JP2004310884A - Tape manufacturing management method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a tape manufacturing management method capable of accurately specifying a defective fault position measured during a process before a cutting process to the tape after cutting. <P>SOLUTION: The manufacturing device 10 comprises a coating process part 12, a calendering process part 14, a heat treatment process part 16, a cutting process part 18, and a final process part 20. A control device of the cutting process 18 calculates N through the formula; N=ä[(h2/h1)X-a]/S truncating the digits below the decimal point}+1 by inputting the width dimension h1 of a web 44 measured by the coating process part 12, the distance X from the edge 44a up to the defective fault position, the width dimension h2 of the web 44 measured by a measuring device 26, and set values of the width dimension a of a margin 88 and the slit width S. Then, the defective fault is specified to the Nth magnetic tape from an end edge 44a, and the defective fault is removed by the final process part 20. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a tape manufacturing management method, and more particularly to a tape manufacturing management method for detecting a defect failure in a preceding process of a cutting process and designating the position of the defect failure for a tape after the cutting process.
[0002]
2. Description of the Related Art A magnetic tape such as a computer backup tape is composed of a coating process for coating a web-like support with a magnetic coating solution, a calendering process for smoothing the surface of the coating layer, and a heat treatment for heat-treating the web. It is manufactured through a process and a cutting process of cutting a wide web (original magnetic tape) into a narrow magnetic tape, and the manufactured magnetic tape is cut into a predetermined length in a final process and incorporated into a product.
[0003]
In the coating process and the calendering process, dot-like defect failures called pinholes and impressions and linear defect failures called coating stripes, creases and wrinkles may occur. Therefore, a detecting device for detecting a defect failure is provided in the coating process and the calendar processing process. For example, the detection device irradiates the surface of the web with laser scanning light, photoelectrically detects the transmitted light with a light receiver, and evaluates the presence or absence of a defect failure based on the photoelectric detection signal (see Patent Document 1). In such a detection apparatus, the position of the defect failure is measured with reference to the edge in the width direction of the magnetic tape. The measured defect failure data is fed back to the control device of each process, and the cause of the defect failure is analyzed by this control device.
[0004]
The defect failure detected by the detection device is designated at the time of the cutting process and removed in the final process. That is, a magnetic tape including a defect failure is designated during the cutting process, and the defect failure is removed when the designated magnetic tape is commercialized in the final process.
[0005]
[Patent Document 1]
JP-A-1-239439 [0006]
[Problems to be solved by the invention]
However, in the conventional method, when the position of the defect failure is specified in the final process, the specified position and the actual position of the defect failure sometimes deviate in the width direction. For this reason, when designating a defect failure, it is necessary to include a magnetic tape for one to two slits as an error range in order to reliably include the defect position. As a result, a defect failure is designated for a normal magnetic tape, and there is a problem that the magnetic tape is removed excessively and productivity is lowered.
[0007]
The present invention has been made in view of such circumstances, and a tape manufacturing management method capable of accurately designating the position of a defect failure measured in the preceding process of the cutting process with respect to the tape after the cutting. The purpose is to provide.
[0008]
[Means for Solving the Problems]
In order to achieve the above object, the invention according to claim 1 includes a cutting step of cutting a wide web into a plurality of narrow tapes, and a pre-process for processing the web at a stage preceding the cutting step, In the tape manufacturing management method in which the position of the defect failure of the web is measured in the width direction of the web in the preceding step, and the position of the measured defect failure is specified in the cutting step, the web in the preceding step The width h1 is detected, the web width h2 is detected in the cutting step, and the designated position of the defect failure is corrected based on the detected h1 and h2.
[0009]
According to the first aspect of the present invention, the web width h1 in the previous process and the web width h2 in the cutting process are detected, and the designated position of the defect failure is corrected using the h1 and h2. Therefore, even when the web contracts in the width direction during the previous process and during the cutting process, the position of the defect failure can be specified accurately. As a result, it is not necessary to designate a defect failure for a normal tape, so that productivity can be improved.
