JP2010264606A - Sheet molding apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a sheet molding apparatus which can improve a yield in sheet molding. <P>SOLUTION: In the sheet molding apparatus, a control section C, based on the position of a pressing member 41 detected by a position detecting means S1, implements ordinary processing to control the operations of a material supply part 1 and a material rolling part 2 in order to adjust the ratio of a delivery output to a supply output within a setting range so that the pressing member 41 positions at a position set in advance. The control section C has: an estimation means C1 which, based on the position of the pressing member 41 detected by the position detecting means S1, estimates a state in which the amount of a material supplied to a material storage part 3 by the material supply part 1 is smaller than that in a steady state; and a terminal period processing means C2 which, when the amount of the material supplied to the material storage part 3 by the material supply part 1 is estimated to be smaller than that in the steady state by the estimation means C1, implements terminal period processing to control the operations of the material supply part 1 and the material rolling part 2 on the setting condition that the ratio of the delivery output to the supply output is increased to exceed the setting range. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention includes a material supply unit that extrudes and supplies a plastically deformable material, a material storage unit that temporarily stores the material supplied from the material supply unit, and a material that is stored in the material storage unit. The material pressing part that presses the member in the pressing direction, the material rolling part that forms and discharges the material stored in the material storage part into a sheet shape with a pair of rolls, and the position in the pressing direction of the pressing member Position detecting means for detecting and a control section for controlling operation are provided, and the position of the pressing member is set in advance based on the position of the pressing member detected by the position detecting means. The material supply unit and the material rolling unit are operated so as to adjust a dispensing output to supply output ratio, which is a ratio of the output of the material supply unit to the output of the material rolling unit, within a set range. System A sheet forming device configured to perform a normal process for.

  In such a sheet forming apparatus, a material that can be plastically deformed is extruded and supplied to the material storage unit by the material supply unit, and in the material storage unit, the material is temporarily stored in a state of being pressed by the pressing member of the material pressing unit, Thus, the material stored in the material storage part is formed into a sheet shape by a pair of rolls of the material rolling part and discharged, and a sheet-like material is manufactured.

By the way, it is necessary to adjust the storage amount of the material in the material storage portion so that the material rolling portion can accurately form a sheet with a predetermined target sheet width.
Accordingly, since the position of the pressing member in the pressing direction varies with the variation in the amount of material stored in the material storing unit, position detecting means for detecting the position of the pressing member in the pressing direction is provided.
And, in a steady state where the material is sufficiently supplied to the material reservoir, based on the position of the pressing member detected by the position detecting means, the position of the pressing member is set to a preset position. A normal process is performed by so-called feedback control for controlling the operation of the material supply unit and the material rolling unit to adjust the payout output to supply output ratio within a set range (see, for example, Patent Document 1). .
Specifically, when the position of the pressing member fluctuates to the side where the amount of material stored in the material storage unit decreases, the operations of the material supply unit and the material rolling unit are controlled so that the payout output to supply output ratio increases. Conversely, when the position of the pressing member fluctuates to the side where the amount of material stored in the material storage portion increases, the operations of the material supply portion and the material rolling portion are controlled so that the ratio of the payout output to the supply output becomes small.

JP 2009-12463 A

By the way, in the sheet forming operation in which the material is formed into a sheet by the sheet forming apparatus, when the material to be formed into a sheet is reduced and the material supply unit supplies less material to the material storage unit, the material supply unit The material supply amount to the material storage part due to is less than the steady-state supply amount.
When the material supply amount is smaller than the steady state supply amount, the material spreading in the material storage portion becomes insufficient, and therefore, as shown in FIG. 7B, a sheet-like material formed by the material rolling portion A narrow portion Ae in which the sheet width becomes narrower than the target sheet width is generated at the end portion of Ws.
In the conventional sheet forming apparatus, as shown in FIG. 7B, the length of such a narrow portion Ae tends to be long.
Further, since the portion where the sheet width is outside the predetermined range may be processed as a defect, an increase in the length of the narrow portion Ae causes a decrease in yield, and conventionally, a yield in sheet forming of a material is reduced. There was room for improvement in improving.

  This invention is made | formed in view of this situation, The objective is to provide the sheet forming apparatus which can improve the yield in sheet forming.

In order to achieve the above object, a sheet forming apparatus according to the present invention includes a material supply unit for extruding and supplying a plastically deformable material, a material storage unit for temporarily storing the material supplied from the material supply unit, A material pressing part that presses the pressing member in the pressing direction to the material stored in the material storage part, and a material rolling that forms and discharges the material stored in the material storage part into a sheet shape with a pair of rolls And a position detecting means for detecting the position of the pressing member in the pressing direction, and a control section for controlling the operation. The control section is positioned at the position of the pressing member detected by the position detecting means. Based on this, the payout output to supply output ratio, which is the ratio of the output of the material supply unit to the output of the material rolling unit, should be adjusted within a set range so that the position of the pressing member is a preset position. A configured sheet forming device to perform the normal process of controlling the operation of the material supply unit and the material rolling unit,
The characteristic configuration is that the control unit
Based on the position of the pressing member detected by the position detector, a state in which the material supply amount by the material supply unit to the material storage unit is less than a steady state in which the normal processing is being performed is estimated. An estimation means;
A setting condition for making the payout output to supply output ratio larger than the set range when the estimation means estimates that the material supply amount by the material supply unit to the material storage unit is smaller than the steady state. And a final processing means for executing a final processing for controlling the operations of the material supply unit and the material rolling unit.

