JP3182964B2 - Sheet roll processing equipment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet roll processing facility for dividing a belt-like sheet such as a plastic film into a plurality of strips, winding the strip into a plurality of strips, and processing the split sheet roll.

[0002]

2. Description of the Related Art A split sheet roll, which is a final product in a sheet roll processing equipment, is formed by winding a belt-shaped sheet continuously formed by a film forming machine and sent out by a winder into a raw material roll as an intermediate product, and a slitter rewinder. By unwinding the belt-like sheet from the material roll, the sheet is cut to a required width and wound up by a required length.

First, in a film forming machine, a raw material resin is melted by heat, and the molten raw material resin is continuously formed into a belt-shaped sheet by a flat or ring-shaped die whose gap is finely adjusted. Therefore, it is necessary to change the raw material, switching of the type of the band-shaped sheet to be molded, switching of the gap and temperature of the die, or switching of the thickness of the band-shaped sheet that requires fine adjustment of the operation speed, inevitable adjustment loss, This is a factor that lowers productivity such as yield and operation rate in a film forming machine.
That is, in this process, the production yield can be improved by continuously operating the film forming machine so as to produce as large a lot as possible without changing the product type and thickness. For example, according to a one-year study on the BOPP film production process, the average production of 10 lots on mill rolls with a diameter of about 800 mm was averaged. A loss of 10 percent has occurred. By doubling this to twice the production lot, each loss ratio is reduced to 10% and 5%.
Can be halved to a percentage loss.

[0004] In addition, the split sheet roll made by the slitter rewinder is required to satisfy various conditions in accordance with the order of the user, and the types thereof are enormous. For example, according to an example of a BOPP film manufacturer, first, there are five types of sheets, ten types of thicknesses, and sheet widths of 300 mm to 200 mm.
Products up to 0 mm have been commercialized in 5 mm increments, and there are about 300 types, 10 types of winding length, 2 types of winding core diameters of 3 inch and 6 inch, and packaging for shipping. It becomes complicated like four forms, and this is the actual situation of the market. Then, all of these conditions are combined to form a product specification, and the product specification of the divided sheet roll as the final product is about 1.2 million types (5 × 10 × 300 × 10 × 2 ×).
4).

In the conventional sheet processing equipment, there is a means for storing a raw roll between a mill roll winder and a slitter rewinder, but the capacity of the roll is relatively small. It was regarded as a buffer between the winder and the off-line operated slitter rewinder. In some cases, even factories lack storage capabilities. Therefore, in order not to stop the flow of the operation, it is inevitable that the raw roll to be produced must be immediately finished into a divided sheet roll as a final product immediately after temporary temporary placement.

[0006] Then, it is too complicated for a human to make a production plan for the slitter, and in this conventional production system, the desired delivery date, which is the just-in-time of the ordered product, is satisfied, and hundreds of specifications for the order are received. It has been a very difficult technique to combine the specifications to directly attain the raw material roll and obtain a high product yield (meaning the production ratio of the ordered product roll to the raw material roll).

[0007]

As a result, the quantity of products that can be shipped by ordering the finished product directly to the raw material roll and being divided and finished is extremely limited. After that, a large amount is sent to the product warehouse.

[0008] From the end products stored in large quantities in the product warehouse, if it is attempted to ship a product that satisfies the needs of the market, that is, a variety of small quantities and an order condition that jumps in with just-in-time delivery, if all products are to be shipped, At least 10 per specification
Even if you have a stock of books, 10 books x 1.2 million types = 1
2 million bottles are theoretically required. Of course, this quantity is a fancy number without reality.

[0009] Even a realistic large product warehouse is the largest one having a capacity equivalent to a production amount of at most one month or at most two months, and several tens of minutes of the above assumed capacity. It is only one scale. Therefore, even with such a product warehouse, it is only halfway,
The reality is that the proportion that can be shipped from the product inventory in accordance with the order conditions is extremely small.

