JP2007038232A - Method for manufacturing metallic endless belt - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a metallic endless belt by which the variation in products and the generation of defective products are sufficiently prevented for a long term and the inspection of secular change of mechanical response automatically is performed without stopping the line. <P>SOLUTION: In the method of manufacturing a metallic endless belt of a desired size by winding a endless-shaped metallic belt material around between a fixed roller and a drawing roller, and the material is extended with the drawing roller while rolling the material with a rolling roller, the load response characteristics which are obtained from each load cell when the rolling roller and the drawing roller are moved at rolling and before the extending of the material is compared with the load response characteristics which are obtained from each load cell when each roller is similarly moved at the initial normal time, and each deviation between mutual characteristics is determined. The present work is performed under load control conditions corrected on the basis of the deviation. The correction is performed by taking the elements of the secular change such as slide resistance generated when the line is operated into consideration. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a metal endless belt such as a CVT (Continuously Variable Transmission) belt.

Conventionally, as a manufacturing method of this type of belt, the tension control is performed so that the plate width or plate thickness of the metal endless belt material (endless metal belt material) becomes the target plate width or target plate thickness, There has been a method of manufacturing a metal endless belt by controlling the tension so that the circumference of the material becomes the target circumference (see Patent Document 1).
However, in the above-described conventional technology, the mechanical system parameter is fixed to the value optimized by the initial adjustment, and the change with time of the load response characteristic obtained from each component of the mechanical system is not taken into consideration. The change affected the machining accuracy, resulting in product variations. In addition, there is a problem that defective products are not found until regular or irregular accuracy inspections are performed, and defective products are frequently generated.
Therefore, in the manufacture of this type of belt, the applicant compared the response characteristics obtained by applying a load for verification at a predetermined number of times of processing with the response characteristics obtained at the initial normal time. We provided a method of performing verification to determine the amount of deviation, and performing processing up to the next verification according to load control conditions for correcting the amount of deviation.

JP-B-2-36321 JP 2004-291050 A

  According to the invention disclosed in Patent Document 2, there is an effect that it is possible to prevent product variations and generation of defective products over a long period of time, but there is still room for improvement in the above-described verification method, and sufficient effects are obtained. There were limits. In addition, the degree of the effect depends on the frequency of performing the test, and the test is performed with the production line stopped, so the productivity is lowered. Further, since the verification is performed artificially, it takes labor and time for the verification operator, and there is a risk of product variations and defective products due to erroneous work.

  The present invention has been made in view of the above circumstances, and can sufficiently prevent product variations and the occurrence of defective products over a long period of time, and does not reduce productivity, and labor and time required for verification work. It is another object of the present invention to provide a method for producing a metal endless belt that eliminates product variations and defective products due to erroneous work.

In order to achieve the above-mentioned object, the invention according to claim 1 of the present invention is characterized in that an endless metal belt material is wound around a fixed roller and a pulling roller so as to be freely circulated, and the rolling roller is In a method for producing a metal endless belt having a desired circumferential width and / or thickness by performing a process in which the tension roller stretches the material while rolling the material with a fixed roller. And a rolling roller load measuring means and a tension roller load measuring means for separately measuring the load applied to the rolling roller and the tension roller, and each measurement during the movement of the rolling roller and the tension roller before rolling and stretching of the material. The load response characteristics obtained from the respective means are compared with the load response characteristics obtained from the respective measurement means during the movement of the respective rollers in the initial normal state. Determine the respective deviation amounts of 互間, the current processing, and performs the corrected load control conditions based on the shift amount.
The invention according to claim 2 of the claims is characterized in that an endless metal belt material is wound around a fixed roller and a pulling roller so as to be freely circulated and the rolling roller is interposed between the fixed roller and the material. In the method for producing a metal endless belt having a desired circumferential width and / or thickness, the tension roller performs a process of stretching the material while rolling the material. A load response characteristic obtained from each measuring means during the movement of the rolling roller and the tension roller after rolling and stretching the material, comprising a rolling roller load measuring means and a tension roller load measuring means for measuring the applied load separately. Are respectively compared with the load response characteristics obtained from the respective measuring means during the movement of the respective rollers in the initial normal state, and the respective deviation amounts are obtained. The processing, and performs the corrected load control conditions based on the shift amount.
Further, in the invention described in claim 3 of the claims, in the invention described in claim 1 or 2, when the calculated deviation amount exceeds a preset threshold value, the fact is notified. It is characterized by.