[0010]
According to the second aspect of the present invention, the specified position of the defect failure is corrected by setting the distance between the edge in the width direction of the web and the defect failure as X in the previous step, and cutting in the cutting step. When the width of the obtained tape is S and the distance from the edge of the web to the first tape in the cutting step is a, N = (((h2 / h1) · X−a) / S The Nth tape from the end edge is designated as a tape having a defect failure with respect to N calculated by (rounded down to the nearest decimal place) +1. Therefore, according to the present invention, it is possible to accurately specify a tape including a defect.
[0011]
According to a third aspect of the present invention, the pre-process is a coating process for applying a coating liquid to the web or a calendering process for smoothing the surface of the coating layer of the web.
[0012]
According to the fourth aspect of the present invention, the cutting position of the web in the cutting step is determined based on the corrected designated position of the defect failure. According to the present invention, since the position of the defect failure is accurately specified using h1 and h2, and the cutting position is determined based on this, the cutting can be performed so that the magnetic tape having the defect failure is minimized. it can.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of a tape manufacturing management method according to the present invention will be described in detail with reference to the accompanying drawings.
[0014]
FIG. 1 is a block diagram showing a configuration of a manufacturing apparatus to which the present invention is applied.
[0015]
As shown in FIG. 1, the manufacturing apparatus 10 includes an application process unit 12, a calendar processing process unit 14, a heat treatment process unit 16, a cutting process unit 18, and a final process unit 20.
[0016]
The coating process unit 12 is a process of coating a belt-like support (hereinafter referred to as a web) 44 (see FIG. 2) with a magnetic coating solution or the like to form a coating layer. In the web 44 on which the coating layer is formed, the coating layer is smoothed in the calendar processing unit 14. Next, by performing heat treatment in the heat treatment process section 16, the thermal shrinkage rate is made uniform and the surface roughness of the magnetic layer surface is made uniform. The wide web 44 manufactured in this way is cut into a large number of narrow magnetic tapes 84 (see FIG. 6) in the cutting process section 18. The cut magnetic tape 84 is cut into a predetermined length in the final process section 20 and incorporated into a product. Below, each process part is demonstrated.
[0017]
FIG. 2 is a configuration diagram showing an embodiment of the coating process unit 12.
[0018]
As shown in the figure, the coating process unit 12 mainly includes a delivery reel device 32, a magnetic liquid coating device 34, a first drying device 36, a back layer liquid coating device 38, a second drying device 40, and a take-up reel device 42. Consists of. The web 44 delivered from the delivery reel device 32 is coated with the magnetic coating solution by the magnetic solution coating device 34, and then conveyed through the first drying device 36, whereby the magnetic layer is dried. Next, the back layer solution is applied to the back surface of the web 44 (the side surface opposite to the coating surface) by the back layer solution coating device 38. And it is conveyed in the 2nd drying apparatus 40 provided with the drying zone and the heat processing zone, and drying and heat processing are performed.
[0019]
The web 44 that has passed through the second drying device 40 is introduced into a defect detection device 46 described later. Then, after a defect failure is detected by the defect detection device 46, the web 44 is taken up by the take-up reel device 42. As a result, the web 44 in which the support is coated with the magnetic coating solution and the back layer coating solution is manufactured.
[0020]
In FIG. 2, the drying zone and the heat treatment zone are provided in the second drying device 40, but the drying zone and the heat treatment zone may be separated as separate devices. Reference numeral 48 in FIG. 2 denotes a suction drum with a groove, and the tension of the web 44 to be conveyed is adjusted by controlling the suction force and rotational speed to adjust the slipping state of the support on the suction drum surface. Or stable conveyance of the web 44. In addition to the draw method using the grooved suction drum 48, the tension adjustment may be performed by a dancer method using a dancer roller.
[0021]
FIG. 3 shows an embodiment of the defect detection device 46.