[0010] Even if a small slitter rewinder is used as a measure for bitterness and the slit reprocessing for adjusting the product width and the winding length is vigorously performed while focusing on the reduction of the yield, the inventory continues to increase rather than decrease. The reality is that when you reach the limit of your inventory capacity, you will have to repeat the profit-free disposal several times a year, choosing a special processing customer that does not disrupt sales prices. .

[0011] These stock products with a low turnover rate are the same current assets as cash and bills at the time of stocktaking of accounts, and even ordinary assets are subject to taxation of 53%. And it causes a lot of loss factors such as loss, pressure on working capital, and management cost of inventory entry / exit, and the existence of this product inventory is a valuable resource that normally generates profits from normal sales activities. Nevertheless, in reality, they lose profits and are a major factor in determining the quality of management.

[0012] Such conventional sheet roll processing equipment and its manual production method involve engineering in which only machines having unit functions are installed in each process, or the mechanical equipment itself is incomplete. Moreover, this is a natural consequence of the fact that production planning and operation management between processes had to rely on human experience and skill.

Accordingly, an object of the present invention is to provide a sheet roll processing equipment capable of obtaining various kinds of divided sheet rolls in just-in-time and with a high yield.

[0014]

Means for Solving the Problems The present invention to achieve the above object, a plurality of divided band Sea required width band-shaped sheet
A sheet divided winder for processing the divided sheet roll by dividing the preparative take only winding a required length, a sorting device which sorts the divided sheet roll, luck of the sheet divided winder
A production planning computer that formulates a transfer plan,
The production planning computer uses a pre-input required
Take-up work including the sheet width and take-up length of the split sheet roll
, Quantity, delivery date or shipping time, and sorting data
And a strip-shaped sheet that can be supplied to a sheet splitting winder.
And save the operation plan of the sheet splitting winder.
When formulating, one of the required divided sheet rolls
Operation plan by searching for items with delivery date or shipping time within
Sheet splitting winder stored and stored as an object of
Information on the belt-shaped sheet that can be supplied to the vehicle and the operation plan
Sheet width of the required split sheet roll stored as the target
Based on the winding specifications and quantity including winding length and
The required divided sheet row for a strip-shaped sheet that can be supplied
How to assign the split sheet
Simulated calculation for how to apply
By deciding to reduce as much as possible
The required splitting machined for each split winding cycle of the split winder
Develop and memorize sheet rolls and prepare them for the sheet splitting winder.
To the control computer obtained above,
Winding specifications including sheet width and winding length for each vehicle, and
Outputs the sorting data, and the sheet splitting winder outputs the
When processing the split sheet roll based on the specified winding specifications
Together, when sending out the processed divided sheet roll,
Sorting data into divided sheet rolls via output device
The sorting device is applied to the sheet roll.
Read the sorted data, and based on the sorted data.
It is characterized by sorting sheet rolls.

[0015]

The production planning computer stores information on the necessary individual divided sheet rolls and information on the band-shaped sheets that can be supplied to the sheet division winding machine, and stores the stored information on the band-shaped sheets. Based on the information on the necessary individual divided sheet rolls, an operation plan of the divided sheet winding machine is made.

The operation plan of the sheet split winder by the production planning computer is executed in a state where the shipping destination or the winding size is different. The divided sheet rolls processed based on such an operation plan need to be once sorted and shipped or stored. Therefore, the sorting device automatically sorts the divided sheet rolls taken out from the sheet dividing and winding machine according to shipping destination, quantity, size, and the like.

[0017]

Next, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is an explanatory diagram showing a block diagram of an embodiment of the present invention. In FIG. 1, reference numeral 1 denotes a production planning computer, 2 denotes a sheet dividing winder, and 3 denotes a sorting device.

The sheet dividing and winding machine 2 is a slitter rewinder in this embodiment, and the material roll 4 is rewinded by a rewinding unit 5.
Then, the strip-shaped sheet 6 is rewound from the raw roll 4 and sent to the slitter device 7, and is wound by the winding unit 8 while being divided into a plurality of pieces by the slitter device 7, thereby forming a divided sheet roll 9.

