CN103287895A - Method of manufacturing web roll, method of winding web roll and method of calculating internal stress - Google Patents

Abstract

The invention provides a method of manufacturing a web roll, a method of winding the web roll, and a method of calculating internal stress. Stress changes in the width direction of a web are also taken into account. The method of manufacturing the web roll and the method of winding the web roll comprises: a dummy roll manufacture procedure for manufacturing a dummy roll for evaluation; a model manufacture procedure for manufacturing segmentation models used for segmenting the web roll into multiple parts along the width direction; a calculation procedure for calculating the stress on account of each segmentation model and with respect to each winding radius; a defect occurrence stress range determination procedure for obtaining a defect occurrence stress range within which defects are likely to occur; a stress recalculation procedure for repeating the calculation procedure by changing the winding conditions till the stress of the specified winding radius range is not within the defect occurrence stress range; and a winding procedure for winding the web on the condition, discovered in the stress recalculation procedure, that the stress of the specified winding radius range is not within the defect occurrence stress range.

Description

Net volume manufacture method, net volume method for winding and internal stress method of calculating

Technical field

The present invention relates to a kind of by going up net volume (web roll) manufacture method and the net volume method for winding that coiling net (web) is made at volume core (winding core), relate in particular to following net volume manufacture method and net volume method for winding, namely, the internal stress that is rolled into the net of web-like by calculating is obtained net volume around condition, and according to the coiling condition of the obtaining net of reeling.

Background technology

In the past, the net of plastics (plastic) etc. was to be wound rolling and the client is given in shipment.Make volume by the long as far as possible net of reeling, that can utilize a volume transports to transport more net, thereby can realize efficient transporting.

But around must be more long, the possibility that formed curly hair is given birth to volume mal-alignment defective etc. will become more big with net volume.Herein, volume mal-alignment defective refers to following defective phenomenon: the state that volume has the position of two side ends of the volume of net to become after rolled up is the state of the position deviation part of initial condition.This volume mal-alignment defective not only can take place when reeling, and also can take place when the volume that carrying has been rolled up.

For the coiling condition of the net that this kind defective can not take place, existing multiple experimental tentative experiment in the past.Its reason is because there is not the few effective Forecasting Methodology of error (simulation (simulation)).And, when the evaluation that the condition of carrying out is obtained, need during the evaluation more than 2 weeks, 1 sample (sample) of be used for estimating hundreds of nets to thousands of meters of will reeling, long during therefore estimating, it is huge that the cost of assess sample also becomes.And, also therefore be difficult to a plurality of conditions are estimated.

Therefore, work out following method, that is: be not to carry out a plurality of experiments, but predict the internal stress of volume by theory, thereby obtain the method for coiling condition.For example, the method for winding of the net of record has disclosed following method in the patent documentation 1: by importing the radial direction Young's modulus of equal value that will be situated between and take into account every the air film thickness between net, thereby utilize theoretical formula to calculate and enforcement value consistent radial direction stress (perhaps being called surface pressure) well, and spread all over winding radius and reach the mode of expectation value with radial direction stress or traversing resistance, decide excellent winding tension figure (tension pattern).

And non-patent literature 1 has disclosed the formula that calculates the internal stress of volume.

The prior art document

Patent documentation

Patent documentation 1: the special fair 7-33198 communique of Japanese Patent

Non-patent literature

Non-patent literature 1:Z. Ha Qier (Hakiel) work, " nonlinear model of the volume stress of coiling (Non linear model for wound roll stresses) ", paper pulp and paper industrial technology association periodical (J.Tech.Assoc.Paper Pulp.Ind.), volume 70 (vol.70), the 113rd page the-the 117th page, distribution in 1987

Summary of the invention

But, in the method for winding of the net that patent documentation 1 discloses, consider thickness distribution or the annular knurl of net, therefore there is the error change greatly and can't bear practical problem.Herein, annular knurl (knurling) refer to be formed on the Width both ends of net, be used for anti-skidding small jog.

Herein, with reference to Figure 19.Figure 19 is the volume block diagram for the inner stress of explanation volume.As shown in figure 19, in volume 10 inside, there is radial direction stress σ _rWith circumferencial direction stress σ _t, described radial direction stress σ _rBe the stress that applies along volume 10 radial direction and to film (film) 31, described circumferencial direction stress σ _tBe the stress that applies along the circumferencial direction of film 31 and to film 31.Shown in partial enlarged drawing 400, that this radial direction stress be multiply by the area gained is vertical resistance N, if the friction coefficient of film is made as μ, and friction force F=μ N then.Thereby if radial direction stress difference, then friction force is also different, therefore when radial direction stress when the Width of volume changes, must consideration radial direction stress.If be formed with annular knurl, then the radial direction stress of this part will be greatly different, therefore when calculated stress, can't utilize the model (model) identical with the part that does not form annular knurl to calculate.

The present invention is in view of this truth, net volume manufacture method and the net volume method for winding of desiring to provide a kind of STRESS VARIATION of the Width with net also to take into account.

Problem of the present invention can solve by each following invention.

Namely, the manufacture method of net volume of the present invention is to be manufactured on the net volume that is wound with net on the volume core, the principal character of the manufacture method of described net volume is to comprise: virtual volume (dummy roll) production process, use the net identical with the net that is used for described net volume, described net is wound on the described volume core, thereby makes the virtual volume of estimating usefulness; The modelling operation is made a plurality of parted patterns (segmentation model), described parted pattern be with described net volume broad ways ring cutting be divided into a plurality of; Calculation process, at each described parted pattern and at each winding radius (winding radius), distribute (winding tension profile) based on circumferencial direction Young's modulus, radial direction Young's modulus and winding tension, obtain any stress at least in circumferencial direction stress and the radial direction stress; Defective generation range of stress determines operation, the described stress of the defective generation winding radius (defect occurrence winding radius) of the defective that takes place according to virtual volume in described virtual volume production process and each winding radius of obtaining in described calculation process is obtained the defective generation range of stress (defect occurrence stress range) that described defective may take place; Stress is calculation process again, change is as in the amplitude of the height of the Width thickness distribution of the winding tension figure of coiling condition, pneumatic press (air press) pressing force figure, film, knurled portion (knurling portion), swing (oscillate) at least one, repeat (repeat) described calculation process, till the stress of scope of the winding radius of regulation no longer is included in the defective generation range of stress; And the coiling operation, be not included in coiling condition in the described defective generation range of stress, the coiling of netting with the stress of the scope of the winding radius of the described regulation found in the calculation process again at described stress.

Thus, make the model that is split to form along the Width of net volume, and each model that is split to form is carried out stress calculation, therefore can obtain the distribution of stress of the whole Width of net volume.Therefore, can correctly know stress, even in the making of virtual volume, number of drawbacks takes place, also can make the net volume that a plurality of defectives are all solved.

And, net volume winding method of the present invention is to be used to form the net volume that is wound with net at the volume core, the principal character of described net volume winding method is to comprise: the virtual volume production process, use the net identical with the net that is used for described net volume, described net is wound on the described volume core, thereby makes the virtual volume of estimating usefulness; The modelling operation is made a plurality of parted patterns, described parted pattern be with described net volume broad ways ring cutting be divided into a plurality of; Calculation process at each described parted pattern and at each winding radius, distributes based on circumferencial direction Young's modulus, radial direction Young's modulus and winding tension, obtains any stress at least in circumferencial direction stress and the radial direction stress; Defective generation range of stress determines operation, the described stress of the defective generation winding radius of the defective that takes place according to virtual volume in described virtual volume production process and each winding radius of obtaining in described calculation process is obtained the defective generation range of stress that described defective may take place; Stress is calculation process again, change is as in the amplitude of the height of the Width thickness distribution of the winding tension figure of coiling condition, pneumatic press pressing force figure, film, knurled portion, swing at least one, repeat described calculation process, till the stress of scope of the winding radius of regulation no longer is included in the defective generation range of stress; And the coiling operation, be not included in coiling condition in the described defective generation range of stress, the coiling of netting with the stress of the scope of the winding radius of the described regulation found in the calculation process again at described stress.

Thus, make the model that is split to form along the Width of net volume, and each model that is split to form is carried out stress calculation, therefore can obtain the distribution of stress of the whole Width of net volume.Therefore, can correctly know stress, even in the making of virtual volume, number of drawbacks takes place, also can obtain the coiling condition that a plurality of defectives all can be eliminated well.

