JP2016196712A - Foreign matter removal device, pre-needle machine system, felt manufacturing system, foreign matter removal method, and felt manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a foreign matter removal device capable of detecting and removing foreign matters including fibrous foreign matters in fiber for manufacturing felt, and a pre-needle machine system, a felt manufacturing system, a foreign matter removal method, and a felt manufacturing method.SOLUTION: A foreign matter removal device 1 comprises: an irradiation unit 32 which irradiates a web 102 formed including fiber for manufacturing felt 100 with an electromagnetic wave; an imaging unit 33 which receives the electromagnetic wave transmitting through the web 102 to obtain transmission image information for the web 102; a detection unit which detects fibrous foreign matters 103 present in the web 102 from the transmission image information; and a removal unit 34 which removes the detected fibrous foreign matters 103 from the web 102.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a foreign substance removing device, a pre-needle machine system, a felt manufacturing system, a foreign substance removing method, and a felt manufacturing method.

  Felt fabrics are widely used in industry as industrial felts such as press cushioning materials as well as papermaking felts.

  Among these, the papermaking felt is a belt-like felt member used in a papermaking machine. A papermaking felt is generally disposed in a press part and used to convey and squeeze wet paper formed in a wire part.

  Such papermaking felt has appropriate wet paper adhesion and peelability (wet paper transportability) for supporting and delivering wet paper, and excellent water squeezing for efficiently squeezing water in the wet paper. Required. Furthermore, the felt for papermaking carries wet paper and squeezes water by squeezing, so it greatly affects the surface of the wet paper. Therefore, wet paper smoothness to smooth the wet paper Is also sought.

  In order to smooth the wet paper, it is important to make the batt fiber layer arranged on the wet paper side of the papermaking felt uniform. If the unevenness of the batt fiber layer is large or the arrangement of the batt fibers is not uniform, the surface of the wet paper tends to be rough.

  On the other hand, devices for detecting foreign materials such as plastic materials, fabric pieces, bands, strings, foil pieces, etc. in fibers, and devices for evaluating webs in spinning machines have been proposed (for example, Patent Documents 1 to 3). .

JP 2005-120563 A JP-A-10-096124 JP 2004-052212 A

  By the way, the raw material for the butt fiber layer of papermaking felt or industrial felt may contain a trace amount of fibrous foreign matter in addition to the target bat fiber. Such fibrous foreign matter often has a fiber diameter different from that of normal bat fibers.

  The present inventors can affect the surface state of the product supported by the felt even when such a fibrous foreign matter that is minute compared to other foreign matters is contained in the raw material of the batt fiber layer. I found the problem and paid attention. For example, in the case of papermaking felt, the shape caused by fibrous foreign matter is transferred to the surface of the wet paper, which can affect the smoothness and printability of the resulting paper. For example, when printing is performed on the obtained paper, a printing defect (white spots) in a shape due to fibrous foreign matters occurs.

  Accordingly, an object of the present invention is to detect a foreign matter including the fibrous foreign matter as described above in a fiber for producing felt, a pre-needle machine system, a felt production system, a foreign matter removal method, and a felt production. It is to provide a method.

  The inventors of the present invention have made extensive studies in order to achieve the above object, and have formed a web from felt-producing fibers and analyzed an image obtained by transmitting an electromagnetic wave, particularly visible light, through the web. As a result of finding that foreign matters including fibrous foreign matters can be detected efficiently and reliably, and as a result of intensive studies, the present invention has been achieved.

That is, the present invention is based on the following technique.
(1) an irradiation unit for irradiating an electromagnetic wave to a web formed including felt-producing fibers;
An imaging unit that receives electromagnetic waves transmitted through the web and obtains transmission image information of the web;
A detection unit for detecting fibrous foreign matter present in the web from the transmission image information;
A foreign matter removing apparatus comprising: a removing unit that removes the detected fibrous foreign matter from the web.
(2) The foreign matter removing apparatus according to (1), wherein the removing unit is configured to remove the fibrous foreign matter together with felt-producing fibers in the vicinity of the fibrous foreign matter.
(3) The foreign matter removing apparatus according to (1) or (2), wherein the removing unit is configured to collect the fibrous foreign matter by suction.
(4) The removal unit includes a suction unit for sucking the fibrous foreign matter,
The foreign matter removing apparatus according to (3), wherein the suction unit is configured to move away from the web during suction.
(5) Furthermore, the foreign material removal apparatus in any one of (1)-(4) which has a web formation part which forms a web by the card process from the raw material containing the fiber for felt manufacture.

(6) The foreign matter removing apparatus according to (5), wherein the basis weight of the formed web is 3 to 30 g / m ² .
(7) The foreign matter removing apparatus according to any one of (1) to (6), wherein the fiber diameter of the detected fibrous foreign matter is 10 to 1000 μm.
(8) The foreign matter removing apparatus according to any one of (1) to (7), wherein the fiber diameter of the detected fibrous foreign matter is 2 to 100 times the average fiber diameter of the felt manufacturing fiber.
(9) The foreign matter removing device according to any one of (1) to (8), wherein the color of the felt manufacturing fiber and the fibrous foreign matter are different.
(10) The foreign matter removing apparatus according to any one of (1) to (9), wherein the electromagnetic wave is visible light, infrared light, or ultraviolet light.
(11) The foreign matter removing apparatus according to any one of (1) to (10), wherein the felt manufacturing fiber is a batt fiber for manufacturing papermaking felt.

(12) The foreign matter removing apparatus according to any one of (1) to (11),
A card portion for carding the felt-producing fiber treated by the foreign matter removing device to form a web;
A pre-needle machine system, comprising: a pre-needle machine unit that performs pre-needle punching on a laminate in which a plurality of webs are laminated.
(13) The foreign matter removing apparatus according to any one of (1) to (11),
A card portion for carding the felt-producing fiber treated by the foreign matter removing device to form a web;
A felt manufacturing system comprising: a needle machine unit that performs needle punching on a laminate in which a plurality of webs are stacked on a base fabric.

