JP3443868B2 - Sheet roll processing equipment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [0001] The present invention relates to a plastic film and the like.
Is divided into a plurality of strips and wound up.
The present invention relates to sheet roll processing equipment for processing into rolls. [0002] 2. Description of the Related Art End products in sheet roll processing equipment
The split sheet roll is continuously formed by a film forming machine.
Winding the belt-shaped sheet sent out by a winder
Into a raw roll, an intermediate product, and slitter wine
While rewinding the belt-like sheet from the raw roll
It is made by cutting to the required width and winding up the required length.
Can be First, in a film forming machine, a raw material resin is melted by heat.
And the molten raw material resin is
Or a ring-shaped die to form a continuous
Type. Therefore, the raw materials need to be changed,
The type of belt-shaped sheet to be used, and the gap and temperature of the die
Alternatively, the thickness of the belt-shaped sheet that requires fine adjustment of the operating speed
Switching is inevitable in the adjustment loss,
This is a factor that lowers productivity such as yield and operation rate.
In other words, this process can be performed without changing the product type and thickness.
Continuous operation of film forming machines to produce large lots
This can improve the production yield. for example
A one-year survey on the production process of BOPP film
According to a mill roll with a diameter of about 800 millimeters
Average production of 10 lots and switch to product type for raw material
Approximately 20% loss, 10
-Cent loss. Double this production lot
, The respective loss ratios are 10% and 5%.
Can be halved to a percentage loss. [0004] Also, it is made with a slitter rewinder.
Divided sheet rolls are available in various types according to the user's order.
Requirements are required, and the number of types is huge
It has become. For example, manufacturers of BOPP films
According to an example of a car, first of all, there are five types of seats,
There are 10 kinds, sheet radiation is from 300 mm to 200
Products up to 0 mm in 5 mm increments
Approximately 300 types, and the winding length is 10 types
Kind, two types of winding core diameter of 3 inches and 6 inches, plus
There are four types of packaging for shipping.
This is the reality of the market. And these conditions
All are combined into a product specification, and the final product
The product specifications of the split sheet roll are approximately 1.2 million types
(5 × 10 × 300 × 10 × 2 ×
4). In a conventional sheet processing facility, a mill
Between the winder and slitter rewinder
Although there is a way to store roles,
Mill rolls with relatively small capacity and operated inline
Slitting wine with winder and offline operation
Is considered to act as a buffer between
Was. In some cases, even factories without storage
You. Therefore, in order not to stop the flow of operations,
In general, the raw material roll to be produced is temporarily
Finally, finish the split sheet roll as the final product
I had to. [0006] Then, humans make a slitter production plan.
Too complicated to plan,
Is the desired delivery date, which is the just-in-time
And combine hundreds of order specification details
By directing it to the web roll,
Even high product yield (products ordered for raw rolls)
Roll production ratio) is an extremely difficult technique
Was. [0007] As a result, the ordered product is
Being directly applied to the stock roll and finished separately
Is extremely limited, and most are expected to receive orders
After being processed to the appropriate product specification as a product, it goes to the product warehouse
It is designed to be sent in large quantities. [0008] Among the final products stored in large quantities in the product warehouse
From the market needs, i.e.
Choose one that satisfies the order conditions that jumps in im delivery date
If you try to ship at least 10
Even if you have a stock of books, 10 books x 1.2 million types = 1
2 million bottles are theoretically required. Of course, this
The quantity is a fancy number without reality. Even in a realistic large product warehouse,
1 month or at most 2 months worth of production
The one with the capacity is the largest,
It is only a few tenths of a scale. Therefore, this
Even product warehouses are only half-finished,
It can be shipped from the product inventory according to the order conditions.
The reality is that the ratio of the actual situation is extremely small. [0010] A small slitter rewinder as a measure against bitterness
Product width and take-up length
Vigorously perform slit reprocessing to match
However, the reality is that inventory continues to increase rather than decrease.
As you approach your capacity limit, you can sell non-profitable
Select a special processing customer that does not confuse selling prices, and
The reality is that you have to repeat it several times. [0011] These inventory products with a low turnover rate are
At the time of accounting, it is the same current asset as cash and bills.
