March 2003 Abstracts

Latest news about automation system from foreign country's references
Kiyoshi Dekula
Metso Automation K.K., Paper Automation Div.

 When we started to produce "Paper" with machine. It’s control is basically manual control or hand made ones. But as everybody can see, control/autiomation system is totally different nowadays related with Paper Machine’s histories.
 As everybody knows that Automation System defined DCS, QCS and MCS have so long history since more than 40 years ago. In that period, there have been many progresses, evolution and devlopment. Also Hardwares and Softwares are changing.
 Based on those histories, I would like to report the latest Automation System defined by DCS, QCS and MCS based on acrtual references.
 Before introducing those refernces, I would like to express my deel appreciation for the people who advised, informed and helped me to make this report.

New Trials Surrounding DCS
Takekazu Takayama
Oji Paper Co., Ltd., Fuji Mill

 In October 2001, an innovative board machine named N-2 started up in our Oji Paper Fuji mill. The design of control system was discussed repeatedly so as to handle this machine very comprehensively.
 During its 25 years history, DCS has grown up and well matured. Nowadays, it seems that there left only nominal differences between one vender and another. On the other hand, many intelligent sensor systems and information systems have also been developed around DCS. From the viewpoint of plant operation, all the systems should be combined and unified to serve operators like a single "seamless system". We think that DCS is a nucleus in such system.
 This paper introduces our basic idea of the control system of N-2. Whole the scope of instrumentation system as well as some application of IT is also discussed.

A New Information System for Paper Roll Handling
Takahiro Shigematsu
Kushiro Mill, Nippon Paper Industries Co., Ltd.

 This paper describes the modifications incorporated in the information system for the existing paper roll handling process. In order to share production, marketing and inventory information between the headquarters and each domestic mill, the paper roll tracking system was replaced in Kushiro Mill. Since the previous system lacked memory, communication bandwidth and expansion capacity, new PC system was introduced. It has successfully consolidated various products information into single database. The next phase is to expand this service to each department by constructing company-wide LAN, and promotes the new system capability to the headquarters.

The Performance of Sheet-break Monitoring System
Takaharu Yokota
Niigata Mill, Hokuetu Paper Industries Co., Ltd.

 As a paper machines are larger and faster; even short-time sheet break causes an enormous loss. When a sheet break occurs, it repeats frequently for the same reason. Therefore, a prompt identification of break reasons in early stage and working out countermeasures are of great importance in improving production efficiency.
 In this report, a subject is sheet-break monitoring system. A sheet-break monitoring system, which is an equipment identifying a breaking stage and reasons by observation camera, is expected to reduce the sheet break.
 Hokuetsu Paper, Niigata mill adopts three types of the sheet-break monitoring systems. This report focuses on comparing functions and performances of each system.

Integration of Control Rooms in the Power Plant and Kraft Pulp Plant by DCS
Akitosi Konno
Daishowa Paper Mfg. Co., Ltd.

 To improve the productivity and to reduce the cost, Daishowa Iwanuma Mill integrated contorol rooms in power plant and Kraft pulp plant to the central control room respectively by introducing DCS. The project was successfully completed in a short period the mill can spare.
 This paper describes the contol system configurations and the change of operations in both plants.

The Newest Technology of Detecting Streak and Line Fault-Algorithm of NASP-Multi 500 System-
Masayoshi Nakata
Techonology Development, Vision System Business DIV, OMRON Corporation

 The measure that detects the streak fault in our company becomes about ten years. As a trend of those days to the next of the Spot-fault inspection system, we developed technology and products, and we developed the Streak-fault inspection system that combined analog-processing technology and special detection algorithm. In the performance of detecting the streak fault, the improvement was continuously achieved up to now. The feature of the streak fault is long, slender, linear, and that the defective signal is a minute level. So, it is beginning of the measure that we adopted the camera and detection algorithm, which is different from these of detecting the spot fault.
 At present, using image-processing technology, we develop the detection algorithm that suited the amount of the features of the streak fault, and have released the products whose detection performance improved. Furthermore, the detection algorithm has evolved by the needs of detecting the scratch fault, the line fault, and the wrinkles fault.
 Thus, it is sure that sensor technology has contributed to the base somewhat to the demand or needs of the paper manufacture industry till present.

