight variations under all operating conditions. 

Moisture Controls
ABB Moisture Control calculates control actions for CD actuators, including the full range of ABB Moisture Actuators, to optimize the moisture profile. By combining advanced control strategies and high performance algorithms, moisture variations are minimized, no matter what the operating conditions.

Ash Control
ABB Ash Control ensures a better quality finished product by enhancing customer machine-direction control. Based on non-continuous measurements, ABB Ash Control reduces ash variability by up to 80%, and enhances performance up to 50%. This allows optimum product quality.

Opacity Control
ABB Opacity Controls enhance the opacity quality in the printing characteristics of your product. This level of accuracy and consistency in your opacity control enables papermakers to minimize the number of rejects and downgrades while conserving raw materials and energy, ensuring an overall quality product.

Coat Weight Control
ABB Coat Weight Controls improve the appearance and printing characteristics of your product, while enhancing runnability in printing and converting operations. Accurate and consistent control of coating applications enables papermakers to reduce rejects and downgrades while conserving raw materials and energy. 

Automatic Grade Change Control
Fast Grade Change eliminates short-term disturbances in sheet moisture, estimates future steam usage based on grade data and determines the nonlinear relationship between paper weight and machine speed, in an effort to eliminate non-modeled process upsets.

Color Controls
These controls include Multivariable Color Control, which manages wet-end dye addition to minimize the difference between the target and measured shade; Dual-Sided Color Control, which coordinates dye additions between top and bottom color control; and Fluorescent Whiteness Control, which maintains fluorescent whitener targets. 

Automatic Shade Change Control
Fast Shade Change fully uses the capability of a coloring process to automate your shade change operation. This control achieves a consistent and optimal shade change operation while boosting and coordinating shade change responses. It also minimizes transition time and reduces colored broke. 

The industry-leading Smart Color Sensor and Smart Color Control package provides papermakers with the most sophisticated color system available to reduce start-up and shade change times, optimize dye usage, minimize rejects, and improve product uniformity. 

ABB Optimizing Controls optimize the process, resulting in fewer sheet breaks, improved product uniformity, faster grade changes and higher production.

Smart Optimizing Controls include:

  • HeadBox Controls
  • Coordinated Speed Change Control
  • Speed Optimization Controls
  • Auto grade Change Controls
  • Stock and Ply Loading
  • Consistency Compensation
  • Crepe Ratio
  • Bulk Compensation
  • Yankee Hood Controls

Data


Headbox Control
Headbox Control can be applied to a wide range of headbox types and wet end process configurations. Its unique design allows users to easily modify headbox control strategies as they adjust the process, without requiring expensive software upgrades. Operators can enter the desired targets in familiar units such as jet-to-wire ratio, rush/drag ratio, rush/drag percent, or rush/drag differences 

Coordinated Speed Change Control
This control features an operator interface that provides information about all the supervisory and regulatory loops, including the status of the individual actuator ramps. By making this control easy to use, utilization will be higher than with conventional systems, leading to fewer sheet breaks, less downtime and an overall increase in average speed and production. 

Speed Optimization Control
This feature builds upon all the advanced capabilities of the Coordinated Speed Change package. Instead of merely calculating the maximum feasible speed for the given conditions, the system will continuously increase the machine speed until a constraint is reached.

Automatic Grade Change Control
The Automatic Grade Change Control package minimizes lost profit potential by making grade changes fast and precise without operator intervention. This package provides a predictive setup feature, which models the desired grade change before it is attempted. 

Stock and Ply Loading
Stock and Ply Loading provides distribution of stock flow feedback and feedforward corrections to multiple stock flow actuators feeding one or more formers or headboxes, allowing for individual stock types and status. Also provides feedforward control to the stock flows for redistribution of ply weights, entered as basis targets or percentages of total dry fiber flow. The optional Stock Initialization module allows coordinated ramping of individual stock flows to new targets based on desired speed and basis weight targets, typically used when starting up or performing a manual grade change.

Consistency Compensation
ABB's Consistency Compensation allows operators of the Ply Loading and Multiple Dry Stock Flow Control features increased flexibility in determining the actual consistency measurement. Operators can choose from using the actual instrument reading, the reading plus a calculated bias, or a constant reference consistency value determined by the lab. The ABB Consistency Compensation feature also allows modes, bias values, and reference values to be changed online.

Crepe Ratio Control
Crepe Ratio Control adjusts the yankee-to-reel speed ratio to maintain the desired amount of crepe. This results in improved bulk, caliper, and softness of the sheet. 

Bulk Compensation
This allows you to adjust the crepe ratio target based on operator entered bulk variation trajectory to improve reel building.

Yankee/Hood Control
Dynamic Yankee/Hood Control maximizes speed-of-response to moisture variations while maintaining the desired drying balance between the hood temperature and yankee steam pressure.

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