JP2007296673A - Position corresponding device and position corresponding method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To accurately perform the positional correspondence of the arranging position of a plurality of the heat bolts provided to the die of an extrusion molding machine with a film thickness measuring position. <P>SOLUTION: When an actuator operation signal (d) is inputted to the specific actuator of the extrusion molding machine 1 and an arithmetic model part 300, the signal similarity of a plurality of film thickness measuring data (r) and the model output signal (m) outputted is calculated to allow a film thickness measuring position where the film thickness measuring data high in the similarity with the model output signal (m) in the film thickness measuring data (r) to positionally correspond as the position corresponding to the arranging position of the specific actuator. In this case, the model coefficient for prescribing the arithmetic model characteristics of the arithmetic model part 300 is adjusted so that the deviation of the film thickness measuring data (r) with the model output signal (m) outputted from the arithmetic model part 300 becomes minimum. By this constitution, the positional correspondence using the arithmetic model part 300 after the model coefficient is adjusted becomes more accurate. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a position association apparatus and a position association method, and in an extrusion molding machine for producing a resin film, the arrangement positions of a plurality of actuators for adjusting the film thickness of the resin film and the width direction of the extruded resin film Position matching with the film thickness measurement position for measuring the film thickness of the resin film at a plurality of positions is performed accurately.

  In the present specification and claims, a resin film and a resin sheet having a thickness greater than that of the resin film are collectively referred to as “resin film”.

As a technique for mass-producing a resin film made of a synthetic resin such as polyester, a melt extrusion method using a die is employed.
A resin film manufacturing plant for manufacturing a resin film by a melt extrusion method using a die is conventionally called an extruder or an extrusion molding system in the industry.

  Here, the extruder will be described with reference to FIG. The extruder 2 of the extrusion molding machine 1 supplies the molten resin to the die 3. The metal die 3 is provided with a lip portion that forms an elongated slit, and a thin resin film 4 is discharged from the slit of the lip portion. The width of the resin film 4 discharged at this time is 1 m, for example, and the film thickness is several mm.

  The discharged resin film 4 is cooled by the cooling roll 5 and then stretched in the longitudinal direction (moving direction of the resin film 4) and the width direction (direction orthogonal to the moving direction of the resin film 4) by the stretching machine 6. . At this time, the width of the resin film 4a formed by stretching the resin film 4 is, for example, 10 m, and the film thickness is on the order of microns.

The resin film 4a stretched in the vertical / width direction is measured by the film thickness measuring instrument 7 at a plurality of locations (for example, 1000 locations) in the width direction of the resin film 4a. As the film thickness measuring instrument 7, a light absorption type utilizing β-rays, X-rays, infrared rays or the like, or a light interference type non-contact type film thickness measuring instrument is used.
And the resin film 4a by which the film thickness measurement was carried out is wound up by the winder 8. FIG.

  The control device 9 sets the slit interval of the slit of the lip part of the die 3 so that the film thickness measured by the film thickness measuring instrument 7 is uniform at each position in the width direction of the resin film 4a. Control is performed so as to adjust at a plurality of locations (for example, 100 locations) in the width direction of the resin film 4.

  In the above example, in the stretching machine 6, the resin film 4 is stretched in the longitudinal direction and the width direction, but may be stretched only in the longitudinal direction or only in the width direction, and may not be stretched.

  Next, the detailed structure of the die 3 and the means for adjusting the slit interval of the slit formed in the lip portion of the die 3 will be described.

  FIG. 8A is a cross-sectional view showing the configuration of the die 3, and FIG. 8B is a view taken in the direction of arrow B in FIG. 8A (in FIG. 8B, the heat bolt support portion 31 is Not shown).

As shown in FIGS. 8A and 8B, the die 3 is provided with a lip portion 3b that forms an elongated slit 3a (extending in the direction perpendicular to the paper surface in FIG. 8A). The lip portion 3b includes a movable lip 3b-1 and a fixed lip 3b-2, and a space formed between the movable lip 3b-1 and the fixed lip 3b-2 is a slit 3a. It has become.
The molten resin supplied from the resin supply path 3c is discharged as a thin resin film 4 from the slit 3a. Therefore, the film thickness of the resin film 4 is prescribed | regulated by the slit space | interval S of the slit 3a.

The die 3 is provided with a plurality of (for example, 100) heat bolts 30 along the width direction of the movable lip 3b-1 of the lip portion 3b (the width direction of the resin film 4). One end side of each heat bolt 30 is rotatably connected to the movable lip 3 b-1, and the other end side is screwed to the heat bolt support portion 31.
The heat bolt support portion 31 is fixedly installed on the die 3.

  Each heat bolt 30 can move and expand and contract in the axial direction. That is, the axial position adjustment of each heat bolt 30 includes “rough adjustment” in which the heat bolt 30 is moved and adjusted in the axial direction, and “fine adjustment” in which the heat bolt 30 is expanded and contracted in the axial direction.

  Thus, the pushing force with respect to the movable side lip 3b-1 changes as each heat bolt 30 moves and expands and contracts in the axial direction. That is, when the heat bolt 30 extends in the axial direction, the pushing force against the movable side lip 3b-1 is increased, and the slit interval S of the portion where the heat bolt 30 is provided becomes narrower. When contracted in the axial direction, the pushing force against the movable side lip 3b-1 becomes weak, and the slit interval S of the portion where the heat bolt 30 is provided becomes wide.

  That is, the heat bolt 30 can be moved in the axial direction by rotating the heat bolt 30 screwed to the heat bolt support portion 31 about the axis. In this way, rough adjustment of the position of the heat bolt 30 (adjustment of the mounting position) can be performed. In this rough adjustment, the operator rotates each heat bolt 30 so that the film thickness of the resin film 4 discharged from the die 3 becomes substantially equal in the width direction of the resin film 4.

  The rough adjustment described above is performed manually by an operator. This rough adjustment is performed at the initial startup of the extrusion molding machine 1 or when the adjustment range becomes larger than the fine adjustment range after long-time operation.

  Further, in a state in which the rotation of the heat bolt 30 with respect to the heat bolt support portion 31 is restrained, the heater provided in the heat bolt 30 is caused to generate heat through current, and the expansion and contraction in the axial direction is caused by the thermal expansion / contraction caused by the heat generation. Can be finely adjusted (adjustment in units of several μm). The value of the current that flows through each heater provided in each heat bolt 30 is controlled by the control device 9.

