JP7679687B2 - Building material manufacturing system, control device, building material manufacturing method, building material, and program - Google Patents

Description

The present invention relates to a building material manufacturing system, a control device, a building material manufacturing method, a building material, and a program.

A long building material used in interior construction work, etc., is known in which a long flat plate member is wound around the periphery of a long rectangular core material. On the inside of the flat plate member, V-shaped grooves extending in the longitudinal direction are cut at the locations where the core material is bent along the corners (see Patent Document 1).

Japanese Patent Application Publication No. 7-148833

The dimensions of the above building materials are influenced in a complex and cumulative manner by the tendencies of various processing equipment, the dimensions of the core material, and the dimensions of the flat plate members. For this reason, in order to maintain the quality of building materials, it is desirable to stabilize the dimensions of building materials. In particular, the position of the cutting grooves in the flat plate members contributes greatly to the dimensions of the building materials, so high precision is required for the position of the cutting grooves.

However, conventionally, the adjustment of the cutting groove position is done by each worker based on the worker's own experience, and there is variation in the cutting groove position between workers, which makes it difficult to maintain quality.

The present invention has been made to solve the above-mentioned problems in the conventional technology, and aims to provide a building material manufacturing system, a control device, a building material manufacturing method, and a building material and program manufactured by such a building material manufacturing method, which can appropriately correct the position of the cutting groove in the flat plate member in the above-mentioned building material and can stably cut the cutting groove.

To achieve the above object, the building material manufacturing system described in the present application is a building material manufacturing system that includes a cutting device that cuts a cutting groove extending in the longitudinal direction on one side of a long flat plate member, and a winding device that bends the flat plate member so that the cutting groove is on the inside and winds it around the periphery of a long rectangular core material, and that manufactures building materials by winding the flat plate member around the core material, and is characterized in that it includes a building material measuring device that measures the dimensions of the manufactured building material, and a control device that controls the cutting device, and the control device is characterized in that it includes a correction means that corrects the cutting position of the cutting device based on the dimensions of the manufactured building material measured by the building material measuring device relative to the tolerances of the dimensions of the building material.

The building material manufacturing system may further include a core material measuring device that measures dimensions related to the core material, and a flat plate member measuring device that measures dimensions related to the flat plate member, and the correction means may further correct the cutting processing position of the cutting device based on the dimensions related to the core material measured by the core material measuring device and the dimensions related to the flat plate member measured by the flat plate member measuring device.

In addition, in the building material manufacturing system, the control device may further include a tolerance adjustment means for adjusting the tolerance of the dimensions related to the building material based on the dimensions related to the core material measured by the core material measuring device and the dimensions related to the flat plate member measured by the flat plate member measuring device.

The building material manufacturing system may further include a groove position measuring device that measures the position of the cutting groove cut into the flat plate member, and the correction means may further correct the cutting position of the cutting device based on the position of the cutting groove measured by the groove position measuring device.

The building material manufacturing system may further include an environmental measurement device that measures the environmental conditions around the winding device, and the correction means may further correct the cutting position of the cutting device based on the environmental conditions around the winding device measured by the environmental measurement device.

The control device described in this application is a control device that controls a cutting device that cuts a cutting groove extending in the longitudinal direction on one side of a long flat plate member in order to manufacture a building material by wrapping the flat plate member around the circumferential surface of a long rectangular core material, and is characterized by having a means for acquiring dimensional measurements of the manufactured building material, and a means for correcting the cutting position of the cutting device based on the acquired dimensional measurements of the manufactured building material relative to the dimensional tolerances of the building material.

The control device may further include a means for acquiring dimensional measurements of the core material and the flat plate member, and a means for correcting the cutting position of the cutting device based on the acquired dimensional measurements of the core material and the flat plate member.

The control device may further include a means for adjusting the tolerance of the dimensions of the building material based on the acquired measured values of the dimensions of the core material and the measured values of the dimensions of the flat plate member.

The control device may further include a means for acquiring position information of the cutting groove, and a means for correcting the cutting position of the cutting device based on the acquired position information of the cutting groove.

The control device may further include a means for acquiring information about the environmental conditions surrounding the winding process in which the flat plate member is bent so that the cutting groove is on the inside and wound around the circumferential surface of the core material, and a means for correcting the cutting position of the cutting device based on the acquired information about the environmental conditions surrounding the winding process.

The method for manufacturing building materials described in the present application uses a cutting device that cuts a cutting groove extending in the longitudinal direction on one side of a long flat plate member, and a winding device that bends the flat plate member so that the cutting groove is on the inside and winds it around the periphery of a long rectangular core material, to manufacture a building material by winding the core material with the flat plate member, and is characterized in that the dimensions of the manufactured building material are measured with a building material measuring device, the cutting device is controlled by a control device, and the cutting position by the cutting device is corrected based on the dimensions of the manufactured building material measured by the building material measuring device relative to the allowable values of the dimensions of the building material, under the control of the control device.

The building materials described in this application are characterized by being manufactured using the above-mentioned building material manufacturing method.

The program described in this application is a program for causing a computer to function as the control device.

According to the present invention, the cutting grooves in the flat plate member are cut stably, making it possible to manufacture building materials by wrapping the flat plate member around the periphery of the core material with high precision and stability.

