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Development of a fully integrated it solution for the paper industry based on emerging opto-electronic and sensory technologies (EMERGPAPE)

Final Report Summary - EMERGPAPE (Development of a fully integrated it solution for the paper industry based on emerging opto-electronic and sensory technologies)

Paper industry is a key element of the European industry, which generates an annual turnover in excess of EUR 400 billion, providing direct employment for over 260 000 people and indirect employment for around four million. Paper is produced in hundreds of different grades - each has to meet certain requirements (some paper buyers impose special requirements). For a small to middle size paper mill this means that the product variety could be exhausting and the paper mill bottom line result often depends completely on the efficiency of the adjustment procedure at grade changes. Even if a manual laboratory makes the final examination of paper for delivery, this will not help very much to improve the efficiency of the paper mill. The mill production personnel have to trust in online instruments.

The scientific / technological objectives consist of integrating existing QCS and DCS solutions in a total IT system and developing advanced subsystems to be integrated on it, based on emerging opto-electronic and sensory technologies.

Accordingly, these are the main results achieved in the whole project:

1. Design and development of sensors based on silicon and IR moisture
The developments that are included in this part are:
i. Basis weight sensor with silicon technology to work in very hard environment with high temperature. This new technology uses silicon detectors often combined with scintillators. The long-term stability has been improved in reference to the high-voltage tubes of older generations. The right choice of detector silicon solution together with the right type of scintillator has solved previous calibration problems.
ii. Ash sensor based on iron 55 isotope. Since the physical process is independent of temperature and disturbances it provides the customer with an absolute way of measuring - independent of otherwise very cumbersome calibration work.
iii. Moisture sensor with a completely new design of the detector head for four wavelengths allowing 'same spot' measurement for all wavelengths in real time. It is based on the principle of Infrared (IR) absorption.
iv. Caliper sensor with 'zafire'-based technology to measure the thickness of the paper in very hard environments with high abrasive forces.
v. Gloss sensor based on photo diode arrays exploiting latest opto-electronic devices.

2. Cross directional control
The cross directional control has been combined with the measurement system in the right way. High-frequency electrical induction in has been used in small segments improving control and energy management. The efficiency and the control accuracy have been improved as well. The results are:
- adaptive and machine optimised control algorithm software for PC;
- advanced functions for mapping and self-tuning;
- grade library stores parameters for control tuning and optimisation.

3. QCS systems
The exploitable results are:
- design and development of profile management algorithms that permit interfacing to cross directional control subsystems;
- design and development of SCADA with the aim to control all the measures made;
- development of simulator and development of QCS.
In conclusion, the QCS consists of a robust O-Frame or C-frame with A/C motor, frequency converter and cogged belt drive assuring high CD resolution.

4. DCS / QCS
The fully integrated system has been concluded and tested. This DCS / QCS system remains as the global solution of previous work and as the main result of the project which integrated the rest of the work.