Production is also subject to 53% tax. And it
Due to loss, pressure on working capital, and management costs for inventory entry / exit
And so on.
Is a valuable source of profit from normal sales activities
Even though it is a resource, it actually eats profits,
This is a major factor that determines the quality of the business. [0012] Such a conventional sheet roll processing equipment
Equipment and the production method by hand are united for each process.
It is engineering that only machines with functions are installed.
Or the machine itself is incomplete or
In addition, production planning and operation management between processes depend on human experience and skill.
It is also a natural consequence of having to do something. Accordingly, the present invention provides various divided sheets.
Rolls can be obtained just in time and with high yield
To provide sheet roll processing equipment that can
You. Further, when operating the sheet splitting winder,
Pre-set a core according to the core specification of the required split sheet roll.
Must be supplied for
Takes time and reduces the productivity of sheet roll processing equipment
Was causing it. That is, conventionally, the core is purchased by size.
If necessary cores are stored,
Is taken out and supplied to a sheet dividing winder.
However, the required core size depends on the required split sheet roll.
Not only depends on the width of the
Even if it is a split sheet roll, the core
The length is the same as the width of the divided sheet roll, or 2 mm
Or 5 millimeters longer.
Changes to Therefore, only a suitable amount of cores of all sizes
This is difficult to store and may increase core inventory.
Results. And the core of the required size or stored
If not, the worker removes the stored core and
The sheet is cut again to the required length and supplied to a sheet splitting winder.
Therefore, it takes time to prepare the core, and in addition to
Unusable core scraps are generated in large quantities, resulting in loss of the core.
There is also a problem that it increases. As described above, conventionally, the production of the sheet splitting winder has been described.
Not only reduces the
Resources and workers, and
Core preparation cost itself due to lower yield
There was a drawback to raise. [0017] Accordingly, the present invention providesOriginal fabric
Rewind the strip from the roll and leave it
Instead, take up the required width and the required winding length.
ProcessSheet splitting winder,The original core
Cut into cores of required length for use in the sheet splitting winder
DoA core cutting device;Operation plan of the sheet split winder
And cutting the core based on the operation plan
Develop core cutting plan for equipmentProduction control computer
Roll processing equipment withThe production tube
The required number of divided sheet rolls to be input
Including sheet thickness, sheet width, take-up length, and allowance for core
When memorizing the winding specifications, quantity, delivery date or shipping time
The sheet division, both wound as the material roll
Sheet thickness, sheet width and width of the belt-shaped sheet used in the winder
Roll specification including the roll length and the winding length.
Memorize the length and formulate an operation plan for the sheet splitting winder
When one of the stored required divided sheet rolls
Operation plan by searching for items with delivery date or shipping time within
As an object of the operation plan,
Required split sheet roll winding specifications and quantity
With the roll specifications of the raw roll used in the sheet splitting winder
Based on, used as the raw roll
Which divided sheet is to be obtained
How to assign, depending on the number of assignments
Simulation operation to minimize the loss of the belt-shaped sheet
Is determined so that each divided winding cycle
Formulate and store the required divided sheet rolls to be processed into
When formulating a cutting plan by the core cutting device,
The stored sheet width and core margin of the required divided sheet roll
The required core length is obtained and stored based on the
Based on the length of the core required and the length of the original core, the length of the original core
How to assign the required core length to
A simulation operation is performed for each assignment method, and
To minimize the risk of
Individual split sheet based on the operation plan of the split winder
Determine the core cutting order so that the roll can be wound
The core cutting plan is determined by the
The winding specifications for each split winding cycle of the split winding machine
In addition to instructing the split winding machine, the core cutting plan
To the core cutting device DoIt is characterized by the following. [0018] [Function] The computer for production management is divided into necessary individual
Information about the sheet roll and the
Memorize information about the feedable strips
Information about the above-mentioned strip-shaped sheet and the required
Based on information about each split sheet roll,
Make an operation plan for the split winder. Further, the production management computer is provided with a sheet
The operation plan of the split winder, the original paper core and the required split sheet
Core cutting plan based on the information on the
Required to execute the operation plan of the sheet splitting winder.