The fine adjustment described above, that is, the control of the amount of current flowing through the heater of each heat bolt 30 is performed by the control device 9. This fine adjustment is performed for the purpose of uniformly controlling the film thickness of the resin film 4a when the resin film 4 is continuously formed after the rough adjustment is completed.
That is, the control device 9 controls the amount of current applied to the heater of each heat bolt 30 so that the film thickness measured by the film thickness measuring instrument 7 is uniform at each position in the width direction of the resin film 4a. Thus, the expansion / contraction amount (fine adjustment amount) of each heat bolt 30 is controlled to adjust the slit interval S of the lip portion 3 b of the die 3.

More specifically, the film thickness measuring instrument 7 measures the film thickness at 1000 film thickness measurement positions R1 to R1000 in the width direction of the resin film 4a, and outputs film thickness measurement data r1 to r1000.
On the other hand, the control device 9 sends actuator operation signals (signals for instructing the amount of current flow) d1 to d100 to the 100 heat bolts 30 (No1 to No100). When the actuator operation signals d1 to d100 are input, the heat bolts 30 of No1 to No100 are thermally expanded and contracted by flowing a current of an energization amount corresponding to the values of the actuator operation signals d1 to d100 to the heater. The slit interval S at the position where the heat bolt 30 is disposed is adjusted to change the film thickness of the resin film 4 at the position where the heat bolt 30 is disposed. Thereby, the slit interval S and the film thickness of the resin fill 4 are changed and adjusted according to the value of the actuator operation signal d.

And the control apparatus 9 calculates | requires the thickness distribution (profile) of the width direction of the resin film 4a from film thickness measurement data r1-r1000, and the film thickness of the resin film 4a becomes equal in each position in the width direction. Actuator operation signals d1 to d100 are sent to each heat bolt 30.
The resin film 4a having a uniform film thickness is manufactured by continuously performing such control when the resin film is manufactured.

In addition to the heat bolt system using a heat bolt as an actuator for adjusting the slit interval, a heater is provided in the lip portion 3b, and the resin discharge rate is changed by changing the resin viscosity discharged from the slit 3a by the heater heat. Thus, there are a lip heater method for adjusting the film thickness and a servo motor method for driving an adjusting bolt by a servo motor.
Even when such an actuator other than the heat bolt system is adopted, each actuator is actuated according to the value of the actuator operation signal sent from the control device 9, and the slit at the position where the actuator is arranged. As a result, the resin film thickness can be adjusted.

JP 2005-254647 A Japanese Patent Application No. 2005-073289

As described above, in the extrusion molding machine 1, the film thickness of the resin film 4a is uniform at each position in the width direction.
The film thickness measuring instrument 7 measures the film thickness at a plurality of locations (for example, 1000 locations) in the width direction of the resin film 4a,
On the basis of the measured film thickness, the control device 9 controls the amount of current applied to the heaters of a plurality of (for example, 100) heat bolts 30 arranged in the width direction of the resin film 4 to thereby control the heat bolts 30. Control the amount of expansion / contraction (fine adjustment)
Thereby, the slit interval S of the lip portion 3 b of the die 3 is adjusted at each position in the width direction of the resin film 4.

Therefore, in order to accurately control the film thickness of the resin film 4a at each position in the width direction,
A plurality of film thickness measurement positions (R1 to R1000) in the width direction of the resin film 4a measured by the film thickness measuring instrument 7,
Arrangement positions (arrangement positions of No1 to No100) of a plurality (No1 to No100) of heat bolts (actuators) 30 provided on the die 3 so as to be aligned in the width direction of the resin film 4, and
It is important that the correspondence relationship is accurately determined.

  If the correspondence between the film thickness measurement position and the position where the heat bolt 30 is arranged is not accurately determined, the film thickness is adjusted at a position different from the position in the width direction to be originally adjusted. The film thickness of the resin film 4a cannot be accurately controlled, and the quality of the product (resin film) is deteriorated.

  If the resin film 4 is uniformly stretched in the width direction at each position in the width direction, the width of the resin film 4 discharged from the die 3 and the width of the resin film 4a measured by the film thickness measuring instrument 7 Thus, the correspondence between the film thickness measurement position and the arrangement position of the heat bolt 30 can be determined simply and accurately.

However, since the stretched state of the resin film 4a varies depending on each position in the width direction, the correspondence cannot be determined using the simple similarity as described above.
The reason why the film stretching state differs depending on the position in the width direction is that a necking phenomenon or the like occurs in the resin film to be manufactured.

Here, the “necking phenomenon” will be described with reference to FIG.
As shown in the figure, the resin film 4 discharged from the slit 3a of the die 3 contracts in the width direction and is shorter than the length in the width direction of the slit 3a. This is called primary necking. This necking phenomenon is caused by the viscoelasticity of the resin (plastic) material.
Thereafter, the resin film 4 is stretched in the width direction by longitudinal stretching by a stretching machine 6 (secondary necking), and stretched in the width direction by lateral stretching (stretching in the width direction).
In both the primary necking and the secondary necking, the amount of shrinkage varies depending on each position in the width direction of the resin film, and in the case of transverse stretching, the amount of stretching varies depending on each position in the width direction of the resin film.

  Such a necking phenomenon or the like causes the film stretch state to vary depending on each position in the width direction.

Therefore, various methods have been conventionally developed to determine the correspondence between the film thickness measurement positions (R1 to R1000) and the arrangement positions (No1 to No100) of the heat bolts (actuators).
Each conventional method will be described below.

As a conventional method, the resin film immediately after being discharged from the die is marked with ink at a position corresponding to a specific actuator, and the corresponding position is determined by observing the marking position at the film thickness measurement position. It was detected.
Although this method is simple, there is a problem that a resin film, a roll or the like is stained with ink.

As another conventional method, a specific actuator is operated by a predetermined amount, and the slit interval at a position corresponding to the specific actuator is changed to intentionally change the film thickness of this portion. At the film thickness measurement position, the corresponding position is detected by detecting the position in the width direction where the film thickness has changed due to the operation of a specific actuator.
However, in this method, the influence of disturbance etc. is large, and it is determined whether the film thickness change measured at the film thickness measurement position is caused by operating a specific actuator or due to disturbance etc. There is a problem that it is difficult to accurately detect the corresponding position.