Advanced Technology for Streak Detection by Full-digital processing
Suzuki Satoshi
COGNEX K.K., Surface Inspection System Division

 COGNEX developed a new web inspection system, "SmatView ICN". This system has the following advanced technologies for streak detection. (1) 12 bit digitalization (4096 gray levels) and full-digital processing, (2) Superior streak detection algorithm, (3) Reliable Defect Identification by over 40 defect features. It allows you to detect scratch (short streak) and moving streak.

The Newly Developed Method Applied for Streak Defects Detection
Minoru Fujita
Vision Systems Engineering, System Components Dept.
Toshiba IT-Solutions Corporation

 The combination of several defect detection channels which sensitivity are optimized for different width and length of defects is verified. The proposed width-length defect model enables us to fully understand the characteristics of the capability of defect detection channels. The image analysis results show that the detection channels can enhance a streak defect.
 Another important feature of defect detection is connectivity analysis, unification and defect classification.
 The newly developed web inspection system, M9000 utilizing these methods provides various aspects of streak defect information to assist understanding of the manufacturing process.

The Latest Technology of Detecting Streaky Flaws
Yoshinobu Sugino
Research and Development Dept., Futec Inc.
As has been the case, many requirements are made to the inspection system.

 Even more diversified requirements are seen because of its possible versatile applications. There are some industries in which , a short while back, it was thought to be hard to apply automatic inspection, but now because of more increased competition, some kind of automatic inspection would be a most effective means to be apart from the other competitors. The competition is not only among domestic but world-wide and is by all means intensifying.
 As to the overall performance, there are two critical points in focus.
 The first is how to most effectively utilize the flaw data for the improvement of product quality and production yield. The inspection system was once regarded as a simple sensor, but the times have changed now and is required to provide an opportunity to becoming more competitive position in the market. The collected data is thought to be even more valuable if it were shared among operators via network. It would be further processed , like SQC analysis , to bring in more benefit.
 The second is , needless to say, the sensitivity itself. Market is going to require defects detected which were used to be not required before. The more sensitive means , more data is gathered.
 It is crucial to make the system more efficient in handling vast flaw data along with improved sensitivity. On top, how to most effectively share that flaw data internally in order to achieve the better result.
 Here I describe briefly about how we can achieve the afore-mentioned balanced performance.

Introduction of Defect Inspection Systems and Their Technology
Junichi Harada
Mitsubishi Rayon Co., Ltd.

 Mitsubishi Rayon has been developing and offering the optical inspection systems using the line CCD cameras, about 10 years. These are being used for the manufacturing processes of the optical-film, the steel or non-steel. In these fields, there is a demand to detect the defects such as uneven surfaces and streaks, which can be finally confirmed with the human eyes. Therefore, we have developed the special image-processing technology to detect the defects accurately. We introduce our image processing technology for the paper manufacturing process.

Pressure Loss Calculation Software-2002
Shigeru Saito
KITZ Corporation, Sales Engineering Dept.

 We would like to introduce you new pressure loss calculation software for piping system, which is the renewed and updated version from one of last year and easier to use. We would like to explain to you mainly additional features from the previous one here, not the same features. The previous software calculated fluid pressure loss based upon virtual installation of valves and elbows on a fixed piping system.
 There had been some differences from the actual piping system with this way, which sometimes created difficulties in handling.
 The new software was programmed to solve this problem. You can design plane and lateral drawings automatically by selecting piping materials from the menu and calculate pressure loss by setting fluid conditions at the piping system.
 Thus, there is no restriction for number of piping system patterns. Users can specify as many piping system patterns as possible.
 Also you can check pressure losses at the specific locations by clicking mouse at any points of the piping system. You can print out the whole piping system to verify it clearly. We hope that this new software will be of great help to you.

Automatic Friction Coefficient Testing Machine
Hirofumi Sagawa
Sagawa Seisakujo Co, Inc.