(14) A method for removing fibrous foreign matter in a raw material containing a fiber for producing felt,
An irradiation step of irradiating the web containing the felt-producing fibers with electromagnetic waves;
An image information acquisition step of obtaining transmitted image information of the web using electromagnetic waves transmitted through the web;
A detection step of detecting fibrous foreign matter in the web from the transmission image information of the web;
A removal step of removing fibrous foreign matter from the web.
(15) A step of forming a web using the felt-producing fiber from which the fibrous foreign matter has been removed by the foreign matter removing method according to (14),
And a step of forming a butt layer on the base fabric by performing needle punching on the laminate in which a plurality of webs are stacked on the base fabric.

  With the above configuration, a foreign matter removing device, a pre-needle machine system, a felt producing system, a foreign matter removing method, and a felt producing method capable of detecting and removing foreign matters including fibrous foreign matters as described above in felt producing fibers are provided. can do.

  In particular, by detecting foreign matter in the web by transmitting electromagnetic waves, particularly visible light, to the web, it is possible to reliably detect not only the surface of the web but also foreign matter buried inside the web. Since the fibrous foreign matter exists in a state where it is intertwined with surrounding fibers and often does not appear on the web surface, such a method of transmitting electromagnetic waves is advantageous.

FIG. 1 is a schematic view showing a foreign matter removing apparatus according to a first embodiment of the present invention. FIG. 2 is a plan view of the foreign matter detection / removal unit provided in the foreign matter removal apparatus shown in FIG. 1 when viewed in plan along the web. FIG. 3 is a schematic cross-sectional view showing the operation of the removing unit provided in the foreign matter removing apparatus shown in FIG. FIG. 4 is a plan layout view showing the outline of the pre-needle machine system according to the second embodiment of the present invention. FIG. 5 is a side view showing a part of the pre-needle machine system shown in FIG. FIG. 6 is a plan layout view showing an overview of the felt manufacturing system according to the present embodiment. FIG. 7 is a side view showing a part of the felt manufacturing system shown in FIG. FIGS. 8A to 8F are photographic images of fibrous foreign matters in the web detected by the foreign matter removing apparatus according to the present invention.

  Hereinafter, the present invention will be described in detail based on preferred embodiments with reference to the drawings.

1. Foreign matter removing device, pre-needle machine system and felt manufacturing system <first embodiment>
First, the first embodiment of the present invention will be described.
FIG. 1 is a schematic view showing a foreign matter removing apparatus according to a first embodiment of the present invention, and FIG. 2 is a plan view of a foreign matter detecting / removing section provided in the foreign matter removing apparatus shown in FIG. FIG. 3 is a schematic cross-sectional view showing the operation of the removing unit provided in the foreign matter removing apparatus shown in FIG. In the drawings, the size of each member is emphasized as appropriate, and does not indicate the actual size or ratio.
A foreign matter removing apparatus 1 shown in FIG. 1 is an apparatus for detecting and removing a foreign matter 103 containing fibrous foreign matter in a felt manufacturing fiber 100.

  Here, the fiber 100 for felt production may be used for the production of any felt, and can be used, for example, for the production of industrial felts such as press cushion materials, papermaking felts and the like. In particular, the felt for papermaking is required to have a uniform and smooth surface in order to improve the smoothness of the wet paper. However, the felt manufacturing fiber 100 treated by the foreign matter removing apparatus 1 is fibrous. Since the foreign matter 103 including the foreign matter is removed, it is suitable for manufacturing a papermaking felt. Furthermore, the felt manufacturing fiber 100 can be used for manufacturing wet paper transport belts, papermaking belts, and the like obtained by impregnating a felt or the like with a resin manufactured using the same. .

  In addition, the felt manufacturing fiber 100 may be used as any raw material of felt, but is generally used as a bat fiber in felt. The bat fiber is exposed on the surface of the felt in the felt. However, since the foreign matter 103 including the fibrous foreign matter is removed from the felt manufacturing fiber 100 processed by the foreign matter removing apparatus 1, the bat fiber is configured. The batt fiber layer to be made becomes uniform and smooth.

  Further, the fiber for producing felt is not particularly limited. For example, nylon 6, nylon 66, nylon 610, nylon 612, nylon 11, nylon 12, nylon 1212, semi-aromatic polyamide, aromatic polyamide, polyester, polyphenylene sulfide , Short fibers made from one or more selected from the group consisting of polyetheretherketone, acrylic, and wool.

  In addition, the fibrous foreign material 103 is not particularly limited. For example, defective fibers (atypical fibers) generated during spinning, such as drip fibers, fused fibers, unstretched fibers, base fabric yarns, animal fibers such as human hair, Examples of the fibers are unintentionally mixed fibers such as colored fibers. The drip fiber is a fiber having a non-constant fiber diameter, is generally cloudy, and has a feather-like surface. The fused fiber is a fiber formed by bonding a plurality of fibers. Unstretched fibers are fibers that have not been stretched in the fiber manufacturing process. These fibers are defective fibers (deformed fibers) generated during spinning, and are usually present in a very small amount in the raw material fibers. In either case, the fiber diameter is generally larger than that of the felt-producing fiber, and the surface condition of the felt is likely to be affected.

The foreign matter removing apparatus 1 shown in FIG. 1 includes a raw cotton opening unit 10, a web forming unit 20, a foreign matter detecting and removing unit 30, and a web collecting unit 40.
The raw cotton opening unit 10 includes a spreader 11 that opens the felt-producing fiber 100 that is a raw material, and an endless transfer belt 12 that transfers the opened spreader 101 to the web forming unit 20. ing.

  The web forming unit 20 is a so-called card machine, and includes a feed roller 21, a take-in roller 22, a pre-cylinder 23, a transformer roller 24, workers 25A and 25B, strippers 26A and 26B, a main cylinder 27, A doffer 28 and a condenser roller 29 are provided. In addition, each roller in the web formation part 20 rotates in the direction of the arrow shown in the figure.