And then, internal stress method of calculating of the present invention is the internal stress method of calculating that is wound with the net volume of net at the volume core, the principal character of described internal stress method of calculating is to comprise: the computation model production process, make a plurality of parted patterns, described parted pattern be with described net volume broad ways ring cutting be divided into a plurality of; And calculation process, at each described parted pattern and at each winding radius, distribute based on circumferencial direction Young's modulus, radial direction Young's modulus and winding tension, obtain any stress at least in circumferencial direction stress and the radial direction stress.

A kind of net volume manufacture method and net volume method for winding can be provided, and its STRESS VARIATION with the Width of net is also taken into account.

Description of drawings

Fig. 1 is the concept map of the 3D modelling of volume.

Fig. 2 is the instruction diagram that each parameter to the volume of cutting apart describes.

Fig. 3 is the skeleton diagram of the section of 2 nets in the expression volume.

Fig. 4 is the figure of Tension Distribution of the Width of expression net.

Fig. 5 is the instruction diagram that is illustrated in the situation that is involved in air between film.

Fig. 6 is the skeleton diagram with the part of the volume section of the direction of central axes.

Fig. 7 is the skeleton diagram of a part of the ring cutting directional profile of volume.

Fig. 8 (A), Fig. 8 (a), Fig. 8 (B), Fig. 8 (b), Fig. 8 (C), Fig. 8 (c) are the charts of expression stress calculation result and measured value.

Fig. 9 is the diagram of circuit of flow process of the method for winding of expression net.

Figure 10 is the ring cutting directional profile skeleton diagram for the volume of explanation otch transfer.

Figure 11 is the chart of the relation of expression winding radius and memberane stress.

Figure 12 (a) is the three-dimensional chart of the relation of the expression coiling length of virtual volume and radial direction stress.Figure 12 (b) is the chart of the relation of the coiling length of axle center of expression virtual volume and radial direction stress.

Figure 13 (a) is the three-dimensional chart of the relation of the expression winding radius of virtual volume and radial direction stress.Figure 13 (b) is the chart of the relation of the winding radius of knurled portions of expression virtual volume and radial direction stress.

Figure 14 is the chart of the relation of the winding radius-central radial direction stress under expression initial condition (IC) and the derivation condition.

Figure 15 is the chart of the relation of the winding radius-annular knurl radial direction stress under expression initial condition (IC) and the derivation condition.

Figure 16 is the chart of the winding radius-memberane stress condition of expression derivation.

Figure 17 (A) is the skeleton diagram of a part of section of the 3D modelling of volume.Figure 17 (B) is in Figure 17 (A), the skeleton diagram of knurled portion during near the film of below.

Figure 18 (A) is the skeleton diagram of a part of section of the 3D modelling of volume.Figure 18 (B) is in Figure 18 (A), the skeleton diagram of the part of the section of the 3D modelling of the part with maximum " film thickness+air film thickness " during near the film of below.

Figure 19 is the volume block diagram for the inner stress of explanation volume.

Figure 20 is the figure of the analog result under the two dimensional model of expression volume internal stress.

Figure 21 is the skeleton diagram of the configuration of expression pressure sensor (sensor) in volume.

Figure 22 is the figure of the measured value of expression volume internal stress.

The explanation of symbol:

10,306: volume

11,12,13,14: cut apart volume

18: the volume core

21,22,23,24: cut apart net

31: film

32: air

33: cut-off rule

34: knurled portions

50: the Pneumatic pressure machine

60: cut apart film

80: the jump part

302: pressure sensor

304: net

400: partial enlarged drawing

A1, a2, a3, a4: thickness

H, ha, ho: the thickness of air layer

L: coiling length

R: winding radius

S1, S2, S3, S4, S5: operation

T, T1, T2, T3, T4: tension force

V: winding speed

W1, W2, W3, W4: width

Wa: film overall with

σ _r: radial direction stress

σ _t: circumferencial direction stress

The specific embodiment

Below, describe in detail for implementing embodiments of the present invention with reference to accompanying drawing.Herein, among the figure, be the similar elements with identical function with the part shown in the identical label.And, in this specification sheets, when using "～" to represent number range, be also contained in the number range with the numerical value of the upper limit shown in "～", lower limit.

The radial direction calculation method for stress of＜volume Intranet 〉

The method of calculating of the internal stress of the net that is rolled into web-like of the present invention is described with reference to accompanying drawing.

(1) existing two-dimensional model

When obtaining the internal stress of the net (hereinafter to be referred as rolling up) that is rolled into web-like by simulation, by making the 3D modelling that cuts mesh (mesh) subtly, can expect to obtain high-precision result.But, under the situation of merely making 3D modelling, still more under the situation of making the 3D modelling that cuts mesh subtly, it is very complicated that calculating can become, the nonlinear ordinary differential equation formula can't be untied sometimes simply, even untie, also can too expend time in the equation that described ordinary differential equation is configured for obtaining the internal stress of the volume equation of namely reeling sometimes.

Therefore, at first, for the precision of the simulation under the existing two dimensional model that carries out (below be called existing simulation) is investigated, and carry out existing simulation, the analogue value and the measured value of the internal stress of volume compared and study.Existing simulation is based on non-patent literature 1 and carries out.It is the results are shown in Figure 20.Figure 20 is the figure of the analog result under the two dimensional model of expression volume internal stress.

And measured value is as shown in figure 21, sandwiches a plurality of pressure sensors 302 midway what net 304 was reeled, utilizes described pressure sensor 302 to measure pressure.Figure 21 is the skeleton diagram of the configuration of expression pressure sensor in volume.Pressure sensor 302 is the winding radius at each regulation, is provided with a plurality of in volume 306 with the Width interval of regulation.The measurement result of pressure sensor 302 is shown in Figure 22.Figure 22 is the figure of the measured value of expression volume internal stress.

With reference to Figure 20, owing to be two dimensional model (will roll up the model of the section of ring cutting), therefore do not consider the influence (thickness distribution of the net of the having or not of annular knurl, Width) of the Width rolled up, under any winding radius, the radial direction stress of Width is fixing.Herein, radial direction stress refers to the radial direction stress netted.Below also be called for short and make radial direction stress.

Relative therewith, with reference to Figure 22 of expression measured value, the radial direction stress at Width both ends that is formed with the volume of annular knurl becomes big.Distinguish that so two dimensional model is the stress of correctly expression reality not.

(2) used 3D modelling among the present invention

(1) summary of 3D modelling

In the present invention, make 3D modelling for the incorrectness of improving the existing two-dimensional model.3D modelling is to make by following manner, that is, as shown in Figure 1 as, will be wound with net (banded pliability supporter) volume 10 broad ways ring cuttings be divided into a plurality of and discretization (discretize).Herein, the ring cutting section of volume is spiral fashion originally, but makes the model of concentric circles in 3D modelling of the present invention.Fig. 1 is the concept map of the 3D modelling of volume.

Next, illustrate in greater detail 3D modelling used among the present invention with reference to accompanying drawing.Fig. 2 is the instruction diagram that each parameter to the volume of cutting apart describes.Fig. 3 is the skeleton diagram of the section of 2 nets in the expression volume.Fig. 4 is the figure of Tension Distribution of the Width of expression net.

As shown in Figure 2, used 3D modelling is to cut apart volume (being also referred to as parted pattern) 11 with having the volume 10 of net (being also referred to as film) to be cut apart with width W 1, W2, W3, W4... (following omission) at volume core 18 volume ring cutting, making respectively, cut apart volume 12, cut apart and roll up 13, cut apart and roll up 14... (following omission) among the present invention.Herein, in this explanation, this 4 cuts apart to describe only to have expressed W1～W4, but this just is divided into example with 4 for convenience of explanation, be not limited to 4 and cut apart, can make according to the form of the volume of simulated object, the precision desiring to obtain and cut apart several models arbitrarily.

Volume 11,12,13 is cut apart in consideration, 14... (following omission) rolls up the volume of cutting apart net 21,22,23,24... (following omission) respectively, considers that the tension force of cutting apart net 21,22,23,24... (following omission) is respectively tension force T1, T2, T3, T4... (following omission).Consider that the thickness of respectively cutting apart net 21,22,23,24... (following omission) is respectively a1, a2, a3, a4.

And, as respectively cutting apart volume 11,12,13, the shared parameter of 14... (following omission), consider winding speed V, coiling length L, film overall with Wa, winding radius r.Winding speed V refer to the to reel speed of net.The coiling length L refers to the length of the net of reeling.Film overall with Wa refers to the overall with of netting, i.e. W1+W2+W3+W4+... (following omission) (in addition, below, film is as identical implication with net).Winding radius r refers to the radius rolled up.

