JP5198352B2 - Touch roll or near roll movement control method and web winding device - Google Patents

Description

  The present invention relates to a touch roll or near roll movement control method interposed when winding a web around a winding core, and a web winding apparatus thereof.

2. Description of the Related Art Conventionally, in a web winding device, a touch roll or a near roll is interposed in winding of a web in order to prevent defects such as winding slip that occur in a winding process. Usually, the touch roll is pressure-bonded to the outermost surface of the web roll formed by winding the web with a substantially constant pressing force. On the other hand, the near roll is used when the web surface has irregularities, or when it is not preferable to press the web excessively during winding, and is positioned at a certain distance from the outermost surface of the web roll. The When winding the web, whether to perform touch winding using a touch roll or near roll using a near roll depends on the type of product and the line speed.
Here, a method of performing movement control of the touch roll or the near roll is known in order to maintain the positional relationship between the web roll and the touch roll or the near roll even when the winding operation is advanced and the web roll diameter is increased.

  For example, in the technique of Patent Document 1 relating to touch roll movement control in a film winder, the film supply speed detected by a sensor provided near the line and the encoder provided in a motor that drives the rotation of the film roll are detected. The film roll diameter is calculated based on the number of rotations of the film roll, and the position of the touch roll is controlled based on the calculated diameter. On the other hand, in Patent Documents 2 and 3, a beam sensor or an ultrasonic sensor is attached to an arm that supports the touch roll or the near roll, and the distance between the touch roll or the near roll and the take-up roll is directly detected by these sensors, and based on the distance. To control the movement of the near roll.

JP 2002-68539 A, paragraphs 0013 to 0026, FIGS. JP-A-5-338873, paragraphs 0006 to 0011, FIGS. JP, 10-194536, A paragraphs 0007-0010, Drawings 3-4

However, when the movement control of the touch roll or the near roll is performed by the web winding device using the technique of Patent Document 1, the web roll diameter cannot be calculated when the line is stopped. For this reason, when the line is stopped after the web roll has been rolled up to some extent, and then restarted, the web roll diameter measured by the operator is input to the web winding device. In addition, when the line is started while the core is changed while the line is stopped and the web is not wound, a worker inputs the core diameter to the web winding device.
However, there is a problem that the operator may input the core diameter or web roll diameter by mistake. For example, when an operator inputs a core diameter or web roll diameter larger than the actual diameter, movement control is started from a position where the touch roll or near roll is too far from the core or web roll. For this reason, if the line is started without being noticed by the operator, defects such as winding deviation occur. On the other hand, if a diameter smaller than the actual diameter is input, the touch roll or near roll comes too close to the core or web roll, the protection control by the limit switch or the like is activated, and the machine stops.

  On the other hand, in the techniques of Patent Documents 2 and 3, the sensor attached to the arm detects the distance between the core or web roll and the near roll or touch roll, regardless of the line stoppage. There is no need to enter the web roll diameter. However, it is often difficult to find a mounting position that does not interfere with other mechanisms (such as an arm or a cutter for replacing the core) attached to the web winding device. Further, the device cost is increased by the amount of the sensor.

  The present invention has been made to solve the above-described conventional problems, and positioning for starting movement control for a touch roll or a near roll that is movement-controlled based on a web roll diameter calculated from a line speed or the like. It is an object of the present invention to provide a movement control method and a web winding device that can accurately perform the operation.

  In order to achieve the object, the touch roll or near roll movement control method according to claim 1 intervenes when the web is wound around the winding core to form the web roll, and has a predetermined relationship with the web roll. In the movement control method of the touch roll or the near roll positioned so as to be held, the load applied to the movement motor by causing the touch roll or the near roll to approach the winding core or the web roll by driving the movement motor. By detecting an increase in torque, a position where the touch roll or the near roll is in contact with the core or the web roll is detected, and an initial position for starting movement control of the touch roll or the near roll is determined based on the position. It is characterized by that.