The invention according to claim 1 of the present invention includes a rolling roller load measuring means and a tension roller load measuring means for separately measuring loads applied to the rolling roller and the pulling roller, and the rolling roller before rolling and stretching the material. The load response characteristics obtained from each measuring means at the time of movement of the pulling roller are compared with the load response characteristics obtained from the respective measuring means at the time of initial normal movement, respectively. The amount of deviation was obtained, and the current machining was performed under load control conditions corrected based on the amount of deviation.
The invention according to claim 2 of the claims includes the same rolling roller load measuring means and pulling roller load measuring means as in the first aspect. Then, the load response characteristics obtained from each measuring means during the movement of the rolling roller and the pulling roller after rolling and stretching of the material, the load obtained from each measuring means during the movement of each similar roller in the initial normal state Each shift amount is obtained by comparing with each of the response characteristics, and the next processing is performed under the load control condition corrected based on the shift amount.
In the invention disclosed in Patent Document 2, as an element that changes with time, sliding resistance generated during operation of the production line, for example, between the guide that guides the roller when it moves and the rotating shaft support of the roller The sliding resistance was not considered. However, according to the first and second aspects of the invention, such sliding resistance is corrected and included in the element that changes over time, and therefore, variations in products and occurrence of defective products are caused. Can be sufficiently prevented over a long period of time. In addition, according to the first and second aspects of the present invention, human labor is eliminated in the test for obtaining the deviation amount of the load response characteristic, which is performed in order to correct the change with time of each component of the mechanical system ( This eliminates the labor and time required for the verification work, and also eliminates product variations and defective products due to erroneous work. Since the test is performed while the production line is in operation, productivity can be improved as compared with a method in which the production line is stopped.
In the first aspect of the present invention, the deviation amount is obtained when the rolling roller and the pulling roller are moved before rolling and stretching the material, and the current machining is performed under a load control condition corrected based on the deviation amount. Is. Further, the invention according to claim 2 is the load control condition in which the deviation amount is obtained when the rolling roller and the pulling roller are moved after rolling and stretching the material, and the next processing is corrected based on the deviation amount. According to the two inventions, it is possible to select whether the test time for obtaining the deviation amount is before or after the processing.
According to the invention described in claim 3 of the scope of claims, in the invention described in claim 1, when the calculated deviation amount exceeds a preset threshold value (at the time of abnormality), the fact is notified. As a result, the abnormality can be known immediately and at a low cost.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In addition, the same code | symbol shows the same or an equivalent part between each figure.
FIG. 1 is an explanatory view of an embodiment of a method for producing a metal endless belt according to the present invention.
In this figure, reference numeral 1 denotes an endless metal belt material, which is wound around a fixed roller 2 and a pulling roller 3 so as to be freely circulated.
The rolling roller 4 is a large-diameter roller that rolls the endless metal belt material 1 with the fixed roller 2. The rolling roller 4 is rotated by a rolling roller rotating motor 5, and the roller surface of the rolling roller 6 can be pressed with a desired force to the roller surface side (in the direction of arrow A) of the fixed roller 2. The rolling load cell 7 is a means for measuring the pressing force (rolling load) of the rolling roller 4 in the direction of arrow A.
The pulling motor 8 is a motor that pulls the pulling roller 3 with a desired force on the side opposite to the fixed roller 2 side (in the direction of arrow B) and applies a tension for stretching the endless metal belt material 1. The tension load cell 9 is means for measuring the tension (tensile load) of the tension roller 3 in the direction of arrow B. The linear gauge 10 is a measuring means for measuring the circumference of the endless metal belt material 1.