Still another conventional method will be described with reference to FIG.
This conventional method automatically determines the correspondence between the film thickness measurement position and the actuator placement position by using a mathematical model in which the actual plant, for example, the extruder 1 shown in FIG. is there.

In this example, the extruder 1 shown in FIG. 7 is used as an actual plant, and the mathematical model unit 101 is a mathematical model in which the extruder 1 that is an actual plant is system-identified.
That is, the mathematical model unit 101 mathematically analyzes the dynamic system that is identified (constructed) based on the input / output data of the extrusion machine 1 that is the actual plant, theoretically considering the operation of each element of the actual plant. It is a model.

More specifically, when the extrusion molding machine 1 is viewed as one dynamic system, when an actuator operation signal d (represented by d as a representative of d1 to d100) is input, at each film thickness measurement position R1 to R1000. Film thickness measurement data r indicating the thickness of the resin film 4a (represented as r on behalf of r1 to r1000) is output.
That is, the extruder 1 can be grasped as a system that outputs the film thickness measurement data r according to the device characteristics of the extruder 1 when the actuator operation signal d is input as a dynamic system.

  The mathematical model unit 101 is constructed based on design data of input / output operations of each element in the extruder 1 so as to identify the extruder 1 as a dynamic system. When input to the mathematical model unit 101, a model output m is output according to the system characteristics identified by the system.

  That is, when an actuator operation signal d is input to the mathematical model unit 101, film thickness measurement data (disturbance of disturbance) output from the actual plant when the actuator operation signal d is input to the actual plant (extrusion molding machine 1). The mathematical model unit 101 outputs a model output signal m which is a signal equivalent to the film thickness measurement data (r) not included.

  That is, when an actuator operation signal d having a predetermined pattern waveform (for example, a stepped pattern waveform) is input to the extrusion molding machine 1 and the mathematical model unit 101 which are actual plants, they are output from the actual plant. The signal waveform (dead time, gain, time constant, etc.) included in the film thickness measurement data r and the signal waveform (dead time, gain, time constant, etc.) of the model output signal m are substantially the same signal waveform (for example, primary delay signal waveform). )

  The film thickness measurement data r includes a variety of disturbance signals, and the film thickness measurement data r includes a signal waveform that has changed due to a change in the pattern waveform of the actuator operation signal d. Yes.

  In the example shown in FIG. 10, in addition to the extruder 1 and the mathematical model unit 101 as an actual plant, an actuator operation signal transmission unit 102, a cross-correlation function calculation unit 103, and a corresponding position detection unit 104 are included. .

The actuator operation signal sending unit 102 outputs an actuator operation signal d having a predetermined pattern waveform (for example, a stepped pattern waveform) to the extrusion machine 1 and the mathematical model unit 101 which are actual plants.
In this case, only the specific actuator (for example, No. 1 heat bolt 30) sends the actuator operation signal d having this predetermined pattern waveform to the actual plant 1, and does not change the value of the actuator operation signal sent to the other actuators. . That is, only the film thickness at the position where the specific actuator is arranged is changed according to the predetermined pattern waveform.

  Then, film thickness measurement data r1 to r1000 indicating the film thickness at each of the film thickness measurement positions R1 to R1000 is output from the extrusion molding machine 1 which is an actual plant, and the mathematical model unit 101 has a predetermined pattern. A model output signal m corresponding to the actuator operation signal d is output.

  The cross-correlation function calculation unit 103 calculates a cross-correlation function value by calculating a cross-correlation function between the film thickness measurement data r1 to r1000 and the model output signal m. That is, it is calculated how much the signal component of each of the film thickness measurement data r1 to r1000 is similar to the model output signal m.

  The corresponding position detection unit 104 determines the film thickness measurement data r having the largest cross-correlation function value for the model output signal m among the film thickness measurement data r1 to r1000, and the film thickness obtained by measuring the film thickness measurement data r. The measurement position R is determined as a film thickness measurement position corresponding to a specific actuator (for example, the No1 arrangement position where the No1 actuator is arranged).

  The specific actuator that inputs the actuator operation signal d having a predetermined pattern waveform is sequentially shifted from No1 to No100, and corresponds to each of the actuators No1 to No100 by performing the above-described determination operation. The film thickness measurement position can be determined.

In the prior art shown in FIG. 10, the mathematical model unit 101 is a mathematical model obtained by theoretically extracting the operation of each element of the actual plant from the design data of the actual plant and identifying (constructing) the system.
However, the operation of the actual plant is different from the operation determined by the design data. For this reason, the input / output characteristics of the mathematical model unit 101 shown in FIG. 10 deviate from the input / output characteristics of the actual plant. As a result, it cannot be said that the correspondence between the film thickness measurement position and the corresponding position of the actuator is completely accurate.

  In view of the above-described prior art, the present invention provides an actual input / output characteristic of a real plant in a position association apparatus and a position association method for obtaining a correspondence relationship between a film thickness measurement position and an actuator arrangement position using a mathematical model. In consideration of the above, by improving the accuracy of the input / output characteristics of the mathematical model, it is possible to more accurately determine the correspondence between the film thickness measurement position and the actuator arrangement position, and the position association apparatus and position association It aims to provide a method.