, if utilize 3D modelling to carry out stress analysis, then have following problems herein, that is: calculating can become very complicated, and being known as the equational non-wire shaped partial equation of reeling can't untie simply.But, by attentively discovering of the inventor: be Width stress and displacement condition of contact by the condition of contact not considering to cut apart between volume, thereby can untie the coiling equation of 3D modelling, and the value that obtains also becomes the value near experiment value.That is, untie the coiling equation respectively obtaining stress by cut apart volume at each, thereby can easily obtain the stress value near experiment value.

Next, describe with reference to Fig. 3.Fig. 3 is the skeleton diagram of 2 films (net) and section convolution commentaries on classics central axes of the coincidence in the expression volume.As shown in Figure 3, mostly the thickness of film (net) 31 is thin at the center, and more toward the outer side, then form more thick (being not limited to this).And, between film 31, there is indrawn air 32.The more past central portion in interval that volume 10 is divided into the cut-off rule 33 of cutting apart volume is more wide, and along with narrowing down towards both ends.

Thus, by the big part of more past variation in thickness, especially more pastly be formed with knurled portions 34 and the big both ends of variation in thickness are then more cut apart subtly, thereby can make the stress Calculation result near experiment value.

Next, describe with reference to Fig. 4.Fig. 4 is the figure of the relation of the expression width position of film and tension force.The transverse axis of Fig. 4 is represented the width position of film, and the longitudinal axis is represented the tension force of film.With Fig. 4 in the lump also with reference to this Fig. 3, as shown in Figure 4, with the thickness of film pro rata tension force become big mode and set tension force.Its reason is, the zone that film thickness is more thick (cutting apart volume), and the tension force that then bears is more big.Cut apart volume and cut apart memberane stress respectively cutting apart in the volume each, so that if the tension force of All Ranges (all cut apart volume) is added up to the tension force that then reaches film.

Particularly, be made as t if will respectively cut apart the thickness of the film of volume _n(m), the tension force that the film overall with the is applied sectional area that is made as the overall with of T (N), film is made as A (m ²), then the tension force of per unit sectional area is T/A (N/m ²).As if the thickness that T/A be multiply by the film of respectively cutting apart volume, the tension force Tn that then can calculate the unit width of respectively cutting apart volume is Tn=[T * t _n/ A] (N/m).

(2) thickness (air film thickness) that is involved in the air layer between film calculates

Next, with reference to accompanying drawing illustrate the method for calculating of the thickness of air layer, described air layer be coiled film with the process that forms volume in, be involved in air between film and the film and be formed on air layer between film.Fig. 5 is the instruction diagram that the expression air is involved in the situation between film.Fig. 5 represents to be wound with the summary of section of the volume 10 of film 31.The thickness that is involved in the air between film is as shown below, uses foil bearing theory (foil bearing theory) and calculates.

As shown in Figure 5, film 31 is subjected to conveyance and is wound on 10 along the direction of arrow.At this moment, air is involved between the film under outermost film (being the film of top side at accompanying drawing) and this film, and the thickness of air layer at this moment is made as ho.

For the air that this is involved in excludes, namely, for thickness (air film thickness) ho that reduces air layer, from Pneumatic pressure machine 50 air is blown and attachedly to press outermost film to outermost film surface, extrude (will look air and be incompressibility and effect that air is expressed into outside the volume is called incompressibility squeezing action (non-compressible squeezing function)) with the air that will be involved in between film.The thickness (air film thickness) of the air layer after will pressing by Pneumatic pressure machine 50 is made as ha.

Herein, to use the situation of Pneumatic pressure machine 50 to describe as example in order to reach squeezing effect (squeezing effect), but not only can adopt the Pneumatic pressure machine, so long as the device that can exert pressure to film surface, then can adopt touch roll various devices such as (contact roll), also can similarly carry out the THICKNESS CALCULATION of air layer.

And then, the thickness of the air layer when following is made as h, that is: with winding film to rolling up on 10, thereby at the outside of this film multilayer-wound film, thus, because of the stress of these films (perpendicular to the stress of the direction of pellicular front), and the inner air that is involved in is further carried out in the same squeezing action (extruding).Below the method for calculating of ho, ha, h is described.

Utilize following formula 1 to obtain the thickness h o of leaked-in air layer when reeling.

$\mathrm{ho}=0.589\×R\×{\left(\frac{6\mathrm{\η}(\mathrm{Vr}+\mathrm{Vw})}{T}\right)}^{\frac{2}{3}}$ Formula 1

Below represent R, η, Vr, Vw, T herein.

R: the radius of volume 10

η: the coefficient of viscosity of air

Vr: the rotative speed of volume (linear velocity in the volume outside)

Vw: the conveyance speed of institute's wound film

T: the tension force of film

Next, use the ho calculate, obtain the thickness h a of the air layer that begins to be involved in after pressing by Pneumatic pressure machine 50 by following formula 2.

${\mathrm{ha}=(\frac{1}{{\mathrm{ho}}^2}+\frac{2\mathrm{LR}}{{\mathrm{\ηRW}}^2}t)}^{-\frac{1}{2}}$ Formula 2

Below represent L, W, t herein.

L: by the air from Pneumatic pressure machine 50 ejection, will be wound in film on 10 and be pressed into 10 the power of rolling up

W: the width of net

T: time

(3) being suitable for the model that is involved in air layer

Next, with reference to Fig. 6, Figure 17 (A), Figure 17 (B), Figure 18 (A), Figure 18 (B) being suitable for the model of the thickness h of the air layer that is involved in back (reel inner) is described.Fig. 6 is the skeleton diagram with the part of the volume section of the direction of central axes.Figure 17 (A) is the skeleton diagram of a part of the section of the 3D modelling when not having other films with " film thickness+air film thickness ", and described " film thickness+air film thickness " is bigger than the integral thickness of the film that comprises knurled portion.Figure 17 (B) is in Figure 17 (A), the skeleton diagram of knurled portion during near the film of below.Figure 18 (A) is the skeleton diagram of a part of the section of the 3D modelling when having other films with " film thickness+air film thickness ", and described " film thickness+air film thickness " is bigger than the integral thickness of the film that comprises knurled portion.Figure 18 (B) is in Figure 18 (A), the skeleton diagram of the part of the section of the 3D modelling of the part with maximum " film thickness+air film thickness " during near the film of below.

In the present invention, consider that film is rigid body.And, for surface, the back side of film, the face of central side of volume is made as the surface, the face in the outside of volume is made as the back side.Herein, as shown in Figure 6, be that example describes with film 31, described film 31 be with along with from core towards two end portions and the mode of the thickness thickening of film forms.But the present invention is not limited to the thickness figure shown in the film 31, no matter is which kind of thickness figure, and all applicable the present invention all belong to scope of the present invention.

If have the film of thickness distribution, film is desired on Width than position, upper two place of thickness portion contact (desire is close) about then establishing.If shown in Figure 17 (A), other that do not have a value with " film thickness+air film thickness h a " are cut apart the film 60 (be called for short and make to cut apart film 60) of volume, maximum film thickness in the thickness of the value of described " film thickness+air film thickness h a " film of respectively cutting apart volume when considering knurled portions 34 also for film a part of is big, then shown in Figure 17 (B), knurled portions 34 is not involved in the air obstruction and is squeezed, its result, the interval of film is determined up and down, and the air film thickness of other zones (zone) is also determined.

Air film for each interlayer of reeling, at this moment, air film thickness h under the knurled portions 34 (perhaps respectively cutting apart the film with maximum film thickness in the film 60) is to obtain by following formula 3A or formula 3B, and shown in Fig. 6, Figure 17 (B), consider in addition cut apart air film thickness under the film 60 equal because of film thickness distribute produce this cut apart the interval at the back side of film surface and the film under it.

${h=(\frac{1}{{\mathrm{ha}}^2}+\frac{2\mathrm{\σ}}{{\mathrm{\ηW}}^2}t)}^{-\frac{1}{2}}$ Formula 3A

Also can replace formula 3A and use the following formula 3B that easily derives from Boyle's law (Boyle ' s law).

$h={(\frac{1}{{\left(\frac{{\mathrm{\σ}}_0+P_{\mathrm{ap}}}{\mathrm{\σ}+P_{\mathrm{ap}}}{h}_a\right)}^2}+\frac{2\mathrm{\σ}}{{\mathrm{\ηW}}^2}t)}^{-\frac{1}{2}}$ Formula 3B

σ: radial direction stress (result of calculation when volume is till the i layer among the Hakiel)

σ ₀: initial radium direction stress (result of calculation when volume is till the i-1 layer among the Hakiel)

P _Ap: barometric pressure

Ha: the thickness of the air layer after pressing with the power of L towards radial direction by pneumatic press.It is the thickness h of the air layer that is involved in when volume is till the i-1 layer in Hakiel after being involved in.