[0022]
As shown in the figure, the defect detection device 46 mainly includes a light source 50 and a rotary mirror 52 disposed above the web 44 and a light receiver 54 disposed below the web 44. The detection light emitted from the light source 50 is swung by the rotary mirror 52 and scanned along the scanning line L extending in the width direction of the web 44. The transmitted light that has passed through the web 44 enters the light receiver 54, and a defect such as a pinhole is detected by the variation in the amount of light. In this defect detection device 46, when the detection light is irradiated to the outside of the web 44, the amount of light detected by the light receiver 54 increases greatly, so that the position of the edge 44 a in the width direction of the web 44 can be detected. it can. The position of the defect failure described above is measured with reference to the position of the edge 44a. Here, let X be the distance from the edge 44a to the defect failure.
[0023]
The defect detection device 46 can also measure the width dimension of the web 44 by detecting the position of the edge 44b opposite to the reference edge 44a. Here, the width dimension of the web 44 in the coating process part 12 is set to h1.
[0024]
The defect failure data detected by the defect detection device 46 described above is stored in the control device 22 (see FIG. 1) such as a personal computer. The control device 22 analyzes the cause of the defect failure based on the data. Then, based on the analysis result, various settings of the magnetic liquid coating device 34 and the back layer coating device 38 in FIG. 2 are corrected, and the drying temperature of the first drying device 36 and the second drying device 40 is adjusted. . Thereby, the defect failure in the application | coating process part 12 can be reduced, and the productivity of the application | coating process part 12 can be improved.
[0025]
The configuration of the defect detection apparatus is not limited to the above-described one, and for example, a reflection type detection apparatus may be used.
[0026]
FIG. 4 is a configuration diagram showing an embodiment of the calendar processing step unit 14.
[0027]
The calendar processing unit 14 mainly includes a delivery reel device 56, calendar rollers 58, 59, 60, a defect detection device 64, and a take-up reel device 62. The roll-shaped web 44 taken up by the take-up reel device 42 shown in FIG. 2 is transferred to the delivery reel device 56 shown in FIG. Then, it is fed out from the delivery reel device 56 and is nipped and conveyed between the calendar rollers 58-60. Thus, the web 44 is calendered to smooth the magnetic layer surface and the back layer surface.
[0028]
The calendered web 44 is introduced into the defect detection device 64. The defect detection device 64 is configured in the same manner as the defect detection device 46 shown in FIG. Therefore, the defect detection device 64 can measure the position of a defect in the web 44 and the width dimension of the web 44. Here, the width dimension of the web 44 in the calendar processing section 14 is h1 ′, and the distance between the edge 44a and the defect failure is X ′.
[0029]
Data of the defect detection device 64 is transmitted to the control device 24 (see FIG. 1) such as a PC. The control device 24 analyzes the cause of the defect failure based on the data of the defect detection device 64. Based on the analysis result, the tension of the web 44 is adjusted. Thereby, the productivity in the calendar process part 14 can be improved.
[0030]
The web 44 that has passed through the defect detection device 64 is taken up by the take-up reel device 62. A plurality of grooved suction drums 65 are also provided on the web transport path for calendar processing, and tension adjustment and stable transport of the web 44 are performed.
[0031]
FIG. 5 shows an embodiment of the heat treatment process section 16.
[0032]
The heat treatment process section 16 performs at least one of heat treatment for making the thermal shrinkage rate of the roll-shaped web 44 uniform and heat treatment for making the surface roughness of the magnetic layer surface of the web 44 uniform.
[0033]
As shown in FIG. 5, the web 44 is carried into a temperature-controlled room 66 in a rolled state, and a shaft 68 inserted into the winding core 67 is spanned between a pair of columns 69 and 69. In order to make the heat shrinkage rate uniform, the temperature in the temperature-controlled room 66 is adjusted to 40 ° C. in this state and held for at least 12 hours, preferably for one week. As another example, in the state of the strip before the web 44 is wound to form the roll strip, the tension is 1.0 to 2.0 kg / m and the temperature of the magnetic recording medium is 140 ° C. The roll-shaped web 44 may be formed by performing a low-tension high-temperature short-time heat treatment for 10 seconds to 60 seconds and then winding.
[0034]
The degree of uniformity of heat shrinkage caused by this heat treatment is within ± 20% of the average value of heat shrinkage in each part in the roll state, and the uniformity of the tension distribution in the width direction of the strip at the time of cutting And, it is preferable for achieving dimensional stability in the final product in a rolled state after being cut.