  The touch roll or near roll movement control method according to claim 2 is the touch roll or near roll movement control method according to claim 1, wherein the touch roll or the near roll can set a plurality of air pressures. Driven by the moving motor via an air cylinder, the detection of the increase in load torque has a threshold value larger than the mechanical friction torque detected before the touch roll or the near roll comes into contact with the core or the web roll. The plurality of air pressures set in advance include a detection air pressure that is set such that a load torque when the touch roll or the near roll comes into contact with the core or the web roll is larger than the threshold value. Before detecting the increase in load torque, the air pressure of the air cylinder should be set to the detection air pressure. The features.

  The touch roll or near roll movement control method according to claim 3 is the touch roll or near roll movement control method according to claim 1 or 2, wherein the core or web roll is moved from a predetermined origin position. The movement distance of the touch roll or the near roll until it touches is calculated, the first diameter of the winding core or the web roll is calculated based on the movement distance, and until the predetermined time elapses from the line start, the first The movement control is performed based on one diameter, and after a predetermined time has elapsed, the movement control is performed based on the second diameter of the web roll calculated from the rotational speed of the winding core and the speed of the line.

  A web winding device according to a fourth aspect uses the touch roll or near roll movement control method according to any one of the first to third aspects.

  In the touch roll or near roll movement control method according to claim 1, by detecting an increase in load torque applied to the moving motor, the position where the touch roll or near roll is actually in contact with the core or web roll is detected. Based on the position, the initial position for starting the movement control of the touch roll or the near roll is determined. Therefore, even if the operator does not input the core diameter or the web roll diameter into the web winding device, the accurate movement control initial position can be determined with a simple configuration. Thereby, winding deviation, a machine stop, etc. by a line starting in the state where a touch roll or a near roll is too close or too far with respect to a core or a web roll can be prevented. Further, since it is not necessary to provide a sensor for directly detecting the distance between the core or web roll and the touch roll or near roll, the cost is reduced.

  In the touch roll or near roll movement control method according to claim 2, the touch roll or the near roll is driven via the air cylinder, and the touch roll or the near roll comes into contact with the core or the web roll when detecting an increase in load torque. A threshold value larger than the mechanical friction torque detected before is set in advance, and the air pressure of the air cylinder is set so that the load torque when the touch roll or near roll comes into contact with the core or web roll is larger than the threshold value. Including the set detection air pressure, the air pressure of the air cylinder is set to the detection air pressure before detecting an increase in load torque. Therefore, it is possible to reliably detect the load torque change of the moving motor when the touch roll or the near roll comes into contact with the core or the web roll.

  In the touch roll or near roll movement control method according to claim 3, the first diameter of the roll or web roll is determined based on the movement distance of the touch roll or near roll from the predetermined origin position until it comes into contact with the roll or web roll. The movement control is performed based on the first diameter until a predetermined time has elapsed from the start of the line, and after the predetermined time has elapsed, the second web roll calculated from the rotational speed of the winding core and the speed of the line is calculated. Movement control is performed based on the diameter. Therefore, immediately after the line start, the movement control of the touch roll or the near roll can be performed based on the accurate diameter of the core or the web roll due to the touch roll or the near roll contacting the web roll. Further, the second diameter of the web roll calculated from the rotation speed and the line speed of the winding core is generally used for movement control of the touch roll or the near roll, but has a large variation immediately after the line start. For this reason, it is possible to accurately control the movement of the touch roll or the near roll by switching to the movement control based on the second diameter after a predetermined time has elapsed from the line start and the second diameter becomes accurate. .

It is a mimetic diagram showing a web winding device in the state of touch winding which winds up a web while a touch roll presses the outside surface of a web roll concerning this embodiment. It is a schematic diagram showing the state of the near winding which winds a web based on this embodiment, keeping a fixed space | interval with respect to a web roll. It is a graph which shows the load torque change of the movement motor accompanying the movement of the touch roll or near roll which concerns on this embodiment. (A) is the case where the air pressure of the air cylinder is the detection air pressure, and (B) is the case of the normal air pressure. It is a schematic diagram which shows the initial position determination process in the movement control of the touch roll or near roll which concerns on this embodiment. It is a flowchart regarding the initial position determination process in the movement control of the touch roll or the near roll according to the present embodiment. It is a flowchart regarding the movement control after the line start of the touch roll or near roll which concerns on this embodiment.

