EP3527518A1 - System and method for manufacturing rolls of web-like material - Google Patents

Abstract

The invention relates to a system and a method for producing rolls from sheet material (9), in particular from a textile composite. The system (1) comprises: - a manufacturing group (2), in which a starting material can be brought into a web-like form in a manufacturing process and wound on parent reels, - a cutting and winding group (3), in which in a cutting and winding process individual rolls with a smaller width can be produced for the parent rolls, - a packing group (4), in which the rolls can be packed in a packing process, and - a higher-level control (5), with which the manufacturing process, the cutting and winding process and the packing process are central In order to be able to ensure a consistently high quality of the rolls, the system (1) has an optical error detection system (19) with which errors in the web-like material can be identified.

Description

The invention relates to a system for producing rolls of sheet material with the features of the preamble of claim 1. Furthermore, the invention relates to a method according to claim 10.

The sheet-like material is, for example, a textile composite or a nonwoven material. Nonwoven material has many uses, for example in the field of hygiene and medicine, but also in technical fields. New properties and application areas are opened up daily.

The production of the sheet-like materials, that is to say in particular the nonwovens, can be effected by means of various, already known production methods.

After making the composite of fibers, so the training as a continuous, web-like material, this is wound onto a mother roll. The parent rolls then have a relatively large axial length and are down to a large diameter wound. Accordingly, these are only suitable for further transport.

In a cutting and winding process adjacent to the actual production process in a cutting and winding group adjacent to the production group, therefore, the mother rolls are unwound again and the web-shaped material is guided through a longitudinal cutting device. In the slitter, strips of reduced width are produced from the sheet-like material. In this case, the longitudinal cutting device is usually adjustable in order to set a desired width of the strips can. In the cutting and winding group, the individual strips are then wound in parallel on individual rolls in rewinders. From a parent role so several individual roles are generated, the diameter and axial length depends on the desired application.

Before the rolls are ready for transport, they are packed in a packing group. They are wrapped, for example, as protection against external influences with a film. For example, the packaging group can have a manipulator for handling the rolls and a rewinder with which the rolls are wrapped with a packaging film or a packaging paper.

The manufacturing group, the cutting and unwinding group and the packaging group are independent units of the plant, between which the parent rolls or individual rolls are transported by means of conveyors. The conveyors have for example one or more trolleys, in each of which a roll can be picked up and transported between the groups.

To optimize the overall process, which begins with the production of the sheet material and ends with the packaging of the finished, individual roles, a higher-level control is provided. With the control, the individual processes can be controlled centrally and monitored if necessary. The higher-level controller comprises, for example, a database and a network connection and communicates with subordinate controllers which are assigned to the respective group. The controls can be designed, for example, in the form of a computer. In this case, the higher-level control integral part of the overall system for Making rolls of sheet material. It is also possible to connect or integrate with a software-based resource planning and management system (Enterprise Resource Planning System) of the role-producing company.

Accordingly, the production of the rolls of web-shaped material, in particular of a textile composite material or of a nonwoven fabric, can take place fully automatically.

A corresponding system is for example off EP 2 041 010A1 known. The higher-level control will be given the appropriate process parameters by the individual groups. Based on these process parameters, the production can be monitored relatively well. Furthermore, the higher-level control can thus be used to optimize the process.

However, not all occurring errors, e.g. lead to defects in the material, based on the process parameters. Thus, for example, in the manufacturing group when producing the sheet-like shape of the material, foreign objects may be included, which can not readily be detected. This then leads to faulty material being wound up on the individual rolls.

The invention is based on the object of specifying a system or a method for producing rolls of sheet material, whereby a high quality of the material wound on the rolls material is ensured. In particular, defects should be reliably detected.

This object is achieved with a system having the features of claim 1 or a method having the features of claim 10. Advantageous embodiments can be found in the subclaims.

In a system for producing rolls of web-shaped material, in particular also from a textile composite, with a production group in which a starting material in a manufacturing process in web form can be brought and wound on parent rolls, with a cutting and Aufwickelgruppe, in a cutting edge and winding process from the parent rolls individual rolls with a smaller width produced are, and with a packaging group in which the rolls are packaged in a packaging process, and with a higher-level control, with the manufacturing process, the cutting and winding process and the packaging process are centrally controlled, the invention provides that the system is an optical error detection system has, are recognizable with the defects in the web-shaped material.