In order to process the endless metal belt material 1 into a metal endless belt having a desired peripheral width and / or thickness (manufacturing a metal endless belt), the arithmetic / control device 12 It is a device that controls 5, 6, 8, etc. according to a preset value (initial setting value).
This calculation / control device 12 determines the change over time in the load response characteristic obtained from each part of the configuration due to the change over time of the mechanical system characteristics in each part (component) shown in FIG. And a function of correcting based on the amount of deviation obtained as a result.
Each function is realized by executing a built-in control program with reference to data such as various parameters recorded in the memory and output signals (measured values) from the load cells 7 and 9, the linear gauge 10, and the like. The

In the configuration shown in FIG. 1, an endless metal belt material 1 wound between a fixed roller 2 and a pulling roller 3 is rolled by a motor 5 while being circulated between the rollers 2 and 3. The roller 4 is pressurized in the direction of arrow A by the motor 6 and is pulled by the motor 8 in the direction of arrow B.
At this time, the rolling load, the tensile load, and the circumferential length of the endless metal belt material 1 are measured by the calculation / control device 12 that receives signals from the load cells 7 and 9 and the linear gauge 10, and the endless metal belt material 1 is It is processed into a metal endless belt having a desired peripheral width and / or a desired thickness (manufactured by a metal endless belt).
As described above, the basic belt manufacturing process is not significantly different from that of the prior art, but in this embodiment, in addition to this, an automatic verification of load response characteristics (automatic verification for obtaining a deviation amount) at each processing time. ), And when there is a deviation exceeding a predetermined value with the load response characteristic obtained at the initial normal time, the deviation is corrected.

This deviation correction will be described below with reference to the flowchart of FIG.
Each processing in FIG. 2 (excluding steps 21 and 33 here) is executed or executed by the arithmetic / control device 12 that has received the measurement values from the load cells 7 and 9.
That is, when the computing / control device 12 puts the endless metal belt material 1 into the production line in step 21, specifically, the material 1 is wound between the fixed roller 2 and the pulling roller 3 so as to be freely circulated and circulated. If it is confirmed that it has been applied (completion of processing preparation), step 22 is executed. Confirmation of machining preparation completion is performed, for example, when a machining start switch ON signal or the like is input.

In step 22, the pulling roller 3 is moved by rapid feed of a constant pattern (a constant speed pattern determined in advance).
Here, “rapid feed” refers to the tension roller 3 up to a position where the processing is performed at a speed higher than that during the actual processing before the processing is actually performed [giving a tension (tensile load)] after the preparation for the processing is completed. To move.
The output signal waveform of the load cell 9, that is, the tension measurement signal waveform for test (tensile load response characteristic) is measured and recorded in the memory in the arithmetic / control device 12 for a certain period of time in which the fast-forwarding performed in step 22 continues. (See step 23).

In step 24, the rolling roller 4 is moved by rapid feed of a constant pattern (a constant speed pattern determined in advance).
Here, “fast forward” refers to the rolling roller up to the position where the machining is performed at a faster speed than the actual machining before the machining is actually performed (applying a pressing force (rolling load)) after the completion of the machining preparation. 4 is to move.
The output signal waveform of the load cell 7, that is, the pressure measurement signal waveform (rolling load response characteristic) for verification is measured for a certain period of time during which fast-forwarding performed in step 24 continues, and is recorded in the memory in the arithmetic / control device 12. (See step 25).

In step 26, during the initial normal state, the output signal waveforms of the load cells 7 and 9 which are obtained and recorded in the same manner as in steps 22 and 24, that is, the reference tension measurement signal waveform and the applied pressure measurement signal waveform ( Read the tensile load response characteristics and rolling load response characteristics).
Then, the test tension measurement signal waveform is compared with the reference tension measurement signal waveform, and the test pressure measurement signal waveform is compared with the reference pressure measurement signal waveform, which are generated between each other. The deviation amount for a predetermined item (control target item) is obtained.