The slitter 7 is disclosed in, for example,
As disclosed in JP-A-142097, the cutting blade 7a for cutting the belt-shaped sheet 6 can be automatically positioned, and corresponds to a division position or a division width instructed by the control computer 10. Thus, the position of the cutting blade 7a is controlled. In addition, as long as the cutting blade has a function of cutting a sheet, not only a mechanical knife such as a sharp-edged knife and a round blade, a pair of round blades for shearing,
Also includes those using ultrasonic waves and laser beams.

The winding section 8, the sheet conveying section 11 including the slitting device 7, and the rewinding section 5 are controlled by the control computer 10, and the winding operation is performed when the required amount of the strip-shaped sheet 6 'is wound. Is automatically stopped.

The control computer 10 not only controls the positioning of the slitter 7 but also supports the divided sheet rolls 9 of the winding section 8 in order to improve the equipment operation rate and the stability of the winding quality. A function for automatically positioning and controlling a support device for each touch roller that comes into contact with the divided sheet roll 9; a function for automatically controlling a mechanism for transporting and mounting and collecting the touch roller to the support device; Further, it is preferable that the apparatus has a function of setting and controlling operating conditions such as the winding tension and the touch pressure of the winding section 8 and the unwinding tension of the unwinding section 5.

Since the production planning computer 1 needs to process enormous data relating to, for example, daily order information, the storage unit naturally has a large capacity. However, since the control computer 10 of the sheet splitting winder 2 and the control computer 12 of the sorting device 3 give priority to the real-time control function of the device, the capacity of the storage unit is usually small. Therefore, it takes time to exchange data directly between the control computers 10 and 14 and the production planning computer 1. Therefore, in this embodiment, although omitted from the drawing, it is effective to provide a relay computer between the two so that mutual communication can be performed smoothly and quickly.

The production planning computer 1 has winding specifications such as sheet type, sheet thickness, divided sheet roll width (divided width), winding length, and winding core size of each required divided sheet roll. , Data on quantity, delivery date or shipping time, etc. are input from the input device 1a at any time.

The production plan computer 1, satisfies the condition of delivery, the yield, to improve the operating rate as possible, information about the required division sheet roll which is stored, and, Sea
It stores a procedure for making an operation plan of the sheet split winder 2 based on information on a strip-shaped sheet serving as an original sheet , including a product type, a sheet thickness, a width, and a length .

When formulating an operation plan, the production planning computer 1 first stores the required divided sheet rolls that need to be created during the period in order to make an operation plan for a certain period of time with priority given to delivery. Information, and collects it for production planning.

[0026] and, then, in order to increase the yield, raw
As to the belt-like sheet to be used, how to allocate division belt-like sheet product to be obtained, so that b <br/> scan the belt-like sheet is minimized by simulating operation for Assignments are also the many ways To decide. In addition, the operating rate is improved by planning the amount of movement of the cutting blade 7a of the slitter device 7 as much as possible when changing the product width.

Thus, the production planning computer 1
A signal for designating a winding specification including a width and a winding length of each of the divided sheet rolls processed in each of the divided winding cycles is transmitted to the control computer 10 of the sheet divided winding machine 2 by the divided winding. Output in units of sampling cycle.

The control computer 10 of the sheet split winder 2 instructs the slitter device 7 and the like to operate based on the winding specification specified by the signal output from the production planning computer 1. As a result, in the slitter 7, the cutting blade 7a is set at the dividing position corresponding to the command.

As described above, the operation plan of the sheet dividing and winding machine 2 established by the production planning computer 1 has different delivery destinations and quantities. The dimensions are also different.

Therefore, in the present invention, even if the same shipping destination and the required number of sheet rolls are wound at different times,
A sorting device 3 having a control computer 12 is provided in order to sort the divided sheet rolls by the sorting device 3 so that they can be shipped together.