  The feed roller 21 and the take-in roller 22 are rollers that supply the spread body 101 opened and transported from the raw cotton opening section 20 to the pre-cylinder 23. The pre-cylinder 23 can cooperate with the worker 25A and the stripper 26A arranged on the peripheral surface thereof to preliminarily open the supplied spread body 101. The pre-cylinder 23, the worker 25A, and the stripper 26A are arranged with a large number of comb teeth on their peripheral surfaces. The worker 25A scraped off the opened body 101 on the pre-cylinder 23 and the stripper 26A was scraped off. The opened body 101 is opened by returning the opened body 101 onto the pre-cylinder 23.

  The transformer roller 24 receives the spread body 101 from the pre-cylinder 23 and supplies it to the main cylinder 27. Here, the transformer roller 24 adjusts the supply amount of the spread body 101 to the main cylinder 27 by adjusting the rotation speed thereof.

  The main cylinder 27 can cooperate with the worker 25B and the stripper 26B disposed on the peripheral surface thereof to open and uniformize the supplied spread body 101. The main cylinder 27, the worker 25B, and the stripper 26B are arranged with a large number of comb teeth on their peripheral surfaces. The worker 25B scraped off the opened body 101 on the main cylinder 27 and the stripper 26B was scraped off. By returning the opened body 101 onto the main cylinder 27, the opened body 101 is opened and aligned along the traveling direction.

  The doffer 28 is disposed so that the peripheral surface thereof faces the peripheral surface of the main cylinder 27, and is configured to rotate at a lower peripheral speed than the main cylinder 27. The doffer 28 increases the basis weight of the opened body 101 by receiving the opened body 101 aligned from the main cylinder 27 at a low speed, and forms the web 102.

  The condenser roller 29 is configured to rotate at a lower peripheral speed than the doffer 28, and adjusts the basis weight by compressing the web 102 formed in the doffer 28.

By such a web forming unit 20, it is possible to continuously form a belt-like web 102 that has been opened and whose basis weight is adjusted.
In the web forming unit, the basis weight of the formed web 102 is not particularly limited, but is, for example, 3 to 30 g / m ² , preferably 5 to 26 g / m ² , and more preferably 7 to 22 g / m ^2. Can be configured.

  The foreign object detection / removal unit 30 includes a plurality of conveyor belts 31A to 31C, an irradiation unit (light source) 32, an imaging unit 33, a removal unit 34, and a control unit (not shown).

  The conveyor belts 31A, 31B, and 31C are endless belts, respectively, along the flow direction in the order of the conveyor belts 31A, 31B, and 31C so as to convey the web 102 from the web forming unit 20 to the web collecting unit 40. Has been placed.

  The irradiation unit 32 is disposed between the transport belt 31A and the transport belt 31B. As illustrated in FIG. 2, the irradiation unit 32 includes a plurality of light sources 321 that emit visible light, and the light sources 321 are respectively along the width direction of the conveyor belts 31 </ b> A and 31 </ b> B, that is, the width direction of the web 102. They are arranged so as to make a pair with and face an imaging means (camera) 331 of the imaging unit 33 described later, and irradiate visible light from below the web 102 toward one main surface of the web 102.

  As described above, the light source of the irradiation unit 32 is disposed so as to be paired with and opposed to the image pickup unit 331 of the image pickup unit 33, thereby suppressing unevenness of transmitted light transmitted through the web 102 due to the position of the light source. . In addition, since the light source of the irradiation part 32 makes a pair with the imaging means 331 of the imaging part 33, in this embodiment, the number of light sources and the number of imaging means correspond.

  Moreover, the illumination intensity of the visible light irradiated to the web 102 by the irradiation part 32 is not specifically limited, What is necessary is just what visible light can permeate | transmit the web 102 moderately, For example, 100,000-700,000 lx, Preferably it is 20 It may be 10,000 to 600,000 lx, more preferably 300,000 to 500,000 lx. Thereby, the visible light can be sufficiently transmitted through the web 102, and the change in the transmittance of the visible light with respect to the change in the state of the web 102 such as when the foreign matter 103 exists in the web 102 can be observed more clearly. .

  The light source is not particularly limited, and examples thereof include (inorganic) light emitting diodes (LEDs), organic light emitting diodes (OLEDs), fluorescent lamps, incandescent lamps, halogen lamps, arc lamps, and cold cathode fluorescent tubes. . Among these, the light source is preferably a light emitting diode (LED), an organic light emitting diode (OLED) or a fluorescent lamp, more preferably a light emitting diode, from the viewpoints of less uneven emission, less heat generation, and high durability. .

Moreover, in this embodiment, although demonstrated as what the irradiation part 32 irradiates visible light, this invention is not limited to this, As long as a fibrous foreign material is detectable, an irradiation part is infrared light, Various electromagnetic waves including ultraviolet light can be applied.
The irradiation unit 32 is connected to a control unit (not shown), and the light sources 321 of the irradiation unit 32 are driven in accordance with instructions from the control unit.

  As shown in FIG. 2, the imaging unit 33 includes a plurality of imaging units 331. The imaging means 331 is arranged along the width direction of the conveyor belts 31A and 31B so that the web 102 can be imaged across the width direction. Further, the imaging unit 331 is disposed so as to face the light source 321 of the irradiation unit 32 as a pair. Each imaging unit 331 can receive transmitted light that has been emitted from a pair of light sources 321 and passed through the web 102 to obtain transmitted image information of the web 102.

  In addition, each of the imaging units 331 is connected to a control unit (not shown). Accordingly, the imaging unit 331 can perform imaging in accordance with an instruction from the control unit, and can transmit transmission image information obtained by imaging to the control unit. In addition, in the imaging unit 331, various imaging conditions such as a light receiving sensitivity (ISO sensitivity) at the time of imaging and a focal length are set according to an instruction from the control unit.

  Further, the imaging unit 331 has an image resolution that can sufficiently detect the foreign matter 103 including the fibrous foreign matter, and the distance from the web 102 is adjusted so that a wide range of the web 102 can be taken. . Such a distance may vary depending on the type and performance of the imaging means 331, and is not particularly limited, but may be, for example, 10 to 100 cm, preferably 20 to 80 cm, and more preferably 40 to 60 cm.

