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2011 March JAPAN TAPPI JOURNAL


Vol.65, No.3 Abstracts


A Practical Total PID Tuning Approach for Chemical Process

Kenzo Fujii
Idemitsu Kosan Co., Ltd.

  This paper presents a useful technology of total PID tuning approach for a large scale plant. The proposed method has two stages. First stage is skill training to operator, and shared part of tuning. Second stage is tuned by engineers using performance based tuning. We were able to obtain actual plant stabilization in a short period by using this approach.


System for Real-time Display Physical Unit of Product

Masamitsu Aoki
Tokai Mill, Oji Specialty Paper Co., Ltd.

  Specialty paper industry in the recent situation, in addition to rising raw material costs, to meet customer demand for small, little more respect, and the production of various kinds.
  So we have to do and how efficient production has become an important issue.
Recently, real-time physical unit of product (cost) by the visibility, awareness raised the cost of manufacturing sites, efforts to optimize the operation conducted. In addition, we were able to confirm the improvement. This article explains about it.


Latest Technology of QCS Caliper Sensor

Takashi Sugawara and Noriyuki Kobayashi
Ishinomaki Mill, Nippon Paper Industries Co., Ltd.

  Measuring the thickness of the web by using conventional caliper sensor has been achieved through the use of dual-side, contacting caliper sensors. Therefore, there has a problem of the flaw on the paper surface and sensor abrasion damage.
  On that occasion, paper makers have been asking for a new type of caliper measurement, which overcomes the weaknesses of contacting caliper. Most of the QCS makers have been using laser sensor to measure the thickness. However, Ishinomaki Mill introduces Yokogawa’s non-contact (one side light-touch) caliper sensor which is based on a combination of two techniques chromatic aberration and confocal displacement. This one can expect the improvement to eliminate the problems of the flaw and marking on the paper, sensor contact abrasion and dirt deposit on the contact.
  This report presents the outline of introducing optical caliper sensor which we introduced into Ishinomaki mill N6.


Our Current Efforts to Advance PLC Technology

Seiji Hori
FA System Dept., Nagoya Works, Mitsubishi Electric Corporation

  Today’s manufacturing industry is expected to further reduce costs and improve production efficiency due to global competition and shortened product life cycles.
  To meet these needs, we have improved the performance and reliability of our new products.
  We would like to introduce our approach, using PLCs, to reduce the total cost of manufacturing.


The Introduction of New Safety Management System Using IT in the Manufacturing Industry

Hidenori Kiyoshi
NITTETSU ELEX Co., Ltd.

  In 2006, the new safety management using IT (Information Technology) was commissioned by the Ministry of Health, Labor and Welfare, in cooperation with the National Institute of Occupational Safety and Health, Japan.
  This report presents the above new safety management and several examples of IT equipment introduced into the manufacturing industry.


Example of 2M/C DCS Renewal

Michitaka Kawasaki
Chuetsu Pulp & Paper Co., Ltd.

  It passed for nearly 22 years after introducing DCS into 2M/C and preformed several times@update from problems in the maintenance.
The μXL system made in Yokogawa Electric Corp. which we introduced in 1996 stops an order in 2000 and maintenance becomes the end in 2010.
  From an aspect of the operation stability, we thought that correspondence of the trouble in late years was difficult and carried out update to CENTUM VP Small made in Yokogawa Electric Corp. at the time of a stop in a fall in thought October, 2009.
  Here, I report an update@example of CENTUM VP Small which we introduced this time.