[0035]
On the other hand, in the case of the heat treatment for making the surface roughness uniform, using the same temperature-controlled room 66 as in FIG. 5, the web 44 after the calendar process is kept in a roll state in a low-temperature temperature-controlled room at 40 ° C. for at least 72 hours. It is recommended to perform heat treatment at low temperature and long time for storage. As another aspect, in a belt-like state before the web 44 is wound to form a roll state, the tension is 0.05 to 4.0 kg / m, and the magnetic recording medium temperature is 140 ° C. for 10 seconds to 30. A heat treatment for a short time at a low tension and for a short time may be performed, and then rolled to form a roll state.
[0036]
As the degree of uniformity of the surface roughness (Ra) brought about by this heat treatment, it is preferable that the surface roughness distribution in each part of the web 44 in the roll state is within ± 30% of the average value of the surface roughness. In this case, it is better that the average surface roughness at each part of the web 44 in the roll state is 4 nm (nanometer) or less.
[0037]
FIG. 6 is a configuration diagram illustrating an embodiment of the cutting process unit 18.
[0038]
As shown in the figure, the cutting process section 18 mainly includes a rewind reel 70, a feed roller 72, a slitter 74, and a take-up hub 76.
[0039]
A heat-treated roll-shaped web 44 is mounted on the rewind reel 70. The web 44 is continuously drawn from the rewind reel 70 by driving the feed roller 72. The feed roller 72 is a roller for running the web 44, and for example, a suction drum is used. The suction drum is a drum that rotates while adsorbing the web 44 on the surface, and a groove is formed on the surface of the drum to increase the holding force of the web 44. As the feed roller 72, other known feed means such as a pair of nip rollers that convey the web 44 while pressing it may be used.
[0040]
The web 44 sent out from the rewinding reel 70 by the feed roller 72 is sent to the slitter 74 while being guided by a plurality of guide rollers 78. The slitter 74 includes a disk-shaped rotating upper blade 80 and a cylindrical rotating lower blade 82, and a plurality of the rotating upper blades 80 are arranged at regular intervals in the width direction of the web 44 (see FIG. 7B). ). Therefore, when the web 44 is introduced between the rotating upper blade 80 and the rotating lower blade 82, the web 44 is wound around the rotating lower blade 82 as a receiving blade by the plurality of rotating upper blades 80. A shearing force is applied, and it is cut into a large number (for example, 100 to 500). Thereby, the magnetic tapes 84 and 84 having a prescribed width dimension Smm (for example, 12.65 mm, 25.4 mm, 3.81 mm, etc.) are manufactured. The magnetic tapes 84 and 84 are wound around the guide rollers 86 and 86 and then wound around the winding hubs 76 and 76. An end 88 (see FIG. 7B) without a magnetic layer is formed at the end of the web 44 in the width direction. The end 88 is cut by the slitter 74 and then removed. . Here, the width dimension of the ear portion 88 is amm.
[0041]
In front of the slitter 74, a measuring device 26 for measuring the width dimension of the web 44 is installed. The measuring device 26 includes a light projecting unit 90 and a light receiving unit 92 that are disposed to face each other with the web 44 interposed therebetween. For example, a light emitting diode is used as the light projecting unit 90 and irradiates light toward the light receiving unit 92. The light receiving unit 92 uses a photodiode, a CCD line sensor, or the like, and receives light emitted from the light projecting unit 90. The light receiving unit 92 is connected to a control device 28 (see FIG. 1) such as a PC, and the control device 28 (see FIG. 1) calculates the width dimension of the web 44 based on the amount of light received by the light receiving unit 92 and the timing. . Here, the width dimension of the web 44 measured in the cutting process part 18 is set to h2. Note that set values such as the slit width S and the width dimension a of the ear 88 are input in advance to the control device 28 of the cutting process unit 18.