  Furthermore, the distance between the adjacent imaging units 331 may be any distance as long as a part of the imaging range of each imaging unit 331 overlaps, for example, 10 to 100 cm, preferably 15 to 80 cm, more preferably 20 to 20 cm. It can be 60 cm.

  Examples of such an image pickup means 331 include a solid-state image pickup device such as a CMOS image sensor and a CCD image sensor, and a device provided with an image pickup tube. Among these, the image pickup unit 331 preferably includes a solid-state image sensor, and more preferably a CCD camera including a CCD image sensor.

  In addition, the imaging means is not limited to the illustrated mode, and can be appropriately selected according to the type of electromagnetic wave irradiated by the irradiation unit.

  Further, the transmission image information obtained by the imaging unit 331 is subjected to A / D conversion processing as necessary, and transmitted to the control unit as digital data.

  The removing unit 34 is disposed on the conveyance belt 31 </ b> C, and is located downstream of the imaging unit 33 in the conveyance direction of the web 102. Further, as shown in FIG. 2, the removal unit 34 includes a plurality of suction units 341, and the plurality of suction units 341 can remove the foreign matter 103 across the width direction of the web 102 as a whole. It is arranged to cross the top.

  Each suction part 341 is a cylindrical body, and one end is connected to a suction device (not shown) through a pipe. Further, one end portion is opposed to the web 102 and is configured to be able to suck foreign matter, particularly fibrous foreign matter in the web 102 from an opening (suction port) 342 provided at the end portion. .

  Note that the fibrous foreign matter 103 is configured to be removed together with the felt-producing fiber 100 in the vicinity of the fibrous foreign matter 103 during suction by the suction unit 341. Since the fibrous foreign matter 103 is usually entangled with other fibers in the web 102, it is efficient to remove the fibrous foreign matter 103 together with the felt manufacturing fibers 100 in the peripheral portion. In addition, it is conceivable that the fibrous foreign matter 103 is blown off by compressed air or the like, but in such a case, the web 102 is simply torn by the wind pressure, and the fibrous foreign matter 103 is not removed.

Further, the suction part 341 is configured to be movable in the approaching / separating direction with respect to the web 102.
The suction unit 341 is configured to be close to the web 102 so as to move to the vicinity of the foreign matter 103 before suction (FIG. 3A), and start to be sucked and separated from the web 102 (see FIG. 3). 3 (b), (c)). Accordingly, the foreign matter 103 is sucked and collected by the suction portion together with the web 102 in the vicinity of the foreign matter 103. On the other hand, the suction part 341 is separated from the web 102 at the same time as the suction as described above, thereby preventing the felt-producing fibers 100 near the fibrous foreign matter 103 from being sucked indefinitely.
Note that suction and movement of the suction unit 341 are performed in accordance with instructions from the control unit.

The suction device connected to the suction unit 341 is not particularly limited, and for example, various types of suction devices such as a turbo blower type, a roots blower type (cyclone type), and an ejector type can be used. Among these, the roots blower type is preferable from the viewpoint of obtaining a stable air volume instantaneously.
The felt manufacturing fiber 100 including the foreign matter 103 sucked in the suction portion 341 is collected by a filter or the like. The collected manufacturing fiber 100 can be reused after the foreign matter 103 is removed.

The control unit is a so-called electronic computer (computer) having an arithmetic device, a storage device, an input unit, and a display unit.
The control unit is connected to each part of the foreign object detection and removal unit 30 and controls them.

  The control unit also functions as a detection unit that analyzes the transmission image information acquired by the imaging unit 33 and detects the foreign matter 103 including the fibrous foreign matter. Specifically, the foreign substance 103 can be detected by extracting dot information of the transmission image information and determining a difference in contrast and color. The detection sensitivity of the foreign matter 103 can be changed by appropriately setting the contrast, color tone, and the like of the transmission image information.

  Information regarding the foreign object detection and removal unit 30 such as the transmission image captured by the imaging unit 33 and information of the detected foreign object 103 can be displayed on the display unit as appropriate. The display means is not particularly limited, and examples thereof include a display, a lamp, a touch panel, a speaker, and the like, and these can be used alone or in combination.

  Further, the control unit includes an input unit, and it is possible to instruct the setting, activation, and termination of the control condition of the foreign object detection / removal unit 30 by the input unit. The input means is not particularly limited. For example, a pointing device such as a mouse, trackball, or pen tablet, a keyboard, a touch panel, or a connection terminal such as an input, output, or input / output terminal, a button, a knob, or the like. These can be used alone or in combination.

  The web collection unit 40 is a storage container, and collects and stores the web 102 conveyed by the conveyance belts 31 </ b> A to 31 </ b> C of the foreign object detection and removal unit 30. The web 102 collected in the web collection unit 40 can be used for producing felt. For example, after this, the card 102 is further subjected to card processing, pre-needle processing is performed to obtain a pre-butt fiber layer, and the base fabric and the pre-bat fiber layer are overlapped to perform needling, thereby forming a felt having the batt fiber layer on the base fabric. Can be obtained. Alternatively, for example, after that, further card processing is performed on the web 102, and a felt having a bat fiber layer on the base fabric can be obtained by performing a needling by stacking the web laminate and the base fabric.

As described above, the foreign matter removing apparatus 1 according to the present embodiment can accurately detect and remove the foreign matter 103 including the fibrous foreign matter that has not been recognized as a foreign matter.
In particular, the fibrous foreign matter 103 in the web 102 is entangled with other fibers and difficult to detect reliably when only the surface of the web 102 is observed, but the transmitted light passing through the web 102 is used. By performing detection, it is possible to reliably detect. The fibrous foreign matter 103 is finer than a plastic material, a woven piece, a band, a string, or a foil piece that has been recognized as a foreign matter. It has not been known that detection is possible using transmission images in which fibers overlap and are reflected in an image.

  In particular, the fibrous foreign material 103 can be reliably removed by removing the fibrous foreign material 103 together with the surrounding fibers from the web 102 by suction.