Calibration of On-line Pulp Consistency Transmitter

Toshiyuki Nagao
Mishima Mill, Daio Paper Corporation

  In order to maintain an accurate fine pulp blend during the mixing process, the proper functioning of flow and consistency transmitters is essential. Apart from microwave measuring systems, standard on-line consistency transmitters generate their readings based on shear stress as registered on the mixing blades. This system yields a relative reading based on accepted, theoretical values | it does not provide a real-time, absolute measurement.
  This is an issue because, even under controlled laboratory conditions, consistency values will vary between samples despite shear stress sensors indicating identical consistency ratings. These meters can be affected by a host of variables, such as pulp materials, temperature, additives, particulate velocities within the pulp or of the pulp itself, turbulence, etc. Insuring the proper operation of these sensors and their maintenance are critical issues in pulp quality control.
  In this paper, we detail how we have re-engineered the calibration process to produce consistent readings from our resistance sensors. Additionally, we discuss some unexpected phenomenon that was observed during the calibration and which may merit additional investigation.


Integration of Electrical and Instrumentation Control Systems

Hiroshi Ota and Takashi Ueno
Paper & Material Handling Systems Engineering Department
Industrial Automation and Drive Systems Division
TOSHIBA MITSUBISHI-ELECTRIC INDUSTRIAL SYSTEMS CORPORATION -TMEIC-

  Electrical and instrumentation control systems have become essential for the operation of all equipment in the field of manufacturing industry. Specification and application of electrical and instrumentation control systems are different. This paper introduces the capability of system unification utilizing unified controllers nv series.


The Solution of Efficiency Improvement and Yield Improvement of High Quality Film

Kunio Yamamoto
Sales Engineering Div., Yokogawa Electric Corporation

  A high quality film is a material used in the market such as the liquid crystal, semiconductors, and the batteries. In the film material industries such as the liquid crystal, semiconductors, and the batteries, a lot of film materials are manufactured to correspond to the diversification of needs and the product-short life cycle.
  The company's that manufactures the performance film being able to respond to speedy development, the improvement of the quality, and the customer demand such as reduction in costs becomes a very important factor. In each enterprise under the environment, the companies are improving promptly quality and lead time in the film manufacturing process. The problem and the solution of this environment are described in this report.


Current Situations and Issues in Instrumentation Work and Meter Maintenance

Masanori Okimoto
Aasahi Kokusai Techneion Co., Ltd.

  Necessary time of difficult steers of a decrease in construction according to a decrease in capital investment and a severe cost reduction demand, etc. aiming at the economic shrinkage period in the future is faced though the instrumentation work and meter maintenance industry grow up riding on the wave of economic development, get over time when Japanese economy is saturated, and came.
  In this report, the idea is described as charge of the technology in the experience, the instrumentation maintenance of the instrumentation charge in the petrochemical facility, and the construction company and the health and safeties about a current problem as the construction company and the approach in the future, etc. based on the experience


Camera Technology for On-line Paper Measurements of QCS

Takuya Akutsu
Honeywell Japan Inc.

  The technological advancement in many fields has vastly improved camera technology in past few years. It is stretching from high sensitivity and high resolution to the compact and the light weight. Then, the image processing technology enable large-capacity and high-speed processing in the same way. This evolution is enough available for the online measurement. I introduce newly three kinds of camera sensors for Honeywell QCS to here.


The Influence of Blanket Type on Printing

Masanori Kawashima
NPi Research Laboratory, Nippon Paper Industries Co., Ltd.
Douglas W. Bousfield
University of Maine

  The development of print gloss is reported for the first time using actual printing inks, coatings and press blanket materials. The print gloss for several blanket textures is measured and the results show that the surface structure of the blanket material has a significant influence on print gloss development. Higher blanket roughness correlates with low gloss. A model, based on the surface tension driven leveling of an ink filament, is proposed to predict the print gloss right after printing. This model predicts the correct gloss dynamics and gives insight into the length scale related to the blanket texture. Ink tack on the press blanket texture is also measured by a rolling nip device, which detects the separation forces at the nip exit. The influence of blanket type on the maximum and minimum pressures is reported. Rough blanket textures are found to correlate with smaller tack forces. The reduction of tack force with increase blanket texture is thought to be related to the earlier onset of cavitation at the nip exit.

Keywords: print gloss, blanket texture, ink filament, gloss dynamics, tack force, cavitation