The configuration of the position matching apparatus of the present invention that solves the above problems is as follows.
A die for discharging a thin resin film from the slit;
It is arranged in the die along the width direction of the resin film discharged from the die, and when an actuator operation signal is input, it operates according to the value of this actuator operation signal, thereby A plurality of actuators for changing the film thickness of the resin film according to the value of the actuator operation signal;
Film thickness that measures the film thickness at multiple film thickness measurement positions in the width direction of the discharged resin film and outputs multiple film thickness measurement data indicating the film thickness of the resin film at each film thickness measurement position Measuring instruments,
In an extrusion machine having
A position associating device for determining a correspondence relationship between the film thickness measurement position and a plurality of arrangement positions where the actuator is arranged,
When the actuator operation signal having a predetermined pattern waveform is input to the actuator, the extrusion molding machine in which the value of the film thickness measurement data changes according to the device characteristics is constructed by system identification. A mathematical model unit that outputs a model output signal whose waveform changes according to the system characteristics identified when the actuator operation signal is input,
Define the system characteristics of the mathematical model so that the residual between the film thickness measurement data and the model output signal is reduced when an actuator operation signal having a predetermined pattern waveform is input to the actuator and the mathematical model unit. A mathematical model coefficient adjustment unit for adjusting the model coefficient to be
When the actuator operation signal having a predetermined pattern waveform is input to the mathematical model unit in which the model coefficient is adjusted with a specific actuator among the plurality of actuators, the model output signal among the plurality of film thickness measurement data Is obtained, and the film thickness measurement position at which the obtained film thickness measurement data is detected is determined to correspond to the arrangement position where the specific actuator is arranged. A position determination unit;
It is characterized by having.

In the configuration of the position matching apparatus of the present invention,
The mathematical model coefficient adjustment unit includes:
A deviation calculating unit for obtaining a deviation between the film thickness measurement data output from the film thickness measuring instrument and the model output signal output from the mathematical model unit;
A coefficient adjusting unit that adjusts a model coefficient that defines a system characteristic of the mathematical model unit using a least squares method or a maximum likelihood method so that the deviation obtained by the deviation calculating unit is minimized. And

In the configuration of the position matching apparatus of the present invention,
The position determination unit
A cross-correlation function calculation unit for obtaining a cross-correlation function value between the plurality of film thickness measurement data and the model output signal;
The film thickness measurement position at which the film thickness measurement data having a large cross-correlation function calculation value with respect to the model output signal is detected among the plurality of film thickness measurement data is determined as the film thickness measurement position corresponding to the specific actuator. And a corresponding position detecting unit.

In the configuration of the position matching apparatus of the present invention,
The position determination unit
An error sum-of-squares calculation unit for obtaining a sum of squared errors between the plurality of film thickness measurement data and the model output signal;
Correspondence to determine a film thickness measurement position at which film thickness measurement data with a small sum of squares of errors with respect to the model output signal is detected as a film thickness measurement position corresponding to the specific actuator among the plurality of film thickness measurement data And a position detector.

In the configuration of the position matching apparatus of the present invention,
The mathematical model used in the mathematical model section is an ARX mathematical model.

The configuration of the position matching method of the present invention is as follows.
A die for discharging a thin resin film from the slit;
It is arranged in the die along the width direction of the resin film discharged from the die, and when an actuator operation signal is input, it operates according to the value of this actuator operation signal, thereby A plurality of actuators for changing the film thickness of the resin film according to the value of the actuator operation signal;
Film thickness that measures the film thickness at multiple film thickness measurement positions in the width direction of the discharged resin film and outputs multiple film thickness measurement data indicating the film thickness of the resin film at each film thickness measurement position Measuring instruments,
In an extrusion machine having
When the actuator operation signal having a predetermined pattern waveform is input to the actuator, the extrusion molding machine in which the value of the film thickness measurement data changes according to the device characteristics is constructed by system identification. Using a mathematical model unit that outputs a model output signal whose waveform changes in accordance with the system characteristics identified when the actuator operation signal is input. A position correlation method for determining a correspondence relationship with the arrangement position of
When the actuator operation signal having a predetermined pattern waveform is input to the actuator and the mathematical model unit, the system characteristics of the mathematical model unit are set so that the residual between the film thickness measurement data and the model output signal is reduced. A mathematical model coefficient adjustment step for adjusting the specified model coefficient;
When the actuator operation signal having a predetermined pattern waveform is input to the mathematical model unit in which the model coefficient is adjusted with a specific actuator among the plurality of actuators, the model output signal among the plurality of film thickness measurement data Is obtained, and the film thickness measurement position at which the obtained film thickness measurement data is detected is determined to correspond to the arrangement position where the specific actuator is arranged. A position determination step;
It is characterized by having.

In the configuration of the position matching method of the present invention,
The procedure for performing the position determining step after the mathematical model coefficient adjusting step is performed a plurality of times.

In the configuration of the position matching method of the present invention,
In the mathematical model coefficient adjustment step,
Finding the deviation between the film thickness measurement data output from the film thickness measuring instrument and the model output signal output from the mathematical model unit,
The model coefficient that defines the system characteristics of the mathematical model unit is adjusted using a least square method or a maximum likelihood method so that the obtained deviation is minimized.

In the configuration of the position matching method of the present invention,
In the position determination step,
Obtain a cross-correlation function value between the plurality of film thickness measurement data and the model output signal,
The film thickness measurement position at which the film thickness measurement data having a large cross-correlation function calculation value with respect to the model output signal is detected among the plurality of film thickness measurement data is determined as the film thickness measurement position corresponding to the specific actuator. It is characterized by doing.

In the configuration of the position matching method of the present invention,
In the position determination step,
Obtaining a sum of squared errors between the plurality of film thickness measurement data and the model output signal;
A film thickness measurement position at which film thickness measurement data having a small sum of squares of errors with respect to the model output signal among a plurality of the film thickness measurement data is detected is determined to be a film thickness measurement position corresponding to the specific actuator. It is characterized by.

In the configuration of the position matching method of the present invention,
The mathematical model used in the mathematical model section is an ARX mathematical model.

In the present invention, when an actuator operation signal is input to a specific actuator of an extrusion machine that is an actual plant and a mathematical model unit, a plurality of film thickness measuring devices output from the extrusion machine that is the actual plant are output. The film thickness measurement position where the film thickness measurement data and the model output signal output from the mathematical model part are obtained, and the film thickness measurement data with the high similarity to the model output signal is measured among the film thickness measurement data. Is associated with the position corresponding to the arrangement position of the specific actuator.
In this case, the model coefficient of the mathematical model part is adjusted so that the deviation between the film thickness measurement data output from the extruder, which is the actual plant, and the model output signal output from the mathematical model part is minimized. ing. That is, since the input / output characteristics of the mathematical model section are adjusted in accordance with the input / output characteristics of the actual plant, the position association using the mathematical model section after adjusting the model coefficients becomes more accurate.

  The best mode for carrying out the present invention will be described below in detail based on examples.