FIG. FIG. 2 is an exploded view showing the configuration of the building material. 1 is a schematic diagram of a building material manufacturing system according to a first embodiment. FIG. 1 is a block diagram showing a configuration of a building material manufacturing system according to a first embodiment. FIG. 1 is a flowchart showing a manufacturing procedure for a building material. 5 is a flowchart showing a part of a processing procedure performed by a control device in the first embodiment. FIG. 13 is a diagram showing an example of a correction table for a first correction unit; FIG. 11 is a diagram showing an example of a correction table for a second correction means; FIG. 11 is a block diagram showing the configuration of a building material manufacturing system in a second embodiment. 10 is a flowchart showing a part of a processing procedure performed by a control device in the second embodiment.

The following describes an embodiment of the present invention with reference to the attached drawings. In the following description, identical parts are given the same reference numerals, and the names and functions of these parts are also the same. Therefore, duplicate descriptions of these parts are omitted.

(Embodiment 1)
- Configuration of building material manufacturing system -
Fig. 1 is a front view showing building material B. Fig. 2 is an exploded view showing the configuration of building material B. In the figure, the symbol W indicates the width direction (left-right direction), with the -W direction (negative W direction) being the left direction and the +W direction (positive W direction) being the right direction. Note that the figure is for convenience of explanation and does not show any dimensional ratios between the components of the actual building material B.

The building material manufacturing system A is a manufacturing system for manufacturing a long building material B that is mainly used for interior construction work. The building material B is manufactured by winding a long flat plate member 9 around the periphery of a long rectangular core material 8 (see Figs. 1 and 2). The core material 8 is made of, for example, ordinary plywood as specified in the Japanese Agricultural Standards (JAS). In this embodiment, the core material 8 is made of softwood plywood. The flat plate member 9 is made of, for example, medium density fiberboard (MDF) or the like. In this embodiment, the flat plate member 9 is made of MDF classified as U-type or M-type by adhesive as specified in JIS A5905. A decorative sheet 90 with a wood grain pattern, for example, is attached to the outer surface of the flat plate member 9 (see Figs. 1 and 2). The decorative sheet 90 is made of, for example, an olefin-based resin sheet or the like.

On the inside of the flat plate member 9, V-shaped cutting grooves 95a to 95d extending in the longitudinal direction are cut at cutting positions Pa to Pd, respectively, according to the places where the flat plate member 9 is bent along the corners 85a to 85d of the core material 8 (see FIG. 2). The cutting grooves 95a to 95d make it possible to bend the flat plate member 9 along the corners 85a to 85d of the core material 8. The flat plate member 9 is bonded to the core material 8 by an adhesive (not shown). For example, a resin-based emulsion is used as the adhesive. In this embodiment, a polyvinyl acetate resin-based emulsion is used as the adhesive. The overall width 96 of the flat plate member 9 is set smaller than the outer circumference of the core material 8. Therefore, when the flat plate member 9 is wrapped around the periphery of the core material 8, dust portions X5 and X6 are formed on the top surface of the building material B by both side ends of the flat plate member 9.

Figure 3 is a schematic diagram of the building material manufacturing system A in the first embodiment. Figure 4 is a block diagram showing the configuration of the building material manufacturing system A in the first embodiment. The building material manufacturing system A is a manufacturing system that cuts the cutting grooves 95a to 95d in the flat plate member 9, bends the flat plate member 9 so that the cutting grooves 95a to 95d are on the inside, and winds the flat plate member 9 around the core material 8 to manufacture the building material B. From the upstream side, the system is equipped with a cutting device 10, an adhesive application device 11, and a winding device 12 (collectively referred to as "various processing devices") (see Figures 3 and 4). On the upstream side of the cutting device 10, a flat plate member input section 191 into which the flat plate member 9 is input is provided. Between the adhesive application device 11 and the winding device 12, a core material input section 190 into which the core material 8 is input is provided. In the building material manufacturing system A, the core material 8, the flat plate member 9, and the building material B are transported by a transport device 19. The transport device 19 is formed, for example, from a conveyor.

The cutting device 10 is a device that cuts the cutting grooves 95a to 95d in sequence into the flat plate member 9.

The adhesive applicator 11 is a device that applies adhesive to the inner surface of the flat plate member 9 that comes into contact with the core material 8.

The winding device 12 is a device that winds the flat plate member 9 around the circumferential surface of the core material 8, and has a pressure roller and a folding arm (not shown). The winding device 12 winds the flat plate member 9 around the circumferential surface of the core material 8 as follows. First, the bottom surface of the core material 8 is pressed against the center of the flat plate member 9 by the pressure roller. Next, both ends of the flat plate member 9 are folded along the corners 85b and 85c of the core material 8 by the folding arm. Then, both ends of the flat plate member 9 are folded along the corners 85a and 85d of the core material 8 by the folding arm, so that the flat plate member 9 is wound around the circumferential surface of the core material 8.

In addition to the above configuration, the building material manufacturing system A includes a core material measuring device 20, a flat member measuring device 21, a building material measuring device 22 (collectively referred to as the "various measuring devices"), and a control device 5 that controls various devices including the cutting device 10 (see Figures 3 and 4).

