SMARTRoll
Over two decades ago, I invented, developed, and field tested the world’s first Smart Roll for the paper industry. This system measures the pressure profile all the way across the sheet in real time during production. The paper makers can see if one end is loaded more heavily than the other or if the ends are loaded more heavily than the center. More recently, I wrote a software module that estimates the potential energy savings for when we correct these profiles. These instrumented coatings should provide a huge step forward towards Industry 4.0 (IIoT) and future digital twins.
Initially, we used optical fiber sensors. Later I developed a plan for more robust sensors and handed the project to a highly capable team who has shipped over 850 units worldwide. The teams at Stowe Woodward, Xerium, and Andritz deserve the credit, and the picture shown is for their new system.
The system uses embedded sensors within the roll coatings that are connected to a wireless link that connects to a base unit. A significant amount of signal processing is performed on the embedded controller that is mounted to the face of the rotating roll.
“Machine Optimization Through Uniform Moisture Profiles,” TAPPI PaperCon 2015 Conference, with Alex Harvey, Glen Harvey, and Eric Gustafson.
5,562,027 Dynamic nip pressure and temperature sensing system
7,392,715; Wireless sensors in roll covers
7,581,456; Wireless sensors in roll covers
7,963,180; Wireless sensors in roll covers
5,699,729 Roll having means for determining pressure distribution (see corrected inventorship)