According to the above characteristic configuration, the material supply unit and the material rolling are performed so as to adjust the payout output to supply output ratio within the set range so that the position of the pressing member detected by the position detection unit is a preset position. Based on the position of the pressing member detected by the position detection means by the estimation means during execution of the normal process for controlling the operation of the part, the material supply amount to the material storage part by the material supply part is more than the steady state. It is estimated whether or not there is a small state.
When it is estimated by the estimation means that the amount of material supplied to the material storage part by the material supply part is less than the steady state, the final processing means causes the material to be set under a setting condition that makes the payout output to supply output ratio larger than the set range. A final process for controlling the operation of the supply unit and the material rolling unit is executed.

That is, as the storage amount of the material in the material storage portion decreases, the pressing member moves to the material side along the pressing direction, so the material is based on the position of the pressing member detected by the position detection means. It is possible to estimate a state in which the amount of material supplied to the material storage unit by the supply unit is smaller than the steady state.
When the estimation unit estimates that the material supply amount to the material storage unit by the material supply unit is smaller than the steady state during the execution of the normal processing by feedback control, the supply of the material is delayed, for example, the current lot Since it is estimated that the end of the work is approaching, the end processing is executed by the end processing means.
In this final processing, since the operation of the material supply unit and the material rolling unit is controlled by so-called feedforward control under a setting condition that makes the payout output to supply output ratio larger than the set range, the amount of material stored in the material storage unit Can be increased effectively.
As a result, the amount of material stored in the material storage portion can be secured close to the amount in a steady state, and the sheet width of the sheet-like material formed by the material rolling portion can be suppressed from being narrowed. For example, as shown in FIG. 7A, the length of the narrow portion Ae generated at the terminal portion of the sheet-like material Ws can be shortened.
Accordingly, it is possible to provide a sheet forming apparatus capable of improving the yield in sheet forming.

  A further characteristic configuration of the sheet forming apparatus according to the present invention is such that the setting condition is such that the output of the material supply unit is larger than the output in the normal processing, so that the payout output to supply output ratio is greater than the set range. This is the condition to increase.

  According to the above characteristic configuration, in the final process, the output of the material supply unit is made larger than the output in the steady process, so the amount of material supply to the material storage unit can be increased, and the material by the material rolling unit The amount of material stored in the material storage unit can be effectively increased without changing the amount of payout from the steady state.

Here, usually, a sheet material processing apparatus is provided on the downstream side of the material rolling section to draw in the sheet material formed in the material rolling section and perform a predetermined process.
And, in order to prevent the sheet-like material from becoming too slack between the material rolling part and the sheet material processing apparatus, or to prevent the sheet-like material from being cut due to the absence of the slack, The payout amount and the processing amount of the sheet material in the sheet material processing apparatus are set to be the same amount or substantially the same amount.
When the sheet material processing apparatus is provided as described above, according to the present characteristic configuration, the material storage amount in the material storage unit can be increased without changing the material discharge amount by the material rolling unit from the normal processing. Therefore, in executing the final process, it is not necessary to change and adjust the processing amount of the sheet material processing apparatus from the normal process, and as a result, the trouble of changing the operating conditions of the sheet processing apparatus is saved.

  A further characteristic configuration of the sheet forming apparatus according to the present invention is that the setting condition is such that the output of the material rolling unit is smaller than the output in the normal processing, whereby the payout output to supply output ratio is less than the set range. This is the condition to increase.

According to the above characteristic configuration, in the final process, the output of the material rolling part is made smaller than the output in the normal process, and the material discharge amount is reduced compared with that in the normal process. It is possible to effectively fill the material in the region adjacent to the sheet, thereby further suppressing the sheet width of the sheet-like material formed by the material rolling portion from being narrowed.
Further, when the present feature configuration is implemented together with the above-described feature configuration in which the setting condition is a condition in which the output ratio of the material supply unit is made larger than the output in the normal process to make the payout output to supply output ratio larger than the set range. Since the amount of material stored in the material storage portion can be increased more effectively, the sheet width of the sheet material formed by the material rolling portion can be further suppressed.
Therefore, the yield in sheet forming can be further improved.

