United States Patent (15) 3,661,701

Al-Shaikh (45) May 9, 1972

(54) METHOD AND APPARATUS FOR OTHER PUBLICATIONS
CONTROLLING RUSH-DRAG INA Pearson; ' Automatic Headbox Operation," Tappi, Vol. 46,
PAPER MACHINE No. 10, Oct. 1963, p. 172A- 195A
(72) Inventor: Abdul-Rahman A. Al-Shaikh, Mount Kisco, Primary Examiner-S. Leon Bashore
N.Y. Assistant Evaminer-Alfred A. D'Andrea, Jr.
(73) Assignee: Westvaco Corporation, New York, N.Y. Attorney-Alfred L. Michaelsen and Robert S. Grimshaw
22 Filed: June 23, 1970 57) ABSTRACT
21 Appl. No.: 49,067 A system for controlling the difference between the velocity of
a pulp slurry discharging from a paper machine headbox and
the speed of the fourdrinier wire onto which said pump slurry
52 U.S. Cl............................... 162/198, 162/259, 162/263 is deposited. The system includes means for deriving a signal
5) Int. Cl......................................................... D21f 1/06 representative of the aforementioned speed differential thus
58) Field of Search ........................., 162/259, 198,263,252 allowing a direct comparison between the actual velocity dif
ferential and the desired velocity differential. The control
56) References Cited system is based upon a differentiated and rearranged form of
the equation v 2gh which is div (g/v)dh, wherein dh' the
UNITED STATES PATENTS rush or drag in units of speed, v' the wire speed, g the
3,077,924 2/1963 Eastwood.............................. 162/259 gravitational constant, and dh the differential head, i.e., that
3,490,689 l/1970 Hart et al........................... 162/252 X part of the total head which gives rise to the velocity dif
ference between the slice velocity and the wire speed, in units
of inches of H 0,
9 Claims, 1 Drawing Figure

25 27

f
LEVEL
CONTROL
2EE =
25 SYSTEM : - 1 f8
22 7tz 2

PRES.
(P) TRANSMITTER
fa al
SPEAD (S)
5f CONTROLLER64364h
50 64.
37 38 Vsp
4 p
TRANSMITTER
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METHOD AND APPARATUS FOR CONTROLLING RUSH SUMMARY OF THE INVENTION
DRAGINA PAPER MACHINE
Functionally, my control system operates in accordance
BACKGROUND OF THE INVENTION with a differentiated and rearranged form of the equation,
i. Field to Which the Invention Pertains v= 2gh
In the manufacture of paper, a dilute aqueous slurry of cel Thus, differentiating the above equation, one obtains
lulose fibers is deposited on a moving foraminous belt referred 2v dv = 2g dh, or
dy a (g/v)dh,
to as the fourdrinier belt or wire. When the water drains away, wherein
the cellulose fibers in the slurry form the resulting paper sheet. 10 dy = the rush or drag, in units of speed
In order to obtain a sheet which has the desired specifica v = the wire speed,
tions, e.g., thickness and basis weight, it is imperative that one g = the gravitational constant, and
control the quantity and velocity of the slurry exiting from the dh = the differential head, i.e., that part of the total head
opening or slice of the paper machine headbox. Moreover, the which gives rise to the velocity difference between the
relationship between slice velocity and the speed of the four 15 slice velocity and the wire speed, in units of inches of
drinier wire determines how successive layers are built up in HO.
the sheet. If wire speed is appreciably less than stock or slice My control system utilizes the above differentiated and
velocity, the fibers will roll, resulting in forward waves across rearranged equation as follows.
the sheet. If wire speed is greatly in excess of stock velocity, Means are provided for generating a signal representative of
backward waves would be formed across the sheet, and a com 20
bing effect on the fiber results. When uniform fiber distribu the fluid head which gives rise to the slice velocity.