  In step 27, the value obtained by subtracting the deviation amount (previous deviation amount) obtained in the previous machining from the deviation amount obtained in step 26 (deviation amount obtained in the current machining: current deviation amount) is the first value. It is determined whether or not the threshold value is exceeded. If the result of this determination is Yes, step 28 is executed, and if it is No, step 29 is executed. Note that the first threshold value is set based on an allowable value determined according to desired processing accuracy.

In step 28, the load control condition used in the machining and the correction function for the load cell measurement value are updated based on the current deviation amount.
That is, when the current deviation amount exceeds the first threshold value, a load control condition for correcting it (current deviation amount) is calculated based on the current deviation amount. Also, during the processing, the actual rolling force and the actual tensile force during the processing are predicted from the output signal values of the load cells 7 and 9, and the load control condition (processing load value) after the correction calculation is controlled by each predicted value. A new load prediction formula for advancing the processing is obtained and updated based on the current deviation amount.

In step 29, it is determined whether or not the current deviation amount is equal to or less than a preset second threshold value (for example, the constant value when the deviation amount from the initial normal time is accumulated and exceeds a certain value). If the result is Yes, step 30 is executed, and if it is No, step 34 is executed.
In step 30, processing is performed using the load control condition and the load prediction formula updated in step. That is, a load control condition for correcting the current deviation amount exceeding the first threshold value is calculated, the load control is performed according to the obtained load control condition, and machining is performed. At this time, the actual rolling force and the actual tensile force during processing are predicted from the output signal values of the load cells 7 and 9 by the load prediction formula, and the load control condition after the correction calculation, that is, the processing load is calculated using each predicted value. The values (rolling load value, tensile load value) are controlled, and processing is performed by the processed load value after the control.
Specifically, the machining load value after the correction calculation is set as a target value, and load control is performed using a feedback signal created based on each predicted value, and machining is performed. Simply, machining may be performed by performing load control using the machining load value created based on each predicted value as the machining load value after the correction calculation.
If correction processing is not performed in step 28, that is, if the current deviation amount does not exceed the first threshold value, and if it is determined in step 29 that the current deviation amount is equal to or smaller than the second threshold value. Uses the load control condition and the load prediction formula after the previous correction (update) calculation to perform load control in the same manner as described above.

In step 31, the pulling roller 3 is moved at a rapid feed.
Here, “rapid feed” refers to the movement of the pulling roller 3 to the position before processing (return) at a speed higher than that during the actual processing after the actual processing is performed (tension (tensile load) is given). That means.
In step 32, the rolling roller 4 is moved by rapid feed.
Here, “rapid feed” moves (returns) the rolling roller 4 to a position before processing at a faster speed than that during actual processing after applying the processing (giving a pressing force (rolling load)). )
In step 33, the product (processed metal endless belt) is taken out, and then the processing is terminated (normal termination).
In step 34, it is notified that the determination result in step 29 is No, that is, an abnormality in which the current deviation amount exceeds the second threshold has occurred, and then the process is terminated (abnormal termination). The notification is performed by a lamp, a buzzer or the like.

By repeating the processes of steps 21 to 34 described above for each processing, automatic verification of load response characteristics (automatic verification for determining the amount of deviation) and deviation correction based on the result of this examination are performed for each machining time.
According to this, it becomes possible to sufficiently prevent variations in products and generation of defective products over a long period of time. In particular, automatic verification and correction eliminates the labor and time required for verification and correction, and eliminates product variations and defective products due to erroneous operations. Further, since the verification and correction are performed while the production line is in operation, productivity can be improved as compared with a method in which the production line is stopped.
Further, in step 34, when the deviation amount exceeds the preset second threshold value (at the time of abnormality), the fact is notified, so that the abnormality can be known immediately and at low cost.