A further characteristic configuration of the sheet forming apparatus according to the present invention is a sheet-like structure between the material rolling section and a sheet material processing apparatus that draws a sheet-shaped material formed in the material rolling section and performs a predetermined process. A buffer part is provided to loosen the material,
On the condition that the time required from the start of the final process until the sheet-like material is no longer loosened in the buffer section is equal to or longer than the time from the start of the final process until the material is not discharged by the material rolling unit. The amount of decrease in the output of the material rolling part is set.

According to the above characteristic configuration, since the sheet material is loosened by the buffer unit between the material rolling unit and the sheet material processing apparatus, the amount of material discharged by the material rolling unit and the sheet material in the sheet material processing apparatus Even if the processing amount varies, it is possible to prevent the sheet material from being cut between the material rolling section and the sheet material processing apparatus.
Then, the time required from the start of the final processing until the sheet-like material sags in the buffer section (hereinafter may be referred to as buffer time) is determined by the material rolling section from the start of the final processing. The amount of decrease in the output of the material rolling part is set under the condition that it is longer than the time until it is no longer performed (hereinafter referred to as allowable deceleration time), so the final processing is executed and the material is discharged by the material rolling part Even if the amount is reduced, the material discharge from the material rolling portion is completed before the looseness of the sheet-like material in the buffer portion is eliminated, and the sheet-like material can be prevented from being cut.

In other words, as the output of the material rolling part is reduced and the amount of material discharged by the material rolling part is reduced, the amount of material stored in the material storage part can be increased. Although the effect of suppressing the narrowing of the sheet width is increased, the smaller the amount of material discharged by the material rolling portion, the faster the loosening of the sheet material in the buffer portion.
And even if the decrease amount of the material discharge amount by the material rolling part is increased, the sheet material is not loosened and the sheet material is not cut, that is, the buffer time can be made longer. To make it possible, it is necessary to lengthen the slack of the sheet-like material in the buffer portion. However, if the slack of the sheet-like material in the buffer portion is lengthened, the apparatus installation area is increased and the apparatus price is also increased.
Therefore, if the reduction amount of the output of the material rolling part is set so as to make the buffer time as short as possible while satisfying the condition that the buffer time is equal to or greater than the allowable deceleration time, the increase in the device installation area and the increase in the device price are suppressed, and The final processing can be executed so as to sufficiently improve the yield in sheet forming of the material while avoiding the cutting of the sheet material between the material rolling unit and the sheet material processing apparatus.

The side view which shows the whole structure of the sheet forming apparatus which concerns on embodiment The top view which shows the principal part of the sheet forming apparatus which concerns on embodiment The figure which shows the time chart in the control action of the sheet forming apparatus which concerns on embodiment The figure explaining the control conditions and effect | action in control operation of the sheet forming apparatus which concerns on embodiment The figure explaining the control conditions and effect | action in control operation of the sheet forming apparatus which concerns on embodiment The figure which shows the flowchart in control operation | movement of the sheet forming apparatus which concerns on embodiment. The figure explaining the shape of the termination part of a sheet-like material

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
As shown in FIGS. 1 and 2, the sheet forming apparatus includes a material supply unit 1 for extruding and supplying a plastically deformable material W, and a material storage for temporarily storing the material W supplied from the material supply unit 1. Part 3 and material pressing part 4 for applying pressure to material W stored in material storage part 3 by pressing pressing member 41 in the pressing direction against material W stored in material storage part 3 The material storage unit 3 is configured to include the material rolling unit 2 that forms and discharges the material W stored in the material storage unit 3 into a sheet shape with a pair of rolls 21, and a control unit C that controls the operation.
Further, the sheet-shaped material Ws is loosened in the conveying section between the material rolling unit 2 and the sheet material processing apparatus 70 that draws the sheet-shaped material Ws formed in the material rolling unit 2 and performs a predetermined process. A buffer unit 60 is provided.

Next, description will be made regarding each part of the sheet forming apparatus.
As shown in FIGS. 1 and 2, the material supply unit 1 includes a biaxial taper screw 11 arranged in parallel, and the material supply unit 1 is controlled by controlling the rotational speed of the taper screw 11. 1 is configured to control the material supply amount.
Incidentally, as the rotational speed of the taper screw 11 is increased, the amount of material supplied by the material supply unit 1 increases, and the rotational speed of the taper screw 11 corresponds to the output of the material supply unit 1.
Then, by switching the rotational speed of the taper screw 11 to four stages of a reference speed, a low speed slower than the reference speed, a first high speed faster than the reference speed, and a second high speed faster than the first high speed. The output of the material supply unit 1 can be switched in four steps.

  The reference speed Vs (rotation / min) of the taper screw 11 is the required processing amount Q (liter / h) per hour of the material W, the extrusion amount q (liter / rotation) per rotation of the taper screw 11, and the taper screw. 11 is determined by the following equation (1).