DESCRIPTION OF EMBODIMENTS Hereinafter, a touch roll or near roll movement control method and a web winding device according to the present invention will be described in detail with reference to the drawings based on embodiments of the present invention.
Although the touch roll 4 and the near roll 5 are separately described below, in the present embodiment, the two are the same roll in the same web winding device 1, and when touch winding is performed depending on the type of product or the like, the touch roll 4 and the near roll 5 are touched. The roll 4 is used, and the near roll 5 is used when performing the near winding.
First, the web winding device 1 in the state of touch winding according to the present embodiment will be outlined based on FIG.

  In FIG. 1, the web W is fed leftward. The winding core 2 is formed in a hollow shape, and both ends thereof are gripped by a pair of chuck mechanisms (not shown), and are rotated by a rotary motor 33 at a predetermined reduction ratio G. The reduction ratio G is defined by a diameter ratio between a timing pulley 35 fixed to the motor drive shaft 34 and a timing pulley (not shown) connected to one of the chuck mechanisms described above. The two timing pulleys are ruled by a timing belt 32. When the web W is wound around the core 2, the web roll 3 is obtained.

  Further, on the upstream side (right side in FIG. 1) of the web winding device 1, a line feed roll 23 and a contact roll 26 for feeding the web W are provided, and the line feed motor 20 is connected to the line at a predetermined reduction ratio. The feed roll 23 is driven to rotate. This reduction ratio is defined by the diameter ratio between the timing pulley 22 fixed to the drive shaft 21 and the timing pulley 24 connected to the line feed roll 23. These two timing pulleys are ruled on the timing belt 25. In addition, a touch roll 4 is provided between the web roll 3 and the line feed roll 23 so as to be movable forward and backward with respect to the core 2 or the web roll 3 by a moving mechanism described later.

  When the line starts and the line feed motor 20 is driven and the rotary motor 33 is driven, the drive shaft 21 of the line feed motor 20 is rotated, and the line from the timing pulley 22, the timing belt 25, and the timing pulley 24 is The rotation of the line feed motor 20 is transmitted to the feed roll 23. Thereby, the web W is line-fed downstream at a predetermined line speed. At the same time, the drive shaft 34 of the rotary motor 33 is rotated, and the rotation of the rotary motor 33 is transmitted to the timing pulley 35, the timing belt 32, and the core 2. Thereby, the web W is wound around the peripheral surface of the web roll 3 via the touch roll 4.

Next, a mechanism related to the movement control of the touch roll 4 will be described.
The rotating shaft of the touch roll 4 is rotatably supported by the bearing 12, and the bearing 12 is fixed to the tip of the air cylinder 7. A linear bearing 11 is fixed to the lower portion of the air cylinder 7, and a linear guide 8 that engages with the linear bearing 11 is laid on a frame 10 fixed to the external fixing member. Therefore, the touch roll 4 and the air cylinder 7 are guided by the linear guide 8 and can travel in the left-right direction in FIG. 1, that is, in the direction approaching / separating from the web roll 3.
A moving motor 6 is attached to the frame 10 at the opposite end (right side in FIG. 1) of the web roll 3 in the linear guide 8. A touch is provided via the air cylinder 7 by a ball screw 9 provided along the moving motor 6 and the linear guide 8 and rotated by the moving motor 6 and a ball screw nut (not shown) fixed to the lower portion of the air cylinder 7. The roll 4 can be advanced and retracted toward the web roll 3.

  Here, the moving motor 6 of the present embodiment may be a simple DC motor or the like as long as the load torque and the current have a proportional relationship. However, the movement control of the touch roll 4 or the near roll 5 is performed with high accuracy after the line start. Considering what to do, AC servo motors, vector motors and the like are preferred. A current detection unit (not shown) is connected to the moving motor 6, and a current value detected by the current detection unit is converted into a load torque by a control unit (not shown).

  As shown in FIG. 2, the mechanism related to the movement control related to the near roll 5 is substantially the same as that related to the touch roll 4. The only difference is that the near roll 5 always maintains a constant distance M with respect to the web roll 3.