If shown in Figure 18 (A), what have value with " film thickness+air film thickness h a " cuts apart film 60, the thickness of the film with maximum film thickness in the film of described " film thickness+air film thickness h a " described parted pattern when considering knurled portions 34 also for film a part of is big, then shown in Figure 18 (B), the air that other ring cutting zones are involved in can counteract and be difficult to extrude air, and the interval of film determines as follows up and down.

Two kinds of methods are arranged, (1) as Figure 18 (B), the size of " the film thickness+air film thickness h a " of the part beyond the knurled portions is cut apart distance between film (distance at the back side of the surface of upper film and following film) up and down as air film thickness during for the cutting apart film and cut apart film under the film and dispose with the interval of air film thickness h a with this of maximum with each.

Perhaps (2) obtain the total of the sectional area that is involved in air of respectively cutting apart film shown in Figure 18 (B) with up and down between film the sectional area in the gap at (between the back side of the surface of upper film and following film) be identical upper film surface and the interval of following film surface, each of this moment cut apart distance between film (distance at the back side of the surface of upper film and following film) up and down as air film thickness.

As mentioned above, it is good to carry out the way precision that the thickness size of Width relatively calculates, thereby it is comparatively desirable, but can not carry out Film Thickness Ratio yet, utilize formula 3A or formula 3B to be involved in extruding without exception to calculate and calculate h but spread all over whole Width, with as the thickness of air film (situation of no annular knurl or annular knurl low and influence little situation etc.).

Like this, by considering the thickness of indrawn air, thereby can be simply and precision well indrawn air influence is carried out numerical analysis, thereby can correctly calculate the distribution of stress of the Width of volume.

(4) Width swing

Width swing (hereinafter to be referred as swing) refers to, when coiled film is rolled up with formation, in the winding film process, makes institute's wound film with respect to volume and relatively moves back and forth along the Width of film.

The method that this swing is applicable to model is described with reference to Fig. 7.Fig. 7 is the skeleton diagram of a part of the ring cutting directional profile of volume.The amplitude of (A) part expression swing of Fig. 7 is the situation of 10mm, and the amplitude of (B) part expression swing of Fig. 7 is the situation of 5mm.Herein, amplitude refers to the distance that broad ways moves by swing.And, in Fig. 7, for example can think 1 scope of cutting apart volume through cutting apart in 3D modelling with the scope that dotted line surrounds.

At this moment, be formed with the part of knurled portions 34 in the scope of dotted line, amplitude is that the situation of 5mm is the situation of 10mm more than amplitude.This just represents that radial direction stress becomes big.For the influence of considering that this kind swing causes, for example with cut apart adjacent the cutting apart under the situation that the film of rolling up B and air layer invade because of swing of the scope of rolling up A, the length of invading part is carried out proportional distribution with the film of rolling up A cutting apart of script and the length of air layer, to calculate film thickness of equal value and air layer thickness of equal value.

At this moment, calculate film thickness and air layer thickness the two.Thus, can also take into full account the influence of swing.Herein, swing refers to the fixed cycle film broad ways be shaken, and there are coiling length cycle and winding radius cycle in this cycle.Coiling length when the coiling length cycle refers to that the coiling length of whenever fixing is carried out 1 reciprocally swinging.And, the increment of the coil diameter when the winding radius cycle refers to carry out 1 reciprocally swinging when coil diameter increases regular length.No matter be under the situation in which kind of cycle, by being suitable for said method, can consider that all the influence of swinging calculates.

(3) the radial direction stress of net and circumferencial direction stress Calculation

According to hereto illustrated model, (formula (with reference to non-patent literature 1) of revising Ha Qier model (Modified Hakiel model) is found the solution, thereby obtains radial direction stress σ to the following correction Ha Qier that air film between indrawn film is taken into account _rAnd circumferencial direction stress σ _t

$r^2\frac{d^2{\mathrm{\δ\σ}}_r}{{\mathrm{dr}}^2}+3r\frac{{\mathrm{d\δ\σ}}_r}{\mathrm{dr}}+(1-\frac{E_t}{E_r}){\mathrm{\δ\σ}}_r=0$ Formula 4

${\mathrm{\σ}}_t=r\frac{{\mathrm{d\σ}}_r}{\mathrm{dr}}+{\mathrm{\σ}}_r$ Formula 5

Below represent r, E herein, _t, E _r

R: winding radius

E _t: the circumferencial direction Young's modulus

E _r: the radial direction Young's modulus

And, radial direction Young's modulus E _rBe to obtain by following formula 6.

$E_r=\frac{\mathrm{tw}+\mathrm{<figure-callout\; id="1"\; label="h\; tw\; E"\; filenames="HDA00002876151000051.png,HDA00002876151000122.png"\; state="\{\{state\}\}">h</figure-callout>}}{\frac{\mathrm{tw}}{E_{}}}$ Formula 6

Tw: the thickness of net

H: air layer thickness

E1: the radial direction Young's modulus of net

E2: the radial direction Young's modulus of air layer

Herein, Et is the physics value of obtaining with common tensile test method.Along the circumferential direction (tangential direction) stretching nets is measured deformation and stress.The slope of deformation-circumferencial direction stress becomes Et.

And, the radial direction Young's modulus E1 of net be by the known K2 of being known as factorial experiments (factor test) (being established by the J.D.Pfeiffer of " paper pulp and paper industry technical ability association will " (Tappi Journal) lining), net is carried out the physics value that stacked compression verification obtains along radial direction.The radial direction Young's modulus E1 that deformation when applying compressive load and the slope of radial direction stress obtain to net.

(4) radial direction stress calculation value and the measured value of net

Next, describe computing value that the radial direction stress Calculation method by above-mentioned net of the present invention obtains and the evaluation of measured value in detail with reference to accompanying drawing.Fig. 8 (A), Fig. 8 (a), Fig. 8 (B), Fig. 8 (b), Fig. 8 (C), Fig. 8 (c) are the charts of expression stress calculation result and measured value.

According to following condition 1～condition 3, utilize computer (computer) to calculate radial direction stress.At this moment, according to condition 1～condition 3 actual coiled films, as shown in figure 21, the working pressure sensor is surveyed radial direction stress.

The film thickness of condition 1: wobble amplitude 5mm, tension force 580N, knurled portions thickness 8 μ m, Width 79.0 μ m～81.5 μ m distributes

The film thickness of condition 2: wobble amplitude 10mm, tension force 580N, knurled portions thickness 8 μ m, Width 79.0 μ m～81.5 μ m distributes

The film thickness of condition 3: wobble amplitude 0mm (not having swing), tension force 580N, knurled portions thickness 8 μ m, Width 79.0 μ m～81.5 μ m distributes

Stress calculation result during condition 1～condition 3 is respectively Fig. 8 (A), Fig. 8 (B), Fig. 8 (C).And the measured value during condition 1～condition 3 is respectively Fig. 8 (a), Fig. 8 (b), Fig. 8 (c).

If comparison diagram 8 (A) and Fig. 8 (a), then as can be known computing value very near measured value.Especially, the variation of the radial direction stress that causes because of the influence of the annular knurl at the Width two ends of film is also calculated near measured value.

By Fig. 8 (B) and Fig. 8 (b), Fig. 8 (C) and Fig. 8 (c) too so situation as can be known be, even the change condition, also can be by calculating the value near measured value.That is, the calculation method for stress of the application of the invention can be obtained the value near measured value.

The net volume winding method of the radial direction stress of＜use volume Intranet 〉

Next, with reference to accompanying drawing the reel method of net of radial direction stress, the circumferencial direction stress of the volume Intranet that use is obtained by said method is described.Fig. 9 is the diagram of circuit of flow process of the method for winding of expression net.

With reference to Fig. 8 (A), Fig. 8 (a), Fig. 8 (B), Fig. 8 (b), Fig. 8 (C), Fig. 8 (c), at first, making the volume of estimating usefulness is virtual volume (S1: the virtual volume production process).The making of virtual volume is to be undertaken by will the film (net) identical with used film (net) in the goods being wound on the core.But the condition that is used for reeling can be suitably.Refer to winding tension distribution, wobble amplitude, annular knurl height, net thickness figure etc. for the condition of reeling herein.

Winding tension distributes and refers to from beginning the variation figure of the winding tension till reel-to-reel finishes.Wobble amplitude refers to the mobile width that causes because of swing.The height of the net surface that the annular knurl height refers to never to form annular knurl till the summit that forms the protuberance that causes because of annular knurl.Net thickness figure refers to the variation figure of the thickness of the Width netted.