tion is desired, the well established principle is to maintain Additionally, means are provided for generating a signal
slice velocity close to wire speed. If the difference between which is speed related to the fluid head which gives rise to the
stock velocity and wire speed is more than 20 or 30 f.p.m., it is slice velocity. In the preferred embodiment of my invention,
difficult to make acceptable paper. 25
the last mentioned means could be a tachometer operatively
The difference between wire speed and slice velocity must connected to the fourdrinier belt in which case the speed
be chosen with regard to the properties desired in the finished signal produced would be representative of the actual wire
paper. For example, if the wire speed is in excess of the slice speed. Alternatively, from the wire speed control loop, one
velocity, a high proportion of the fibers will be drawn into the could utilize the wire speed set point signal which,
machine direction. This result is desirable in certain grades of 30 presumably, would equal the actual wire speed. As another al
paper, e.g., spinning and twisting papers. ternative, means could be provided for generating a signal
In the paper industry, the term rush-drag is used to refer to representative of the desired slice velocity.
the difference between slice velocity and wire speed. If the Irrespective of the nature of the particular speed signal util
slice velocity is in excess of the wire speed, it is said that the ized, the speed signal is squared as opposed to the approach
stock is "rushing the wire.' Alternatively, if the slice velocity 35 utilized by the prior art wherein the fluid head signal was sub
is less than the wire speed, it is said that the stock is "dragging jected to a square root operation.
the wire.' A rush-drag of zero indicates that the velocity of the After appropriate scaling and signal conversion, the square
stock discharging from the paper machine headbox, i.e., the of the speed signal is compared with the fluid head signal to
slice velocity, is exactly equal to the wire speed. A rush of 10 obtain a difference signal which, physically, is representative
f.p.m. means that the slice velocity is 10 f.p.m. greater than 40 of the differential head, i.e., that part of the total head which
the wire speed. A drag of 10 f.p.m. means that the slice corresponds to the rush-drag velocity. The differential head
velocity is 10 f.p.m. less than thc wire speed. signal is divided by the speed signal thus providing a signal
As previously indicated, an excessive rush or drag cannot be which is representative of the actual rush-drag. Means are
tolerated. However, it is quite common for a papermaker to then provided for comparing this latter signal to a rush-drag
desire that his system operate with a relatively small rush or 45 set point to obtain a second difference signal. Control means
drag, depending upon the grade of paper to be manufactured. are provided for controlling the rush-drag in response to this
Although the desired rush or drag is quite critical, it is also second difference signal.
often quite small in absolute value. For example, a rush or
drag of ten feet per minute might be desired. One can ap DESCRIPTION OF DRAWINGS
preciate the magnitude of the problem of controlling this rela 50 The FIGURE is a functional, schematic representation of
tively small speed differential when it is understood that paper my control system and the appropriate papermaking ap
machines commonly operate with wire speeds of 2,500 feet paratus associated therewith.
per minute.
The control of rush-drag is the field to which this invention DETALED DESCRIPTION OF THE INVENTION
pertains. 55
2. Prior Art Referring to the FIGURE, the preferred embodiment of my
In attempting to control rush-drag, the prior art established invention, there is shown therein a paper machine headbox 16
that slice velocity could not be measured directly. However, containing an aqueous pulp slurry or stock 17. Stock pump 12
from fluid dynamic considerations, it was perceived that one pumps the stock to the headbox 16 through conduit 11. While
could obtain an inferential measurement of slice velocity by 60 there are many approaches available to control stock flow to a
measuring the fluid head which gave rise to the slice velocity. paper machine headbox, the apparatus arrangement of the
Once the fluid head had been measured, a signal representa FIGURE contemplates that the stock flow in the conduit 11 to
tive of slice velocity, V, could be obtained through the use of the paper machine headbox 16 will be controlled by manipu
the equation, lating the speed of the stock pump 12.