  Vs = Q / (q × ηs × 60) (Equation 1)

The two rolls 21 of the material rolling unit 2 are arranged side by side in the vertical direction with the axis oriented in the horizontal direction, and one (the lower side in this embodiment) is driven and rotated by a rotary drive device M such as a motor. The other (the upper side in this embodiment) is interlocked and connected from one roll 21 via a gear (not shown). The two rolls 21 may be configured to be individually driven and rotated by being transmitted to a driving device (not shown) such as an individual motor.
The upper roll 21 is attached to the material rolling section main body 50 so as to be movable up and down so as to be close to and away from the lower roll 21, and an operating device 51 is provided for moving up and down by a fluid pressure cylinder. is there.

And it is comprised so that the material discharge | emission amount by the material rolling part 2 may be controlled by controlling the rotational speed of the roll 21. FIG.
Incidentally, as the rotational speed of the roll 21 is increased, the amount of material discharged by the material rolling section 2 is increased, and the rotational speed of the roll 21 corresponds to the output of the material rolling section 2.
In this embodiment, the output of the material rolling unit 2 can be switched to two stages by switching the rotation speed of the roll 21 to a reference speed and a low speed that is lower than the reference speed.

  The reference speed Vr (m / min) of the roll 21 is the required processing amount Q (liter / h) per hour of the material W, the sheet width w (mm), the sheet thickness t (mm), and the rolling efficiency ηr of the roll 21. Is defined by the following equation 2.

Vr = Q × 10 ³ / (w × t × ηr × 60) (Equation 2)

In addition, the material rolling section 2 provided with the pair of rolls 21 has the material rolling section main body 50 supported on the rail 52 via the support ring 53, so that the material rolling section 2 can be used when maintenance or trouble occurs. It is provided so that it can be moved away from and near to the supply unit 1.
Further, the sheet forming apparatus includes two rolls in the material rolling unit 2 on a surface P (hereinafter sometimes referred to as a reference surface) including a rotation axis of the biaxial taper screw 11 of the material supply unit 1. The gap formed between 21 is located.

  As shown in FIGS. 1, 2, 4, and 5, the material storage unit 3 is disposed between the material supply unit 1 and the material rolling unit 2 on both the left and right sides in the direction of material extrusion from the material supply unit 1. The side wall (not shown) and the bottom wall 32 are provided, and an upper opening 31 having an upper opening 31 at the top is formed, and a receiving port 34 for receiving the material W pushed out from the material supply unit 1 is provided.

As shown in FIG. 1 and FIG. 2, the material pressing portion 4 has a pressing force that presets the material W stored in the material storage portion 3 by the pressing member 41 and the material pressing surface 41 a of the pressing member 41. An actuator 42 for pressing and a link mechanism 43 for transmitting the force of the actuator 42 to the pressing member 41 are provided.
In the present embodiment, the pressing force for pressing the material W by the pressing member 41 is configured to be switched between two stages of low pressure and high pressure.
As the actuator 42, a hydraulic cylinder, a pneumatic cylinder, an electric cylinder, or the like can be used.
Further, the link mechanism 43 includes a seesaw-like lever member 43b in which the swing shaft 43a is positioned outside the material storage unit 3.

  The pressing member 41 is disposed in the upper opening 31 of the material storage unit 3, and the material pressing unit 4 is used to press the material W stored in the material storage unit 3 by the pressing member 41 downward from above (described above). In a direction approaching the reference plane P).

In the present embodiment, the actuator 42 is disposed on the lower side of the sheet forming apparatus, so that the pressing member 41 can be completely opened from the material reservoir 3 and the space above the upper opening 31 is effective. Even if the pressing member 41 is not disassembled and the roll 21 is not moved, the material storage unit 3 can be inspected and cleaned.
Further, by disposing the actuator 42 on the lower side of the sheet forming apparatus, it is possible to increase the arm ratio of the link mechanism 43 and reduce the thrust generated by the actuator 42.

  The area of the material pressing surface 41a of the pressing member 41 is the area of the upper opening 31 of the material storage part 3 (here, the area of the upper opening 31 is the upper part of the two rolls 21 of the material rolling part 2). 30 to 95% of the area of the surface of the roll 21 that includes the rotation axis of the roll 21 and parallel to the reference plane P), especially when it is necessary to prevent the material W from protruding, set to 85 to 95%. Like to do.

By the way, since the material pressing part 4 presses the material W stored in the material storage part 3 by applying a predetermined constant pressure from above, the amount of the material W stored in the material storage part 3 Accordingly, the position of the material pressing surface 41a of the pressing member 41 varies within a predetermined range.
Therefore, a position detection sensor S1 is provided as position detection means for detecting the position of the pressing member 41 (actually, the material pressing surface 41a) in the pressing direction.
In the present embodiment, the position detection sensor S1 is configured by a rotary encoder that detects the rotation angle of the lever member 43b with respect to the swing shaft 43a.
That is, as the lever member 43b swings around the swing shaft 43a, the pressing member 41 moves in the vertical direction, and as the position of the pressing member 41 in the vertical direction increases, the pressing member 41 with respect to the reference plane P is increased. The angle of the material pressing surface 41a (hereinafter simply referred to as the angle of the material pressing surface 41a) is increased. The variation in the angle of the material pressing surface 41a is also a variation in the separation distance between the material pressing surface 41a and the reference surface P, as shown in FIGS.
Therefore, a correlation between the detection information of the position detection sensor S1 and the angle of the material pressing surface 41a is obtained in advance, and the position detection sensor S1 detects the angle of the material pressing surface 41a as a position in the pressing direction of the pressing member 41. It is comprised so that it may do.