Next, specific examples of the control target items will be described with reference to FIGS.
FIG. 3 (pattern 301) shows a speed pattern at the time of rapid feed (movement) of the roller 3 or 4 in step 22 or 24 in FIG. 2, here, the tension roller 3 in step 22. The fast forward speed pattern 301 is used to perform fast feed. In FIG. 3, t0 is the start point of the fast feed movement of the pulling roller 3, tn is the end point of the fast feed movement, and t1 to tn-1 are periods during which the pulling roller 3 is moving at a constant speed between t0 and tn. The same applies to FIGS. 4 and 5 described later.
Mechanical system such as a sliding resistance generated during operation of the production line, for example, a sliding resistance between a guide (not shown) for guiding the roller 3 when it is moved and a rotating shaft support (not shown) of the roller 3 When the change over time of each of the components increases and the response characteristics of the components change, the torque generated by the motor 8 changes in order to maintain the same speed pattern 301. This change (load response change) is detected by the load cell 9.
FIG. 4 (waveform 401) shows the output signal waveform of the load cell 9 at step 23 when the pulling roller 3 is fast-fed at the fast feed speed pattern 301 shown in FIG. The measurement signal waveform (tensile load response ft at normal initial stage) is shown.
FIG. 5 (waveform 501) shows the output signal of the load cell 9 in step 23 when the pulling roller 3 is fast-fed at the fast-feed speed pattern 301 shown in FIG. 3 in step 22 in FIG. A waveform, that is, a tension measurement signal waveform (current tensile load response ft) is shown.

The load response ft is evaluated by the evaluation formula frk to obtain a section load evaluation value.
Here, the evaluation formula frk is a function for obtaining an average value of the load response ft between times tk-1 and tk.
The section load evaluation value f0k (k = 1 to n) in FIG. 4 and the section load evaluation value f1k (k = 1 to n) in FIG. 5 are expressed as time tk as shown in the following equations (1) and (2). This is a value obtained by evaluating the load response ft between -1 and tk using the evaluation formula frk.
f0k = frk (ft, tk-1, tk) (1)
f1k = frk (ft, tk-1, tk) (2)
Then, the deviation d in step 26 in FIG. 2, that is, the deviation d between the initial normal state and the current tensile load response ft is the section load evaluation values f0k and f1k obtained by the above equations (1) and (2). From the section deviation amount dk = f1k-f0k, from each section deviation amount dk (k = 1 to n), using the evaluation function fdn as a value representing the deviation amount of the entire load response at the time of rapid feed, It calculates | requires like following Formula (3).
d = fdn (d1, d2, ..., dn) (3)
This deviation amount d is used as the current deviation amount at step 27 in FIG. 2 (previous deviation amount at the next machining) and the current deviation amount at step 29.

The machining parameters P1 to Pm representing the load control conditions in step 28 in FIG. 2 are calculated as shown in the following equation (4) using the function fm having the section deviation amount dk obtained in step 26 as an argument.
Pm = fm (d1, d2,…, dn) (4)
A new machining pattern with the machining parameters P1 to Pm is created (the machining pattern is corrected), and the machining pattern is used as a load control condition, thereby performing machining with the deviation d corrected (see step 30).
Further, during processing, a function (load prediction formula) fc (Fin, Fin, a load value (actual tensile force) Fin measured by the load cell 9 and an interval deviation dk obtained in step 26 in FIG. d1, d2,..., dn) are used to obtain a predicted processing load (actual tensile force prediction value) Fc as shown in the following equation (5).
Fc = fc (Fin, d1, d2, ..., dn) (5)
Then, using this calculated processing load predicted value Fc, the control of the load control condition by the new processing pattern described above, that is, the processing load value is operated, and the load control is performed by the processing load value after the operation. Then, a process is performed in which the shift amount d is corrected (the shift is eliminated) (see step 30).