The core material measuring device 20 is a device that measures dimensions related to the core material 8, and is provided in the core material input section 190. In this embodiment, the "dimensions related to the core material" include the width 86 and thickness 87 of the core material 8 (see FIG. 2).

The core material measuring device 20 has a width measuring section 200 that measures the width 86 of the core material 8, and a thickness measuring section 201 that measures the thickness 87 of the core material 8 (see FIG. 4). For example, a contact displacement gauge is used for the width measuring section 200 and the thickness measuring section 201.

The core material measuring device 20 outputs the measurements taken by the width measuring unit 200 and the thickness measuring unit 201 to the control device 5 as core material dimension measurements.

The flat plate member measuring device 21 is a device for measuring dimensions related to the flat plate member 9, and is provided in the flat plate member input section 191. In this embodiment, the "dimensions related to the flat plate member" include the thickness 97 of the flat plate member 9 (see FIG. 2).

The flat member measuring device 21 has a flat member thickness measuring section 210 that measures the thickness 97 of the flat member 9 (see FIG. 4). The flat member thickness measuring section 210 uses, for example, a laser displacement meter.

The flat member measuring device 21 outputs the measurement value measured by the flat member thickness measuring unit 210 to the control device 5 as the flat member dimension measurement value.

The building material measuring device 22 is a device for measuring dimensions related to the manufactured building material B, and is provided downstream of the winding device 12. In this embodiment, the "dimensions related to the building material" include various measurements such as the widths X1, X2 at both the top and bottom ends of the building material B, the thicknesses X3, X4 at both the left and right ends of the building material B, the width of the chipped portions X5, X6, the gaps X7-X14 between the side surfaces of the cut grooves 95a-95d of the flat plate member 9 at the corners of the building material B where the side surfaces face each other, and the waviness X15, X16 of the chipped portions X5, X6 (see FIG. 1). In this embodiment, the "external dimensions" of the building material B refer to the widths X1, X2 and thicknesses X3, X4.

The building material measuring device 22 has an outer dimension measuring section 220 that measures the outer dimensions of building material B, a gap measuring section 221 that measures gaps X7 to X14, a dust measuring section 222 that measures the width of dust sections X5 and X6 of building material B, and a waviness measuring section 223 that measures waviness X15 and X16 (see FIG. 4). For example, a contact type displacement meter is used for the outer dimension measuring section 220. For example, a laser displacement meter is used for the gap measuring section 221, and for example, a scanning type laser displacement meter is used for the dust measuring section 222 and the waviness measuring section 223.

The building material measuring device 22 outputs the measurements taken by the external dimension measuring unit 220, the gap measuring unit 221, the dust measuring unit 222 and the waviness measuring unit 223 to the control device 5 as building material dimension measurement values.

The control device 5 is communicatively connected to the cutting device 10, adhesive application device 11, winding device 12, core material measuring device 20, flat plate component measuring device 21, building material measuring device 22 and conveying device 19.

The control device 5 has a processing unit 50 such as a CPU (Central Processing Unit), a storage unit 51 including a non-volatile memory such as a ROM (Read Only Memory) and a volatile memory such as a RAM (Random Access Memory), a display unit 52 consisting of a liquid crystal display or the like that shows the cutting processing state of the cutting device 10, and an input unit 53 that acquires data from an external device (see FIG. 4). The processing unit 50, storage unit 51, display unit 52, and input unit 53 are connected to each other by a bus line (not shown).

The memory unit 51 stores a control program 510, cutting parameters 511, dimensional reference values 512, building material dimensional tolerances 513, and a correction table 514. The memory unit 51 also stores measurement values (not shown) obtained from various measuring devices.

The control program 510 is stored in the ROM of the storage unit 51. Under the control of the processing unit 50, the control program 510 stored in the ROM is read out and loaded onto the RAM, whereby the control program 510 is executed. Note that the control program 510 is not limited to the above, and may be read from a recording medium such as a HDD, or downloaded from a network such as a LAN (Local Area Network).

The cutting parameters 511 include the machining width and cutting positions Pa to Pd of the cutting grooves 95a to 95d. In this embodiment, the cutting positions Pa to Pd are set as distance values to the right (+W direction) of the left edge (-W direction edge) of the flat plate member 9, which is the machining origin O (see FIG. 2).

The dimension reference values 512 include reference values corresponding to the dimensions of the core material 8 and the dimensions of the flat plate member 9.

The building material dimension tolerances 513 correspond to the "dimension tolerances for building materials" described in the claims, and include the upper and lower limits of the allowable range for each dimension for building material B.

The correction table 514 (514a, 514b) is a calculation table used to correct the cutting positions Pa to Pd of the cutting grooves 95a to 95d. The correction table 514 contains predetermined correction conditions, correction amounts, and correction directions.

-Manufacturing procedures for building materials-
FIG. 5 is a flow chart showing the manufacturing procedure of the building material B.
Next, a procedure for manufacturing the building material B by the building material manufacturing system A as described above will be described with reference to the flow chart of FIG.

First, after the flat plate member 9 is fed into the flat plate member feed section 191, in step S1, the processing section 50 of the control device 5 causes the flat plate member measuring device 21 to measure the thickness 97 of the flat plate member 9. In step S2, the processing section 50 causes the cutting device 10 to cut the cutting grooves 95a to 95d into the flat plate member 9. In step S3, the processing section 50 causes the adhesive application device 11 to apply adhesive to the inner surface of the flat plate member 9.