As shown in FIGS. 4 and 5, when the pressing member 41 is located at the lower limit position, the material pressing surface 41 a is parallel to the reference surface P and is perpendicular to the reference surface P in the direction of the receiving port 34. It is disposed so as to be located at substantially the same position as the upper edge portion.
That is, the position of the pressing member 41 in the pressing direction is the lower limit position when the angle of the material pressing surface 41a is 0 °, and increases as the angle of the material pressing surface 41a increases from 0 °.

  As shown in FIG. 1, in the vicinity of the exit of the material rolling unit 2, a sheet for detecting whether or not a sheet is discharged is detected by detecting the presence or absence of a sheet-like material Ws in which the material W is formed into a sheet shape by a pair of rolls 21. A detection sensor S2 is provided.

As shown in FIG. 1 and FIG. 5, a buffer unit 60 is provided in the conveyance unit between the material rolling unit 2 and the sheet material processing apparatus 70, and the buffer unit 60 has a conveyance surface on the side of the material rolling unit 2. The roller conveyor 61 is provided so as to be inclined downward, and the pressing roller 62 presses the sheet-like material Ws with a predetermined pressing force in a state of being freely movable up and down.
Then, in a state where the pressing roller 62 is received on the conveying surface of the roller conveyor 61, the amount of looseness of the sheet-like material Ws becomes maximum.
The sheet material processing apparatus 70 performs a predetermined process by drawing the sheet material Ws at a predetermined pull-in speed, and detailed description and illustration thereof are omitted. For example, there is one configured to fold the sheet-like material Ws into an accordion shape.

The control operation of the control unit C will be described.
As shown in FIG. 3, the control unit C sequentially executes a filling process, a normal process, and a final process for each lot, and controls the operation of the taper screw 11 and the roll 21 in each process.
Here, in the configuration of the present application, normal processing and final processing are automated. Although details of each process will be described later, since the present application is characterized by an end process, means for executing the end process will be described first.

In the present invention, the control unit C moves to the material storage unit 3 by the material supply unit 1 based on the position of the pressing member 41 detected by the position detection sensor S1 (in this embodiment, the angle α of the material pressing surface 41a). The estimation unit C1 that estimates a state in which the material supply amount is smaller than the steady state in which the normal processing is performed, and the estimation unit C1 causes the material supply amount to the material storage unit 3 by the material supply unit 1 to be lower than the steady state. When it is estimated that there are few, the material supply part 1 and material on the setting conditions which make the payout output versus supply output ratio which is a ratio of the output of the material supply part 1 with respect to the output of the material rolling part 2 larger than the setting range in normal processing There is provided final processing means C2 for executing final processing for controlling the operation of the rolling unit 2. Here, the steady state refers to a state in which normal processing is constantly executed.
In the present embodiment, the setting condition is such that the output of the material supply unit 1 is larger than the output in the normal process and the output of the material rolling unit 2 is smaller than the output in the normal process, so Is a condition for making the value larger than the set range.

  The control unit C is configured using a sequencer, and the estimation unit C1 and the final processing unit C2 are provided in the control unit C in a program format.

Next, a control operation of the entire sheet forming operation for forming the material W into a sheet will be described with reference to FIGS.
3 shows a time chart of the control operation, FIGS. 4 and 5 show processing conditions and actions in each processing, and FIG. 6 shows a flowchart of the control operation.

The control unit C first determines that the amount of material W stored in the material storage unit 3 is equal to the material rolling unit 2 until the angle α of the material pressing surface 41a detected by the position detection sensor S1 reaches the balance setting angle K1. The filling process for supplying the material W to the material storage unit 3 is executed so that the sheet can be formed by the above (steps # 1 and # 2).
Here, when the operator takes in the material W into the sheet forming apparatus, the management of the filling process is executed by the operator's switch operation, and thereafter, a series of processes are automatically executed.

Here, when the material W is formed into a sheet shape by the material rolling unit 2, a target sheet width range is set as a target sheet width range.
The balance setting angle K1 corresponds to the amount of material stored in the material storage unit 3 that can be properly formed in the material rolling unit 2 so that the sheet width is within the target sheet width range and variations are reduced. To set.

