The winder machine is a vital component in paper mills. Their function is to transform large paper reels and slice them into desired roll widths for downstream processing.
Any disruption to the operation of the winder machine can halt production for the entire mill.
This is a huge problem. Why?
If the drive motor fails on a winder machine, that 2-6 hours of downtime would cost the mill between $20,000-$60,000 when factoring in repair cost, labor cost, and lost production.
The dynamic setup of the winder system makes it challenging to maintain due to various moving parts that are prone to failure. Considering that a winder only runs 50% of the time, it must run at least twice as fast as the paper machine in order to keep up with production, which spells problems for machine health.
The intermittent machine motion and constant ramping up and down of speed makes monitoring a winder system by conventional means a challenge.
Traditional measurements like route-based or wireless monitoring cannot easily detect and diagnose problems during the infrequent movements or without correlating data with run speed. Not to mention it’s dangerous to access measurement points when the machine is running.
The mechanical drive, usually an electric motor, is vulnerable to bearing and rotor bar failures. This motor is constantly going through cycles from start-to-full speed, causing high stress and damage to the motor.
SPREADER, RIDER AND GUIDE ROLLS
The spreader and rider rolls are vulnerable bearing failures.
The slitter has a set of knives/blades that are subject to wear over time. Poor precision of the roll can lead to premature failure and inconsistencies in the quality of the sheet.
The KCF Technologies IoT Hub uniquely addresses the needs of a Winder Machine.
It comes packaged with up to 7 wired sensors that continuously monitor key inflection points in the conveyance system and wirelessly transfer data to a Base Station. Data acquisition is triggered through connection to the system controls, enabling synchronized measurements with known operation points.
Consistent measurements are obtained for more accurate monitoring, diagnosis, and action, so you can validate when maintenance is performed correctly. Or when it’s not.
Variations in cycle time are correlated with measurements of the IoT Hub to identify issues and enable proactive solutions. Custom dashboard integrations mean your real-time data is accessible 24/7.
Now the Operations and Maintenance teams can monitor machine health, securely and remotely, at any time.
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