<Second Embodiment>
Next, a second embodiment of the present invention will be described.
FIG. 4 is a plan view showing an outline of the pre-needle machine system according to the present embodiment, and FIG. 5 is a side view showing a part of the pre-needle machine system shown in FIG. In addition, in the figure, the same code | symbol is attached | subjected about the structure same as the structure of the 1st embodiment mentioned above.
Hereinafter, differences between the present embodiment and the first embodiment will be described in detail, and description of similar matters will be omitted.

  The pre-needle machine system 2 according to the present embodiment shown in FIGS. 4 and 5 is configured such that the card unit 60 and the pre-needle machine unit 80 are added to the foreign matter removing apparatus 1A to form the pre-needle machine system 2. Thus, it is different from the foreign matter removing apparatus 1 according to the first embodiment.

  The pre-needle machine system 2 includes a foreign matter removing apparatus 1A, a first cross wrapper 50A, a card unit 60, a second cross wrapper 50B, an ink line 70, and a pre-needle machine unit 80. .

  The foreign matter removing apparatus 1A is obtained by omitting the web collection unit 40 in the foreign matter removing apparatus 1 according to the first embodiment. The web 102 from which the foreign matter has been removed by the foreign matter removing apparatus 1A is conveyed to the first cross wrapper 50A.

The first cross wrapper 50A overlaps the web 102 conveyed from the foreign matter removing apparatus 1A on a plurality of sheets to form a laminated body, and the web 102 is fed in the conveying direction of the laminated body of the web 102. Is changed by 90 ° from the angle and supplied to the card unit 60.
The first cross wrapper 50A is not particularly limited, but may be a mountain cross wrapper, a horizontal cross wrapper, or the like.

The card unit 60 includes a card machine 61 and transport belts 62A and 62B.
The conveyance belt 62 </ b> A conveys the laminated body of webs supplied from the first cross wrapper 50 </ b> A to the card machine 61.

  The card machine 61 has the same configuration as that of the web forming unit 20, reopens the supplied laminated body of the webs 102, and forms the webs 102 again. The opening of the web 102 in the card machine 61 differs from the opening in the web forming unit 20 described above in the 90 ° opening direction. Thus, sufficient opening can be performed by performing opening from different directions.

  The conveyor belt 62B further conveys the web 102 supplied from the card machine 61 to the second cross wrapper 50B.

  The second cross wrapper 50B has a mechanism similar to that of the first cross wrapper 50A. The web 102 conveyed from the card unit 60 is stacked on a plurality of sheets to form a laminate 104, and the web 102 The transport direction of the laminated body 104 is changed by 90 ° from the transport direction of the supplied web 102 and transported to the ink line 70.

  The ink line 70 has a conveyance belt, and conveys the laminated body 104 formed in the second cross wrapper 50 </ b> B to the pre-needle machine unit 80.

  The pre-needle machine unit 80 includes a feed table 81, a machine main body 82, a needle unit 83 provided in the machine main body 82, recovery belts 84 and 85, and a take-up roll 86.

The feed table 81 conveys the laminated body 104 conveyed from the ink line 70 to the machine main body 82 while guiding it.
In the machine body 82, needle punching is performed on the supplied laminated body 104 in a needle portion 83 having a needle board 831 and a bed plate 832 provided with a plurality of needles. Thereby, the sheet | seat 105 which consists of the prebat fiber layer which the fibers 100 for felt manufacture in the laminated body 104 intertwined is formed.

  The sheet 105 is wound and collected by the take-up roll 86 while being supported by the collection belts 84 and 85.

  The pre-needle machine system 2 according to the present embodiment has the advantage that, in addition to the effects according to the first embodiment, the removal of the foreign matters 103 including fibrous foreign matters and the formation of the pre-butt fiber layer can be performed at once. Have. Further, since the needle punching for forming the bat fiber layer on the base fabric and the card processing are performed separately, the difference in the conveyance speed of the web 102 between the card processing (opening processing) and the needle punching processing by the needle machine is determined. There is no need to consider.

  In addition, the sheet | seat 105 which consists of a pre bat fiber layer can be used as a bat fiber layer in felt by being provided to a needle machine and needling in the state laminated | stacked with the base fabric.

<Third embodiment>
Next, a third embodiment of the present invention will be described.
FIG. 6 is a plan view showing an outline of the felt manufacturing system according to the present embodiment, and FIG. 7 is a side view showing a part of the felt manufacturing system shown in FIG. In addition, the same code | symbol is attached | subjected about the structure same as the structure of the 1st embodiment mentioned above and the 2nd embodiment in the figure.

Hereinafter, the difference between the first embodiment and the second embodiment of the present embodiment will be described in detail, and description of similar matters will be omitted.
The felt manufacturing system 3 according to this embodiment shown in FIGS. 6 and 7 is different from the pre-needle machine system 80 in that the pre-needle machine section 80 is changed to a needle machine section 90. Different from the machine system 2.

  The needle machine unit 90 includes a feed table 91, a plurality (three in this embodiment) of support rolls 92, and a machine main body 93.

  The feed table 91 and the three support rolls 92 are configured such that a base fabric 200 used for producing felt can be put on the feed table 91 and the three support rolls 92. Further, the feed table 91 and the three support rolls 92 can apply tension to the inserted base cloth 200 and can rotate the base cloth 200 along its length direction.

  The machine main body 93 has two needle portions 94A and 94B in its casing. The two needle portions 94A and 94B are arranged in parallel in the vertical direction in the machine main body 93, and are configured to allow the inserted base cloth 200 to pass therethrough.

  The needle portions 94A and 94B have needle boards 941A and 941B provided at the upper part and bed plates 942A and 942B provided at the lower part, respectively. Accordingly, the needle portion 94A can be needle punched from the outer peripheral surface side of the base fabric 200, and the needle portion 94B is configured to be capable of needle punching from the inner peripheral surface side of the base fabric 200.

  Then, when the laminated body 104 in which the plurality of webs 102 are stacked is supplied from the feed table 91, the laminated body 104 is laminated on the base fabric 200 to form a new laminated body 300. Then, needle punching can be performed on the laminate 300 by the needle board 941A and the bed plate 942A in the needle portion 94A. Thereby, the felt manufacturing fiber 100 in the laminate 104 is entangled with the base fabric 200, and a batt fiber layer including the felt manufacturing fiber 100 is formed on the base fabric 200.