  Subsequently, when the angle α of the material pressing surface 41a detected by the position detection sensor S1 reaches the setting angle K1 for balancing, the control unit C continues until the setting angle K2 for starting the final processing is decreased. Based on the angle α (position of the pressing member 41) of the material pressing surface 41a detected by the position detection sensor S1, while forming the material W into a sheet shape in the material rolling unit 2, the angle of the material pressing surface 41a The material supply unit 1 and the material are adjusted so that the payout output to supply output ratio is adjusted within the set range so that α becomes the set angle K1 for balance (the position of the pressing member 41 is set in advance). The normal process by the feedback control which controls the action | operation of the rolling part 2 is performed (steps # 2-4).

  While the normal control is being performed, the estimation unit C1 of the control unit C applies the material storage unit 3 to the material storage unit 3 based on the angle α of the material pressing surface 41a detected by the position detection sensor S1. When it is estimated whether or not the material supply amount is smaller than the steady state, and the angle α of the material pressing surface 41a detected by the position detection sensor S1 decreases to the set angle K2 for starting the final process, the material supply unit 1 It is estimated that the amount of material supplied to the material storage unit 3 is less than the steady state.

When the estimation unit C1 estimates that the material supply amount from the material supply unit 1 to the material storage unit 3 is smaller than the steady state, the final processing unit C2 of the control unit C uses the sheet detection sensor S2 to detect the sheet. The above-described final process is executed until no discharge is detected, and when no sheet discharge is detected by the sheet detection sensor S2, a stop process for stopping the operation of the sheet forming apparatus is executed (steps # 4 to # 7). ).
Incidentally, the setting angle K2 for starting the final process is the lower limit value of the storage amount of the material storage unit 3 in which the sheet rolling can be performed in the material rolling unit 2 so that the sheet width is equal to or larger than the lower limit value of the target sheet width range. Set according to.

  The setting angle K1 for balancing and the setting angle K2 for starting final processing are set under the condition of K2 <K1.

Further explanation will be given for each of the above processes.
In the filling process, the control unit C stops the roll 21 to stop the material rolling unit 2 from discharging the material W, and the material pressing unit 4 so as to reduce the pressing force of the material W by the pressing member 41. In a state where the actuator 42 is controlled, the rotational speed of the taper screw 11 is adjusted to the first high speed.
In this filling process, the rotational speed of the taper screw 11 is adjusted to the first high speed to increase the material supply amount by the material supply unit 1, so that the material W can be quickly supplied to the empty material storage unit 3. And sheet forming can be started quickly.
In addition, by reducing the pressing force of the material W by the pressing member 41, the pressing member 41 can be raised smoothly with an increase in the amount of material W stored in the material storage portion 3. Before starting the sheet molding, the material W is prevented from being excessively supplied to the material storage unit 3 to prevent the roll 21 and the like from being damaged by the excessive supply of the material W.

In the normal process, the control unit C controls the actuator 42 so that the pressing force of the material W by the pressing member 41 becomes high so that the angle α of the material pressing surface 41a becomes the setting angle K1 for balancing. The rotation speed of the taper screw 11 is adjusted to adjust the rotation speed of the roll 21 to the reference speed.
The adjustment of the rotation speed of the taper screw 11 will be described.
That is, the lower set value α _L of the balance angle is set under the condition of K2 <α _L <K1, and the higher set value α _H of the balance angle is set under the condition of α _H > K1, and is detected by the position detection sensor S1. The rotational speed Vs of the taper screw 11 is adjusted as follows based on the angle α, the lower set value α _L and the upper set value α _H of the material pressing surface 41a.
When K2 <α <α _L, when Vs = first speed α _L ≦ α ≦ α _H, when Vs = reference speed α> α _H, Vs = low speed

That is, the design value of the amount of material W discharged by the roll 21 when the rotation speed of the roll 21 (corresponding to the output of the material rolling part 2) is adjusted to the reference speed is set as the reference output Or _N of the material rolling part 2. The amount of the material W supplied to the material reservoir 3 by the taper screw 11 when the rotational speed of the taper screw 11 (corresponding to the output of the material supply unit 1) is adjusted to a low speed, a reference speed, and a first high speed. Are the low output Os _L , the reference output Os _N , and the first high output Os _H1 of the material supply unit 1, the setting range of the payout output to supply output ratio is (Os _L / Or _N ) to ( Os _H1 / Or _N ).

  In this normal processing, the sheet rolling is performed in the material rolling unit 2 in a state where the amount of material W stored in the material storing unit 3 is appropriately maintained, so that the sheet width is reduced within the target sheet width range. It is possible to produce a high-quality sheet material Ws that can be molded and has little variation in sheet width.