Before or after S1 or simultaneously, make parted pattern by said method, described parted pattern be with volume broad ways ring cutting be divided into a plurality of (modelling operations), use identical with goods (namely, identical with virtual volume) circumferencial direction Young's modulus and radial direction Young's modulus come solution formula 4, formula 5, thereby at each winding radius and at each parted pattern, obtain radial direction stress and the circumferencial direction stress (S2: calculation process) of virtual volume.In addition, when being recited as stress calculation hereinafter, all refer to radial direction stress calculation or the circumferencial direction stress calculation of being undertaken by said method.

Next, carry out limit stress evaluation (S3: limit stress determines operation).The limit stress evaluation refers to evaluation as described below, that is: the various defectives that take place during for the making virtual volume, namely rolling up mal-alignment (winding misalignment), otch transfer (cut edge transfer), recess (recess), black-tape, volume wrinkle (winding crinkle), chrysanthemum shape decorative pattern (chrysanthemum-like marking) etc. is at what meters of counting from volume core side (to rephrase the statement, winding radius for what millimeter the time) investigate, by the stress calculation result who in S2, carries out, obtain the radial direction stress σ of this moment _rWith circumferencial direction stress σ _tBelow various defectives are described.

(1) volume mal-alignment

Volume mal-alignment defective refers to following phenomenon: the state that volume has the position of two side ends of the volume of net to become after rolled up is the state of the position deviation part of initial condition.For the countermeasure of this defective, must be with radial direction stress σ _rHeighten.

(2) otch shifts

Otch shifts and refers to: shown in Fig. 8 (A), Fig. 8 (a), Fig. 8 (B), Fig. 8 (b), Fig. 8 (C), Fig. 8 (c), if cover the volume film on the jump part 80 of the roll set that when roll set film 31 on the volume core, produces, then covering the jump that also can produce on the film of volume.For the countermeasure of this defective, must be with radial direction stress σ _rTurn down.Figure 10 is the ring cutting directional profile skeleton diagram for the volume of explanation otch transfer.Will inevitably produce jump at rolling part, the jump that produces because of the influence of this jump can diminish along with the carrying out of winding film, finally reaches below the grade (level) of no goods shape problem.It is short as far as possible to reach the grade of no goods shape problem coiling length till following, film so, can obtain non-defective unit morely, thereby ideal comparatively.

(3) chrysanthemum shape decorative pattern

Chrysanthemum shape decorative pattern refers to following defective: because along the circumferential direction compressing, cause film to produce buckling and film becomes the state of fluctuating.If observe from the end face side of volume, then this defective seems as chrysanthemum shape decorative pattern.For the countermeasure of this defective, just in case circumferencial direction stress σ _tFor negative (minus), then as far as possible with circumferencial direction stress σ _tBe adjusted near positive value, in order to avoid circumferencial direction stress σ _tBe compression (bearing).

(4) recess depressed deformation

The recess depressed deformation refers to following defective: net is absorbed in and depressed deformation on the surface of recess depressed deformation volume.For the countermeasure of this defective, must will be involved in air film thickness and turn down.

(5) black-tape

When coiled film, the protuberance of film can overlap in same position sometimes.At this moment, along with volume is extremely multiple, have the part that strong pressure puts on protuberance, thereby cause this part to be adhered to, perhaps because pressure extends, thereby cause the quality of goods to descend.And, if observe this part from the outside, then seem the band as black.Black-tape defective that Here it is.For the countermeasure of this defective, the amplitude of swing must be transferred greatly, perhaps with radial direction stress σ _rTurn down.

(6) volume wrinkle

Volume wrinkle defective produces the defective of wrinkle when referring to coiled film.For the countermeasure of this defective, must be with circumferencial direction stress σ _tTurn down.

Next, in order to obtain the defective that takes place in the virtual volume in the scope of the winding radius of regulation (on will the specification at goods, the scope that the winding radius of defective should not take place is called the scope of the winding radius of regulation) in not recurrent coiling condition, and carry out following operation.Namely, radial direction stress, the defective generation radial direction stress as circumferencial direction stress, defective generation circumferencial direction stress during according to the generation defective, obtaining the range of stress that this defective may take place is defective generation range of stress (defective generation range of stress determines operation).Particularly as follows.

Under the situation of volume mal-alignment defective, the following range of stress of defective generation radial direction stress is defective generation range of stress.

Shift at otch under the situation of defective, the above range of stress of defective generation radial direction stress is defective generation range of stress.

Under the situation of chrysanthemum shape patterned defect, the following range of stress of defective generation circumferencial direction stress is defective generation range of stress.

Under the situation of recess defective, it is defective generation air film thickness range that defective is involved in the above thickness scope of air film thickness.

Under the situation of black-tape defective, the above range of stress of defective generation radial direction stress is defective generation range of stress.

Under the situation of volume wrinkle defective, the following above range of stress of defective generation circumferencial direction stress is defective generation range of stress.

Next, so that the mode of defective can not take place in the scope of the winding radius of stipulating, namely, no longer be included in mode in the defective generation range of stress with the stress (radial direction stress, circumferencial direction stress) in the scope of winding radius of regulation, change at least a stress calculation (S4: stress is calculation process again) of carrying out in the amplitude of height, swing of Width thickness distribution, the knurled portion of winding tension figure as the coiling condition, film.This stress calculation is to change the coiling condition to carry out repeatedly, until obtain not the coiling condition (stress of the volume in the scope of the winding radius of regulation no longer is included in the coiling condition in the defective generation range of stress) of defective takes place in can the scope at the winding radius of regulation till.Thus, the stress of scope that can derive the winding radius of regulation can not be included in the coiling condition in the defective generation range of stress.

Come coiled film (net) on the volume core by the coiling condition of using this derivation, thereby can make the net volume of goods.

Herein, the winding tension figure refers to: as shown in figure 10, the winding radius when carrying out winding film is corresponding, the variation figure of the memberane stress when reeling.Figure 11 is the chart of the relation of expression winding radius and memberane stress.

At last, come actual coiled film (S5) according to the coiling condition of obtaining.

Like this, will be used for obtaining of coiling condition by the stress calculation of the volume inside of 3D modelling, thereby can obtain the coiling condition that defective can not take place and carry out actual evaluation hardly.These stress calculation and the operation of obtaining the coiling condition can use computer to carry out.By making computer carry out above-mentioned calculating formula and calculation process, as long as input coiling condition just can be carried out stress calculation and pictorialization.

＜estimate

Next, for method for winding of the present invention, kind A and these two kinds of optical thin films of kind B are estimated.

(1) evaluation of kind A

At first, make the virtual volume of kind A, otch took place before coiling length 100m the virtual volume of kind A shifts, at coil diameter

The position volume mal-alignment takes place.The coiling condition of this moment is as follows.

Roll set tension force 650N has rolled up tension force and is 580N and made the tension force linear change from roll set till having rolled up.

Annular knurl height 6 μ m (thickness of knurled portions is the height 6 μ m gained that the thickness of film added annular knurl)

Wobble amplitude 10mm

Therefore, based on the manufacturing conditions of virtual volume, the variation of the radial direction stress when obtaining the coiling length that makes film and winding radius and change by calculation method for stress of the present invention.It is the results are shown in Figure 12 (a), Figure 12 (b), Figure 13 (a), Figure 13 (b).

Figure 12 (a) is the three-dimensional chart of the relation of the expression coiling length of virtual volume and radial direction stress.Figure 12 (b) is the chart of the relation of the coiling length of axle center of expression virtual volume and radial direction stress.Figure 13 (a) is the three-dimensional chart of the relation of the expression winding radius of virtual volume and radial direction stress.Figure 13 (b) is the chart of the relation of the winding radius of knurled portions of expression virtual volume and radial direction stress.

Effectively the stress of goods portion (beyond the both ends of volume) is more big, and then more easy generation otch shifts defective.Therefore, Figure 12 (b) is to be representative and for core with effective goods portion among Width, and transverse axis is made as coiling length (m), the longitudinal axis is made as radial direction stress makes chart.

With reference to Figure 12 (b), be that the 100m place otch takes place shifts defective in coiling length, therefore if the radial direction stress when reading (obtaining with calculating) coiling length and be 100m from chart (solid line) then is 0.088MPa.

Thereby, if the generation coiling length of otch defective will be made as for example below the 30m as expected value, then as long as shown in the dotted line of Figure 12 (b), only obtaining in coiling length is that 30m is when following, the value of radial direction stress reaches the above coiling condition of radial direction stress that the otch defective can not take place, and reels according to this condition and to get final product.Herein, above-mentioned expected value can be selected arbitrary value according to goods, and above-mentioned value is an example, and the present invention is not limited to this value.