[Device configuration]
FIG. 1 shows a position associating device according to a first embodiment of the present invention, which is applied to the extruder 1 shown in FIG. 7 as an actual plant.
The position matching apparatus according to the first embodiment includes an extruder 1 as an actual plant, an actuator operation signal transmission unit 200, a mathematical model unit 300, a mathematical model coefficient adjustment unit 400, and a position determination unit 500. It is configured.

  The configuration and operation of the extruder 1 are the same as those described above with reference to FIGS.

  The actuator operation signal sending unit 200 outputs an actuator operation signal d having a predetermined pattern waveform (for example, a step-like pattern waveform) to the extruder 1 and the mathematical model unit 300 which are actual plants.

  Although the ARX mathematical model is used as the mathematical model unit 300 in this example, a mathematical model having another model structure such as ARMAX, OE, or BJ can also be used.

  When an actuator operation signal d (represented by d representing d1 to d100) is input, the mathematical model unit 300 represents film thickness measurement data r (represented as r representing r1 to r1000) according to the device characteristics. Is constructed using the ARX mathematical model based on the design data of the input / output operations of each element in the extruder 1 so as to identify the system 1 as a dynamic system that outputs. When the actuator operation signal d is input, the mathematical model unit 300 outputs a model output m according to the system characteristics identified by the system. In this example, the mathematical model unit 300 has 100 input terminals # 1 to # 100 and 100 output terminals M1 to M100.

  The mathematical model coefficient adjustment unit 400 includes a deviation calculation unit 401 and a coefficient adjustment unit 402 that performs calculation using a least square method or a maximum likelihood method.

  The position determination unit 500 includes a cross-correlation function calculation unit 501 as a signal similarity determination unit and a corresponding position detection unit 502.

[Device operation]
The operation of the first embodiment is as follows.
(1) a first-stage operation of adjusting (tuning) a model coefficient defining the system characteristics of the mathematical model of the mathematical model unit 300 according to the characteristics of the actual plant (extruder 1) to be actually applied;
(2) Using the mathematical model 300 in which the model coefficients are adjusted as described above, the correspondence between the film thickness measurement positions R1 to R1000 and the arrangement positions of No1 to No100 of the actuator (heat bolt 30) is determined. There are two stages of operation.
In the following, the operation of the first stage and the operation of the second stage will be described separately.

[Operation of the first stage]
In order to perform the operation of the first stage, the actuators (heat bolts) 30 of No. 1 to No. 100 of the extrusion molding machine 1 and the input terminals # 1 to # 100 of the mathematical model unit 300 are combined into the following 10 groups (C1 To C10).
C1 = No1, No11, No21, No31, No41, No51, No61, No71, No81, No91, # 1, # 11, # 21, # 31, # 41, # 51, # 61, # 71, # 81, # 91
C2 = No2, No12, No22, No32, No42, No52, No62, No72, No82, No92, # 2, # 12, # 22, # 32, # 42, # 52, # 62, # 72, # 82, # 92
C3 = No3, No13, No23, No33, No43, No53, No63, No73, No83, No93, # 3, # 13, # 23, # 33, # 43, # 53, # 63, # 73, # 83, # 93
C4 = No4, No14, No24, No34, No44, No54, No64, No74, No84, No94, # 4, # 14, # 24, # 34, # 44, # 54, # 64, # 74, # 84, # 94
C5 = No5, No15, No25, No35, No45, No55, No65, No75, No85, No95, # 5, # 15, # 25, # 35, # 45, # 55, # 65, # 75, # 85, # 95
C6 = No6, No16, No26, No36, No46, No56, No66, No76, No86, No96, # 6, # 16, # 26, # 36, # 46, # 56, # 66, # 76, # 86, # 96
C7 = No7, No17, No27, No37, No47, No57, No67, No77, No87, No97, # 7, # 17, # 27, # 37, # 47, # 57, # 67, # 77, # 87, # 97
C8 = No8, No18, No28, No38, No48, No58, No68, No78, No98, # 8, # 18, # 28, # 38, # 48, # 58, # 68, # 78, # 88, # 98
C9 = No9, No19, No29, No39, No49, No59, No69, No79, No89, No99, # 9, # 19, # 29, # 39, # 49, # 59, # 69, # 79, # 89, # 99
C10 = No10, No20, No30, No40, No50, No60, No70, No80, No90, No100, # 10, # 20, # 30, # 40, # 50, # 60, # 70, # 80, # 90, # 100

The reason why the groups are divided in this manner is that there is an interval between the one specific actuator (heat bolt) 30 and another specific other actuator (heat bolt) 30 so that eight actuators exist. If this is the case, mutual interference between one actuator and another actuator is negligible, so in this example, there are nine actuators so that there are nine actuators between one particular actuator and another particular actuator. It is divided.
For example, taking into account that changing the film thickness at the No1 position by operating the No1 actuator does not affect the film thickness at the position where the No11 actuator is located. It is divided.

The actuator operation signal sending unit 200 includes actuators No. 1, No. 21, No. 41, No. 61, and No. 81 in the first set, and # 1, # 21, # 41, # 61, and # 81 of the mathematical model unit 300. An actuator operation signal d having a stepped pattern waveform as shown in FIG. 2A is sent to the input terminal.
The actuator operation signal sending unit 200 includes actuators No. 11, No. 31, No. 51, No. 71, and No. 91 in the first set, and # 11, # 31, # 51, # 71, and # 91 in the mathematical model unit 300. The actuator operation signal d (−) having a pattern waveform obtained by reversing the polarity of the actuator operation signal d having a stepped pattern waveform as shown in FIG.
Note that the actuator operation signals having a specific (predetermined) pattern waveform as shown in FIGS. 2A and 2B are not input to the other actuators and the other input terminals of the mathematical model unit 300. There is no actuator operation.

  In this way, film thickness measurement data r1 to r1000 indicating the film thickness at each of the film thickness measurement positions R1 to R1000 is output from the extrusion molding machine 1 which is an actual plant, and from the mathematical model unit 300, Model output signals m1 to m100 are output.

