JP4425021B2 - Sheet body production method and defect removal system - Google Patents

Description

The present invention relates to a defect removal method for removing a defective portion of a web, and more specifically, a sheet body production method for producing a sheet body by cutting a web with a predetermined width and cutting the web into a predetermined length. Relates to removal system.

  For example, a sheet of a photographic photosensitive material such as an X-ray film is produced through various processes such as a film forming process and a coating process. The sheet body is produced by cutting (slit) with a predetermined width while pulling out the web from the original fabric, and then cutting with a predetermined length.

  In addition, the sheet bodies produced in this way are accumulated by a predetermined number, and after being packaged and packed, they are shipped as products.

  By the way, the web used for the production of the sheet body may have defects such as coating failure and scratches during the production process such as the coating process, and this defect causes the product quality of the sheet body to deteriorate. For this reason, it is necessary to detect the defect in advance and discard the sheet body in which the defect has occurred.

  When a defect is detected in the web state and processed into a sheet body, in order to dispose of only the sheet body in which the defect has occurred without waste, the defect position can be clarified and the defect position can be accurately detected. There is a need to.

  From here, when perforating the width direction end of the web according to the defect position and detecting the defect position in the downstream process, the sheet body such as a photosensitive material is irradiated by irradiating light such as ultraviolet light. Proposals have been made to enable detection of defect positions without adverse effects (see, for example, Patent Document 1).

  On the other hand, when a web-specific ID information code is formed and accurate actual confirmation is performed, a defect information code indicating defect position information is formed together with the ID information code, and the position information code is combined with the ID information code. Proposals have been made so that the defect position can be grasped more accurately by detecting (see, for example, Patent Document 2 and Patent Document 3).

  There has also been a proposal that enables detection of a more accurate defect position by forming a timing creation code on the web (see, for example, Patent Document 4).

  However, when a sheet body is produced, a narrow web is produced by slitting a wide web drawn from the original fabric, and the narrow web is cut into a predetermined length. In addition, the defective portion is discarded for each booklet in which a predetermined number of sheets or sheets are stacked.

For this reason, even if information indicating the defect position is formed at the end in the width direction of the wide original fabric, it is difficult to detect the defect position on a small-width web or sheet. For this reason, it is necessary to dispose of the sheet in consideration of the error.
Japanese Patent Publication No. 6-68773 JP 2000-20635 A JP 2001-155111 A JP 2003-186131 A

The present invention has been made in view of the above fact, when producing a sheet having a predetermined size from the wide web, production of sheet which produces a sheet with accurate and efficient discarding the defective portion It is an object of the present invention to propose a method and a defect removal system for removing defective portions .

In order to achieve the above object, the sheet body production method of the present invention produced a raw material obtained by winding a web in a roll shape in the raw material production step, and was produced in the raw material production step in a cutting step . said web drawn from raw, each slit web of plural rows which produced and cut into a predetermined width, in the cutting step, a method of producing sheet material to produce a sheet member is cut to length the detecting surface faults on the web by the surface inspection device in raw production step, the first indicator position in the width direction及beauty length side direction on the web of the detected said surface fault is identified From the first index of the plurality of slit webs formed by cutting and detecting the first index from the web cut in the cutting step. Identified surface fault Only the slit web contained, at least a slit web of the surface faults longitudinally along positions marked a second index which is specified, from the sheet produced in the cutting step, the second Based on the index, the sheet body including the surface failure is discarded to produce a sheet body including no surface failure .

According to the present invention, the original when producing anti-production web raw in, winding the web of surface inspection into a roll I line. In this case, when detecting the surface faults on the web, marking the position along the width direction及beauty length side direction of the web of the surface failure of the first indicator Ru JP Teisu the web.

  When a narrow slit web is produced by cutting the web in the cutting process, the first index formed on the web is detected, and the slit web in which the corresponding surface failure appears is specified and specified. The slit web is marked with a second index capable of identifying at least the slit web longitudinal direction position of the surface failure.

  Thereafter, the second index is detected when the slit web is cut, and the sheet body produced by cutting the slit web is discarded based on the second index.

Thus, when producing a sheet and producing a sheet body by cutting the web pulled out from this sheet for each slit web, the sheet body including the surface failure is accurately identified and discarded , A sheet body free from surface failure can be produced .