The core can be supplied to a sheet splitting winder. [0020] BRIEF DESCRIPTION OF THE DRAWINGS FIG.
Will be explained. FIG. 1 is a block diagram of an embodiment of the present invention.
FIG. 1 is an explanatory diagram of a sheet, and in FIG.
Split winding machine, 2 is a core cutting device, 3 is a computer for production management
Data. In this embodiment, the sheet splitting winder 1 is
It is a liter rewinder, and rolls the raw roll 4
And rewind the belt-like sheet 6 from the raw roll 4
Send to slitter 7
Take up around the winding core 9 with the winding unit 8 while dividing into
A divided sheet roll 10 is made. The material roll 4 is processed by the sheet splitting winder 1.
The raw material roll storage (not shown)
The raw material roll 4 that is stored in the storage device
The sheet is then supplied to the sheet splitting winder 1 by a transport mechanism (not shown).
Can be paid. Sheet including the winding section 8 and the slitter 7
The transport unit 11 and the rewinding unit 5 are connected to the control computer 12.
Under control, take up the required amount of split strip-shaped sheet 6 '
The winding operation is automatically stopped when the
You. The slitter 7 is disclosed in, for example,
As disclosed in JP-A-142097 and the like,
Automatic positioning of the cutting blade 7a for cutting the sheet 6 is possible
It is a well-known one and is instructed by the control computer 12.
Cutting blade 7a at the position corresponding to the dividing position or dividing width
Can be opened. The sheet is cut by a cutting blade.
Knives with sharp edges, round blades,
Not only mechanical such as a pair of round blades for shearing,
Also includes those using ultrasonic waves and laser beams. The control computer 12 is used in this embodiment.
Is to improve the operation rate and the stability of winding quality
In addition, not only the positioning control of the slitter 7 but also the winding
Apparatus for supporting the split sheet roll 10 of the part 8
And each touch row that comes into contact with the divided sheet roll 10
Function to control the automatic positioning of the support device
A mechanism for transporting the rollers to the support device for mounting and collection
Function, and the winding tension and
Setting and control of operating conditions such as the pressure in the rewinding section and the unwinding tension of the unwinding section 5.
It has functions and the like. The core cutting device 2 is, for example,
As shown in JP-A-30715, the cutting blade is placed along the winding core.
It has a cutting mechanism 13 that can be moved,
The core 14 is cut by controlling the cutting mechanism 13 by the computer 14.
The length can be changed automatically.
Then, a fixed length of the original core is supplied to the original core supplying device (not shown).
) Automatically supplied from the
Can be automatically cut out from the cutting mechanism 13
I can do it. The production management computer 3 is, for example,
It is necessary to process a huge amount of data
Since it is necessary, the capacity of the storage unit naturally increases. However,
Control computer 12 of the sheet split winder 1, core cutting
The control computer 14 of the device 2 is a real-time
Storage capacity is usually small to give priority to
No. Therefore, the control computers 12 and 14 and the production
Exchange data directly with the management computer 3
Doing so takes time. Therefore, it is omitted in the figure,
Provide a relay computer between the two for mutual communication
It is effective to perform the operation smoothly and quickly. The production management computer 3 has individual locations.
Sheet type, sheet thickness, and split sheet
Roll width (division width), winding length, margin of the core
For winding specifications such as the difference between the split sheet roll width and the core length
Data, quantity, delivery date or shipping date, etc.
Is input from the input device 3a at any time. The production management computer 3 is shown in FIG.
Material roll stored in the material roll storage device
Individual sheet type, sheet thickness, sheet width, winding length, etc.
Given the data on the roll specifications of the
Information about the web-like sheet
It can be stored in the storage unit. The production management computer 3 is provided with
To improve the yield and utilization rate as much as possible.
Information on required split sheet rolls,
Sheet winding based on the information about
The procedure for making an operation plan of the machine 1 is stored. Furthermore,
Based on the data on the operation plan of the sheet split winder 1
Memorizes the procedure for making the core cutting plan of the core cutting device 2.
are doing. Formulation of an operation plan for the sheet split winder 1
When the production management computer 3 first arrives in time for delivery
To make an operation plan for a certain period of time
The required split sheet rolls that need to be created in the meantime,
Search from stored information, collect it, and
set to target. Then, in order to increase the yield,
Of the product to be obtained
How to assign the
Simulate the application method to minimize the loss
To decide. Also, when changing the product width, the slitter
The moving amount of the cutting blade 7a of the setting unit 7 is as small as possible.