The deviation calculation unit 401 of the mathematical model coefficient adjustment unit 400 obtains 100 average film thickness data r (av) obtained by combining 10 adjacent film thickness measurement data.
That means
Average film thickness measurement data r (av) 1 obtained by averaging the film thickness measurement data r1 to r10;
Average film thickness measurement data r (av) 2 obtained by averaging the film thickness measurement data r11 to r20;
Average film thickness measurement data r (av) 3 obtained by averaging the film thickness measurement data r21 to r30;
Average film thickness measurement data r (av) 4 obtained by averaging the film thickness measurement data r31 to r40;
Average film thickness measurement data r (av) 5 obtained by averaging the film thickness measurement data r41 to r50;
...
...
Average film thickness measurement data r (av) 96 obtained by averaging the film thickness measurement data r951 to r960;
Average film thickness measurement data r (av) 97 obtained by averaging the film thickness measurement data r961 to r970;
Average film thickness measurement data r (av) 98 obtained by averaging the film thickness measurement data r971 to r980;
Average film thickness measurement data r (av) 99 obtained by averaging the film thickness measurement data r981 to r990;
Average film thickness measurement data r (av) 100 obtained by averaging the film thickness measurement data r991 to r1000 is obtained.

Next, the deviation calculator 401
An error (residual) Δ1 to an error (residual) Δ100 obtained by individually comparing the average film thickness measurement data r (av) 1 to r (av) 100 and the model outputs m1 to m100 is obtained.
For example, error (residual) Δ1 = r (av) 1−m1 and error (residual) Δ100 = r (av) 100−m100.

  The coefficient adjustment unit 402 uses the least squares method or the maximum likelihood method based on the error (residual) Δ1 to the error (residual) Δ100 so that the error (residual) is minimized. The coefficient that defines the system characteristics of the system will be adjusted.

Incidentally, the ARX mathematical model is described by the following equation using polynomials A (q) and B (q) using a shift operator.
A (q) r (k) = B (q) u (k−n _k ) + w (k)
However, u is an input, r is an output, k is a sample number, _nk is delayed, and w (k) is white noise.
The coefficient of the ARX mathematical model defines input / output characteristics of an actual plant.

In this way, the actuator operation signal d having a predetermined pattern waveform (for example, a stepped pattern waveform) is input to each actuator of the first set C1 and the input terminal of the mathematical model unit 300, and the coefficient adjustment of the mathematical model unit 300 is performed. In the same manner, the actuator operation signal d is sequentially input to the input terminals of the second to tenth actuators and the mathematical model unit 300 to adjust the coefficients of the mathematical model unit 300 in the same manner.
In this way, coefficient adjustment (tuning) of the mathematical model of the mathematical model unit 300 is performed.

[Second stage operation]
When the adjustment of the model coefficient of the mathematical model unit 300 is completed by the operation of the first stage described above, the correspondence between the film thickness measurement position and the actuator placement position using the mathematical model unit 300 after the correction of the model coefficient is completed. The operation of the second stage for obtaining the relationship is performed.

The mathematical model unit 300 has 100 input terminals and 100 output terminals, but in this second stage operation, there is one input terminal (for example, # 50) and one output terminal (for example, # 50). M50) is used.
This is because, if the model coefficients of the mathematical model are adjusted, when the same actuator operation signal is input to the input terminals of # 1 to # 100, the output is performed from the output terminals of M1 to M100. This is because the model output signals to be processed are substantially the same.
Therefore, in the second stage operation, the mathematical model unit 300 will be described as one model output signal m being output.

First, a correspondence relationship between the arrangement positions of the actuators No. 1, No. 11, No. 21, No. 31, No. 41, No. 51, No. 61, No. 71, No. 81, and No. 91 and the film thickness measurement positions included in the first set C1 is found.

The actuator operation signal transmitting unit 200 includes step No. 1 pattern waveforms as shown in FIG. 2A to the actuators No. 1, No. 21, No. 41, No. 61, No. 81 and the mathematical model unit 300 in the first set. The actuator operation signal d is sent.
In addition, the actuator operation signal transmission unit 200 includes actuators No. 11, No. 31, No. 51, No. 71, and No. 91 in the first set, and actuator operations having a stepped pattern waveform as shown in FIG. An actuator operation signal d (−) having a pattern waveform obtained by reversing the signal d from positive to negative is transmitted.
In addition, the actuator operation signal having a specific waveform as shown in FIGS. 2A and 2B is not input to the other actuators, and the other actuators are not operated.

  In this way, film thickness measurement data r1 to r1000 indicating the film thickness at each of the film thickness measurement positions R1 to R1000 is output from the extrusion molding machine 1 which is an actual plant, and from the mathematical model unit 300, A model output signal m is output.

  A cross-correlation function calculation unit 501 of the position determination unit 500 calculates a cross-correlation function value by calculating a cross-correlation function between the film thickness measurement data r1 to r1000 and the model output signal m. That is, it is calculated how much the signal component of each of the film thickness measurement data r1 to r1000 is similar to the model output signal m.

This cross-correlation function value S _ty is a function defined by the following equation (1).

The corresponding position detection unit 502 of the position determination unit 500 determines whether the model output signal m as shown in FIG. 3A or the model output signal m is positive or negative among the film thickness measurement data r1 to r1000. ) 10 film thickness measurement data r having a large cross-correlation function value S _ty for the model output signal m (−) as shown in FIG. And the film thickness measurement position R which measured these 10 film thickness measurement data r is arrangement | positioning of the actuator of No1, No11, No21, No31, No41, No51, No61, No71, No81, No91 of 1st group C1. The film thickness measurement position corresponding to the position is determined.

When the cross-correlation function value S _ty having a large value cannot be simply detected, for example, the following signal processing is performed to obtain the film thickness measurement position corresponding to the specific actuator placement position.

4, the cross-correlation function value S _ty 8~S _ty 14 is a cross-correlation function values for the model output signal m of the thickness measurement data R8 to R14.
If such cross-correlation function values S _ty 8 to S _ty 14 appear when the actuator operation signal d (−) is input to the No. 11 actuator, it cannot be determined which cross-correlation function value should be adopted. .

Therefore around the cross-correlation function value S _ty 11, it selects the cross-correlation function value S _ty 8~S _ty 14 in predetermined within a predetermined range α First, the values of these cross-correlation function values S _ty 8~S _ty 14 Of these, a value equal to or greater than a certain threshold β is cut out, an intermediate value or a centroid value of the cut out value is obtained, and a position where there is a cross-correlation function value serving as the intermediate value or the centroid value corresponds to the actuator placement position of No11 This is defined as the film thickness measurement position.

