Keeping Track

Voith’s Innovative NipDynamics Roll Cover Sensor System Provides Real-time Insights to Significantly Reduce Downtimes

paperasia
  • Embedded sensor-based system for roll covers provides reliable real-time nip condition monitoring, even during full-speed operation and high temperatures
  • Innovative digital solution enables early detection of critical issues to support faster troubleshooting and proactive process control without downtimes
  • Improves runability, production efficiency and product quality

Voith is expanding its digital portfolio with the launch of NipDynamics, its innovative roll cover sensor system. Directly embedded in roll covers, the robust sensors continuously measure nip conditions, even while the machine is running at full speed in high temperatures and with paper in the nip. As a result, papermakers gain valuable real-time insights into actual operating conditions without having to shut down production.

The advantages of reliable monitoring of roll cover conditions
When roll cover conditions are effectively monitored, paper mills can reduce the risk of operational issues, including roll misalignments, cover failures and paper breaks caused by nip profile inconsistencies. Left undetected, such issues can negatively impact product quality and lead to unplanned downtimes.

While conventional static analysis tools can help optimise the nip profile and roll alignment, they are limited in scope. Many existing monitoring systems can only be used when the machine is shut down, and there is no paper in the nip. They typically provide only a snapshot of roll conditions. With such tools, it’s impossible to carry out a proper assessment of the performance of the roll covers under real operating conditions.

NipDynamics, providing real-time data at full speed
NipDynamics captures data from inside the roll cover while the machine is running. This allows operators to analyse actual operating conditions more easily, more precisely, and in real time.

The NipDynamics system consists of robust sensors that can be directly embedded in all types of roll covers to provide accurate measurements across the entire paper production process, from the forming to reeling section.

From sensors to customisable 3D representation
As the sensors are durable, heat-resistant and ultra-thin, they do not affect the profile, performance or service life of the roll cover. At the same time, the sensors are also super sensitive. They measure nip pressure profiles across the entire width of the cover to provide an accurate rotational frequency output.

Measurement data is collected and transmitted wirelessly. The digital solution provides a customizable 3D visualisation of live measurements and stores the data, allowing operators to review past performance and analyse specific time periods.

Proven performance in the field: customer experiences with NipDynamics
Since its first field installations, NipDynamics has demonstrated its value across a wide range of paper machine applications. At a European MG cylinder application, NipDynamics enabled optimisation of the nip profile and operating conditions over an extended installation period. The customer realized documented savings of approximately EUR45,000 and subsequently decided to equip an additional roll with the technology, highlighting the value of continuous online nip monitoring.

In a reel drum application in Europe, where average loading conditions are as low as approximately 2 kN/m, the system proved its exceptional sensitivity and measurement capability. The resulting process insights helped the mill better understand winding-related quality issues and supported efforts to enhance winding performance while reducing quality costs.

A recent installation on a tissue pressure roll delivered valuable insights from the very first day of operation. NipDynamics identified a localised low line load that correlated with a wet stripe in the paper profile, allowing the mill to quickly pinpoint and address a previously hidden process deviation.

NipDynamics gives papermakers continuous insights into nip conditions during actual production. By making previously unidentified nip issues visible at an early stage, our new monitoring system supports faster troubleshooting and a more proactive process control. As potential issues are flagged early and more accurately, mills can better plan optimisation and maintenance measures, avoiding unnecessary downtimes.

Ralf Moser, Global Product Manager Roll Covers for the Finishing Section & Doctoring Solutions at Voith Paper

About Voith Group
The Voith Group is a global technology company. With its broad portfolio of systems, products, services and digital applications, Voith sets standards in the markets of energy, paper, raw materials and transport. Founded in 1867, Voith today has around 21,000 employees, sales of EUR4.8 billion and locations in over 60 countries worldwide and thus is one of the larger family-owned companies in Europe.

The Group Division Voith Paper is part of the Voith Group. As the full-line supplier to the paper industry, it provides the largest range of technologies, services and products on the market and offers paper manufacturers holistic solutions from one source. The company’s continuous stream of innovations facilitates resource-conserving production and helps customers minimise their carbon footprint. With its leading automation products and digitalisation solutions from the Papermaking 4.0 portfolio, Voith offers its customers state-of-the-art digital technologies to improve plant availability and efficiency for all sections of the production process.