The Quad Plus team started with a thorough analysis of existing equipment and careful consideration of the paper mill’s customers. Our experts have years of experience sizing the coordinated drives of a paper machine according to TAPPI standards, and our solution included sectionalizing the drives from the wet end to the reel and installed an AC coordinated drive lineup with a master controller supplied by the mill’s preferred PLC vendor.
We then provided a system to aid in the speed regulation of the entire machine and its various sections. With the addition of two HMIs (computer screens with graphical representations of the machine), operators could utilize a single, centralized location to monitor and control the process. To improve safety, we also added an additional I/O, safety processor, and safety-rated VFDs.
Before the upgrade, the speed and draws of the machine were performed manually by operators using potentiometers. By automating the line, the current workforce is able to focus on value-added areas rather than operation, and the younger, more inexperienced workforce can come on board as the automation helps to ease training concerns. Lastly, the line shaft and the DC motor replacement will help the mill enjoy less downtime for maintenance.