  On the other hand, in the needle part 94B, when a laminated body of bat fibers, for example, a pre-butt layer, is supplied to the inner peripheral surface of the base cloth 200, the needle board 941B and the bed plate 942B are used to form the pre-bat layer and the base cloth 200. A needle punch can be performed.

  The felt manufacturing system 3 according to the present embodiment has the advantage that, in addition to the effects according to the first embodiment, the removal of the foreign matter 103 including the fibrous foreign matter 103 and the production of the felt can be performed collectively.

2. The foreign matter removing method and felts manufacturing method will now be described a preferred embodiment of the foreign matter removing method and felting process of the present invention.

The foreign matter removing method of the present invention is a method for removing fibrous foreign matter in a raw material containing a fiber for producing felt,
An irradiation step of irradiating the web containing the felt-producing fibers with electromagnetic waves;
An image information acquisition step for obtaining transmitted image information of the web based on electromagnetic waves transmitted through the web;
A detection step of detecting fibrous foreign matter in the web from the transmission image information of the web;
Removing the fibrous foreign matter from the web.

Further, the felt manufacturing method of the present invention includes a step of forming a web using a fiber for producing felt from which fibrous foreign matter has been removed by the foreign matter removing method,
A step of performing needle punching on the laminated body in which a plurality of laminated webs are overlapped with the base fabric to form a bat layer on the base fabric.

Details will be described below. For ease of explanation, description will be made assuming that the felt manufacturing system 3 according to the third embodiment described above is used.
First, the web 102 is formed from the raw material containing the felt manufacturing fiber 100 (web forming step).
Formation of the web 102 is performed by supplying the felt manufacturing fiber 100 to the web forming unit 20 and performing card processing.

The basis weight of the formed web 102 is not particularly limited, but is, for example, 3 to 30 g / m ² , preferably 5 to 26 g / m ² , and more preferably 7 to 22 g / m ² . The web 102 having such a basis weight can sufficiently transmit visible light (electromagnetic waves), and it is relatively easy to detect foreign matter including fibrous foreign matter.

Next, the web 102 is irradiated with visible light (irradiation process).
Specifically, visible light is irradiated from one light source 321 of the irradiation unit 32 toward one main surface of the web 102 from below the web 102.
In addition, although the illumination intensity of visible light is not specifically limited, For example, it can be set as the range mentioned above.

Next, the transmitted image information of the web is obtained using the transmitted light transmitted through the web 102 (image information acquisition step).
Specifically, the imaging means 331 of the imaging unit 33 receives transmitted light emitted from the paired light sources 321 and passed through the web 102 to obtain transmitted image information of the web 102.

Further, various imaging conditions such as the light receiving sensitivity (ISO sensitivity) of the imaging unit 331 at the time of imaging and the focal length are appropriately input by inputting to the control unit or by setting in advance in the control unit. Can be set and changed.
For example, when acquiring image information of a light weight web of ^{3 to} 15 g / m ² , an appropriate image can be obtained by adjusting the dimming function in the control unit in order to prevent the acquired image from being whitened out. Information can be acquired.

Further, since the obtained transmission image information is usually analog data, it is preferable to perform A / D conversion to obtain digital data.
The transmission image information converted into digital data by the imaging unit 331 is transmitted to the control unit, and is used for removing foreign matters including fibrous foreign matters.

Next, the foreign matter 103 including the fibrous foreign matter in the web 102 is detected from the transmission image information of the web 102 (detection step).
The foreign object 103 can be detected by obtaining the outline of the foreign object 103 in the transmission image information and determining whether or not the object is a foreign object. This processing and determination are performed by a control unit that also serves as a detection unit.

Specifically, for example, the control unit extracts dot information from the transmission image information, calculates information regarding the color difference and contrast ratio between adjacent dots, and obtains two-dimensional data in which the information is mapped.
Next, in the mapped two-dimensional data, the shape of a part having a color difference and a contrast ratio different from those of other parts is identified, and the foreign substance 103 including a fibrous foreign substance is detected. When the foreign matter 103 is detected, the control unit instructs the removal unit 34 to remove the foreign matter.

The foreign matter 103 including the fibrous foreign matter is often larger in diameter and thickness than the felt-producing fiber 100. In such a case, only the felt-producing fiber 100 in the web 102 exists. The transmittance of visible light is smaller than that of the portion that performs. The difference in transmittance in the web 102 is reflected in the contrast ratio between adjacent dots in the transmission image information.
Further, when the colors of the felt manufacturing fiber 100 and the fibrous foreign matter 103 are different, such a color difference is reflected in the color difference between adjacent dots in the transmission image information.
Therefore, the difference in information such as the contrast ratio and color difference between adjacent dots in the transmission image information is useful for detecting the foreign matter 103 including the fibrous foreign matter.

Moreover, the fiber diameter of the fibrous foreign material 103 to be detected is not particularly limited, but may be, for example, 10 to 1000 μm, preferably 50 to 800 μm, and more preferably 80 to 500 μm. The fibrous foreign matter 103 having such a fiber diameter is likely to affect the state of the felt surface when used in the felt, and on the other hand, since the fiber diameter is relatively small, it is removed when the felt manufacturing fiber 100 is manufactured. Difficult to do.
In the papermaking felt, when fibers having a fiber diameter of 100 μm or more are mixed in the vat fiber, the shape thereof is easily transferred to the wet paper to be carried and the obtained paper. In such a case, there may be a problem (whiteout) that the printing is not properly performed at a portion where the shape is transferred during printing.

  The fiber diameter of the fibrous foreign matter 103 detected is not particularly limited, but is 2 to 100 times, preferably 3 to 50 times, more preferably 4 to 20 times the average fiber diameter of the felt manufacturing fiber 100. . Within the above range, the difference in transmittance by visible light between the fibrous foreign material 103 and the felt manufacturing fiber 100 is easily clarified, and the fibrous foreign material 103 can be detected more reliably. Further, the fibrous foreign matter 103 having such a fiber diameter reduces the uniformity and smoothness of the felt surface.