According to this embodiment, the sheet split winding machine 2
The sheet roll 9 taken out of the packaging device 13
Is supplied to the sorting device 3 via a transport device (not shown). Further, if necessary, the sheet may be further processed into a narrower divided sheet roll by a secondary slitter rewinder (not shown) and then supplied to the sorting device 3 via the packaging device 13. The production planning computer 1 sorts the divided sheet rolls 9 in the sorting device 3 in order to automatically sort the divided sheet rolls 9 in addition to making an operation plan of the divided sheet winding machine 2. Is prepared for each of the divided sheet rolls 9, and when the divided sheet roll 9 is sent out from the sheet dividing and winding machine 2,
The sorting computer 9 gives individual sorting data to each divided sheet roll 9 by the output device 14. This sorting data may be directly applied to the divided sheet roll 9 by, for example, printing, pasting a label on which the data is written, or the like. However, in this embodiment, in order to prevent the divided sheet roll 9 from being damaged during transportation. In addition, since the wafers are transported by being placed on individual transport tables (not shown),
For example, a known storage device having an SRAM or the like and capable of writing and reading data in a magnetically non-contact manner is provided, and writing is performed on the storage device.

Control computer 12 of sorting device 3
Reads the sorting data from the supplied divided sheet rolls 9 by a known data reading device 15, and controls the sorting unit 16 based on the contents of the read sorting data.

FIG. 2 shows an example of the sorting section 16. In FIG. 2, the sorting unit 16 includes a carry-in conveyor 17 from the upstream process.
Of the divided sheet rolls 9 supplied to the storage conveyors 19 are selectively supplied from the distribution conveyor 18 onto a plurality of branching storage conveyors 19. Then, the sorted divided sheet rolls 9 are stored at predetermined intervals on the storage conveyor I9. When all of the predetermined number of divided sheet rolls 9 are collected, the set of divided sheet rolls 9 is transferred to the collection conveyor 2 via the branching device 20.
1 and transferred from the collection conveyor 21 to the unloading conveyor 22 via the branching device 20 and sent out to downstream processes. In this way, even when the number of sorting destinations is very large, when all the necessary divided sheet rolls are completed, the sheet rolls are carried out, and a new classification can be sorted there, so that the number of storage conveyors can be reduced.

In the case of this embodiment, a balletizer 23 is provided downstream of the sorting device 3, and the divided sheet roll 9 is placed on a pallet (not shown) and is shipped or temporarily stored. Then, the sorting device 3 sorts the divided sheet rolls 9 in pallet units. The sorting conditions by the sorting device 3 may be, for example, according to the delivery destination or the storage destination, if necessary.
By dimensions such as transport flights, transportation means, winding width, winding length, etc.
Items related to the delivery, dimensions, processing, and the like of the divided sheet rolls, such as the packaging form, the processing after the sorting device, or the combination of these items, may be set.

The embodiment of the present invention is not limited to the above-described embodiment shown in FIG. 1, but can be variously changed without changing the gist of the present invention. For example, in the operation planning procedure of the sheet splitting winder stored in the production planning computer, the set values of the conditions of the operation plan may be changed, or the contents or order of the processing operations may be changed. In addition, the production planning computer transmits a signal for designating a winding specification such as a division position or a division width and a winding length of the belt-shaped sheet based on an operation plan formulated by the production plan and a specification of a necessary material roll. Through the highway,
In addition to sending the command directly to the control computer of each machine, the operation may be commanded to each machine by displaying the command content only at the terminal device. In this case, for example, in the sheet dividing and winding machine, the operator sets the division position or division width and the winding length of the belt-shaped sheet based on the display.

Further, the sorting apparatus may be operated semi-automatically or manually based on the setting operation of the operator. Also, the data that constitutes the information about the required divided sheet rolls and the information about the raw rolls may be changed according to the design conditions of the system.