Furthermore, after the core material 8 is fed into the core material feed section 190, in step S4, the processing section 50 causes the core material measuring device 20 to measure the width 86 and thickness 87 of the core material 8. After step S4, the processing section 50 causes the conveying device 19 to convey the core material 8 to the winding device 12.

In step S5, the processing unit 50 causes the winding device 12 to wind the flat member 9 around the circumferential surface of the core material 8. Step S5 corresponds to the "winding process" described in the claims. Finally, in step S6, the processing unit 50 causes the building material measuring device 22 to measure the dimensions of the building material B, thereby completing the production of the building material B.

The timing at which the processing unit 50 causes the core material measuring device 20 to measure the width 86 and thickness 87 of the core material 8 is not limited to the above, and may be, for example, before the processing unit 50 causes the cutting device 10 to cut the cutting grooves 95a to 95d.

The dimensions of the building material B manufactured by the building material manufacturing system A as described above are influenced in a complex and cumulative manner by the tendencies of the various processing devices, the dimensions of the core material 8, and the dimensions of the flat plate member 9. In order to maintain the quality of the building material B, it is desirable to stabilize the dimensions of the building material B. In particular, the positions of the cutting grooves 95a-95d have a large contribution to the dimensions of the building material B, so high precision is required for the positions of the cutting grooves 95a-95d.

The control device 5 described in this application is equipped with a correction means for correcting the cutting positions Pa to Pd of the cutting grooves 95a to 95d of the flat plate member 9. The correction means makes it possible to wind the flat plate member 9 around the circumferential surface of the core material 8 with high precision and stability.

In this embodiment, the correction means includes a first correction means for correcting the cutting positions Pa to Pd of the cutting parameters 511 based on the dimensions of the core material 8 measured by the core material measuring device 20 and the dimensions of the flat plate member 9 measured by the flat plate member measuring device 21, and a second correction means for correcting the cutting positions Pa to Pd of the cutting parameters 511 based on the dimensions of the building material B measured by the building material measuring device 22 relative to the building material dimension tolerance 513.

The first correction means corrects the cutting positions Pa to Pd to match the dimensions of the core material 8 and the dimensions of the flat plate member 9, which has the effect of reducing the influence of the dimensions of the core material 8 and the dimensions of the flat plate member 9 on the dimensions of the building material B.

When the dimensions of building material B are larger or smaller than the building material dimension tolerance 513, the second correction means corrects the cutting processing positions Pa to Pd to offset the deviation of the dimensions of building material B from the building material dimension tolerance 513, thereby reducing the effect of various processing devices on the dimensions of building material B.

The control device 5 in this embodiment further includes a tolerance adjustment means for adjusting the building material dimension tolerance 513 based on the dimensions of the core material 8 measured by the core material measuring device 20 and the dimensions of the flat plate member 9 measured by the flat plate member measuring device 21. The tolerance adjustment means has the effect of setting the building material dimension tolerance 513 with high precision in accordance with the core material 8 and the flat plate member 9.

Figure 6 is a flowchart showing part of the processing procedure by the control device 5 in embodiment 1. Figure 7 is a diagram showing an example of a correction table 514a for the first correction means. Figure 8 is a diagram showing an example of a correction table 514b for the second correction means. Note that, for ease of explanation, the correction amounts for the cutting positions Pa to Pd are omitted from Figures 7 and 8.

Next, the processing procedure of the correction means and the tolerance adjustment means by the control device 5 will be explained using the flowchart in FIG. 6.

- Processing procedure by the control device -
First, in step S51, the processing unit 50 of the control device 5 acquires core material dimension measurement values from the core material measuring device 20 at the input unit 53. In step S52, the processing unit 50 acquires flat member dimension measurement values from the flat member measuring device 21 at the input unit 53. The processing unit 50 stores the acquired core material dimension measurement values and flat member dimension measurement values in the memory unit 51. Note that in step S51, the core material dimension measurement values measured by the core material measuring device 20 may be manually input at the input unit 53. Similarly, in step S52, the flat member dimension measurement values measured by the flat member measuring device 21 may be manually input at the input unit 53.

In step S521, the processing unit 50 determines whether there is a difference of a predetermined value or more between the core material dimension measurement value and the flat plate member dimension measurement value and the corresponding dimension reference value 512. If there is a difference of a predetermined value or more between the core material dimension measurement value and the flat plate member dimension measurement value and the corresponding dimension reference value 512, the processing unit 50 proceeds to step S522 to execute the processing of the first correction means.