 Automatic Friction Coefficient Testing Machine adapted to ISO 15359 is composed of a main body and a personal computer instrument apparatus.
 Installation of samples is more convenient by utilizing weight with clamp mechanism. Automatic measurement will eliminate individual errors. It is highly reproducible.

New Visual Inspection System of Paper & Film-Build "Ultra-high-resolution Visual-Inspection System" by TECHNOS Neuro-Vision5000K-
Yoshiro Yamada

 The Paper Industry is known of very fast work speed as well as the cold mill in the Steel Industry. The mass production of polarizing film and diffusion film which will be the materials of the display device is progressing by using the high speed production technology. TECHNOS holds a world patent of anew technology systems. And we again developed a visual automatic inspection system which has the best accuracy in the world. This new system is buildup a function called Mini-Movement of human eyes. Our new system is able to find the minutest defect to a low-contrast spot. 10000m every minute in the high speed line by only one camera. This new system has a accuracy of 1000 times of a former CCD line camera (equal of 4000 pixels). As we developed this marvelous system 5000K, we can deliver within 48 hours upon receipt of an order and are able to install within 3 hours.

HBS pulping (5) -Chemical Structure and Properties of HBS Lignin-
Hideaki Nagaoka
Nippon Paper Chemicals Co., Ltd.
Yoshihiro Sano
Laboratory of Wood Chemistry, Graduate School of Agriculture, Hokkaido University

 Chips of fir (T) (A. Sachalinensis Mast.) as softwood and birch (B)(B. platyphylla var. japonica Hara) as hardwood were pulped by HBS pulping process with fresh HBS of 1,4-butanediol and its recovered solvents (RHBS-1 and 2) prepared from spent liquors. HBS lignins (HL), that is, BL-1-3 and TL-1-3 were isolated in yields of 90-150% based of chips from the spent liquors of birch and fir, respectively. Furthermore, HL was fractionated into ether insolubles (IS) and solubles (S) to analyze. Each the lignin was subjected to elemental, spectral spectrographic (UV and NMR), thermomechanical, gel permeation chromatographic analyses, determination of
 hydroxyl groups, and also nitrobenzene oxidation.

Keywords: Pulping with high boiling solvent, softwood, hardwood, lignin, chemical structure, softening point, average molecular weight

Manufacturing of Magnetic Papermaking Fibers and Paper ( PartT)-Preparation of Magnetite-Loaded Pulps at their Lumen by in situ Synthesis-
Katsuhisa Fujiwara and Masaaki Morikawa
Paper Industrial Research Institute of Ehime Prefecture

 Magnetic pulps loaded with magnetite (Fe3O4) in the pulp lumen were prepared by in situ synthesis. The synthetic conditions for forming magnetite includes the following three steps: a) dispersion of pulp in a ferrous salt solution, b) addition of an alkali to the ferrous salt, and c) air-bubbling. The main factors influencing the magnetite formation were the added amount of the alkali to the ferrous salt solution containing pulp, i.e. the pH value, and the successive reaction temperature to form magnetite. Magnetite was formed in the temperature range from 50 to 90°C, when the added amount of the alkali was nearly equivalent to that of the ferrous salt present in the pulp suspension. The alkaline addition level for magnetite formation was expanded in the range from 0.6 to 4.0 equivalent to that of the ferrous salt at the reaction temperature of more than 90°C. The magnetite formed in the pulp lumen was observed by means of a scanning electron microscope. X-ray diffraction analysis of the magnetite formed in the pulp lumen showed that it had a spinel-type crystal structure with cubic system, because its lattice planes [311], [440] and [220] were detected at diffraction angles 2 of 35.4, 62.6 and 30.1°, respectively. The particle size of the magnetite was 0.3m on average, and distributed in the range from 0.2 to 0.4m. The magnetite contents in the pulp were 23-33% (based on dry weight of the loaded pulps). The magnetite-loaded pulp with 30.4% magnetite content had saturation magnetization and remanent magnetization values of 16.3 and 3.6 emu/g of magnetite-loaded pulp, respectively, and had a coercive force of 240 Oe.

Keywords: Magnetic paper making pulp, Magnetite-loaded pulp, Pulp lumen, in situ synthesis, Lumen-loading