In the final processing, the final processing means C2 of the control unit C controls the actuator 42 so that the pressing force of the material W by the pressing member 41 is increased, and the rotational speed of the taper screw 11 is set to the second high speed. Adjust the rotation speed of the roll 21 to a low speed.
That is, when the rotational speed of the roll 21 (corresponding to the output of the material rolling part 2) is adjusted to a low speed, the design value of the amount of the material W discharged by the roll 21 is set to the low output Or _L of the material rolling part 2. When the rotational speed of the taper screw 11 (corresponding to the output of the material supply unit 1) is adjusted to the second high speed, the design value of the amount of the material W supplied to the material storage unit 3 by the taper screw 11 is supplied to the material. The second high output Os _H2 of the unit 1 is assumed.
Then, the final processing means C2 of the control unit C controls the operation of the material supply unit 1 and the material rolling unit 2 so that the payout output to supply output ratio is (Os _H2 / Or _L ) in the final processing. Thus, the final processing means C2 of the control unit C in the final processing has a payout output to supply output ratio larger than the set range ((Os _L / Or _N ) to (Os _H1 / Or _N )) in the normal processing. The operation of the material supply unit 1 and the material rolling unit 2 is controlled under the set conditions.
In this embodiment, as described above, the setting condition is such that the output of the material supply unit 1 is larger than the output in the normal process and the output of the material rolling unit 2 is smaller than the output in the normal process. The supply output ratio is set to be larger than the set range.

Here, an example of setting the speed difference of the roll 21 between the normal process and the final process when the rotational speed of the roll 21 is decelerated in the final process compared to the normal process will be described.
As the speed difference is increased, the width of the sheet-like material Ws formed in the material rolling unit 2 can be suppressed from becoming narrower than a predetermined set value.
However, even if the speed difference is increased, if the sheet-like material Ws is similarly fed out by the material rolling unit 2 even after the looseness of the sheet-like material Ws in the buffer unit 60 is eliminated, the sheet-like material Ws Will be disconnected.
Therefore, the buffer time T2 (sec) required from the start of the final process until the looseness of the sheet material Ws in the buffer unit 60 is eliminated. It is necessary to set the speed difference so that it is longer than the allowable deceleration time T1 (sec) until Ws) is not paid out.

That is, as shown in FIG. 5, the length L1 of the sheet-like material Ws when the slack becomes maximum between the center of the gap between the pair of rolls 21 and the end of the roller conveyor 61 of the buffer unit 60 (= La + Lb), and the length L2 of the sheet-like material Ws when the slack disappears, the difference ΔL (mm) is L1-L2.
Then, the reference speed of the rolls 21 Vr (m / mim), when the low speed _{Vr d (m / mim),} Vr d low speed is set so as to satisfy the equation 3 below.

T2 = [ΔL / (Vr−Vr _d )] × 60 × 10 ⁻³ ≧ T1 (Equation 3)

Here, the lengths L1 and L2 of the sheet-like material Ws are values determined by the design conditions of the sheet forming apparatus, and can be set in advance. Further, the deceleration allowable time T1 is the amount of material W stored in the material storage unit 3 when the estimation unit C1 estimates that the material supply amount by the material supply unit 1 to the material storage unit 3 is less than the steady state, and It is obtained based on the output of the material rolling section 2 in the final process.
When set to a value or as close as possible value to the value satisfying the low speed Vr _d T2 = T1, suppress the width of the sheet-like material Ws is narrowed while avoiding the sheet-like material Ws is cut Is the best to do

  In the stop process, the control unit C stops the sheet forming apparatus by stopping the operation of the taper screw 11 of the material supply unit 1, the actuator 42 of the material pressing unit 4, the roll 21 of the material rolling unit 2, and the like.

Next, the shape of the sheet-like material Ws formed in the material rolling part 2 is compared between the case where the final process as described above is executed and the case where it is not executed.
When the final process is not executed, as shown by a two-dot chain line in FIG. 3, the angle α of the material pressing surface 41a detected by the position detection sensor S1 decreases to the set angle K2 for starting the final process. Then, the rotational speed of the taper screw 11 is adjusted to the first high speed and the rotational speed of the roll 21 is adjusted to the reference speed while the actuator 42 is controlled so that the pressing force of the material W by the pressing member 41 becomes high. To do.

As shown in FIGS. 3 and 7, when the final process is executed, the sheet width is set to a predetermined value at the end portion of the sheet-like material Ws formed in the material rolling unit 2 as compared with the case where the final process is not executed. It is possible to shorten the length of the narrow portion Ae that becomes narrower than that.
Therefore, it can be seen that the yield in sheet forming can be improved by executing the final process.

[Another embodiment]
Next, another embodiment will be described.
(A) A specific setting example of the setting condition for making the payout output to supply output ratio larger than the setting range is not limited to the setting example illustrated in the above embodiment.
For example, the output of the material supply unit 1 may be made larger than the output in the normal process while the output of the material rolling unit 2 is maintained at the output in the normal process.
When this setting example is applied to the above-described embodiment, in the final process, the rotation speed of the taper screw 11 is set to the second high speed while the actuator 42 is controlled so that the pressing force of the material W by the pressing member 41 becomes high. The speed is adjusted to adjust the rotation speed of the roll 21 to the reference speed.