With the aid of the optical defect detection system it is possible to reliably detect defects in the sheet-like material which differ from the defect-free material, for example due to changes in thickness, discoloration, contamination, particles of foreign bodies or simply different refractive indices. The process reliability can be increased and ensure a high quality of the wound on the rolls material. An optical fault detection system enables non-contact monitoring and simultaneously high processing speeds. For example, the web-shaped material is moved at a speed of 1000 meters per minute and faster. The optical error detection system then no load of the material. Rather, the non-contact monitoring allows a frictionless and error-free, wear-free operation. The system according to the invention can be incorporated, for example, in a high-bay warehouse or other logistics system.

The optical error detection system can be arranged in the production group in front of a winding device. As a result, an error detection in the manufacturing group is possible, the error detection is carried out before winding on the mother roll. It can thus be ensured that the errors in the material are identified and further, in particular automatic measures are initiated, which may be influenced by an operator.

The optical defect detection system may also be disposed in the cutting and winding group between a decoiler and a slitter. The error detection then takes place after the unwinding of the mother roll, before the material is cut into longitudinal strips.

Another possibility is to place the optical defect detection system in the cutting and winding group between the slitter and rewinders. Optionally, while the optical error detection system is divided, to be able to detect separately the individual strips produced in the longitudinal cutting device. As a result, an individual monitoring of the individual roles and the strip width and the generated cut edges is possible.

The optical error detection system preferably has at least one camera and at least one illumination device. The illumination device can generate light in the visible or non-visible region, for example infrared radiation. The camera is then tuned to the radiation emitted by the illumination device so that the defects can be reliably detected.

The optical defect detection system may also include a camera disposed in the packaging group. With such a design, for example, a roller mirror of the role can be detected. Also, for example, verification of an applied label is possible, e.g. in one embodiment as a barcode reader.

An optical error detection can thus be provided at different points of the system, with a monitoring at several positions is possible.

The optical error detection system advantageously has an evaluation device, which includes image processing and error detection and optionally an error classification. As a result, an evaluation is possible almost in real time, for example, the burden of the higher-level control is kept low. It is not only possible to detect at all, whether there are defects, but also to determine immediately which type of error it is. For example, holes and irregularities can be identified as such, but also trapped foreign objects such as insects or smaller objects can be detected. In addition, a texture, so a surface finish of the material, as well as prints are monitored and thus ensure the uniformity of the material. Even with printed nonwovens can thus be a quality control. The type of defect can then be detected and output in a corresponding error message.

It is particularly preferred that a data connection is formed between the optical error detection system and the higher-level control. Error messages can then be sent directly from the optical fault detection system to the parent Be passed control that can take appropriate action. For example, the higher-level control can then identify individual rolls or regions of the sheet-like material as scrap or even interrupt the plant operation. The error messages can then be saved in a log.

For narrow web widths, a single camera is sufficient for the optical error detection system. In particular, for larger web widths, the optical error detection system in a preferred embodiment, at least two cameras, each detecting a portion of the width of the web-shaped material. The cameras can also capture a slightly overlapping area to ensure that the entire width of the web is monitored. The cameras can detect the passing materials, for example, line by line and thus allow relatively high transport speeds of the material of 1000 m / min and above.

In a preferred embodiment, the illumination device is arranged on a same side of the sheet material as the camera. In this case, the illumination device may for example be directed obliquely or perpendicularly to a surface of the material. The camera then captures the reflected light. This is particularly suitable for materials with high optical density.

In an alternative embodiment, the illumination device is arranged on a side of the sheet-like material facing away from the camera. For example, the camera is located above the illumination device. The illumination device then provides, as it were, a fluoroscopy of the material passed by. For materials with low optical density or high transparency so malpositions can be well recognized.

Preferably, a sensitivity of the optical error detection system and / or a maximum size of tolerable defects is adjustable. Depending on the required application of the material produced then more or fewer defects can be allowed. With lower demands on the quality of the material wound on the rolls of the rejects can be kept low, at the same time with the same system also a high quality can be achieved.

In a method for producing rolls of sheet material with such a system, the invention provides that the web-like material is scanned web width with an optical error detection system and an error message is output when detecting a fault.

The error detection system may have one or more cameras to detect the material over its entire width. A linear detection is sufficient. Errors that are usually identified by a change in the optical properties can thus be reliably detected. By issuing an error message, a corresponding reaction can take place. The error message is passed, for example, to the higher-level controller, which then automatically initiates further actions, such as issuing an alarm, observing the system or only marking individual roles or areas of the material as faulty. Furthermore, logging of the error messages can take place.