  Note that the detection condition (detection program) can be changed as appropriate in accordance with the fibrous foreign matter 103 to be detected. Alternatively, a plurality of types of fibrous foreign matter 103 may be detected simultaneously using a plurality of detection conditions.

  Moreover, when the present inventors performed the test using the apparatus provided with the structure similar to the irradiation part 32, the imaging part 33, and the detection part which were mentioned above, Fig.8 (a)-FIG.8 (f) It was possible to detect the fibrous foreign matter as shown in FIG.

  FIGS. 8A to 8F are photographic images of fibrous foreign matters in the web detected by the foreign matter removing apparatus according to the present invention. The fibrous foreign matter shown in FIG. 8 (a) is a drip fiber having a fiber diameter of 0.23 mm, and the fibrous foreign matter shown in FIG. 8 (b) is a fused fiber having a fiber diameter of 0.15 mm. The fibrous foreign matter shown in FIG. 8 (c) is an unstretched fiber having a fiber diameter of 0.12 mm, and the fibrous foreign matter shown in FIG. 8 (d) is a base fabric yarn having a fiber diameter of 0.12 mm. The fibrous foreign matter shown in FIG. 8 (e) is human hair with a fiber diameter of 0.10 mm, and the fibrous foreign matter shown in FIG. 8 (f) is a colored fiber with a fiber diameter of 0.04 mm.

Next, the foreign matter 103 including the detected fibrous foreign matter is removed from the web 102 (removal step).
Specifically, the control unit instructs the removal unit 34 to perform the foreign matter 103. This instruction includes information on the position of the foreign matter 103 such as a fibrous foreign matter in the web 102. Next, the removal unit 34 operates at a position where the foreign matter 103 such as the fibrous foreign matter of the web 102 to be conveyed exists according to the instruction, and removes the foreign matter 103 such as the fibrous foreign matter from the web 102.

  When the foreign matter 103 including the fibrous foreign matter is detected, the removing unit 34 first approaches the suction portion 341 corresponding to the position where the fibrous foreign matter is present in the width direction (FIG. 3A). . Next, when a foreign object is conveyed near the suction port of the suction unit 341, the suction unit 341 starts suction and starts to be separated from the web 102 (FIG. 3B). Thereby, the foreign matter is sucked and collected by the suction portion together with the web 102 in the vicinity of the foreign matter (FIG. 3C). On the other hand, the suction part 341 is separated from the web 102 at the same time as the suction as described above, thereby preventing the felt-producing fibers 100 near the fibrous foreign matter 103 from being sucked indefinitely.

The suction power of the suction part 341 is not particularly limited. For example, the total suction power of each suction part 341 is 500 to 3000 W, preferably 750 to 2500 W, and more preferably 1000 to 2000 W. it can. Here, the suction power can be defined in JIS C 9108, for example.
Moreover, the vacuum degree of the suction part 341 is not particularly limited, but may be, for example, 10 to 90 kPa, preferably 20 to 80 kPa, and more preferably 30 to 70 kPa.

  As described above, the foreign matter 103 including the fibrous foreign matter can be detected and removed from the raw material containing the felt manufacturing fiber. In addition, the above-described method can detect and remove the foreign matter 103 while continuously conveying the formed web 102. Moreover, the felt manufacturing fiber 100 from which the foreign matter 103 has been removed in this manner can be used for manufacturing felt as described in the following steps, for example.

Next, a plurality of webs 102 from which foreign matter 103 obtained as described above has been removed are stacked by the first cross wrapper 50A (first stacking step). The number of webs to be laminated is not particularly limited. For example, the basis weight of the laminated body is 30 to 300 g / m ² , preferably 50 to 200 g / m ² , more preferably 60 to 150 g / m ^2. Lamination can be performed.

  Next, the web stack obtained in the first laminating step is subjected to card processing by the card machine 61 to form the web 102 again (card processing step).

Next, a plurality of cards 102 are stacked by the second cross wrapper 50B to form a stacked body 104 (second stacking step). The number of cards 102 to be stacked is not particularly limited. For example, the basis weight of the stacked stacked body 104 is 30 to 300 g / m ² , preferably 50 to 200 g / m ² , more preferably 60 to 150 g / m ² . Lamination can be performed as follows.

  Next, the laminate 104 obtained by laminating a plurality of webs and the outer peripheral surface of the endless base fabric in the feed table 91 are overlapped, and the obtained laminate 104 is subjected to needle punching in the needle portion 94A of the needle machine unit 90, The felt manufacturing fiber 100 is entangled and integrated with the base fabric 200 to form a batt fiber layer including the felt manufacturing fiber (needling step).

  On the other hand, on the inner peripheral surface of the base fabric 200, a sheet of bat fiber is supplied from a roll (not shown), the sheet and the base fabric 200 are laminated, needle punching is performed at the needle portion 94B, and the bat fiber is then used as the base fabric. The bat fiber layer on the inner peripheral surface side is formed by being intertwined with 200. In addition, the bat fiber provided on the inner peripheral surface side may have foreign matters removed by the foreign matter removing method described above, or may be used without applying the foreign matter removing method described above.

  By the above, the felt in which the batt fiber layer was formed on the base fabric can be obtained. In such a felt, foreign matters including fibrous foreign matters are removed from the bat fiber layer on the outer peripheral surface thereof. Therefore, it is useful, for example, as a papermaking felt. That is, when the obtained felt is used as a papermaking felt, the bat fiber layer on the outer peripheral surface is uniform and smooth, so that the smoothness of the wet paper carried in the press part can be improved. Moreover, the printability of the paper manufactured using such a felt becomes excellent.

  In addition, the felt obtained as described above can be used, for example, for manufacturing an industrial felt such as a cushion material for press, a wet paper web transfer belt using the felt as a material, and a papermaking belt. Is possible.

  As mentioned above, although this invention was demonstrated in detail based on suitable embodiment, this invention is not limited to this, Each structure can be substituted with the arbitrary things which can exhibit the same function, or arbitrary The configuration of can also be added.