<First correction means>
In step S522, the processing unit 50 corrects the cutting positions Pa to Pd based on the core dimension measurement value and the flat plate member dimension measurement value (first correction means). In this embodiment, the processing unit 50 executes the processing of the first correction means according to the correction table 514a. The correction table 514a is a table that associates the core dimension measurement value and the flat plate member dimension measurement value with the corresponding dimension reference value 512, and the correction amount and correction direction of the cutting positions Pa to Pd. In the correction table 514a, the item "dimension" is a column showing the dimension related to the core material 8 and the dimension related to the flat plate member 9. In this embodiment, the item "dimension" is set with "core width" corresponding to the width 86 of the core material 8, "core thickness" corresponding to the thickness 87 of the core material 8, and "flat plate member thickness" corresponding to the thickness 97 of the flat plate member 9. The item "measurement value-reference value" is a column showing the condition (formula) for the difference between the core dimension measurement value or the flat plate member dimension measurement value and the corresponding dimension reference value 512. The item "Cutting position to be corrected" is a column showing cutting positions Pa to Pd that are to be corrected when the conditions shown in the item "Measured value-Reference value" are satisfied. The item "Correction direction" is a column showing the correction direction of the cutting position to be corrected in the -W direction or the +W direction.

When the differences between the core material dimension measurement values and flat plate member dimension measurement values stored in the memory unit 51 and their corresponding dimension reference values 512 satisfy the conditions indicated by the item "Measurement value - Reference value", the processing unit 50 corrects the cutting processing position to be corrected under those conditions in the correction direction set in the item "Correction direction".

For example, as shown in FIG. 7, if the measured value of the width 86 of the core material 8 is greater than the corresponding dimensional reference value 512, the processing unit 50 corrects the cutting positions Pc, Pd to the +W direction. This increases the distance between the cutting positions Pb and Pc to match the width 86 of the core material 8, thereby reducing the wobble (gap) between the flat plate member 9 and the core material 8. On the other hand, if the measured value of the width 86 of the core material 8 is smaller than the corresponding dimensional reference value 512, the processing unit 50 corrects the cutting positions Pc, Pd to the -W direction.

Similarly, if the measured value of the thickness 87 of the core material 8 is greater than the corresponding dimension reference value 512, the processing unit 50 corrects the cutting positions Pb to Pd in the +W direction. The amount of correction for the cutting position Pd at this time is set to be greater than the amount of correction for the cutting positions Pb, Pc. As a result, the distance between the cutting positions Pa and Pb and the distance between the cutting positions Pc and Pd increase in accordance with the thickness 87 of the core material 8, reducing the wobble (gap) between the flat plate member 9 and the core material 8. On the other hand, if the measured value of the thickness 87 of the core material 8 is smaller than the corresponding dimension reference value 512, the processing unit 50 corrects the cutting positions Pb to Pd in the -W direction.

Furthermore, if the measured value of the thickness 97 of the flat plate member 9 is greater than the corresponding dimensional reference value 512, the processing unit 50 corrects the cutting positions Pb-Pd to the +W direction. This adjusts the inner surface of the flat plate member 9 to match the width 86 and thickness 87 of the core material 8, thereby reducing the wobble (gap) between the flat plate member 9 and the core material 8. On the other hand, if the measured value of the thickness 97 of the flat plate member 9 is smaller than the corresponding dimensional reference value 512, the processing unit 50 corrects the cutting positions Pb-Pd to the -W direction.

In this embodiment, the processing unit 50 executes the processing of the first correction means each time building material B is manufactured, but of course this is not limited to this, and may be executed, for example, every time a predetermined number of building materials B are manufactured.

The correction amount for each of the cutting positions Pa to Pd in the first correction means may be a variable value based on the measured core material dimensions and the measured flat plate member dimensions, or may be a preset fixed value. In addition, the correction amount for each of the cutting positions Pa to Pd in the first correction means may be different from each other.

<Tolerance Adjustment Means>
Next, in step S523, the processing unit 50 adjusts the building material dimension tolerance 513 based on the core material dimension measurement value and the flat plate member dimension measurement value (tolerance adjustment means). For example, if the measurement value of the width 86 of the core material 8 is 1 mm larger than the corresponding dimension reference value 512, the processing unit 50 adjusts the building material dimension tolerance 513 corresponding to each of the widths X1 and X2 of the building material B to shift by +1 mm. Similarly, if the measurement value of the thickness 87 of the core material 8 is 1 mm larger than the corresponding dimension reference value 512, the processing unit 50 adjusts the building material dimension tolerance 513 corresponding to each of the thicknesses X3 and X4 of the building material B to shift by +1 mm. If the measurement value of the thickness 97 of the flat plate member 9 is 1 mm larger than the corresponding dimension reference value 512, the processing unit 50 adjusts the building material dimension tolerance 513 corresponding to each of the widths X1 and X2 and thicknesses X3 and X4 of the building material B to shift by +2 mm.

In this embodiment, the processing unit 50 executes the processing of the tolerance adjustment means for the building material dimension tolerance 513 corresponding to the external dimensions of building material B, but of course this is not limited to this and may be executed for, for example, gaps X7 to X14 of building material B.

The adjustment amount of the building material dimension tolerance 513 may be a variable value based on the core material dimension measurement value and the flat plate member dimension measurement value as described above, or it may be a preset fixed value.

In step S53, the processing unit 50 passes the cutting positions Pa to Pd of the cutting parameters 511 to the cutting device 10 as instruction values, and instructs the cutting device 10 to cut the cutting grooves 95a to 95d.

In step S55, the processing unit 50 acquires the building material dimension measurement values from the building material measuring device 22 through the input unit 53. The processing unit 50 stores the acquired building material dimension measurement values in the memory unit 51. Note that in step S55, the building material dimension measurement values measured by the building material measuring device 22 may be manually input through the input unit 53.