Next, in FIG. 3, the air pressure of the air cylinder 7 and the load torque change of the moving motor 6 will be outlined. When the touch roll 4 or the near roll 5 approaches the core 2 or the web roll 3 by the moving mechanism described above and actually comes into contact, the load torque of the moving motor 6 needs to overcome the reaction force of the air cylinder 7. 3 Increases as shown in (A) and (B).
However, during the movement before the touch roll 4 or the near roll 5 comes into contact with the web roll 1 or the core 2, the moving motor 6 requires a load torque corresponding to mechanical friction such as a linear guide. Therefore, the load torque threshold for detecting that the touch roll 4 or the near roll 5 is in contact with the web roll 3 or the core 2 is set to be larger than the mechanical frictional torque, and the moving motor 6 at the time of the contact. It is necessary to set the air pressure of the air cylinder 7 so that the load torque of the air cylinder 7 becomes larger than the threshold value.

  In the present embodiment, the air pressure sent to the air cylinder 7 is provided with two stages of a detection air pressure Pa and a weaker normal air pressure Pb by an air pressure control valve (not shown). The switching of the air pressure can be performed based on a command from a control unit (not shown) by the action of an air pressure control valve of an air pipe (not shown). As shown in FIG. 3A, when the air pressure of the air cylinder 7 is the detection air pressure Pa, when the touch roll 4 or the near roll 5 comes into contact with the web roll 3 or the core 2, the load torque of the moving motor 6 is It becomes larger than a threshold value, and a contact can be detected. As shown in FIG. 3B, when the touch roll 4 or the near roll 5 is in contact with the web roll 3 or the core 2 in the case of the normal air pressure Pb, the load torque does not become larger than the threshold value, so the contact is detected well. Can not.

Next, an initial position determination process for starting movement control of the touch roll 4 or the near roll 5 in the winding device having the above-described configuration will be described with reference to FIGS.
FIG. 4 shows an initial position determination process for the core 2, and the initial position determination process for the core 2 will be described below. However, the initial position determination for the web roll 3 that has been wound to some extent is performed in the same manner as described below. Is called.
As shown in FIG. 4, in a state before the start of movement control, the touch roll 4 or the near roll 5 is at a position closest to the moving motor 6 on the linear guide 8 (right side in FIG. 4) as represented by a solid line. . The tip end of the web roll side of the touch roll 4 or near roll 5 at this time is set as the origin position.
As shown in FIG. 5, before starting the line, the operator presses an approach start button to bring the touch roll 4 or the near roll 5 closer to the core 2. Then, in step (hereinafter referred to as S) 1, the air pressure in the air cylinder 7 is switched from the weak normal air pressure Pb to the strong detection air pressure Pa in accordance with a command from a control unit (not shown).

Next, in S <b> 2, the moving motor 6 rotates, and the touch roll 4 or the near roll 5 moves together with the air cylinder 7 to the core 2 side (left side in FIG. 4).
If the touch roll 4 or the near roll 5 does not come into contact with the winding core 2 even if it moves to some extent, the load torque of the moving motor 6 does not exceed the threshold (S3: NO), and a control unit (not shown) is used to prevent erroneous determination in S4 The timer built in is reset, the process returns to S2, and the moving motor 6 further rotates to move the touch roll 4 or the near roll 5 to the core 2 side.
Thereafter, the touch roll 4 or the rear roll 5 is in contact with the core 2 at the position indicated by the dotted line in FIG. 4 (the front end of the touch roll 4 or near roll 5 at this time is the stop position). It becomes. At this time, as shown in FIG. 3A, since the air pressure of the air cylinder 7 is the detection air pressure, the load torque applied to the moving motor 6 exceeds the threshold value. In this case (S3: YES), in S5, a control unit (not shown) sets a built-in timer for preventing erroneous determination, and integrates the time from when the load torque of the mobile motor 6 exceeds the threshold value. . Then, unless the set time is counted up by the built-in timer (S6: NO), the processes of S3 to S5 are repeated.
When the set time has elapsed and the timer is counted up (S6: YES), the rotation of the moving motor 6 is controlled so as to stop the touch roll 4 or the near roll 5 in S7.