  In this way, the film thickness measurement positions corresponding to the arrangement positions of the actuators No. 1, No. 11, No. 21, No. 31, No. 41, No. 51, No. 61, No. 71, No. 81 and No. 91 are determined.

  When the film thickness measurement positions corresponding to the positions of the actuators No. 1, No. 11, No. 21, No. 31, No. 41, No. 51, No. 61, No. 71, No. 81 and No. 91 of the first set C1 are thus determined, The film thickness measurement positions corresponding to the arrangement positions of the actuators of the second to tenth groups C2 to C10 are sequentially determined.

  If such a determination is made, data indicating the positional relationship thus associated is output. When the film thickness of the actual plant (extrusion generator 1) is controlled, the actuator corresponding to the film thickness measurement position is controlled based on this positional relationship data.

When the operation of the second stage is completed, the model coefficient of the mathematical model unit 300 may be adjusted again by returning to the operation of the first stage again.
At the time of this readjustment, the positional relationship between the film thickness measurement position and the actuator arrangement position is already known from the second stage operation. For this reason, the reference of the average film thickness measurement data r (av) 1 to the average film thickness measurement data r (av) 10 is utilized by using the already known “positional relationship between the film thickness measurement position and the actuator arrangement position”. Then, the combination of the film thickness data r is selected again.
For example, in the first stage, the average film thickness measurement data r (av) 1 is an average of the film thickness measurement data r1 to r10. Is more accurately known, the data to be averaged is, for example, film thickness measurement data r1 to r8 using this positional relationship.

  When the one-stage operation (model coefficient adjustment) is completed again, the second-stage operation can be performed again to obtain a more accurate corresponding positional relationship.

  That is, by repeating the first stage operation and the second stage operation, a more accurate corresponding positional relationship can be obtained.

  Next, a position association apparatus according to Embodiment 2 of the present invention will be described with reference to FIG.

In the second embodiment shown in FIG. 5, the position determination unit 500A includes an error square sum calculation unit 503 as a signal similarity determination unit and a corresponding position detection unit 504.
Other configurations and operations are the same as those of the first embodiment shown in FIG.

Error sum-of-squares calculation part 503 calculates each error sum of squares of each film thickness measurement data r1-r1000 and model output signal m.
That is, Σ (ym−yr1) to Σ (ym−yr1000) are obtained.
Here, ym is the value of the model output signal m, and yr1 to yr1000 are the values of the film thickness measurement data r1 to r1000, respectively.
The error sum of squares decreases as the ratio of the film thickness measurement data r to the model output signal m increases. Incidentally, the cross-correlation function calculation value used in Example 1 becomes larger as the ratio of the film thickness measurement data r similar to the model output signal m increases.

  The corresponding position detection unit 504 obtains an inversion error square sum for which the error square sums Σ (ym−yr1) to Σ (ym−yr1000) are determined, and the corresponding position detection unit in FIG. The same determination processing as that performed by 502 is performed, and the film thickness measurement position R corresponding to the arrangement positions of the actuators No. 1 to No. 100 is obtained.

  In the second embodiment, the error sum-of-squares calculation unit 503 serving as the signal similarity determination unit performs an error sum-of-squares calculation with a smaller calculation burden than the cross-correlation function calculation. Can be reduced.

In each of the above embodiments, the actuator operation signal d having a predetermined pattern waveform is input to all the actuators, and 100 film thickness measurement positions R corresponding to the arrangement positions of the No. 1 to No. 100 actuators are obtained. The processing can be speeded up as follows without being limited to such a method.
That is, among the actuators No. 1 to No. 100, the actuator operation signal d having a predetermined pattern waveform is input only to the actuators at predetermined intervals, and the film thickness measurement positions R corresponding to the actuator arrangement positions at predetermined intervals are obtained. . The film thickness measurement positions corresponding to the remaining actuators are obtained by interpolating the already obtained film thickness measurement positions.
In this way, the calculation for the corresponding position is reduced, and the calculation load is reduced as a whole.

  Moreover, in each said Example, although an actuator is operated and position matching is carried out for every group of C1-C10, the actuator is operated one by one, and it corresponds to the operated one actuator. The film thickness measurement position may be obtained.

Furthermore, the waveform of the actuator operation signal d is not limited to a step-like signal waveform, and various pattern waveforms can be employed.
For example, as shown in FIG. 6, the signal value can be set to a constant value with a large signal value in the initial period t <b> 1 and a small signal value in the subsequent period t <b> 2 from the signal input time point. In the pattern waveform of FIG. 6, since the actuator operation signal value in the initial period t1 is large, the film thickness of the resin film can be changed quickly, and in the subsequent period t2, the actuator operation signal value is small, so the film thickness of the resin film Overshoot of thickness change can be prevented. As a result, it is possible to perform the position matching process while achieving a rapid change in the film thickness of the resin film and prevention of overshoot.
Note that the time interval between the periods t1 and t2 and the signal value during the periods t1 and t2 can be appropriately designed in consideration of the film thickness change amount, the film thickness change upper limit value, and the like.

The block block diagram which shows the position matching apparatus which concerns on Example 1 of this invention. The wave form diagram which shows an actuator operation signal. The wave form diagram which shows a model output signal. The characteristic view which shows an example of a cross correlation function value. The block block diagram which shows the position matching apparatus which concerns on Example 2 of this invention. The wave form diagram which shows an actuator operation signal. The block diagram which shows an extrusion molding machine. The block diagram which shows die | dye. Explanatory drawing which shows a necking phenomenon. The block block diagram which shows the conventional position matching apparatus.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Extruder 2 Extruder 3 Die 3a Slit 3b Lip part 3b-2 Movable side lip 3b-2 Fixed side lip 3c Resin supply path 4, 4a Resin film 5 Cooling roll 6 Stretching machine 7 Film thickness measuring instrument 8 Winding machine DESCRIPTION OF SYMBOLS 9 Control apparatus 30 Heat bolt 31 Heat bolt support part 200 Actuator operation signal transmission part 300 Mathematical model part 400 Mathematical model coefficient adjustment part 401 Deviation calculation part 402 Coefficient adjustment part 500, 500A Position determination part 501 Cross correlation function calculation part 502 Corresponding position Detection unit 503 Error sum of squares calculation unit 504 Corresponding position detection unit r1 to r1000 Film thickness measurement data m, m1 to m100 Model output signal