The present invention can also be applied to a case where the belt-shaped sheet is made of a material other than a plastic film, such as paper or a thin metal plate. The sheet dividing and winding machine may be not only a slitter rewinder but also an inline type, for example, in which a belt-shaped sheet sent from a sheet manufacturing apparatus is directly taken out and divided and taken up. In some cases, an in-line type sheet splitting winder is used, and the raw roll storage device is replaced with a belt-shaped sheet manufacturing device. The raw roll to be subjected to the operation plan may be an unmanufactured roll or a roll that is to be manufactured by the required time.

The sorting device is not limited to the one shown in FIG. 2 as long as it has a function of automatically sorting the divided sheet rolls without having any specific structural conditions.
For example, the distribution conveyor 18 may be arranged at a position on the collection conveyor 21 shown in FIG. 2 to distribute the divided sheet rolls 9 to the storage conveyors 19 on both sides, or the distribution and collection, or the loading and unloading may be performed by one conveyor. It may also serve as a single sorting / collecting conveyor and a plurality of sorting conveyors branching from it, or a plurality of storage conveyors may be provided so as to intersect between a set of sorting conveyors and a collecting conveyor. May be used. The storage conveyor 19 in FIG. 2 transports and stores the divided sheet rolls in a direction perpendicular to the longitudinal direction, but may transport and store the divided sheet rolls in the longitudinal direction.

Further, the apparatus does not have a sorting section composed of a plurality of conveyors as shown in FIG. 2, but is configured to perform three-dimensional sorting using a stacker overhead crane or the like. It may move to the sorting position.

[0040] In a further, the previously assigned identification data for matching the previously goods and information on the split sheet roll,
The sorting data of each divided sheet roll is stored in a computer, the assigned identification data is read at the time of sorting, and the sorting data for the divided sheet roll corresponding to the identification data is called from the computer to control the sorting unit. It may be something.

[0041]

According to the present invention, it is possible to supply a sheet to a sheet winding machine.
Since the operation plan of the sheet splitting winder is made based on information on the strip-shaped sheets that can be supplied and the necessary split sheet rolls, it is not necessary to manufacture a large number of unordered split sheet rolls as in the past. . Therefore, a conventional product warehouse is not required, and it is not necessary to store or take out unordered divided sheet rolls in a large amount in the product warehouse, and the number of workers can be greatly reduced. In addition, since a large number of unordered products do not fall asleep in the product warehouse, the yield is improved, and the productivity for dropped raw materials, energy, and the like is significantly improved. In addition, the economic burden of taxing inventory is greatly reduced.

[0042] Further, the band-like sheet produced in the film machine or the like, rather than after machining the division sheet roll as conventional products as of being stored in a product warehouse, bulk roll storage not cut device to keep left original fabric roll of semi-finished products can be processed to the width and length required is taken out when needed. The resulting lead time is greatly reduced. For example, it is possible to make a production plan on a daily basis, and it is also possible to ship a product the day after an order is received.

Further, since the divided sheet rolls processed by the divided sheet winding machine based on the operation plan are sorted by the sorting device, the productivity can be improved without worrying about the complexity of the sorting work of the divided sheet rolls. It is possible to make an operation plan in which the priority is given. In addition, no sorting operator is required, and the sorting is completed in a short time, so that the time until shipment is greatly reduced.

Accordingly, it is possible to provide a split sheet roll processing equipment capable of obtaining a wide variety of split sheet rolls in a just-in-time and high yield, and the use of the equipment of the present invention significantly increases the manufacturing cost of the split sheet rolls. In this way, it is possible to expand the competition to win orders in terms of cost and delivery time.

For example, even if at least one material roll is in stock for each combination of the type and thickness of the belt-shaped sheet, if 50 material rolls are stocked as semi-finished products, it depends on the quantity. First of all, the prerequisites are to meet the market needs of any product specifications with just-in-time delivery conditions, and to be able to respond to orders for all specifications within the handling range with integrated production and sales, with a high combination yield and a production plan consisting of only ordered products. To establish.