  For example, in the above-described embodiment, the foreign substance removing device, the pre-needle machine system, and the felt manufacturing system have been described as integrated devices, but the present invention is not limited to this. For example, the foreign substance removing device, the pre-needle machine system, and the felt manufacturing system may be configured such that the respective parts constituting the device and the system are physically separated from each other.

  Further, for example, in the above-described embodiment, the foreign substance removing device has been described as including a plurality of light sources, imaging units, and suction units, but the invention is not limited thereto. For example, the number of the light source, the imaging unit, and the suction unit can be appropriately selected according to the function and configuration of the light source, the single imaging unit, and the suction unit. Further, for example, the numbers of light sources, imaging means, and suction units do not have to match.

The light source may be one light source provided across the width direction of the web.
The suction unit may include one slit-like suction port provided across the width direction of the web. In this case, for example, the suction port may be sealed by a plurality of lids, and only the lid corresponding to the position of the foreign object may be operated as appropriate to open a part of the suction port.

  In addition, for example, in the above-described embodiment, the felt-producing fiber from which foreign matter has been removed is continuously used for producing the felt. However, the felt producing method of the present invention is not limited to this. For example, after removing the foreign matter, the felt-producing fiber may be once collected and stored, and then used for producing the felt. Similarly, the fiber for producing felt may be used for producing a sheet for a pre-butt fiber layer through card processing after removing foreign matters. In this case, it is stored as necessary and then used for the production of felt.

DESCRIPTION OF SYMBOLS 1, 1A: Foreign material removal apparatus, 2: Pre-needle machine system, 3: Felt manufacturing system, 10: Raw fiber opening part, 11: Opening machine, 12: Conveyor belt, 20: Web formation part, 21: Feed roller, 22 : Takein roller, 23: Pre-cylinder, 24: Trans roller, 25A, 25B: Worker, 26A, 26B: Stripper, 27: Main cylinder, 28: Doffer, 29: Condenser roller, 30: Foreign matter detection and removal unit, 31A, 31B, 31C: Conveying belt, 32: Irradiation unit, 321: Light source, 33: Imaging unit, 331: Imaging means, 34: Removal unit, 341: Suction unit, 40: Web collection unit,

50A, 50B: Cross wrapper, 60: Card section, 61: Card machine, 62A, 62B: Conveying belt, 70: Ink line, 80: Pre-needle machine section, 81: Feed table, 82: Machine body, 83: Needle section , 831: Needle board, 832: Bed plate, 84, 85: Collection belt, 86: Roll, 90: Needle machine part, 91: Feed table, 92: Support roll, 93: Machine body, 94A, 94B: Needle part, 941A, 941B: Needle board, 942A, 942B: Bed plate,

100: Fiber for producing felt, 101: Opened body, 102: Web, 103: Foreign matter (fibrous foreign matter), 104: Laminated body, 105: Sheet, 200: Base fabric, 300: Laminated body

Claims (15)

An irradiation unit for irradiating an electromagnetic wave to a web formed by including felt-producing fibers;
An imaging unit that receives electromagnetic waves transmitted through the web and obtains transmission image information of the web;
A detection unit for detecting fibrous foreign matter present in the web from the transmission image information;
A foreign matter removing apparatus comprising: a removing unit that removes the detected fibrous foreign matter from the web.   The foreign matter removing apparatus according to claim 1, wherein the removing unit is configured to remove the fibrous foreign matter together with felt manufacturing fibers in the vicinity of the fibrous foreign matter.   The foreign matter removing apparatus according to claim 1, wherein the removing unit is configured to collect the fibrous foreign matter by suction. The removal unit includes a suction unit for sucking the fibrous foreign matter,
The foreign matter removing apparatus according to claim 3, wherein the suction unit is configured to move away from the web during suction.   Furthermore, the foreign material removal apparatus as described in any one of Claims 1-4 which has a web formation part which forms a web by the card process from the raw material containing the fiber for felt manufacture. The foreign matter removing apparatus according to claim 5, wherein the weight of the formed web is 3 to 30 g / m ² .   The foreign matter removing apparatus according to any one of claims 1 to 6, wherein a fiber diameter of the detected fibrous foreign matter is 10 to 1000 µm.   The foreign matter removing apparatus according to any one of claims 1 to 7, wherein the fiber diameter of the detected fibrous foreign matter is 2 to 100 times the average fiber diameter of the felt manufacturing fiber.   The foreign matter removing apparatus according to any one of claims 1 to 8, wherein the color of the felt manufacturing fiber and the fibrous foreign matter are different.   The foreign matter removing apparatus according to any one of claims 1 to 9, wherein the electromagnetic wave is visible light, infrared light, or ultraviolet light.   The foreign matter removing apparatus according to any one of claims 1 to 10, wherein the felt manufacturing fiber is a papermaking felt manufacturing batt fiber. The foreign matter removing apparatus according to any one of claims 1 to 11,
A card portion for carding the felt-producing fiber treated by the foreign matter removing device to form a web;
A pre-needle machine system, comprising: a pre-needle machine unit that performs pre-needle punching on a laminate in which a plurality of webs are laminated. The foreign matter removing apparatus according to any one of claims 1 to 11,
A card portion for carding the felt-producing fiber treated by the foreign matter removing device to form a web;
A felt manufacturing system comprising: a needle machine unit that performs needle punching on a laminate in which a plurality of webs are stacked on a base fabric. A method for removing fibrous foreign matter in a raw material containing felt-producing fibers,
An irradiation step of irradiating the web containing the felt-producing fibers with electromagnetic waves;
An image information acquisition step of obtaining transmitted image information of the web using electromagnetic waves transmitted through the web;
A detection step of detecting fibrous foreign matter in the web from the transmission image information of the web;
A removal step of removing fibrous foreign matter from the web. Forming a web using felt-producing fibers from which fibrous foreign matter has been removed by the foreign matter removing method according to claim 14;
And a step of forming a butt layer on the base fabric by performing needle punching on the laminate in which a plurality of webs are stacked on the base fabric.