Next, in S8, the core diameter is calculated by a control unit (not shown) based on the moving distance of the touch roll 4 or the near roll 5 from the origin position to the stop position. As shown in FIG. 4, when the distance from the origin position to the winding rotation center of the core 2 is L0 (mm) and the movement distance from the origin position to the stop position is L1 (mm), the core diameter d ( mm) is d = 2 (L0-L1)
It is represented by

  Next, in S9, the core diameter d calculated in S8 is set as a first diameter D1 (mm) described later. In S10, when the touch roll 4 or the near roll 5 is used as the near roll 5 (S10: YES), in S11, the moving motor 6 rotates in the reverse direction, and the near roll 5 is moved away from the core 2 by a certain distance M. Move. When used as the touch roll 4 (S10: NO), the touch roll 4 remains at the stop position described above (see FIG. 4).

  Next, in S12, after the pressure setting of the air cylinder 7 is returned from the detection air pressure to the normal air pressure, the initial position determination process of the touch roll 4 or the near roll 5 is ended.

Next, the movement control after the line start will be described with reference to FIG.
After the start of the line, the touch roll 4 or the near roll 5 is controlled to move so as to maintain the same distance relationship even if the web roll 3 is rolled up. This is because a control unit (not shown) calculates the diameter of the web roll 3 The moving motor 6 is driven to rotate so as to move the touch roll 4 or the near roll 5 by the amount of movement calculated based on the above.

  Here, the line start is performed in a state where the above-described initial position determination process is completed and the touch roll 4 or the near roll 5 is stopped at an appropriate initial position. In S21, movement control is performed based on the first diameter D1 set in S9 of the initial position determination process described above. That is, in S21, the touch roll 4 remains at the stop position (see FIG. 4), and the near roll 5 remains at a position separated from the core 2 by a fixed distance M from the stop position.

Thereafter, in S22, the second diameter of the web roll 3 is calculated. Specifically, the second diameter D2 (mm) is V (m / min) as the line speed at which the web W is supplied, and Nw (rev / min) as the rotation speed of the core 2, that is, the rotation speed of the web roll 3. Then,
D2 = 1000V / πNw
It is calculated by the following formula.
Here, the line speed V is a line speed command value preset in a control unit (not shown) in the web winding device 1 described above, or a rotational speed of a line feed motor that drives a line feed roll 23 serving as a line speed reference. Etc. Further, the rotational speed of the core 2 can be obtained from the rotational speed of the rotary motor 33 and the reduction ratio G described above. The rotational speed of the rotary motor 33 is determined based on a preset command value or the rotary motor 33 as an encoder. It is calculated | required by providing etc.

  In S23, when a predetermined time elapses from the line start, in S24, the winding diameter that is the basis of the movement control is switched from the first diameter D1 to the second diameter D2, and the touch roll 4 or until the line stops. The movement control of the near roll 5 is performed.

  As described above, in the touch roll or near roll movement control method according to this embodiment, the touch roll 4 or the near roll 5 is actually in contact with the core 2 or the web roll 3 by detecting an increase in load torque applied to the movement motor 6. The initial position for starting the movement control of the touch roll 4 or the near roll 5 is determined based on the obtained position. Therefore, an appropriate movement control initial position can be determined with a simple configuration without inputting the diameters of the web roll 3 and the core 2. As a result, it is possible to prevent winding slippage or machine stoppage due to the start of the line in a state where the touch roll 4 or the near roll 5 is too close or too far from the core 2 or the web roll 3. Moreover, since it is not necessary to provide a sensor for directly detecting the distance between the core 2 or the web roll 3 and the touch roll 4 or the near roll 5, the cost is reduced.

