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
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.
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.
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.
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.
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.