Vibration sensors can be used in paper making systems and methods to determine various aspects of the paper making operation. Vibration sensors, for example, positioned on cleaning blades configured to clean various deposits off of rollers in a paper making system can output vibration data that can be indicative of the vibration of the blade. The vibration data can be analyzed in order to characterize the cause of the vibration and/or the location of the vibration within a paper making system. If the vibration data satisfies a predetermined condition, a corrective action can be initiated. Different corrective actions can be initiated based on the characterized cause and/or location of the vibration in order to effectively improve the operation of the system while minimizing costly system shut downs and major maintenance.

Integration of clothing performance into production planning, scheduling and execution of papermaking machines yields paper products with consistent acceptable quality with minimum downtime and inventory. Linking the selection and operation of papermaking machines to their respective clothing performances improves clothing life cycle. Selected operating parameters of a papermaking machine and historical clothing data are indicative of the machine's clothing condition. Order scheduling engine identifies manufacturing times for particular grades of product and generates order blocks. Papermaking machines are assigned to execute specific order blocks with provision that each machine completes execution of the assigned orders without any anticipated breakage of the wire or felts.

A controller reference trajectory design technique to enable high-performing automatic grade change performed by a model predictive control (MPC). Techniques include: (1) automatic determination of appropriate process output reference trajectory delays to enable optimum coordination of process input movements; (2) providing the entire planning process output reference trajectory ramp at the start of the grade change instead of just incrementally as the grade change progresses, again enabling movement of the process inputs to drive process outputs along the planned future path instead of just towards the current target; and (3) use of the process input forced ramping to allow linear ramping of process inputs with optimal coordination of other process input movements to keep all process outputs following the desired trajectories. The technical benefits are faster and higher performing grade changes. In addition, the use of this technology allows easier setup and maintenance of the automatic grade change package.

A method of controlling a paper product converting line. The method includes unwinding a paper web from a parent roll on a converting line, the converting line having a plurality of operational parameters, the paper web including a plurality of sections in a sequence, and a plurality of marks, each mark being associated with an action score, at least one action score having an action value, reading at least one of the marks, obtaining the action score associated with a second one of the marks, the second of the marks being a next mark with an action value after the one read mark, calculating a distance between the at least one read mark and the second one, changing at least one operational parameter of the converting line based upon the action score, and converting the paper web into a paper product.

A method of producing a paper product by forming a paper web on a paper machine, the web including a plurality of sections, analyzing the web, marking the web, winding the web to form a parent roll after the web has been inspected and marked, assigning an action score to each section of the web, at least one action score having an action value, unwinding a web from a parent roll, reading at least one of a plurality of marks with a mark reading unit, obtaining the action score associated with a second one of the marks, calculating a distance between a mark read by the reading unit and the second one of the marks, changing at least one operational parameter of a converting line based upon the action score of the second of the marks when the distance is less than a threshold, and converting the paper web.

Controlling a multiple-array, sheetmaking cross-directional process with a multivariable model predictive controller (MPC) employs a cost function incorporating a prediction horizon. The MPC provides a measurement profile target reference trajectory over the prediction horizon of the MPC cost function. Improved CD-MPC performance is achieved by employing a measurement profile target reference trajectory over the prediction horizon in the MPC cost function. A series of target profiles creates a reference trajectory to bring the cross-direction measurements smoothly from their current profile to the final target. By carefully designing the reference trajectory, the CD-MPC exhibits a good measurement response without aggressive control action. The current measurement target profile can be filtered through a first order plus deadtime process at each controller update and repeating the filter operation once for each step of the MPC prediction horizon generates a full reference trajectory for the profile.

A system for producing a paper product. The system includes a paper machine, an analysis tool, and a converting line. The paper machine forms a paper web having a plurality of sections, inspects the paper web to identify web properties, and marks the paper web with a plurality of marks. The analysis tool assigns action scores to each section of the paper web based upon the identified properties that section of the paper web. The converting line reads at least one of the plurality of marks on the paper web, obtains the action score associated with a second one of the plurality of marks, calculates a distance between the at least one mark read by the reading unit and the second one of the plurality of marks, and changes at least one operational parameter of the converting line when the calculated distance is less than a threshold.

A method includes generating a model associated with cross-directional fiber orientation of a web, which includes identifying spatial frequency characteristics of a fiber orientation (FO) process. The method also includes providing the model for control of the FO process. Generating the model could include performing a spatial impulse test of the FO process, and long wavelength responses of the FO process can be identified by performing a spatial long wavelength test of the FO process or by retrieving information from a historical database. Actuator edge padding can be applied to the model in order to generate a controller model. A controller can be used to control the process based on the controller model. At least one parameter of the controller model can be dynamically adjusted during operation of the controller. The controller can change average fiber orientation angle profiles and twist profiles by only adjusting slice lip actuators in a headbox.

A system, method, and/or apparatus is provided for establishing targets or setpoints of speed parameters for the operation of a papermaking machine that is based on the square point of the paper sheet being produced. The square point of the paper sheet is determined in response to one or more speed parameters and associated one or more fiber distribution parameters for the paper sheet that are measured a plurality of times during the papermaking process and analyzed to determine the square point based on the measurements.

To provide a sheet former capable of suitably regulating the thickness of a sheet forming body in a width direction in response to factors changing with time. A sheet former includes at least one vessel which stores slurry as a raw material, a wire cylinder immersed in the slurry inside the vessel and making sheets from solid components in the slurry while being rotated, and a sheet-forming amount regulator which regulates an amount of the solid components for making sheets by the wire cylinder in a width direction in accordance with a thickness of a sheet forming body in the approximately width direction formed for making sheets by the wire cylinder.