[0042]
As described above, the control device 22 of the coating process unit 12 in FIG. 1 stores the width dimension h1 of the web 44 and the distance X until the defect failure, and the control device 24 of the calendar processing process unit 14 stores the width dimension h1. The width dimension h1 'of the web 44 and the distance X' to the defect failure are stored. The control devices 22 and 24 are connected to the control device 28 of the cutting process unit 18, and distances X and X ′ width dimensions h 1 and h 1 ′ until the defect failure are input to the control device 28. Further, data of the width dimension h <b> 2 measured by the measuring device 26 is input to the control device 28. Further, the slit width S and the width dimension a of the ear portion 88 are input to the control device 28 in advance.
[0043]
When these data are input, the control device 28 corrects the designated position of the defect failure. That is, the integer N is calculated by the following equation.
[0044]
N = (((h2 / h1) · X−a) / S rounded down to the nearest decimal point) + 1 + 1
For the calculated N, the Nth magnetic tape 84 from the edge 44a of the web 44 is designated as a magnetic tape 84 having a defect. When correcting the position of the defect failure measured by the calendar processing step unit 14, N may be calculated by substituting X for X ′ and h1 for h1 ′ in Equation 1.
[0045]
The control device 30 of the final process unit 20 cuts the magnetic tape 84 based on the data recorded in the control device 28 of the cutting process unit 18. That is, with respect to the magnetic tape 84 for which no defect failure is designated, the magnetic tape 84 is cut into predetermined lengths and incorporated into the product, and the magnetic tape 84 for which the defect failure is designated is prevented from entering. Is cut to a predetermined length. As a result, the magnetic tape 84 free from defects can be incorporated into the product.
[0046]
Next, the operation of the manufacturing apparatus 10 configured as described above will be described with reference to FIGS. 7 (a) and 7 (b). FIG. 7A shows a state in which a defect failure is detected in the coating process unit 12, and FIG. 7B shows a state in which cutting is performed in the cutting process unit 18.
[0047]
When the web 44 is dried by the coating process unit 12 or when the web 44 is heat-treated by the heat treatment process unit 16, the web 44 is thermally contracted. For this reason, if the defect failure is designated as it is according to the values of the distances X and X ′ to the defect failure measured by the coating process unit 12 and the calendar processing process unit 14, the actual position may be shifted.
[0048]
For example, as shown in FIG. 7A, when a defect failure occurs at a position of a distance X from the edge 44a, the actual position of the defect failure is a distance X at the cutting step shown in FIG. It may be out of position. As a result, although a defect failure actually exists in the fourth magnetic tape 84 from the edge 44a, the defect failure is designated for the third magnetic tape 84 from the edge 44a. For this reason, conventionally, the normal third magnetic tape 84 had to be removed in excess.
[0049]
On the other hand, in the present embodiment, the width dimension h1 (or h1 ′) when the defect is inspected and the width dimension h2 at the time of slitting are measured, and the width dimensions h1 and h2 and the above-described formula 1 are used. The position of defect failure was corrected. In Equation 1, the position of the defect failure is corrected for the change in the width dimension by multiplying X (or X ′) by (h2 / h1). Therefore, it is possible to accurately specify the magnetic tape 84 including the defect failure. As a result, a defect failure is not designated for the normal magnetic tape 84, so that productivity can be improved.
[0050]
In the above-described embodiment, the width dimension a of the ear 88 is set as a set value. However, a separate measurement unit may be provided to measure the width dimension a and input it to the control device 28. Thereby, the precision of the designated position of a defect failure can be improved more.
[0051]
Further, the following equation may be used instead of the above equation 1.
[0052]
N = (((h2 / h1) · X−a) / S rounded up)
Furthermore, in the above-described embodiment, the measurement data is input from the control device 22 of the coating process unit 12 or the control device 24 of the calendar processing process unit 14, but the measurement data is directly input from the defect detection devices 46 and 64. May be input.
[0053]
Next, the manufacturing apparatus of 2nd Embodiment is demonstrated.