In step S551, the processing unit 50 determines whether the building material dimension measurement values are within the range of the building material dimension tolerance values 513. Here, "when the building material dimension measurement values are within the range of the building material dimension tolerance values 513" refers to when each of the building material dimension measurement values is smaller than the upper limit value of the building material dimension tolerance values 513 and larger than the lower limit value of the building material dimension tolerance values 513. When the building material dimension measurement values are not within the range of the corresponding building material dimension tolerance values 513, the processing unit 50 proceeds to step S552 to execute processing of the second correction means.

<Second correction means>
In step S552, the processing unit 50 corrects the cutting positions Pa to Pd based on the building material dimension measurement value relative to the building material dimension tolerance 513 (second correction means). In this embodiment, the processing unit 50 executes the processing of the second correction means according to the correction table 514b. The correction table 514b is a table that associates the building material dimension measurement value with the corresponding building material dimension tolerance 513, and the correction amount and correction direction of the cutting positions Pa to Pd. In the correction table 514b, the item "Xn (building material dimension)" is a column indicating the dimension related to the building material B. The item "measurement value" is a column indicating the condition (formula) of the building material dimension measurement value relative to the building material dimension tolerance 513. Specifically, the item "measurement value" is set with both or either one of the condition (formula) when the building material dimension measurement value is larger than the upper limit value of the corresponding building material dimension tolerance 513 and the condition (formula) when the building material dimension measurement value is smaller than the lower limit value of the corresponding building material dimension tolerance 513. The item "Cutting position to be corrected" indicates the cutting position to be corrected among the cutting positions Pa to Pd when the condition indicated by the item "Measured value" is satisfied. The item "Correction direction" indicates the correction direction of the cutting position to be corrected in the -W direction or the +W direction.

When the building material dimension measurement values stored in the memory unit 51 satisfy each condition indicated by the item "Measurement value", the processing unit 50 corrects the cutting processing position to be corrected under that condition in the correction direction set in the item "Correction direction".

For example, as shown in FIG. 8, if the measured value of width X1 of building material B is greater than the upper limit of the corresponding building material dimension tolerance 513, the processing unit 50 corrects the cutting positions Pc and Pd to the -W direction. This reduces the distance between cutting positions Pb and Pc, and the edges of cutting grooves 95b and 95c approach corners 85b and 85c of the core material 8, respectively, thereby reducing width X1 of building material B.

Similarly, if the measured value of thickness X4 of building material B is greater than the upper limit of the corresponding building material dimension tolerance 513, the processing unit 50 corrects the cutting position Pd to the -W direction side. This reduces the distance between cutting positions Pc and Pd, and the edges of cutting grooves 95c and 95d approach corners 85c and 85d of core material 8, respectively, thereby reducing thickness X4 of building material B.

In addition, if the measured value of gap X7 of building material B is greater than the upper limit value of the corresponding building material dimension tolerance 513, the processing unit 50 corrects the cutting positions Pb-Pd to the -W direction side. This reduces the distance between cutting positions Pa and Pb, and the edges of cutting grooves 95a and 95b approach the corners 85a and 85b of the core material 8, respectively, thereby reducing gap X7 of building material B.

Furthermore, when the measured value of the waviness X15 of the dust portion X5 of the building material B is greater than the upper limit value of the corresponding building material dimension tolerance 513, the outer surface of the flat plate member 9 or the decorative sheet 90 at the dust portion X5 is wavy due to the distance between the cutting positions Pa and Pb and the distance between the cutting positions Pb and Pc being small relative to the width 86 and thickness 87 of the core material 8. To eliminate this, the processing unit 50 corrects the cutting positions Pb to Pd to the +W direction side. The correction amount of the cutting position Pc at this time is set to be greater than the correction amount of the cutting position Pb. As a result, the distance between the cutting positions Pa and Pb and the distance between the cutting positions Pb and Pc increases in accordance with the width 86 and thickness 87 of the core material 8, thereby reducing the waviness of the outer surface of the flat plate member 9 or the decorative sheet 90.

In this embodiment, the processing unit 50 executes the processing of the second correction means after cutting processing by the cutting device 10. Therefore, the cutting processing positions Pa to Pd corrected by the second correction means become effective from the manufacturing of the building material B after the processing of the second correction means is executed.

In this embodiment, the processing unit 50 executes the processing of the second correction means for each lot of building material B, but of course this is not limited to this and may be executed for each production of building material B. Also, in this embodiment, the building material dimension measurement value referenced in steps S551 and S552 is the average value for each lot of the building material dimension measurement values stored in the memory unit 51, but of course this is not limited to this and may be the average value obtained by removing the maximum and minimum values from the building material dimension measurement values for each lot.

The correction amount for each of the cutting positions Pa to Pd in the second correction means may be a variable value based on the difference between the building material dimension measurement value and the building material dimension tolerance value 513, or may be a preset fixed value. In addition, the correction amount for each of the cutting positions Pa to Pd in the second correction means may be different from each other.

The flat plate member 9 and cutting device 10 are not limited to the above, and may be, for example, a plate member 9 that is bent along the corners 85b, 85c of the core material 8 and covers the bottom and lower parts of both sides of the core material 8, and the cutting device 10 cuts cutting grooves 95b, 95c into the flat plate member 9 according to the corners 85b, 85c of the core material 8.