And one of purpose that forms knurled portion is: the protuberance by knurled portion strengthens radial direction stress, thereby strengthens friction force, to prevent from rolling up mal-alignment.Thereby for the volume mal-alignment, key is to investigate the radial direction stress of knurled portions.

Therefore, the radial direction stress at Width both ends shown in Figure 13 (a), that get volume (knurled portions) is the longitudinal axis, gets winding radius (mm) and be the chart of the transverse axis solid line for Figure 13 (b).Owing at coil diameter 520mm place the volume mal-alignment has taken place, therefore if the radial direction stress when obtaining (by calculating) and roll up mal-alignment according to the chart of this solid line then is 0.15MPa.

The out-of-alignment winding radius of volume takes place for example to reach as 93.5% of total winding radius of expected value be more than the 575mm in order to make, as long as the dotted line of Figure 13 (b), only obtain at winding radius during greater than 575mm, radial direction stress is less than the coiling condition of 0.15MPa, and reels according to this condition and to get final product.Herein, the expected value that the out-of-alignment winding radius of volume takes place can adopt % value arbitrarily according to goods, and above-mentioned value is example, and the present invention is not limited to this value.

The stress of the knurled portions when herein, some chain lines of Figure 13 (b) are represented the condition of dotted line of Figure 12 (b).Namely, as can be known be: if change winding tension in order to tackle the otch defective, with the radial direction stress shown in the dotted line that reaches Figure 12 (b), although then the otch defective is alleviated, but shown in some chain lines of Figure 13 (b), volume mal-alignment defective can worsen on the contrary.

So, change winding tension alleviating the relation that otch defective and the way of volume mal-alignment defective are in balance (trade off) each other, as if one good, then another person is with variation.Therefore, the otch defective is to change winding tension to deal with, and volume mal-alignment defective is to change swing width to deal with.This is because even do not change winding tension, but as long as change swing width, the radial direction stress of knurled portions just can change.

So, to change winding tension in order to prevent the otch defective, to change swing width in order preventing from rolling up the mal-alignment defective, at this moment, amount to the simulation more than 100 times, thereby derive the coiling condition that can prevent otch defective and volume mal-alignment defective simultaneously.It is the results are shown in Figure 14, Figure 15.

Figure 14 is the chart of the relation of the winding radius-central portion radial direction stress under expression initial condition (IC) and the derivation condition.Figure 15 is the chart of the relation of the winding radius-knurled portions radial direction stress under expression initial condition (IC) and the derivation condition.The dotted line of Figure 14 is represented to make the tension force linear change from roll set tension force 650N till having rolled up tension force 580N, and the coiling result under the initial condition (IC) of annular knurl amplitude 10mm.And the solid line of Figure 14 is represented the new condition that derives, and namely makes the tension force linear change from roll set tension force 550N till having rolled up tension force 550N, and the coiling result under the wobble amplitude 5mm.

And the dotted line of Figure 15 is represented the coiling result under the initial condition (IC) identical with the dotted line of Figure 14, and the solid line of Figure 15 is represented the coiling result under the condition of the new derivation identical with the solid line of Figure 14.As Figure 14, shown in Figure 15, by changing tension force and annular knurl amplitude, can reduce the radial direction stress of the central portion of volume, and the radial direction stress of knurled portions is risen.Its result successfully makes otch shift defective and optimizes simultaneously with this two side of volume mal-alignment defective.

Like this, according to the present invention, can use the simulation that does not take cost and time to derive flawless coiling condition.

(2) evaluation of kind B

Next, the evaluation to kind B describes.Kind B also be with kind A similarly, make virtual volume, and the coil diameter scope that the otch defective takes place and the coil diameter that volume mal-alignment defective takes place estimated.Next, simulate (stress calculation of the present invention) repeatedly to derive the coiling condition of optimizing defective.

Herein, kind B is different from kind A, is the kind that can't change wobble amplitude in the design of commodity.Therefore, derive following coiling condition, that is: the winding tension that only changes film makes otch defective and the coiling condition of rolling up the two optimization of mal-alignment defective.

It is the results are shown in Figure 16.Figure 16 is the chart of the winding radius-memberane stress condition of expression derivation.The dotted line of Figure 16 is represented initial condition (IC), and solid line is represented the new coiling condition that derives.

As shown in figure 16, the new condition that derives is: soon, make when reeling that tension force is linear to rise after begin to reel, make subsequently that tension force is linear to descend.By adopting this kind winding tension to distribute, even do not change the annular knurl amplitude, for tension force, also can make the otch defective and the two optimization of volume mal-alignment defective that are in the balance relation.

Consider this be because: therefore the otch defective is near generation roll set, the tension force of roll set is reduced than initial condition (IC), and the out-of-alignment coiling of volume is taking place in the near future, improves tension force than initial condition (IC).

But the coiling condition of winding radius and tension force distributes and has countless versions, derives which kind of condition for suitably by existing evaluation, is impossible in reality.The method according to this invention, the derivation that not only makes existing impossible coiling condition distribute becomes possibility, and evaluation cost, evaluation experimental time also can significantly reduce.For example, in the coiling condition of above-mentioned kind A, B derives, evaluation time can be reduced to existing about 1/6 (being reduced to 50 hours by 300 hours).

Will be for the coiling condition that derives among existing coiling condition and the present invention, also comprise the coiling quality and sum up the results are shown in table 1.Table 1 is the table that existence conditions and derivation condition and coiling quality are summarized.

Table 1

In table 1, multiple spot tension force figure refers to: when making tension force figure linear change, slope changes figure (becoming broken line) repeatedly halfway.The existing type of film thickness figure refers to that the Width central portion is thin and figure that two ends are thick, smooth (flat) refer to thickness at Width for fixing.

And, following respectively the reel assessment of fault grade of quality of expression.

The volume mal-alignment is estimated alignment situation or the entanglement of the end face (side) of the volume of reeling.

Excellent: departing from of no Width and rolling up gallantly.(in the bias 3mm)

Very: can see departing from of Width.(3mm～10mm)

Difference: have the position of significantly departing from Width.

The jump that otch shifts roll set is transferred to the film that covers volume and the fault of being out of shape.

Excellent: as to count from the volume core and almost can't see otch more than the 15m and shift.

Very: count from the volume core and to see faintly more than the 15m that otch shifts.

Differ from: count from the volume core and see significantly more than the 15m that otch shifts.

Black-tape is also referred to as adhesion (blocking), refers to that thin layer and thin layer connect airtight in the volume of reeling each other, and the result is pasted together and is the part of transparent outward appearance.Under the big situation of winding radius direction stress, this black-tape can worsen.This black-tape is not have the state that is involved in air layer fully.

Excellent: as to can't see black-tape.

Very: see a little black-tape.

Difference: black-tape takes place in the almost whole surface at volume.

Volume wrinkle (horizontal scroll wrinkle) net is compressed in a circumferential direction, and the fault of wrinkle distortion takes place in the direction parallel with wireline reel the result.

Excellent: as to can't see the volume wrinkle.

Very: see faint volume wrinkle.

Difference: see the net bending and the obvious wrinkle of distortion.

The surface of depression/corner angle volume is absorbed in, but is not the beautiful curvature for the section circle, but sees the fault of the deformation place of having edges and corners everywhere.

Excellent: can't see the corner angle distortion on the surface of volume.

Very: see faint corner angle distortion on the surface of volume.

Difference: see the obvious edges and corners distortion on wide scope ground, the surface of volume.

As shown in table 1, reel according to the coiling condition that derives by the present invention, thereby can make the good flawless volume of coiling quality.

In addition, in above-mentioned evaluation, be example with volume mal-alignment defective and otch defective, the evaluation that is used for this defective is alleviated is illustrated, but in the present invention, be not limited to these defectives, can obtain the coiling condition that any defectives such as making volume mal-alignment, otch transfer, black-tape, volume wrinkle, depression/corner angle all becomes good.

This be because: no matter be which kind of defective, all can be by radial direction stress, circumferencial direction stress and any one condition of carrying out of being involved in the air film be obtained and goodization, and can simulate coiling condition for this goodization in the present invention.