y = 2gh or v = W2gh 65 The particular headbox 16 depicted in the FIGURE is of the
Thus, in the prior art systems, a signal, h, representative of closed or pressurized variety. That is to say, there is an air pad
the fluid head was obtained and was put through a square root or high pressure zone 15 maintained in the headbox above the
extractor and, by appropriate scaling of the signals, the mul stock 17. Further, in the particular configuration shown in the
tiplication by 2g was simultaneously accomplished with the FIGURE, the air pressure in the zone 15 is utilized to control
result that the output from the square root extractor was a 70 the level of the stock 17 within the headbox 16. Thus, pressure
signal representative of the slice velocity, V. Similtaneously, measurements are made at 20 and 21 to obtain a differential
the wire speed was measured and compared to the previously pressure signal indicative of the level of the stock 17 in the
obtained slice velocity signal. The difference signal resulting headbox. The two pressure measurements thus made are pro
from this comparison was a signal representative of the vided to a level control system 22 which provides a level con
prevailing rush-drag condition. 75 trol signal 23. The level control signal 23 is used to actuate a
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valve 25 through the valve actuator 24. The valve 25 controls differentiator pressure transmitter 37. The differential pres
the flow of air through the conduit 26, thus controlling the sure transmitter 37 is a commercially available transducer
pressure in the zone 15. The details of the level control system which provides an electrical analog output signal proportional
have not been shown in the FIGURE, since such systems are to the input differential pressure. Such units are available with
well known to those skilled in the paper making art. great sensitivity. For example, one can obtain differential
The stock 17 in the headbox 16 is discharged as at 18, onto pressure transmitters with a total range of 10 inches of water
the moving, fourdrinier wire 19. At point 30 there is provided or less, i.e., the output signal will vary over its full range for a
a speed takeoff to tachometer 31. Tachometer 31 is a stan variation in the differential input signal of -5 to +5 inches of
dard, commercially available transducer having an input shaft Wate.
and means for providing an electrical output signal propor 10 The electrical analog output signal 39 from the differential
tional to the angular velocity of the input shaft. Through ap pressure transmitter 37 is representative of the differential
propriate gearing and knowing the diameter of the rotating head since it results from a comparison of the actual total head
means supplying the input angular velocity, the output of the and the wire speed expressed in terms of fluid head. Having
tachometer will be proportional to the linear velocity or actual now obtained a signal which is representative of the dif
wire speed of the fourdrinier belt 19. The electrical output of 15 ferential head, dh, it will be recalled that
the tachometer 31 may be either digital or analog depending
upon the particular transducer which is selected. The embodi Utilizing the above equation, the signal 39 representing the
ment shown in the FIGURE contemplates that the output differential head dh and the signal 75b representing wire speed
signal 32 of the tachometer 31 will be an electrical analog 20 v, are supplied to element 40 which is a standard commer
signal, e.g., 10 to 50 ma. The output signal 32 which is cially available analog dividing unit, i.e., the output signal 41
representative of wire speed is divided into two equal parts, from the divider 40 is equal to signal 39 divided by signal 75b.
32a and 32b, both of which are equal to the signal 32. Further, as was the case with the squarer element 33, multipli
Signal 32a is utilized in a local speed control loop. Thus, a cation by a constant can be achieved through appropriate
set point station 63 provides a signal 64 which is representa 25 scaling of the output signal. Thus, the output signal 41 from
tive of the desired wire speed. The wire speed set point signal the divider 40 is so scaled as to provide a multiplication by a
64a, (signal 64a equals signal 64) and the signal 32a represen constant, viz, g. Alternatively, in place of a straight divider
tative of the actual wire speed are compared by summing junc unit, a multiplier divider unit could be employed which per
tion 65, thus providing a difference signal 66 which is trans forms the function (A)(B)/C. With this latter approach, A
mitted to a wire speed controller 50. Wire speed controller 50 30 could equal g, B would equal signal 39 and C would equal
may be a standard analog controller which produces an output signal 75b. In any case, pure analog dividers or multiplier
dividers are commercially available from numerous manufac
control signal 52 in response to the input difference signal 66. turers.
