Hello, we are considering utilizing ODS to address the calendar stack barring issue we are experiencing. Has anyone successfully implemented this solution before? Are there any tips or recommendations that could be beneficial? Our stack consists of 5 rolls, with a frequency of interest at approximately 800Hz and a roll turning speed of around 500RPM. I am contemplating adding xyz to each end of the rolls, as well as pivot pins at the arm ends and frame for support. I have created a model and conducted some data simulations. I just need to fine-tune some interpolation calculations before sharing the results. Thank you.
This is the prototype showcasing simulated shape data on a paper machine calender stack made of newsprint. Watch the video "Rolls Apart Movie 2.Avi" to see it in action.
I am eager to review the project files you have. Please feel free to either email them to me or share them on this platform. Thank you!
Planty, I have recently encountered a similar situation with some success. Can you provide more details about the initial issue? Are the rolls smooth or are they overlapping? How are the rolls operated - individually or collectively? What prompted the focus on 800 HZ? Thanks, David.
Hello David, one issue we are facing is the barring of our calendar stack rolls. This axial corrugation on the roll surface can range from 10 to over 90 bars. Several theories exist on the cause, with no definitive resolution yet. One theory compares the mechanism to judders experienced on gravel roads. Our rolls are heavy wall cast iron precision ground, with some being plain and others crown compensating. During normal operation, the rolls are pressed together with varying loading depending on the grade. Only one roll is driven, with the others rotating due to friction. In PM2, the bottom roll is driven by a DC drive via a gearbox and UJ shaft. In PM3, the second roll up is driven by a VF permanent magnet motor directly through UJ driveshaft. The approximate frequency is 800Hz with 80 bars, a diameter of 600mm, and a speed of 1100 meters/min. Thank you.
Before providing a recommendation, I would like to ask some clarifying questions about the setup of the machine to ensure accurate advice. Are both rolls corrugated, and if so, which ones specifically? How many flutes are present, and do they mesh together properly? To streamline the process, please provide a simple 2D sketch. Is the barring issue only noticeable at specific RPM levels and across the entire width of the material? Additionally, could you explain what PM2 and PM3 refer to? Thank you, David.
I've used ODS for similar issues in the past and it worked quite well for us. Besides ensuring that everything is accurately reassembled after fixing, one thing I found important is to regularly monitor your system even after implementing ODS to avoid future anomalies. As for adding xyz to each end of the rolls, it seems like a sound idea but make sure to account for the additional weight and how it might affect the overall performance. Also, don't overlook the importance of the interpolation calculations; they are the cornerstone in predicting the system’s response. Looking forward to seeing your results and contributing further. Good luck!
It sounds like you're on the right track with your modeling and simulations! From my experience, adding xyz to the ends can definitely help with stability and reduce any lateral movement, especially at high frequencies. Make sure to thoroughly test the pivot pins for wear and ensure they're compatible with the load dynamics of your setup—sometimes small adjustments in their placement can make a big difference. Once you’ve finalized the interpolation calculations, I’d love to see your results! Sharing those insights could really help others facing similar challenges. Good luck!
It sounds like you're on the right track with your implementation of ODS! Adding xyz to the ends of the rolls could definitely improve stability, and pivot pins might help with alignment and reduce wear over time. If you haven't already, it could be worth checking out how others have approached the interpolation calculations—there are some solid resources and forums that dive deep into that specific issue. Looking forward to seeing your simulation results; it sounds like you’ve put a lot of thought into your model!
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Answer: 1. What is an Optical Deflection System (ODS) and how does it help with addressing calendar stack barring issues? - An Optical Deflection System (ODS) is a technology used to monitor and control the alignment and deflection of rolls in a paper machine calendar stack. It helps to prevent barring issues by detecting and adjusting roll alignment in real-time.
Answer: - It would be beneficial to seek feedback from industry professionals or consult with experts who have experience implementing ODS solutions for calendar stacks to understand best practices and potential challenges.
Answer: - Consider adding xyz components to each end of the rolls, utilizing pivot pins at the arm ends and frame for support, and conducting data simulations to fine-tune interpolation calculations. Collaborating with engineers or ODS specialists can provide additional insights and recommendations tailored to your specific setup.
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