(Embodiment 2)
FIG. 9 is a block diagram showing the configuration of a building material manufacturing system A in the second embodiment.

In addition to the configuration described in embodiment 1, the building material manufacturing system A in embodiment 2 includes a groove position measuring device 23 and an environmental measuring device 24.

The groove position measuring device 23 is a device that measures the positions of the cutting grooves 95a to 95d that are cut into the flat plate member 9, and is provided downstream of the cutting device 10 and upstream of the adhesive application device 11. The groove position measuring device 23 may be, for example, a three-dimensional measuring device.

The groove position measuring device 23 outputs the distance value to the right (+W direction side) of the flat plate member 9, with the left edge (-W direction edge) as the measurement origin, to the control device 5 as the groove measurement position.

The environmental measuring device 24 is a device that measures the environmental condition around the winding device 12 and is provided around the winding device 12. In this embodiment, the "environmental condition" refers to humidity. A humidity sensor is used for the environmental measuring device 24.

The environmental measurement device 24 outputs the humidity around the winding device 12 to the control device 5 as an environmental measurement value.

In the memory unit 51 of the control device 5 in the second embodiment, an environmental standard value 515 corresponding to the environmental state is stored. For example, the environmental state measured on the previous day is used as the environmental standard value 515. In addition, the memory unit 51 stores the groove measurement position obtained from the groove position measuring device 23 and the environmental measurement value obtained from the environmental measuring device 24.

The control device 5 in the second embodiment includes a third correction means for correcting the cutting positions Pa to Pd of the cutting parameters 511 based on the environmental conditions around the winding device 12 measured by the environmental measurement device 24, and a fourth correction means for correcting the cutting positions Pa to Pd of the cutting parameters 511 based on the positions of the cutting grooves 95a to 95d measured by the groove position measurement device 23.

The third correction means corrects the cutting positions Pa to Pd to match the environmental conditions around the winding device 12 measured by the environmental measurement device 24, thereby reducing the effect of the environmental conditions on the dimensions of the building material B.

The fourth correction means corrects the cutting positions Pa to Pd in a direction that offsets the deviation in the position of the cutting grooves 95a to 95d caused by the tendency of the cutting device 10, resulting in the effect of stabilizing the positions of the cutting grooves 95a to 95d.

Figure 10 is a flowchart showing part of the processing procedure performed by the control device 5 in embodiment 2.

Next, the processing procedure of the correction means by the control device 5 in embodiment 2 will be described using the flowchart in FIG. 10. Note that steps from step 55 (obtaining the measured building material dimensions) onwards are the same as in embodiment 1, and the description thereof will be omitted.

In step S50, the processing unit 50 of the control device 5 acquires the environmental measurement values from the environmental measuring device 24 at the input unit 53. The processing unit 50 stores the acquired environmental measurement values in the memory unit 51. Note that in step S50, the environmental measurement values measured by the environmental measuring device 24 may be manually input at the input unit 53.

In step S501, the processing unit 50 determines whether there is a difference of a predetermined value or more between the environmental measurement value and the environmental reference value 515 corresponding to the environmental measurement value. If there is a difference of a predetermined value or more between the environmental measurement value and the environmental reference value 515 corresponding to the environmental measurement value, the processing unit 50 proceeds to step S502 to execute the processing of the third correction means.

<Third correction means>
In step S502, the processing section 50 corrects the cutting positions Pa to Pd based on the environmental measurement values (third correction means).

For example, if the measured humidity value is higher than the corresponding environmental standard value 515, it is assumed that the core material 8 has expanded, and the processing unit 50 corrects the cutting positions Pb to Pd in the +W direction to match the core material 8. The amount of correction for the cutting position Pc is set to be greater than the amount of correction for the cutting position Pb, and the amount of correction for the cutting position Pd is set to be greater than the amount of correction for the cutting position Pc. As a result, the distance between the cutting positions Pa and Pb, the distance between the cutting positions Pb and Pc, and the distance between the cutting positions Pc and Pd increase in accordance with the width 86 and thickness 87 of the expanded core material 8, thereby reducing the rattling (gaps) between the flat plate member 9 and the core material 8.

Note that each correction amount in the third correction means may be a variable value based on the environmental measurement value, or may be a preset fixed value.

After the cutting process in step S53, in step S54, the processing unit 50 acquires the groove measurement position from the groove position measuring device 23 through the input unit 53. The processing unit 50 stores the acquired groove measurement position in the memory unit 51. Note that in step S54, the groove measurement position measured by the groove position measuring device 23 may be manually input through the input unit 53.

In step S541, the processing unit 50 determines whether there is a difference of a predetermined value or more between the groove measurement position and the instruction values of the cutting positions Pa to Pd passed to the cutting device 10. If there is a difference of a predetermined value or more between the groove measurement position and the instruction values of the corresponding cutting positions Pa to Pd, the processing unit 50 proceeds to step S542 to execute the processing of the fourth correction means.

<Fourth correction means>
In step S542, the processing section 50 corrects the cutting positions Pa to Pd based on the groove measurement positions (fourth correction section).