Plan to improve utilization. Thus, the production management computer 3
When the operation plan of the sheet splitting winder 1 is completed, the winding
Make a core cutting plan. At that time, firstly,
Sheet that has been entered and memorized the core length of the
It is obtained from the data of the roll width and the core margin and stored. What
Contact us if you always use a core with the same length as the divided sheet roll width.
If the split sheet roll radiating without inputting the core margin
The length may be the core length. Next, it is operated by the sheet splitting winder 1.
For the core required to execute the transfer plan,
Based on the length of the core and the length of the original core, the individual required for the original core
How to allocate the core of the
Perform a simulated calculation on how to apply so that the loss is minimized
And data on the operation plan of the sheet splitting winder 1
In time for winding individual split sheet rolls
Determine the core cutting order. And the core cutting plan
When the setting is completed, the core cutting device 2 is connected through the communication line 15.
Of core cutting plan data to the control computer 14
Power. Computer 14 for controlling core winding device 2
Is the core cut received from the production management computer 3.
The cutting mechanism 13 is controlled based on the plan data. in addition
Therefore, in the cutting mechanism 13, the core is cut to a required length.
You. In this embodiment, the cut core is used as a control computer.
(Not shown) controlled by the printer 14
Output device such as a printer or labeler.
Split winding cycle number in split winder 1, sheet split
Use of a winding core such as a winding position number in the winding section 8 of the winding machine 1
Data on the time of use and place of use are given. Soshi
The sheet is separated by a transport mechanism and a sorting device (not shown).
Automatically sort to the required position of the winding unit 8 of the split winder 1
Supplied. Therefore, it is easy to handle the cut core
Thus, the preparation work of the core can be performed smoothly. In addition,
The core cutting device 2 supplies a core to a plurality of sheet winding machines.
If necessary, place the number of the sheet splitting winder on the cut core.
Number, and the necessary sheet division winder 1
What is necessary is just to make it possible to supply it by sorting it out. Further, the production management computer 3
When the operation plan for the split winder 1 is completed, the sheet
The split winding machine 1 is supplied to the control computer 12 of the split winding machine 1.
About individual divided sheet rolls processed for each cycle
Signal to specify the winding specifications, including the radiation and winding length
Is output in divided winding cycles. Also not shown
The material roll storage device has a signal to specify the necessary material roll.
Output a signal. Computer for controlling the sheet split winder 1
12 is a signal output from the production management computer 3
The operation based on the winding specifications specified in
7 etc. As a result, the slitter 7 is turned off.
The cutting blade 7a comes to the division position corresponding to the command. Also shown
The production roll computer does not
The material roll specified by data 3 is taken out at appropriate times and
Is supplied to the sheet dividing winder 1. An embodiment of the present invention is an implementation of the above described embodiment shown in FIG.
The invention is not limited to the examples, and may be variously changed without changing the gist of the invention.
Can be For example, stored on a production management computer
The operation planning procedure for the sheet split winder
The setting value of a job, or the content or order of processing operations
It may be. Also, the production management computer
The division position of the belt-shaped sheet based on the operation plan formulated by
Take-up specifications such as division width and take-up length, and necessary roll
Specify the signal to specify the specifications, and specify the cutting length or cutting position of the core.
Signal for each device via the data highway.
Not only send it directly to the computer for controlling the machine, but also
Display the contents of the command before
Operation may be commanded. In that case, for example, sheet division
The winding machine and core cutting device are operated by the operator based on the display.
Sets the division position or division width and winding length of the belt-shaped sheet.
Will be. Also, for production management of the sheet splitting winder 1
Separate computer for core cutting planning
Set up the core cutting plan from the production management computer
Of the operation plan of the sheet splitting winder 1 to the computer for
Data through the communication line, and
It is good to make a core cutting plan by the computer,
If the capacity, processing speed, etc.