Also, the operation plan of a slitter rewinder, which is prepared by a computer rather than by a human, is complicated in terms of the number of orders received and the types of products.
Even when the amount reaches one million, it is possible to formulate a production plan (95% to 99.5%) that always makes the product yield (the production ratio of the ordered product roll to the raw roll) the logically highest ratio. The yield difference with this production and sales system creates unequal cost competitiveness. In conventional factories, management after storage in a product warehouse is unclear (reprocessing, stock disposal, etc.), and it is difficult to clearly grasp the yield. It is estimated that the percent stop and 1
A 0% to 15% increase in product yield will create a new cost competitiveness of 350 to 500 million yen per year for a production plant with a production volume of 3.5 billion yen per year.

Further, the sheet roll processing equipment according to the present invention is not a person skilled in conventional production planning and operation management of each process device, but a computer-based system.
Because the network manages all processes and information numerically and accurately in real time in an integrated and real-time manner, it is possible to automatically manage up to the income and expenditure integrated with the production and sales, and there is a direct merit of labor saving. There is no variation.

Further, by utilizing the mill roll storage for storing a large number of raw rolls, the frequency of changing the lot of the film forming machine can be reduced, and as a result, the effect of improving the yield on the upstream side is increased. .

[Brief description of the drawings]

FIG. 1 is an explanatory diagram for describing an embodiment of the present invention.

FIG. 2 is a schematic plan view of a sorting unit in the sorting device.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Production planning computer 2 Sheet winding machine 3 Sorting device 6 Strip-shaped sheet 9 Split sheet roll

──────────────────────────────────────────────────の Continuation of the front page (51) Int.Cl. ⁷ identification code FI B65H 35/02 B65H 35/02 (58) Field surveyed (Int.Cl. ⁷ , DB name) B65G 1/00-1/20 B26D 1/00-1/24 B26D 3/00-3/30 B26D 5/00-5/42 B23D 15/00-19/08 B23D 23/00-31/04 B23D 33/00-35/00 B65H 35 / 00-35/10

Claims (2)

(57) [Claims] A plurality of divided band according to claim 1] band-like sheet the required width
A sheet splitting winder for processing into a divided sheet roll by dividing the sheet into required sheets and winding the required length , a sorting device for sorting the split sheet roll, and a sheet splitting winder.
A production planning computer for formulating an operation plan,
The production planning computer receives the required division
Winding including sheet width and winding length for sheet roll
Specify specifications, quantity, delivery or shipping date, and sorting data
Remember, the strip-shaped sheet that can be supplied to the sheet splitting winder
Information about the sheet and the operation plan of the sheet splitting winder
When formulating the required split sheet rolls,
Search for items with delivery date or shipping time within the period and
Sheet division winding stored as the object of the image and stored
Information on the web-like sheet that can be supplied to the machine;
Required divided seat row stored as the target of the operation plan
Take-up specifications, including sheet width and take-up length
Based on the required
How to assign the split strips on the split sheet roll
Simulation operation for multiple assignments of
By minimizing the loss of
Therefore, it is necessary to process each split winding cycle of the sheet split winder.
Divide and roll the divided sheet roll
In the control computer provided in the machine,
Take-up specifications including sheet width and take-up length for each take-up cycle,
And output the sorting data.
Processes split sheet rolls based on the output winding specifications
And when the processed divided sheet roll is sent out
The sorting data is output to a split sheet via an output device.
Roll, the sorting device is configured to control the sheet roll
Read the sorting data assigned to the
Sorting the divided sheet rolls based on data
Sheet roll processing equipment that. 2. The sheet roll processing equipment according to claim 1,
Can be supplied by the production planning computer.
Strip of required split sheet roll for flexible strip
When deciding how to allocate the sheets, the loss of the belt-like sheet
In addition to minimizing
When changing the cutting blade of the slitter
Sheet roll processing setting decided to be unnecessary
Equipment.