The above has described the case of correcting the load control condition (deviation amount d) related to the pulling roller 3, but the control of the load control condition (deviation amount d) is also applied to the rolling roller 4 as in the case of the pulling roller 3 described above. Is performed, and processing with the shift amount d corrected is performed.
In this case, FIG. 3 corresponds to a speed pattern at the time of rapid feed of the rolling roller 4 in step 24 in FIG. FIG. 4 shows the output signal waveform of the load cell 7 in step 25 when the rolling roller 4 is fast-fed at the speed pattern shown in FIG. 3 in step 24 in FIG. 2 at the initial normal state, that is, the rolling load in the initial normal state. Corresponds to response. Further, FIG. 5 shows the output signal waveform of the load cell 7 in the same step 25 when the rolling roller 4 is fast-fed at the speed pattern shown in FIG. 3 in step 24 in FIG. Corresponds to load response.

In the present invention, the following modifications can be made to the above embodiment.
That is, the generated torque values of the rolling motor and the tension motor may be used as a substitute for the load value (load response characteristic) measured by the rolling load cell and the tension load cell.
Also, when the tension roller and rolling roller are moved, a load cell is newly installed between each guide for guiding the roller and the roller rotating shaft support (not shown), and the load response is measured by the rolling load cell and the tension load cell. It is good also as a substitute of the load value (load response characteristic) to be performed.
The load control condition and load prediction formula correction (deviation correction) is not performed when the difference between the deviation amount when the previous correction is performed and the deviation amount during the current machining exceeds the first threshold value (each machining) It may be performed every time. Further, automatic verification of load response characteristics (automatic verification for obtaining a deviation amount) and deviation correction based on the verification result may be performed every predetermined number of machining operations.
Furthermore, the automatic verification of load response characteristics and the timing of deviation correction based on this verification result are not performed when the tension roller or rolling roller is moved before processing, but when it is moved after processing (during return movement). It is also possible to move. In the case of the time of movement after machining (at the time of return movement), machining based on the load control condition whose deviation has been corrected is after the next machining.

It is explanatory drawing of one Embodiment of the method of this invention. It is a flowchart for demonstrating the shift | offset | difference correction in a method same as the above. It is a figure which similarly shows the rapid feed speed pattern of a roller. It is a wave form diagram which similarly shows the tensile load response at the time of initial normal. It is a wave form diagram which similarly shows the tensile load response at the time of a process this time.

Explanation of symbols

1: endless metal belt material, 2: fixed roller, 3: tension roller, 4: rolling roller, 5, 6, 8: motor, 7: rolling load cell (rolling roller load measuring means), 9: tensioning load cell (tensioning roller) Load measuring means), 12: calculation / control device.

Claims (3)

An endless metal belt material is wrapped around a fixed roller and a pulling roller so as to be freely circulated, and the pulling roller stretches the material while the rolling roller rolls the material with the fixed roller. In a method for producing a metal endless belt having a desired circumference and having a desired plate width and / or thickness,
A rolling roller load measuring means and a tensile roller load measuring means for measuring the load applied to the rolling roller and the pulling roller separately;
The load response characteristics obtained from the respective measuring means during the movement of the rolling roller and the pulling roller before rolling and stretching of the material are obtained from the respective measuring means during the movement of the respective rollers in the initial normal state. A method for manufacturing a metal endless belt, wherein each deviation amount is obtained by comparing with each of the obtained load response characteristics, and the current machining is performed under a load control condition corrected based on the deviation amount . An endless metal belt material is wrapped around a fixed roller and a pulling roller so as to be freely circulated, and the pulling roller stretches the material while the rolling roller rolls the material with the fixed roller. In a method for producing a metal endless belt having a desired circumference and having a desired plate width and / or thickness,
A rolling roller load measuring means and a tensile roller load measuring means for measuring the load applied to the rolling roller and the pulling roller separately;
The load response characteristics obtained from the respective measuring means during the movement of the rolling roller and the pulling roller after the rolling and stretching of the material are obtained from the respective measuring means during the movement of the respective rollers in the initial normal state. A method for manufacturing a metal endless belt, wherein each deviation amount is obtained by comparing with each of the obtained load response characteristics, and the next processing is performed under a load control condition corrected based on the deviation amount . The metal endless belt manufacturing method according to claim 1, wherein when the calculated deviation amount exceeds a preset threshold value, the fact is notified.

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