Depending on the nature of the errors identified, it may result in defective parts of the material being removed after unwinding and before cutting. Alternatively, a dispenser can be moved laterally to cause damage to damaged parts of the material as little as possible economic damage. Alternatively, damaged rolls can also be removed before packaging in the packaging process.

In this case, a sensitivity and a maximum size of tolerable defects are preferably specified. As a result, it is possible to address the required quality of the material in order, for example, to minimize waste in cases where a lower quality is sufficient or a higher number of defects is acceptable.

Fig. 1

ein typisches Anlagenlayout,

Fig. 2

das Anlagenlayout nach Fig. 1 mit alternativer Positionierung eines Fehlererkennungssystems,

Fig. 3

eine mögliche Anordnung des Fehlererkennungssystems,

Fig. 4

eine alternative Anordnung des Fehlererkennungssystems.

The invention will be described in more detail below with reference to a preferred embodiment in conjunction with the drawings. Here is a schematic view:

Fig. 1

a typical plant layout,

Fig. 2

the system layout Fig. 1 with alternative positioning of an error detection system,

Fig. 3

a possible arrangement of the error detection system,

Fig. 4

an alternative arrangement of the error detection system.

In FIG. 1 schematically a typical layout of a plant for producing rolls of web-shaped material is shown. The plant 1 has a production group 2, a cutting and winding group 3 and a packaging group 4. Furthermore, the system 1 has a higher-level control 5, with which the individual process steps can be monitored and controlled. Data connections 6, 7, 8 between the controller 5 and the production group 2, the cutting and winding group 3 and the packaging group 4 are shown schematically.

The starting materials, which in the production group 2 are combined into a sheet-like material and which, for example, represent a nonwoven, are wound up as a web-shaped material 9 in a winder 10 onto a mother roll. The mother roll wraps the web-like material along the way.

When the master roll has reached a corresponding diameter, the mother roll is transported to the cutting and winding group 3 after cutting the web-like material and wound a new mother roll in the winder 10.

In the cutting and winding group 3, the mother roll is unwound in an unwinder 11. The web-shaped material 9 is then passed through a longitudinal cutting device 12 and cut into longitudinal strips. The number of longitudinal strips and roll diameter depends on the intended use. In subsequent winder 13, the web-shaped material is wound into a number of strips corresponding number of rollers. The individual rolls are then transported by the cutting and winding group 3 to the packaging group 4.

In order to be able to produce strips of different widths and a different number of strips, the longitudinal cutting device 12 has longitudinal cutting devices movable in the cross-machine direction.

In the packaging group 4, the individual roles are detected with a manipulator 14 and placed vertically. Subsequently, they are transported via a conveyor system 15 to at least one rewinder 16 and wrapped there, for example, with a protective film. Via a conveyor 17, the wrapped rollers then pass into an output in direction 18, for example to a labeling position or to an output. In the labeling position, the finished rolls can be closed with a label. Optionally, a label may also be previously provided on the roll core in addition to a label outside the roll. Each roll is marked and identified with a label before the roll is wrapped in a film with a foil. On the film then one or more labels is applied with which the container can be identified by roles. Then the wrapped roll is placed on a pallet and wrapped again together with the pallet in a foil. For easier readability, these can also be provided with barcodes of various types. The wrapped and labeled rolls can then be transported to their destination.

The system 1 may have other elements, such as a warehouse for empty parent rolls and for wound parent rolls or an intermediate storage for the finished wound single roles between the cutting and winding group 3 and the packaging group 4. The individual groups may include other equipment components.

An optical error detection system 19 is arranged in this embodiment in front of the winder 10 in the manufacturing group 2. With the aid of the optical defect detection system 19, the sheet-like material is scanned strip-shaped over the entire width. Defects that are characterized by a change in the optical properties of the sheet material can be detected by the optical error detection system 19. In the error detection system 19, not only the detection, but also a processing and an error detection and error classification. If errors are detected, they will be sent over a data line 24 transmitted to the higher-level controller 5. The higher-level controller 5 then initiates corresponding actions.

Fig. 2 shows the plant layout Fig. 1 However, the optical defect detection system 19 is not arranged in the manufacturing group 2, but in the cutting and winding group 3. In this case, the optical error detection system between unwinder 11 and longitudinal cutting device 12 is positioned. This represents a particularly preferred variant, since errors that have arisen during the first winding up can thus be detected. In this case, an assignment of the error to the subsequently cut longitudinal paths or the individual roles is possible

In FIG. 3 FIG. 2 shows a schematic side view of the optical defect detection system 19. The optical defect detection system 19 comprises a camera 20 and a lighting device 21. The lighting device 21 is arranged on another side of the sheet material 9 than the camera 20. For example, the camera 20 is located above and the lighting device 21 below the sheet material 9 the sheet-like material 9 is transilluminated, which should have a corresponding optical transparency. Deviations of the optical properties caused by flaws can thus be reliably detected by the camera 20.

