Voith is expanding its digi-tal 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 ma-chine 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 pro-duction.
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 misalign-ments, cover failures, and paper breaks caused by nip profile in-consistencies. Left undetected, such issues can negatively impact product quality and lead to unplanned downtimes.
While conventional static analysis tools can help optimize 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 un-der 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 analyze actual operat-ing conditions more easily, more precisely, and in real time.
The NipDynamics system consists of robust sensors that can be di-rectly 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 customizable 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 digi-tal solution provides a customizable 3D visualization of live meas-urements and stores the data, allowing operators to review past performance and analyze 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 Eu-ropean MG cylinder application, NipDynamics enabled optimiza-tion of the nip profile and operating conditions over an extended installation period. The customer realized documented savings of approximately €45,000 and subsequently decided to equip an ad-ditional roll with the technology, highlighting the value of continu-ous online nip monitoring.
In a reel drum application in Europe, where average loading condi-tions 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 perfor-mance while reducing quality costs.
A recent installation on a tissue pressure roll delivered valuable in-sights from the very first day of operation. NipDynamics identified a localized 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.
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 € 4.8 billion and locations in over 60 countries worldwide and thus is one of the larger family-owned companies in Europe.