For example, if the measurement position of the cutting groove 95a is located on the +W side of the indicated value of the cutting position Pa, the processing unit 50 corrects the cutting position Pa to the -W side. This corrects the deviation of the cutting grooves 95a to 95d relative to the cutting position Pa, stabilizing the positions of the cutting grooves 95a to 95d.

In addition, each correction amount in the fourth correction means may be a variable value based on the groove measurement position, or may be a preset fixed value.

The above embodiments and examples are illustrative in all respects and are not intended to be a basis for restrictive interpretation. Therefore, the technical scope of the present invention is not interpreted solely by the above embodiments and examples, but is defined based on the claims. Furthermore, all modifications within the scope and meaning equivalent to the claims are included.

The combination of the processes of the first correction means, the second correction means, the third correction means, the fourth correction means, and the tolerance adjustment means by the processing unit 50 is not limited to those described in the above embodiment, and may be, for example, the processes of the second correction means and the fourth correction means.

A Building material manufacturing system B Building material 10 Cutting device 11 Adhesive application device 12 Winding device 19 Conveying device 20 Core material measuring device 21 Flat plate member measuring device 22 Building material measuring device 23 Groove position measuring device 24 Environment measuring device 5 Control device 50 Processing unit 51 Memory unit 514 Correction table 8 Core material 9 Flat plate member

Claims (13)

A building material manufacturing system including: a cutting device that cuts a cutting groove extending in a longitudinal direction on one surface of a long flat plate member; and a winding device that bends the flat plate member so that the cutting groove is on the inside, and winds the flat plate member on a peripheral surface of a long rectangular columnar core material, the system winding the flat plate member around the core material to manufacture a building material,
A building material measuring device for measuring dimensions of manufactured building materials;
A control device for controlling the cutting device;
Equipped with
The control device includes:
A building material manufacturing system comprising a correction means for correcting a cutting processing position by the cutting device based on the dimensions of the manufactured building material measured by the building material measuring device relative to the dimensional tolerances of the building material. The building material manufacturing system according to claim 1,
A core material measuring device for measuring dimensions related to the core material;
A flat member measuring device for measuring dimensions of the flat member,
The building material manufacturing system is further characterized in that the correction means corrects the cutting processing position by the cutting device based on the dimensions of the core material measured by the core material measuring device and the dimensions of the flat plate member measured by the flat plate member measuring device. The building material manufacturing system according to claim 2,
The control device includes:
A building material manufacturing system characterized by further comprising a tolerance adjustment means for adjusting the tolerance of dimensions related to the building material based on the dimensions related to the core material measured by the core material measuring device and the dimensions related to the flat plate member measured by the flat plate member measuring device. A building material manufacturing system according to any one of claims 1 to 3,
A groove position measuring device for measuring the position of a cutting groove cut into the flat plate member is further provided.
The building material manufacturing system is further characterized in that the correction means corrects the cutting position of the cutting device based on the position of the cutting groove measured by the groove position measuring device. A building material manufacturing system according to any one of claims 1 to 4,
An environmental measurement device for measuring an environmental condition around the winding device is further provided,
The building material manufacturing system is further characterized in that the correction means corrects the cutting position of the cutting device based on the environmental condition around the winding device measured by the environmental measuring device. A control device for controlling a cutting device that cuts a cutting groove extending in a longitudinal direction on one surface of a long flat plate member in order to manufacture a building material by winding the long flat plate member around a circumferential surface of a long rectangular columnar core material, comprising:
means for obtaining dimensional measurements relating to the manufactured building material;
A means for correcting a cutting position of the cutting device based on the acquired measurement values of the dimensions of the manufactured building material relative to the tolerances of the dimensions of the building material;
A control device comprising: The control device according to claim 6,
A means for acquiring dimensional measurements of the core material and dimensional measurements of the flat plate member;
and a means for correcting a cutting position performed by the cutting device based on the acquired dimensional measurement values of the core material and the dimensional measurement values of the flat plate member. The control device according to claim 7,
A control device further comprising a means for adjusting dimensional tolerances for the building material based on the acquired dimensional measurement values for the core material and the dimensional measurement values for the flat plate member. A control device according to any one of claims 6 to 8,
A means for acquiring position information of the cutting groove;
and a means for correcting a cutting position performed by the cutting device based on the acquired position information of the cutting groove. A control device according to any one of claims 6 to 9,
a means for acquiring information regarding an environmental condition surrounding a winding process in which the flat plate member is bent so that the cut groove is on the inside and then wound around the circumferential surface of the core material;
and a means for correcting a cutting position performed by the cutting device based on the acquired information on an environmental condition around the winding process. A method for manufacturing a building material, comprising the steps of: a cutting device for cutting a cutting groove extending in a longitudinal direction on one surface of a long flat plate member; and a winding device for bending the flat plate member so that the cutting groove is on the inside, and winding the core material around a long rectangular columnar core material, the method comprising the steps of:
The dimensions of the manufactured building materials are measured using a building material measuring device.
The cutting device is controlled by a control device,
A building material manufacturing method, characterized in that, under the control of the control device, the cutting processing position by the cutting device is corrected based on the dimensions of the manufactured building material measured by the building material measuring device relative to the dimensional tolerances of the building material. A building material produced by the building material production method described in claim 11. A program for causing a computer to function as a control device according to any one of claims 6 to 10.

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