[0054]
The manufacturing apparatus of the second embodiment does not set the width dimension a and the slit width S of the ear portion 88 in advance, but based on the width dimensions h1 and h1 ′ of the web 44 and the distances X and X ′ to the defect failure. The width dimension a and the slit width S are set. That is, when the widths h1 and h1 ′ of the web 44 and the distances X and X ′ to the defect failure are input to the control device 28 of the cutting process unit 18, the control device 28 is designated as having the defect failure. The width dimension a of the ear portion 88 and the slit width S are calculated so that the magnetic tape 84 is minimized. For example, when a linear defect occurs in the width direction of the web 44, a and S are calculated using Equation 1 so that the designated magnetic tape 84 is reduced. Thereby, the magnetic tape 84 which has a defect failure can be reduced, and productivity can be improved.
[0055]
【The invention's effect】
As described above, according to the tape manufacturing management method of the present invention, the web width h1 in the previous process and the web width h2 in the cutting process are detected, and the defect failure is designated using these h1 and h2. Since the position is corrected, even when the web contracts in the width direction during the previous process and during the cutting process, the position of the defect failure can be specified accurately. As a result, it is not necessary to designate a tape having a defect or failure, and productivity can be improved.
[Brief description of the drawings]
FIG. 1 is a block diagram showing a configuration of a manufacturing apparatus to which a tape manufacturing management method according to the present invention is applied. FIG. 2 is a block diagram showing an embodiment of a coating process section. FIG. 3 is an embodiment of a defect detection apparatus. FIG. 4 is a configuration diagram showing an embodiment of a calendar processing section. FIG. 5 is a configuration diagram showing an embodiment of a heat treatment section. FIG. 6 is a configuration diagram showing an embodiment of a cutting section. FIG. 7 is a diagram for explaining the operation of the present invention.
DESCRIPTION OF SYMBOLS 10 ... Manufacturing apparatus, 12 ... Application | coating process part, 14 ... Calendar processing process part, 16 ... Heat treatment process part, 18 ... Cutting process part, 20 ... Final process part, 22, 24, 28, 30 ... Control apparatus, 26 ... Measurement Device: 32 ... Delivery reel device, 34 ... Magnetic liquid coating device, 36 ... First drying device, 38 ... Back layer liquid coating device, 40 ... Second drying device, 42 ... Winding reel device, 44 ... Web, 46 ... Defect detection device 48 ... Suction drum with groove, 50 ... Light source, 52 ... Rotating mirror, 54 ... Light receiver, 56 ... Delivery reel device, 58-60 ... Calendar roller, 62 ... Take-up reel device, 64 ... Defect detection device 65 ... Suction drum, 66 ... Constant temperature chamber, 67 ... Core, 68 ... Shaft, 69 ... Post, 70 ... Rewinding reel, 72 ... Feed roller, 74 ... Slitter, 76 ... Winding hub, 78 ... Guide roller, 80 ... rotating upper blade, 2 ... rotating lower blade 84 ... magnetic tape, 86 ... guide roller, 88 ... ear, 90 ... projecting portion, 92 ... light-receiving part

Claims (4)

A cutting step of cutting a wide web into a plurality of narrow tapes, and a pre-process for processing the web in a preceding stage of the cutting process, wherein the position of a defect in the web is determined in the pre-process. In the tape manufacturing management method of measuring in the direction and designating the position of the measured defect failure during the cutting step,
The width h1 of the web is detected in the previous step, the width h2 of the web is detected in the cutting step, and the designated position of the defect failure is corrected based on the detected h1 and h2. Tape manufacturing management method. Correction of the designated position of the defect failure is
In the preceding process, the distance between the edge in the width direction of the web and the defect failure is X, the width of the tape obtained by cutting in the cutting process is S, and from the edge of the web in the cutting process When the distance to the first tape is a,
N = (((h2 / h1) · X−a) / S is rounded down) +1
2. The tape manufacturing management method according to claim 1, wherein the Nth tape from the edge is designated as a tape having a defect and failure with respect to N calculated in step 1. 3. The tape manufacturing management method according to claim 1, wherein the pre-process is a coating process for coating a coating liquid on the web, or a calendar processing process for smoothing a surface of a coating layer of the web. . 2. The tape manufacturing management method according to claim 1, wherein a cutting position of the web in the cutting step is determined based on the corrected designated position of the defect failure.

Images