The output signal 52, which is a wire speed control signal, is Having performed the computation
transmitted to the speed drive unit 51, wherein a device such
as a silicon controlled rectifier may be used to control the 35
drive motors in response to the control signal 52. Thus, the it will be appreciated that the signal 41 is equal to dv, i.e.,
speed of the wire is maintained constant and equal to the signal 41 is representative of the actual rush-drag condition.
speed set point 64. Since a signal has now been obtained which is representative
Signal 32b, which is equal to signal 32 and representative of of the actual rush-drag, a comparison can now be effected
the actual wire speed, is transmitted to one terminal, i.e., ter 40 with a rush-drag set point signal. Thus, there is employed ele
minal 72, of a three-position switch 70. The switch position ment 42 which is a standard, commercially available analog
shown in the FIGURE represents the preferred embodiment drag set-point station which would provide an output signal (rush
of my invention, i.e., the signal being transmitted through the set-point) 43 compatible with the rest of the system, e.g.,
switch 70 is the signal 32b which is representative of actual 10 to 15 ma, which is compared with signal 41 by summing
wire speed. With the switch in the position shown in the 45 junction 44. The output signal 45 from the summing junction
44 is equal to the difference, if any, between the actual rush
FIGURE, the signal 75 would equal signal 32b, i.e., the signal drag signal 41 and the desired rush-drag represented by the
75 would be representative of the actual wire speed. Signal rush-drag signal 43. Having obtained a rush-drag error or dif
75a and 75b are equal to signal 75. ference signal, viz, signal 45, a number of approaches may be
Signal 75a is utilized as an input to element 33 which is a 50 utilized to effect control of rush-drag. For example, in my
standard, commercially available squarer, i.e., a unit which preferred embodiment as shown in the FIGURE, the error
produces an output signal equal to the square of the input signal 45 is applied to a standard analog controller 46 which,
signal. Moreover, by appropriate scaling of the output signal, preferably, would be a two action controller. The output or
multiplication by a constant may be achieved. Thus, the out control signal 47 from the controller 46 would be utilized to
put signal 34 from a squarer 33 is adjusted so as to be equal to 55 alter the speed of the stock pump 12 and thus alter the total
the square of the signal 75a divided by 2g (g = the gravitional head resulting in a change in the slice velocity in order to
constant) and, physically is representative of the wire speed in reestablish the correct rush-drag condition.
terms of a fluid head, i.e., h = v/2g. Signal 34 is provided to a As heretofore pointed out, the preferred embodiment of my
current to pressure transducer 35 which produces a pressure invention contemplates that the speed related signal or speed
output signal 38. The current to pressure transducer 35 is a 60 signal will be the actual wire speed, i.e., as shown in the
commercially available unit which, typically, would provide
an output pressure ranging from 3 to 15 psi for an input cur wire speedthesetsignal
FIGURE 32 B. As an alternate embodiment, the
point signal could be utilized in which case the
rent signal of 10 to 50 ma. pole 74 of the switch 70 as shown in the FIGURE would be
At the base of the headbox 16, a pressure tap 29 is provided. positioned to contact terminal 71. Assuming that the speed
Of course, the pressure measured at 29 will be the total head 65 control loop was performing its function, i.e., maintaining the
h, i.e., the fluid head giving rise to the slice velocity which is actual wire speed equal to the desired wire speed, it will be ap
equal to the sum of the pressure generated by the stock 17 in preciated that the actual wire speed will equal the wire speed
the headbox 16 plus the air pressure maintained in the zone set point and thus the remainder of the control system will per
15. The total head, h, as measured at point 29 is transmitted form as previously described. However, it is desirable to have
by a conduit 80 to a pressure transmitter 81. The output 36 of 70 available the alternate approach of utilizing a signal other than
the pressure transmitter 81 is a 3-15 psi signal which is pro the output of the tachometer 31 since either the tachometer
portional to the pressure measured at 29. The output signal 36 31 or another component of the wire speed control loop may
is transmitted to a narrow range differential pressure trans fail in which case the wire speed could be set at a fixed value
mitter 37. Simultaneously, the pressure output signal 38 from and the output of the wire speed set point unit 63 could be
the current to pressure transducer 35 is also supplied to the 75 utilized by placing the switch 70 in position 71.