In the cross-machine direction, a plurality of cameras 20 can be arranged next to each other in order to achieve a scan of the entire width of the web-shaped material. The scanned strips, which may be e.g. to act on lines, even slightly overlap.

FIG. 4 shows an alternative arrangement of the illumination device 21. This is arranged on the same side of the sheet material 9 as the camera 20. In this case, the light emitted by the illumination device and reflected by the web-shaped material 9 light is detected by the camera 20. Changes in the optical properties of the sheet material caused by imperfections are then reliably detected by the camera 20. This arrangement is particularly suitable for web-like materials with a low optical transmission.

In FIGS. 3 and 4 is exemplified that the sheet material is guided over guide rollers 22, 23. Alternative embodiments are also possible. For example, the web-like material can be guided over an optically transparent plate and supported by this.

The invention is not limited to the above-described embodiments. Varied modifications are possible instead. For example, the optical defect detection system 19 may be arranged not only in front of the winder 10 in the manufacturing group 2 but also in the cutting and winding group 3. There are again different positioning possibilities, for example before or after the longitudinal cutting device 12.

By providing the optical fault recognition system, the system according to the invention enables non-contact monitoring of the quality of the web-shaped material produced and thus a consistently high quality of the individual rollers. An optical fault detection system works very reliably and virtually maintenance-free. In particular, there is no impairment of the web-shaped material itself.

All of the claims, description and drawings resulting features and advantages, including design details, spatial arrangements and method steps may be essential to the invention both in itself and in a variety of combinations.

LIST OF REFERENCE NUMBERS

1

investment

2

production group

3

Cutting and winding group

4

packaging group

5

control

6

data connections

7

data connections

8th

data connections

9

material

10

winders

11

liquidator

12

Slitter

13

rewinder

14

manipulator

15

conveyor system

16

rewinder

17

Conveyor

18

output device

19

Fault detection system

20

camera

21

lighting device

22

leadership

23

leadership

24

Data Connection

Claims (11)

Plant (1) for producing rolls of web-shaped material (9), in particular of a textile composite, with: a production group (2) in which a starting material can be brought into a web-like form in a production process and can be wound onto mother rolls, a cutting and winding group (3) in which, in a cutting and winding process, individual rolls of lesser width can be produced from the mother rolls, a packaging group (4) in which the rolls are packable in a packaging process, and a superordinate control (5), with which the manufacturing process, the cutting and winding process and the packaging process are centrally controllable, characterized in that it comprises an optical error detection system (19) can be seen with the error in the web-shaped material. Installation according to claim 1, characterized in that the optical defect detection system (19) in the manufacturing group (2) in front of a winding device (10), in the cutting and Aufwickelgruppe (3) between an unwinder (11) and a longitudinal cutting device (12) and / or in the cutting and winding group (3) between the longitudinal cutting device (12) and rewinders (13) is arranged. Installation according to claim 1 or 2, characterized in that the optical defect detection system (19) has at least one camera (20) and at least one illumination device (21). Installation according to one of the preceding claims, characterized in that the optical error detection system (19) comprises an evaluation device which comprises image processing and error detection and optionally error classification. Installation according to one of the preceding claims, characterized in that between the optical error detection system (19) and the higher-level control (5), a data connection (24) is formed. Installation according to one of the preceding claims, characterized in that the optical defect detection system (19) at least one, in particular at least two cameras (20), each of which detects a part of the width of the web-shaped material (9). Installation according to one of the preceding claims, characterized in that the illumination device (21) is arranged on a same side of the sheet-like material (9) as the camera (20). Installation according to one of the preceding claims, characterized in that the illumination device (21) on one of the camera (20) facing away from the sheet material (9) is arranged. Installation according to one of the preceding claims, characterized in that a sensitivity of the optical error detection system (19) and / or a maximum size of tolerable defects is adjustable. Method for producing rolls of sheet-like material with a plant according to one of the preceding claims, characterized in that the sheet-like material (9) is scanned web width with an optical error detection system (19) and an error message is output when detecting a defect. A method according to claim 10, characterized in that a sensitivity and a maximum size of tolerable defects are specified.

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