Claims (11)

A die for discharging a thin resin film from the slit;
It is arranged in the die along the width direction of the resin film discharged from the die, and when an actuator operation signal is input, it operates according to the value of this actuator operation signal, thereby A plurality of actuators for changing the film thickness of the resin film according to the value of the actuator operation signal;
Film thickness that measures the film thickness at multiple film thickness measurement positions in the width direction of the discharged resin film and outputs multiple film thickness measurement data indicating the film thickness of the resin film at each film thickness measurement position Measuring instruments,
In an extrusion machine having
A position associating device for determining a correspondence relationship between the film thickness measurement position and a plurality of arrangement positions where the actuator is arranged,
When the actuator operation signal having a predetermined pattern waveform is input to the actuator, the extrusion molding machine in which the value of the film thickness measurement data changes according to the device characteristics is constructed by system identification. A mathematical model unit that outputs a model output signal whose waveform changes according to the system characteristics identified when the actuator operation signal is input,
Define the system characteristics of the mathematical model so that the residual between the film thickness measurement data and the model output signal is reduced when an actuator operation signal having a predetermined pattern waveform is input to the actuator and the mathematical model unit. A mathematical model coefficient adjustment unit for adjusting the model coefficient to be
When the actuator operation signal having a predetermined pattern waveform is input to the mathematical model unit in which the model coefficient is adjusted with a specific actuator among the plurality of actuators, the model output signal among the plurality of film thickness measurement data Is obtained, and the film thickness measurement position at which the obtained film thickness measurement data is detected is determined to correspond to the arrangement position where the specific actuator is arranged. A position determination unit;
The position matching apparatus characterized by having. In claim 1,
The mathematical model coefficient adjustment unit includes:
A deviation calculating unit for obtaining a deviation between the film thickness measurement data output from the film thickness measuring instrument and the model output signal output from the mathematical model unit;
A coefficient adjusting unit that adjusts a model coefficient that defines a system characteristic of the mathematical model unit using a least squares method or a maximum likelihood method so that the deviation obtained by the deviation calculating unit is minimized. A position matching apparatus. In claim 1,
The position determination unit
A cross-correlation function calculation unit for obtaining a cross-correlation function value between the plurality of film thickness measurement data and the model output signal;
The film thickness measurement position at which the film thickness measurement data having a large cross-correlation function calculation value with respect to the model output signal is detected among the plurality of film thickness measurement data is determined as the film thickness measurement position corresponding to the specific actuator. And a corresponding position detecting unit. In claim 1,
The position determination unit
An error sum-of-squares calculation unit for obtaining a sum of squared errors between the plurality of film thickness measurement data and the model output signal;
Correspondence to determine a film thickness measurement position at which film thickness measurement data with a small sum of squares of errors with respect to the model output signal is detected as a film thickness measurement position corresponding to the specific actuator among the plurality of film thickness measurement data A position associating device comprising a position detecting unit. In any one of Claims 1 thru | or 4,
The position matching apparatus, wherein the mathematical model used in the mathematical model section is an ARX mathematical model. A die for discharging a thin resin film from the slit;
It is arranged in the die along the width direction of the resin film discharged from the die, and when an actuator operation signal is input, it operates according to the value of this actuator operation signal, thereby A plurality of actuators for changing the film thickness of the resin film according to the value of the actuator operation signal;
Film thickness that measures the film thickness at multiple film thickness measurement positions in the width direction of the discharged resin film and outputs multiple film thickness measurement data indicating the film thickness of the resin film at each film thickness measurement position Measuring instruments,
In an extrusion machine having
When the actuator operation signal having a predetermined pattern waveform is input to the actuator, the extrusion molding machine in which the value of the film thickness measurement data changes according to the device characteristics is constructed by system identification. Using a mathematical model unit that outputs a model output signal whose waveform changes in accordance with the system characteristics identified when the actuator operation signal is input. A position correlation method for determining a correspondence relationship with the arrangement position of
When the actuator operation signal having a predetermined pattern waveform is input to the actuator and the mathematical model unit, the system characteristics of the mathematical model unit are set so that the residual between the film thickness measurement data and the model output signal is reduced. A mathematical model coefficient adjustment step for adjusting the specified model coefficient;
When the actuator operation signal having a predetermined pattern waveform is input to the mathematical model unit in which the model coefficient is adjusted with a specific actuator among the plurality of actuators, the model output signal among the plurality of film thickness measurement data Is obtained, and the film thickness measurement position at which the obtained film thickness measurement data is detected is determined to correspond to the arrangement position where the specific actuator is arranged. A position determination step;
The position matching method characterized by having. In claim 6,
A position associating method comprising performing the position determining step a plurality of times after the mathematical model coefficient adjusting step. In claim 6 or claim 7,
In the mathematical model coefficient adjustment step,
Finding the deviation between the film thickness measurement data output from the film thickness measuring instrument and the model output signal output from the mathematical model unit,
A position associating method comprising adjusting a model coefficient defining a system characteristic of the mathematical model unit using a least square method or a maximum likelihood method so that the obtained deviation is minimized. In claim 6 or claim 7,
In the position determination step,
Obtain a cross-correlation function value between the plurality of film thickness measurement data and the model output signal,
The film thickness measurement position at which the film thickness measurement data having a large cross-correlation function calculation value with respect to the model output signal is detected among the plurality of film thickness measurement data is determined as the film thickness measurement position corresponding to the specific actuator. A position association method characterized by: In claim 6 or claim 7,
In the position determination step,
Obtaining a sum of squared errors between the plurality of film thickness measurement data and the model output signal;
A film thickness measurement position at which film thickness measurement data having a small sum of squares of errors with respect to the model output signal among a plurality of the film thickness measurement data is detected is determined to be a film thickness measurement position corresponding to the specific actuator. A position matching method characterized by In any one of Claim 6 thru | or Claim 10,
The position matching method, wherein the mathematical model used in the mathematical model section is an ARX mathematical model.

Images