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3,661,701
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Still another embodiment of my invention could be realized signal to produce a second difference signal; and
by placing switch 70 in position 73 wherein terminal 73 is h. means for controlling said slice velocity in response to
receiving signal 62 from set point station 61. Set point station said second difference signal.
61 would be component of the type previously described with 2. The system of claim 1 wherein said means for providing a
respect to set point station 63 except that the signal which is speed signal provides a speed signal which is representative of
supplied would be a speed signal representative of the desired desired wire speed.
slice velocity or, otherwise stated, a signal representative of 3. The system of claim 1 wherein said means for providing a
the desired total head but expressed in terms of feet per speed signal provides a speed representative of the desired
minute. Thus, when utilizing this embodiment of my inven slice velocity.
tion, if one desired to maintain a total head of 150 inches of O 4. The system of claim 1 wherein said means for providing a
water, this total head could be expressed in terms of feet per speed signal provides a speed signal representative of actual
minute by utilizing the equation v = 2gh. If, in actuality, the wire speed.
output 62 of the set point unit 61 is adjusted to provide a slice 5. The system of claim 4 wherein said means for controlling
velocity set point equal to the desired total head, it will be ap comprises:
preciated that the rush-drag set point 43 will be set equal to 15 a means for generating a control signal in response to said
zero since, under such circumstances, my invention would es difference signal; and
sentially comprise a total head control system rather than a b. means for controlling the stock flow to the paper machine
rush-drag control system. headbox in response to said control signal.
Having hereinbefore set forth numerous embodiments of 20 6. The system of claim 5 which comprises:
my invention, it will be understood that there are still other a means for providing a set point signal representative of
and further embodiments which will be perceived by those the desired wire speed;
skilled in the art to which this invention pertains. For example, b. means for comparing said set point signal with said signal
the embodiments of my invention previously described representative of the actual wire speed to produce a wire
presupposed a substantially electronic control implementa 25 c. speed means
difference signal; and
for controlling the wire speed in response to said
tion. Of course, my invention as herein disclosed is clearly wire speed difference signal.
amenable to a pneumatic implementation. Similarly, although
the embodiments of my invention herein described presup the7.stock The system of claim 6 wherein said means for controlling
flow comprises means for controlling the speed of
pose an analog implementation, those skilled in the art will un the stock pump.
derstand that my invention can be implemented through the 30 8. The system of claim 6 wherein said means for controlling
use of digital means, i.e., a digital computer programmed to the stock flow comprises means for controlling the bypass flow
perform the necessary computations, comparisons, and other around the stock pump.
functions previously described. 9. An improvement in the method of controlling the
claim:
velocity of a slurry exiting from a paper machine headbox with
1. A system for controlling the velocity of a slurry exiting 35 respect
from a paper machine headbox with respect to the speed of depositedto including the speed of the wire on to which the slurry is
the steps of obtaining a first signal
the wire onto which the slurry is deposited which comprises: representative of the total head in the headbox and obtaining a
a. means for providing a first signal representative of the second signal representative of the actual wire speed, wherein
total head in said headbox; the improvement comprises the steps of:
b. means for providing a speed signal related to said slice 40 a. obtaining a third signal representative of the square of the
velocity; wire speed signal multiplied by a constant;
c. means receiving said speed signal and producing a third b. comparing said third signal to said first signal to obtain a
signal equal to the square of said speed signal multiplied first difference signal;
by a constant; c. dividing said first difference signal by said second signal
d. means for comparing said first and third signals to 45 and multiplying by a constant to produce a fourth signal;
produce a first difference signal; d. obtaining a set point signal representative of the desired
e. means for dividing said first difference signal by said difference between the slice velocity and the actual wire
speed signal and multiplying by a constant to produce a speed;
fourth signal; e. comparing said set point signal to said fourth signal to ob
f. means for providing a fifth signal representative of the 50 tain a second difference signal; and
desired difference between slice velocity and said speed f. controlling the stock flow to the headbox in response to
signal; said second difference signal.
g. means for comparing said fifth signal and said fourth ck ck xk ck ck

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