Claims (12)

1. the manufacture method of a net volume is manufactured on the net volume that is wound with net on the volume core, and the manufacture method of described net volume is characterised in that and comprises:

The virtual volume production process uses the net identical with the described net that is used for described net volume, described net is wound on the described volume core, thereby makes the virtual volume of estimating usefulness;

The computation model production process is made a plurality of parted patterns, described parted pattern be with described net volume broad ways ring cutting be divided into a plurality of;

Calculation process at each described parted pattern and at each winding radius, distributes based on circumferencial direction Young's modulus, radial direction Young's modulus and winding tension, obtains any stress at least in circumferencial direction stress and the radial direction stress;

Defective generation range of stress determines operation, according to the described stress of the defective generation winding radius of the defective that takes place at virtual volume described in the described virtual volume production process and each described winding radius of in described calculation process, obtaining, obtain the defective generation range of stress that described defective may take place;

Stress is calculation process again, change is as the amplitude of the height of the Width thickness distribution of the winding tension figure of coiling condition, pneumatic press pressing force figure, film, knurled portion, swing and in the cycle at least one, repeat described calculation process, till the stress of scope of the winding radius of regulation no longer is included in the described defective generation range of stress; And

The coiling operation is not included in described coiling condition in the described defective generation range of stress with the stress of the scope of the winding radius of the described regulation obtained in the calculation process again at described stress, carries out the coiling of described net.

2. net volume manufacture method according to claim 1 is characterized in that, in described calculation process, as the σ of described radial direction stress _rBe to utilize by the following formula that will be involved in correction Ha Qier that air film takes into account and derive to obtain,

$r^2\frac{d^2{\mathrm{\&delta;\&sigma;}}_r}{{\mathrm{dr}}^2}+3r\frac{{\mathrm{d\&delta;\&sigma;}}_r}{\mathrm{dr}}+(1-\frac{E_t}{E_r}){\mathrm{\&delta;\&sigma;}}_r=0$

R: winding radius

Et: circumferencial direction Young's modulus

Er: the radial direction Young's modulus,

σ as described circumferencial direction stress _tBe to utilize by the following formula that will describedly be involved in the described Ha Qier of correction that air film takes into account and derive to obtain,

${\mathrm{\&sigma;}}_t=r\frac{{\mathrm{d\&sigma;}}_r}{\mathrm{dr}}+{\mathrm{\&sigma;}}_r.$

3. net volume manufacture method according to claim 2 is characterized in that, when asking the described thickness that is involved in air film, utilizes following formula 1 to obtain the outermost air film thickness h of described net volume o,

$\mathrm{ho}=0.589\&times;R\&times;{\left(\frac{6\mathrm{\&eta;}(\mathrm{Vr}+\mathrm{Vw})}{T}\right)}^{\frac{2}{3}}$ Formula 1

R: the radius of net volume

η: the coefficient of viscosity of air

Vr: the rotative speed of net volume

Vw: the conveyance speed of institute's wound film

T: pro rata the tension force of film integral is distributed to the value of the tension force of each described parted pattern with the film thickness of described parted pattern

Use the ho that obtains in the described formula 1, utilize following formula 2 to obtain air film thickness h a, described air film thickness h a spreads all over whole Width and a part of pressing outermost described net with the power of L towards radial direction, to reduce the air film thickness behind the described outermost air thickness

${\mathrm{ha}=(\frac{1}{{\mathrm{ho}}^2}+\frac{2\mathrm{LR}}{{\mathrm{\&eta;RW}}^2}t)}^{-\frac{1}{2}}$ Formula 2

L: the power that film is pressed into net volume

W: the width of net volume

The film of other parted patterns that if there is no has the value of " film thickness+air film thickness h a ", the thickness of the film with maximum film thickness in the film of the value of described " film thickness+air film thickness h a " the described parted pattern when considering described annular knurl also for film a part of is big, then obtain air film thickness h under the film with described maximum film thickness by following formula 3A or formula 3B, and for the air film thickness under the film beyond the film with described maximum film thickness, consider that then film is rigid body and will distribute the interval at the back side of the described film surface that produces and the film under the described film as the described thickness that is involved in air film because of film thickness

${h=(\frac{1}{{\mathrm{ha}}^2}+\frac{2\mathrm{\&sigma;}}{{\mathrm{\&eta;W}}^2}t)}^{-\frac{1}{2}}$ Formula 3A

$h={(\frac{1}{{\left(\frac{{\mathrm{\&sigma;}}_0+P_{\mathrm{ap}}}{\mathrm{\&sigma;}+P_{\mathrm{ap}}}{h}_a\right)}^2}+\frac{2\mathrm{\&sigma;}}{{\mathrm{\&eta;W}}^2}t)}^{-\frac{1}{2}}$ Formula 3B

σ: radial direction stress

σ ₀: initial radium direction stress

P _Ap: barometric pressure

Ha: the air film thickness after pressing with the power of L towards radial direction by pneumatic press is the air film thickness h that is involved in when volume is till the i-1 layer in Ha Qier after being involved in

If there is the film of described other parted patterns of the value with described " film thickness+air film thickness h a ", the thickness of the film with maximum film thickness in the film of the value of described " film thickness+air film thickness h a " the described parted pattern when considering described annular knurl also for film a part of is big, then when considering that film is that the size of " film thickness+air film thickness h a " of rigid body and part beyond the described knurled portion is during for the cutting apart film and the described film of cutting apart under the film and dispose with the interval of described air film thickness h a of maximum, with the distance at the surface of each upper film and the back side of following film as the described thickness that is involved in air film, the total area of perhaps obtaining the sectional area that is involved in air in each parted pattern is identical upper film surface and the interval of following film surface with the sectional area in the gap at the back side of the surface of upper film and following film, and the distance at the back side of the surface of described each upper film that will be at this moment and following film is as the described thickness that is involved in air film.

4. net volume manufacture method according to claim 3, it is characterized in that, when asking the described thickness that is involved in air film and described film thickness, cause because of swing with the film of other parted patterns of the scope adjacency of certain parted pattern and situation that air layer is invaded under, then the length of the part that will invade from described other parted patterns and the film of described certain parted pattern and the length of air layer are carried out proportional distribution, with as film thickness of equal value and air film thickness of equal value.

5. a net volume method for winding is used to form the net volume that is wound with net at the volume core, and described net volume method for winding is characterised in that and comprises:

The virtual volume production process uses the net identical with the described net that is used for described net volume, described net is wound on the described volume core, thereby makes the virtual volume of estimating usefulness;

The computation model production process is made a plurality of parted patterns, described parted pattern be with described net volume broad ways ring cutting be divided into a plurality of;

Calculation process at each described parted pattern and at each winding radius, distributes based on circumferencial direction Young's modulus, radial direction Young's modulus and winding tension, obtains any stress at least in circumferencial direction stress and the radial direction stress;

Defective generation range of stress determines operation, according to the described stress of the defective generation winding radius of the defective that takes place at virtual volume described in the described virtual volume production process and each described winding radius of in described calculation process, obtaining, obtain the defective generation range of stress that described defective may take place;

Stress is calculation process again, change is as the amplitude of the height of the Width thickness distribution of the winding tension figure of coiling condition, pneumatic press pressing force figure, film, knurled portion, swing and in the cycle at least one, repeat described calculation process, till the stress of scope of the winding radius of regulation no longer is included in the described defective generation range of stress; And

The coiling operation is not included in described coiling condition in the described defective generation range of stress with the stress of the scope of the winding radius of the described regulation found in the calculation process again at described stress, carries out the coiling of described net.

6. net volume method for winding according to claim 5 is characterized in that, in described calculation process, as the σ of described radial direction stress _rBe to utilize by the following formula that will be involved in correction Ha Qier that air film takes into account and derive to obtain,

$r^2\frac{d^2{\mathrm{\&delta;\&sigma;}}_r}{{\mathrm{dr}}^2}+3r\frac{{\mathrm{d\&delta;\&sigma;}}_r}{\mathrm{dr}}+(1-\frac{E_t}{E_r}){\mathrm{\&delta;\&sigma;}}_r=0$

R: winding radius

Et: circumferencial direction Young's modulus

Er: the radial direction Young's modulus,

σ as described circumferencial direction stress _tBe to utilize by the following formula that will describedly be involved in the described Ha Qier of correction that air film takes into account and derive to obtain,

${\mathrm{\&sigma;}}_t=r\frac{{\mathrm{d\&sigma;}}_r}{\mathrm{dr}}+{\mathrm{\&sigma;}}_r.$

7. net volume method for winding according to claim 6 is characterized in that, when asking the described thickness that is involved in air film, utilizes following formula 1 to obtain the outermost air film thickness h of described net volume o,

$\mathrm{ho}=0.589\&times;R\&times;{\left(\frac{6\mathrm{\&eta;}(\mathrm{Vr}+\mathrm{Vw})}{T}\right)}^{\frac{2}{3}}$ Formula 1

R: the radius of net volume

η: the coefficient of viscosity of air

Vr: the rotative speed of net volume

Vw: the conveyance speed of institute's wound film

T: pro rata the tension force of film integral is distributed to the value of the tension force of each described parted pattern with the film thickness of described parted pattern

