Realization of Rewinder With a Reduced Number of Sensors

When adequately maintained, the mechanical system of rewinders and similar machines in paper industry may have a significantly longer service life than its electrical and control systems. Over the lifetime of the facility, a rewinder may experience several major maintenance cycles, and these generally include significant upgrades to the electrical drive and control system. These upgrades present an opportunity to modify the design of the control system to eliminate some of the sensors or to provide signal redundancy by using state estimation. During such major reconstruction of a paper-board rewinder, it was noticed that the shipping-roll radius and the web tension force can be accurately estimated from the measurements available within the drive's control system. This paper presents the implementation of the two estimators on a commercial production rewinder. Test results from the equipment in service show that the measured signals can be supplemented with the estimated ones to provide an alternative in the event of sensor malfunction or to enable trending of accuracy of calibration. Both applications have an entitlement to reduce the downtime of the rewinder, as the replacement of the faulted sensor can be scheduled for the next planned idle period of the machine.