We will equip the core cutting device with a computer that is also used
You may do it. The computer for production planning
Narrow width that cannot be processed by the sheet split winder 1 shown in FIG.
Secondary sheet winding for processing a large split sheet roll
It is also possible to formulate an operation plan for the machine at the same time.
No. In the present invention, the belt-shaped sheet is made of paper, metal thin film.
When it is something other than plastic film, such as a board
Can also be applied. The sheet splitting winder is a slitter
As well as from sheet production equipment
Take out the strip-shaped sheet directly and wind it up separately
It may be of an inline format. Also,
Raw roll storage using a line type sheet splitting winder
In some cases, the apparatus may be replaced with a belt-shaped sheet manufacturing apparatus. Ma
Material rolls that are subject to operation planning are not manufactured
But if it ’s something that ’s going to be made by the time it ’s needed,
Good. The core cutting device is a production management computer.
The core can be cut to the length specified by the computer.
If the turret has multiple axes, the structure is not limited.
It does not have to be attached, it does not have a shaft
Or a cutting device with a plurality of cutting blades
Good, and core using laser beam instead of round blade
May be cut. Also, it can handle multiple types of core diameters.
Can be used, or winding of multiple sheet winding machines
What can cut a core collectively may be sufficient. Also, the core
Information about the supplier, etc. is provided directly on the core by printing
Or use a labeler to write the information
A bell may be attached, and the type and output of information
The form of force can be changed as needed,
In some cases, it is not applied to the core. Also, turn off the sorting operation
Sorting device or sorting controlled in conjunction with the cutting mechanism
To control the reading operation by reading the information given to the core.
The core may be supplied to the sheet splitting winder via the separating device.
If the sorting operation is not too complicated, use a sorting device.
The core may be supplied without the intermediary of the core. Sheets handled by the production management computer
Information processed to manage the operation of the split winder and the core
Information to be processed to manage the operation of the cutting device
Large amounts. Therefore, their operation management is distributed processing
Two production management computers in parallel
You may make it so. Especially for large production lines and multiple
This is especially true for integrated operation management of production lines. When cutting a plastic core, use a saw blade.
Or use a metal sheet to wind it around a metal core.
Metal core may be cut with a sawing machine or cut off
It may be cut and finished using a cutting tool. [0042] According to the present invention, the necessary divided seat row is provided.
Operation plan of sheet splitting winder based on
, So that there is no split sheet roll as before
Need not be manufactured in large quantities. Therefore, the traditional product warehouse
Is unnecessary, and large numbers of unordered split sheet rolls are produced
Eliminates the need to store or remove in the warehouse,
Workers can be largely eliminated. Moreover, a large amount of product warehouse
Improves yield because unordered products do not fall asleep
And the productivity of dropped raw materials and energy
Improve. In addition, the tax on inventory items
The burden will be greatly reduced. Further, a strip shape for making a divided sheet roll.
The sheet is divided into a conventional sheet roll
Instead of storing it in a product warehouse.
For example, semi-finished raw rolls are stored in the raw roll storage device.
Since it is stored as it is, remove the raw roll when necessary.
It can be processed to the required width and length. That
Lead time is greatly reduced. For example, one day
You can make a production plan in units, and the next
It will also be possible to ship on the day. Therefore, a wide variety of divided sheet rolls
Can be obtained just in time and with high yield
Split sheet roll processing equipment can be provided.
Use of Ming's equipment greatly increases split sheet roll manufacturing costs
Save money and win orders in cost and delivery
Dispute can be developed in an advantageous manner. That is, in the present invention, the raw material cloth which is a semi-finished product is used.
A large amount of files in the mill roll storage
It is best to adopt a production method in which specifications are
There is also a feature. And according to the invention, for example,
At least one web for each combination of sheet type and thickness
Even if rolls are kept in stock, 50 rolls of stock roll
If you stock it with the product, depending on the quantity,
Just-in-time delivery requirements for product specification market needs
For all specifications in the handling range
With a combined yield, we can respond to production plans with only ordered products
Precondition is satisfied. In addition, a computer is used instead of a human.