Use the ho that obtains in the described formula 1, utilize following formula 2 to obtain air film thickness h a, described air film thickness h a spreads all over whole Width and a part of pressing outermost described net with the power of L towards radial direction, to reduce the air film thickness behind the described outermost air thickness

${\mathrm{ha}=(\frac{1}{{\mathrm{ho}}^2}+\frac{2\mathrm{LR}}{{\mathrm{\&eta;RW}}^2}t)}^{-\frac{1}{2}}$ Formula 2

L: the power that film is pressed into net volume

W: the width of net volume

The film of other parted patterns that if there is no has the value of " film thickness+air film thickness h a ", the thickness of the film with maximum film thickness in the film of the value of described " film thickness+air film thickness h a " the described parted pattern when considering described annular knurl also for film a part of is big, then obtain air film thickness h under the film with described maximum film thickness by following formula 3A or formula 3B, and for the air film thickness under the film beyond the film with described maximum film thickness, consider that then film is rigid body and will distribute the interval at the back side of the described film surface that produces and the film under the described film as the described thickness that is involved in air film because of film thickness

${h=(\frac{1}{{\mathrm{ha}}^2}+\frac{2\mathrm{\&sigma;}}{{\mathrm{\&eta;W}}^2}t)}^{-\frac{1}{2}}$ Formula 3A

$h={(\frac{1}{{\left(\frac{{\mathrm{\&sigma;}}_0+P_{\mathrm{ap}}}{\mathrm{\&sigma;}+P_{\mathrm{ap}}}{h}_a\right)}^2}+\frac{2\mathrm{\&sigma;}}{{\mathrm{\&eta;W}}^2}t)}^{-\frac{1}{2}}$ Formula 3B

σ: radial direction stress

σ ₀: initial radium direction stress

P _Ap: barometric pressure

Ha: the air film thickness after pressing with the power of L towards radial direction by pneumatic press is the air film thickness h that is involved in when volume is till the i-1 layer in Ha Qier after being involved in

If there is the film of described other parted patterns of the value with described " film thickness+air film thickness h a ", the thickness of the film with maximum film thickness in the film of the value of described " film thickness+air film thickness h a " the described parted pattern when considering described annular knurl also for film a part of is big, then when considering that film is that the size of " film thickness+air film thickness h a " of rigid body and part beyond the described knurled portion is during for the cutting apart film and the described film of cutting apart under the film and dispose with the interval of described air film thickness h a of maximum, with the distance at the surface of each upper film and the back side of following film as the described thickness that is involved in air film, the total area of perhaps obtaining the sectional area that is involved in air in each parted pattern is identical upper film surface and the interval of following film surface with the sectional area in the gap at the back side of the surface of upper film and following film, and the distance at the back side of the surface of described each upper film that will be at this moment and following film is as the described thickness that is involved in air film.

8. net volume method for winding according to claim 7, it is characterized in that, when asking the described thickness that is involved in air film and described film thickness, cause because of swing with the film of other parted patterns of the scope adjacency of certain parted pattern and situation that air layer is invaded under, then the length of the part that will invade from described other parted patterns and the film of described certain parted pattern and the length of air layer are carried out proportional distribution, with as film thickness of equal value and air film thickness of equal value.

9. an internal stress method of calculating is the internal stress method of calculating that is wound with the net volume of net at the volume core, and described internal stress method of calculating is characterised in that and comprises:

The computation model production process is made a plurality of parted patterns, described parted pattern be with described net volume broad ways ring cutting be divided into a plurality of; And

Calculation process at each described parted pattern and at each winding radius, distributes based on circumferencial direction Young's modulus, radial direction Young's modulus and winding tension, obtains any stress at least in circumferencial direction stress and the radial direction stress.

10. internal stress method of calculating according to claim 9 is characterized in that, in described calculation process, as the σ of described radial direction stress _rBe to utilize by the following formula that will be involved in correction Ha Qier that air film takes into account and derive to obtain,

$r^2\frac{d^2{\mathrm{\&delta;\&sigma;}}_r}{{\mathrm{dr}}^2}+3r\frac{{\mathrm{d\&delta;\&sigma;}}_r}{\mathrm{dr}}+(1-\frac{E_t}{E_r}){\mathrm{\&delta;\&sigma;}}_r=0$

R: winding radius

Et: circumferencial direction Young's modulus

Er: the radial direction Young's modulus,

σ as described circumferencial direction stress _tBe to utilize by the following formula that will describedly be involved in the described Ha Qier of correction that air film takes into account and derive to obtain,

${\mathrm{\&sigma;}}_t=r\frac{{\mathrm{d\&sigma;}}_r}{\mathrm{dr}}+{\mathrm{\&sigma;}}_r.$

11. internal stress method of calculating according to claim 10 is characterized in that, when asking the described thickness that is involved in air film, utilizes following formula 1 to obtain the outermost air film thickness h of described net volume o,

$\mathrm{ho}=0.589\&times;R\&times;{\left(\frac{6\mathrm{\&eta;}(\mathrm{Vr}+\mathrm{Vw})}{T}\right)}^{\frac{2}{3}}$ Formula 1

R: the radius of net volume

η: the coefficient of viscosity of air

Vr: the rotative speed of net volume

Vw: the conveyance speed of institute's wound film

T: pro rata the tension force of film integral is distributed to the value of the tension force of each described parted pattern with the film thickness of described parted pattern

Use the ho that obtains in the described formula 1, utilize following formula 2 to obtain air film thickness h a, described air film thickness h a spreads all over whole Width and a part of pressing outermost described net with the power of L towards radial direction, to reduce the air film thickness behind the described outermost air thickness

${\mathrm{ha}=(\frac{1}{{\mathrm{ho}}^2}+\frac{2\mathrm{LR}}{{\mathrm{\&eta;RW}}^2}t)}^{-\frac{1}{2}}$ Formula 2

L: the power that film is pressed into net volume

W: the width of net volume

The film of other parted patterns that if there is no has the value of " film thickness+air film thickness h a ", the thickness of the film with maximum film thickness in the film of the value of described " film thickness+air film thickness h a " the described parted pattern when considering described annular knurl also for film a part of is big, then obtain air film thickness h under the film with described maximum film thickness by following formula 3A or formula 3B, and for the air film thickness under the film beyond the film with described maximum film thickness, consider that then film is rigid body and will distribute the interval at the back side of the described film surface that produces and the film under the described film as the described thickness that is involved in air film because of film thickness

${h=(\frac{1}{{\mathrm{ha}}^2}+\frac{2\mathrm{\&sigma;}}{{\mathrm{\&eta;W}}^2}t)}^{-\frac{1}{2}}$ Formula 3A

$h={(\frac{1}{{\left(\frac{{\mathrm{\&sigma;}}_0+P_{\mathrm{ap}}}{\mathrm{\&sigma;}+P_{\mathrm{ap}}}{h}_a\right)}^2}+\frac{2\mathrm{\&sigma;}}{{\mathrm{\&eta;W}}^2}t)}^{-\frac{1}{2}}$ Formula 3B

σ: radial direction stress

σ ₀: initial radium direction stress

P _Ap: barometric pressure

Ha: the air film thickness after pressing with the power of L towards radial direction by pneumatic press is the air film thickness h that is involved in when volume is till the i-1 layer in Ha Qier after being involved in

If there is the film of described other parted patterns of the value with described " film thickness+air film thickness h a ", the thickness of the film with maximum film thickness in the film of the value of described " film thickness+air film thickness h a " the described parted pattern when considering described annular knurl also for film a part of is big, then when considering that film is that the size of " film thickness+air film thickness h a " of rigid body and part beyond the described knurled portion is during for the cutting apart film and the described film of cutting apart under the film and dispose with the interval of described air film thickness h a of maximum, with the distance at the surface of each upper film and the back side of following film as the described thickness that is involved in air film, the total area of perhaps obtaining the sectional area that is involved in air in each parted pattern is identical upper film surface and the interval of following film surface with the sectional area in the gap at the back side of the surface of upper film and following film, and the distance at the back side of the surface of described each upper film that will be at this moment and following film is as the described thickness that is involved in air film.

12. internal stress method of calculating according to claim 11, it is characterized in that, when asking the described thickness that is involved in air film and described film thickness, cause because of swing with the film of other parted patterns of the scope adjacency of certain parted pattern and situation that air layer is invaded under, then the length of the part that will invade from described other parted patterns and the film of described certain parted pattern and the length of air layer are carried out proportional distribution, with as film thickness of equal value and air film thickness of equal value.

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