Further, the output of the material rolling unit 2 may be made smaller than the output in the normal process while the output of the material supply unit 1 is maintained at the output in the normal process.
When this setting example is applied to the above-described embodiment, the rotation speed of the taper screw 11 is set to the speed in the normal process, that is, the low speed while the actuator 42 is controlled so that the pressing force of the material W by the pressing member 41 becomes high. The rotation speed of the roll 21 is adjusted to a low speed by adjusting the speed, the reference speed, or the first high speed.

(B) In normal processing, the control mode of the material supply unit 1 and the material rolling unit 2 for adjusting the payout output to supply output ratio within the set range is the control mode described in the above embodiment, that is, material rolling. It is not limited to the control mode in which the output of the material supply unit 1 (rotational speed of the taper screw 11) is changed and adjusted while the output of the unit 2 (rotational speed of the roll 21) is maintained constant.
For example, a control mode in which the output of the material rolling unit 2 is changed and adjusted in a state where the output of the material supply unit 1 is maintained constant is also possible. Both the output of the material supply unit 1 and the output of the material rolling unit 2 are changed and adjusted. A control form may be used.
In this case, when the position of the pressing member 41 detected by the position detection sensor S1 fluctuates to the side where the storage amount of the material W decreases, the output of the material supply unit 1 is increased and the output of the material rolling unit 2 is increased. When the position of the pressing member 41 detected by the position detection sensor S1 fluctuates to the side where the amount of stored material W increases, the output of the material supply unit 1 is decreased. On the side, the output of the material rolling unit 2 is changed and adjusted to the increase side.

(C) The specific configuration of the position detection sensor S1 is not limited to the rotary encoder exemplified in the above embodiment.
For example, a linear encoder that detects the position of the pressing member 41 in the pressing direction may be used.
In addition, when the pressing member 41 is located at a position where the material supply amount to the material storing unit 2 by the material supplying unit 1 should be estimated to be less than the steady state, a proximity switch provided to detect the pressing member 41 It may be configured.

(D) In the final process, the pressing force of the material W by the pressing member 41 may be higher than that in the normal process. In this case, since the material W can be further filled in the material reservoir 1, it is possible to further suppress the reduction in the sheet width of the sheet-like material Ws formed by the material rolling unit 2. Thus, the yield in sheet forming can be further improved.

(E) The bottom wall 32 provided in the above embodiment may be omitted, and the lower roll 21 may be provided in contact with or close to the member forming the receiving port 34.

  As described above, a sheet forming apparatus that can improve the yield in sheet forming can be provided.

DESCRIPTION OF SYMBOLS 1 Material supply part 2 Material rolling part 3 Material storage part 4 Material press part 21 Roll 41 Press member 60 Buffer part 70 Sheet material processing apparatus C Control part C1 Estimating means C2 Final process means S1 Position detection means W Material Ws Sheet-like material

Claims (4)

A material supply unit for extruding and supplying a plastically deformable material;
A material storage section for temporarily storing the material supplied from the material supply section;
A material pressing unit that presses the pressing member in the pressing direction against the material stored in the material storing unit;
A material rolling section that forms and discharges the material stored in the material storage section into a sheet shape with a pair of rolls,
Position detecting means for detecting the position of the pressing member in the pressing direction;
And a control unit for controlling the operation,
Based on the position of the pressing member detected by the position detection means, the material supply unit with respect to the output of the material rolling unit so that the position of the pressing member is set in advance. A sheet forming apparatus configured to perform a normal process for controlling the operation of the material supply unit and the material rolling unit to adjust a payout output to supply output ratio that is a ratio of the output of ,
The controller is
Based on the position of the pressing member detected by the position detector, a state in which the material supply amount by the material supply unit to the material storage unit is less than a steady state in which the normal processing is being performed is estimated. An estimation means;
A setting condition for making the payout output to supply output ratio larger than the set range when the estimation means estimates that the material supply amount by the material supply unit to the material storage unit is smaller than the steady state. A sheet forming apparatus comprising final processing means for performing final processing for controlling operations of the material supply unit and the material rolling unit.   2. The sheet forming apparatus according to claim 1, wherein the setting condition is a condition for increasing the output to supply output ratio to be greater than the setting range by making the output of the material supply unit larger than the output in the normal processing. .   3. The sheet according to claim 1, wherein the setting condition is a condition for making the ratio of the delivery output to the supply output larger than the setting range by making the output of the material rolling section smaller than the output in the normal processing. Molding equipment. Between the material rolling part and the sheet material processing apparatus that draws in the sheet material formed in the material rolling part and performs a predetermined process, a buffer part that loosens the sheet material is provided,
On the condition that the time required from the start of the final process until the sheet-like material is no longer loosened in the buffer section is equal to or longer than the time from the start of the final process until the material is not discharged by the material rolling unit. The sheet forming apparatus according to claim 3, wherein a reduction amount of the output of the material rolling section is set.

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