The operation plan of the slitter rewinder is
The number of products and the types of products are complicated,
Even when it reaches 100,000, the product yield is always
Production that produces the highest logical ratio of the order product roll production ratio)
Plan (95% to 99.5%)
Can be determined. The yield difference due to this production and sales system is
Create differential cost competitiveness. In conventional factories,
Management after storage in storage is unclear (such as reprocessing and inventory disposal)
It is not possible to grasp the yield clearly because
Yield is 80% to 85% at best
Presumed to stop at cents, 1
Product yield improvement from 0% to 15%
One year for a production plant with a production volume of 3.5 billion yen
To create new cost competitiveness of 350 to 500 million yen
I do. Further, the sheet roll processing equipment according to the present invention
Is the conventional skill in production planning and operation management of each process equipment.
A computer-based system,
The network is integrated and real-time
Since all processes and information are managed numerically, production and sales are integrated.
Can be automatically managed up to a
There is a lit and there is no variation in operation. Further, a mill roll for storing a large amount of raw rolls
The use of roll storage makes it possible to lock film forming machines.
Switching frequency can be reduced, resulting in upstream
The effect of improving the yield on the side is also increased. Then, the sheet is taken up by a sheet dividing take-up machine.
Suitable for cores of various lengths according to the core specifications of the sheet roll
So that it can be supplied at times,
In addition, there is no need to purchase and store cores by size.
The labor of warehouse management can be saved. Conventionally, a roll which has been purchased
If none of the cores fit in the dimensions,
Cut the stock core to the required length before starting
Need to be supplied to
And a loss of the core increases, resulting in an irregular core.
A problem arises, but the problem can be solved. Also, based on the winding core cutting plan,
Marking when and where to use the core
It is also possible to sort the core for each winding position,
As a result, a large number of
It is possible to prepare and supply the core in a timely manner.
It is also possible to facilitate the wearing operation. Therefore, various sizes of winding cores
By supplying to the sheet splitting winder in a toe-in time
And the labor and cost for preparing the core are greatly increased
Can be reduced.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an explanatory diagram for describing an embodiment of the present invention. [Description of Signs] 1 Sheet dividing winder 2 Core cutting device 3 Production management computer 6 Strip-shaped sheet 9 Core 10 Split sheet roll

Claims (1)

(57) [Claims] [Claim 1] Rewinding a belt-like sheet from a raw material roll
Take the required width by winding around the core while splitting
A sheet split winding machine for processing into a split sheet roll having a required winding length, and an original winding core having a required length used in the sheet split winding machine.
A core cutting device for cutting into a core and an operation plan for the sheet splitting winder are formulated, and
Based on the operation plan, the core cutting plan of the core cutting device is
A sheet roll processing equipment and a production management computer to formulate the required dividing the production management computer is inputted
Sheet thickness, sheet width, winding length and core of roll
The winding specifications including the margin, quantity, delivery date or shipping time
Remember and wound as the raw roll,
Sheet thickness of the strip-shaped sheet used in the sheet splitting winder,
Raw roll specification including sheet width and winding length, and before
The length of the original winding core is stored and stored when the operation plan of the sheet splitting winder is formulated.
Delivery time within a certain period of
Search for items at the time of shipment and record them as targets of the operation plan.
The required divided seat row stored as the target of the operation plan
And the quantity used for the sheet splitting winder.
Based on the specifications of the material roll to be used,
For the belt-shaped sheet to be used
How to assign the divided strips
Is simulated for the various assignments
Decide to minimize sheet loss
The required amount to be processed for each of the divided winding cycles
Developing and storing split sheet rolls, when formulating a cutting plan with the core cutting device,
The stored sheet width and core margin of the required divided sheet roll
Based on the required core length is obtained and stored, based on the stored required core length and the original core length,
Assignment of the required core length to the length of the original core
And simulate the number of assignments
To minimize the loss of the original core.
Based on the operation plan of the sheet splitting winder.
In time to wind up each individual sheet roll.
Formulate a core cutting plan by determining the core cutting order
Then, for each of the divided winding cycles of the sheet divided winding machine formulated above,
Instructing the winding specification to the sheet splitting winder,
A sheet roll processing facility that issues a command to a core cutting device for a fixed core cutting plan .