  Further, the touch roll 4 or the near roll 5 is driven via the air cylinder 7, and in the detection of an increase in load torque, the touch roll 4 or the near roll 5 is larger than the mechanical friction torque before the touch roll 4 or the near roll 5 contacts the core 2 or the web roll 3. A threshold value is set in advance, and the air pressure of the air cylinder 7 is the detection air set so that the load torque when the touch roll 4 or the near roll 5 contacts the winding core 2 or the web roll 3 is larger than the threshold value. The air pressure of the air cylinder 7 is set to the detection air pressure before detecting an increase in load torque. Therefore, it is possible to reliably detect a load torque change of the moving motor 6 when the touch roll 4 or the near roll 5 contacts the winding core 2 or the web roll 3.

  Further, the first diameter of the core 2 or the web roll 3 is calculated based on the moving distance of the touch roll 4 or the near roll 5 from the origin position to the stop position in contact with the core 2 or the web roll 3, and a predetermined time from the line start is calculated. Until the passage of time, movement control is performed based on the first diameter, and after a predetermined time has elapsed, movement control is performed based on the second diameter of the web roll calculated from the rotational speed and line speed of the core. Therefore, immediately after the line start, the movement control of the touch roll 4 or the near roll 5 can be performed based on the accurate first diameter when the touch roll 4 or the near roll 5 is in contact with the core 2 or the web roll 3. Further, the second diameter of the web roll calculated from the rotational speed and the line speed of the core 2 has a large variation immediately after the start of the line, and therefore the second diameter becomes accurate after a predetermined time has elapsed. The movement control based on the diameter can be switched, and the movement control of the touch roll 4 or the near roll 5 can be accurately performed after the line start.

  Note that this embodiment does not limit the gist of the present invention, and various improvements and modifications can be made without departing from the gist of the present invention. For example, in this embodiment, the movement control start position is positioned before the line start, but it may be performed after the line start. In this case, switching from the movement control based on the first diameter to the movement control based on the second diameter is performed after a predetermined time has elapsed since the touch roll or the near roll is brought into contact with the web roll. In the present embodiment, the touch roll or the near roll is switched from the first diameter obtained by contacting the core or the web roll after a predetermined time from the line start to the second diameter obtained by another calculation. It is conceivable to make another adjustment in order to make the transition from the first diameter to the second diameter smooth, such as reflecting the numerical value of the first diameter in the numerical value of the two diameters.

DESCRIPTION OF SYMBOLS 1 Web winding device 2 Winding core 3 Web roll 4 Touch roll 5 Near roll 6 Moving motor 7 Air cylinder
8 Linear guide
9 Ball screw 11 Linear bearing 20 Line feed motor
33 Rotation motor W web M Distance between web roll or core and near roll in near winding
D1 First diameter of core or web roll D2 Second diameter of web roll

Claims (4)

In the touch roll or near roll movement control method, which is interposed when the web is wound around the core and the web roll is formed, and is positioned so as to maintain a predetermined relationship with the web roll.
The touch roll or the near roll is moved closer to the core or the web roll by driving a moving motor,
By detecting an increase in load torque applied to the moving motor, a position where the touch roll or the near roll is in contact with the winding core or the web roll is detected, and movement control of the touch roll or the near roll is started based on the position. A touch roll or near roll movement control method, wherein an initial position to be determined is determined. The touch roll or the near roll is driven by the moving motor via an air cylinder capable of setting a plurality of air pressures,
In the detection of the load torque increase, a threshold larger than the mechanical friction torque detected before the touch roll or the near roll comes into contact with the core or the web roll is set in advance.
The plurality of air pressures include a detection air pressure set so that a load torque when the touch roll or the near roll is in contact with the core or the web roll is larger than the threshold value,
2. The touch roll or two-roll movement control method according to claim 1, wherein an air pressure of the air cylinder is set to the detection air pressure before detecting an increase in the load torque. Calculate the moving distance of the touch roll or the near roll from a predetermined origin position until it comes into contact with the core or the web roll,
Based on the moving distance, a first diameter of the core or the web roll is calculated,
The movement control is performed based on the first diameter until a predetermined time has elapsed from the start of the line, and after the predetermined time has elapsed, the second diameter of the web roll is calculated from the rotational speed of the core and the speed of the line. 3. The touch roll or near roll movement control method according to claim 1, wherein movement control is performed based on the movement control.   A web winding device using the touch roll or near roll movement control method according to any one of claims 1 to 3.

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