Defect removal system of the present invention is to cut the raw production process for producing raw of wound web into a roll, the pulled out by said web from raw produced in raw production process to a predetermined width And a cutting process for producing a plurality of slit webs, and a cutting process for producing a sheet body by cutting each of the slit webs to a predetermined length. A defect removal system that disposes of a body, the surface inspection means that is provided in the raw fabric production process and detects a surface failure on the web by specifying the position in the longitudinal direction and the width direction of the web, and a first marking means for forming a first index position on the web of the surface faults detected by the surface detector is identified on the web, it forms the web provided in the cutting step A first reading means for reading the fault information on the web, including a position along the width direction及beauty length side direction of the web relative to the surface faults in question detects the first indication that is, the first along the longitudinal direction of at least the surface faults on the answering exists surface failure answer from the slit web of said plural rows formed by the cutting process on the basis of the failure information on the web Rittouebu read by the reading means A second marking means for forming a second index whose position is specified; and a slit web for the surface failure corresponding to the detected second index formed in the slit web provided in the cutting step. second reading means for reading the fault information on the slit web including a position along the longitudinal direction of, or of the sheet produced by the cutting step Based on said second of said failure information on the slit web read by the reading means, including and a discarded unit for discarding the surface faults include Resid over preparative body specified by said fault information.

According to the present invention, when a web is rolled up in the roll production process, a surface failure (surface defect) on the web is detected by the surface inspection means. At this time, the surface inspection means detects the web width direction position and the web longitudinal direction position of the surface defect.

The first marking means marks the web with a first index that identifies a surface failure on the web based on the detection result of the surface inspection means.

  When forming the slit web by slitting the original fabric to a predetermined width in the cutting step, the first index formed on the web is read by the first reading means, and the failure information contained in the first index is read. Based on this, the second index is marked on the slit web. At this time, the second index includes failure information that can specify the slit web longitudinal position of the surface failure on the slit web.

  In the cutting step, the slit web is cut into a predetermined length to produce a sheet body. At this time, the second index formed on the slit web is read by the second reading means. The discarding unit selects and discards the sheet body based on the second index read by the second reading unit.

As a result, even when a slit web having a small width is formed from a wide web drawn from the original fabric, and the sheet is produced by cutting the slit web into a predetermined length, a surface failure that is a defective portion occurs. The sheet body can be accurately determined and discarded efficiently.

  The cutting process of the production system applied to the present invention produces a slit roll obtained by winding the slit web into a roll, and the cutting process cuts the slit web to a predetermined length while pulling out the slit web. It is also possible to produce a sheet body.

Further, the defect removal system according to claim 3 of the present invention, the second index to be marked on the slit web by said second marking means, as the failure information on the slit web, said surface corresponding failure There and whether continuous in the longitudinal direction of the slit web, including information in the longitudinal direction at both ends along is identified slit web when the surface failure is continuous in the longitudinal direction of the slit web.

  According to the present invention, when the sheet is produced by cutting the slit web, the second index formed on the slit web is whether or not there is a surface failure across the plurality of sheets, For the surface failure that straddles, failure information that can determine the start position and end position of the surface failure is included.

  As a result, the sheet can be efficiently discarded.

As such a discarding means applied to the present invention, the sheet body in which the surface failure has occurred may be discarded one by one. Further, as the discarding means, when the production system includes a stacking step of forming a book in which a predetermined number of sheet bodies are stacked, a first discarding process for stacking the sheet bodies before stacking by the stacking means, and stacking It is also possible to perform the second disposal of discarding the books accumulated by the means, and this makes it possible to efficiently discard the sheet body according to the surface failure.
Further, the defect removal system of the present invention creates a failure map indicating the position of the surface failure on the web based on the detection result of the surface detection means, and each type of the surface failure based on the failure map. Including setting means for setting failure information on the web including the second marking means forming the second index including the failure information on the web set by the setting means on the slit web. It may be what you do.

As described above, according to the present invention, when a wide web drawn from an original fabric is slit to form a narrow slit web, the slit web is cut into a predetermined length to produce a sheet body. Since the position of the surface failure on the slit web can be accurately identified from the surface failure detected when the raw material is produced, the sheet body in which the surface failure has occurred can be accurately and efficiently discarded and the surface The excellent effect that the sheet body which does not have a failure can be produced is obtained.

  Hereinafter, an example of an embodiment of the present invention will be described in detail with reference to the drawings. FIG. 1 shows a schematic configuration of a production system 10 applied to the present embodiment. In the present embodiment, an X-ray film is applied as an example of a sheet body, and the production of the X-ray film will be described as an example. It can be applied to the production of photographic photosensitive materials such as recording paper, photographic paper, and photographic film.

  The production system 10 includes a film forming process 12 and a coating process 14, and is processed into a sheet-shaped X-ray film (hereinafter referred to as "sheet 16") having a predetermined size through the film forming process 12 and the coating process 14. The raw fabric 20 is produced by winding the wide web 18 to be rolled up.

  In addition, the production system 10 includes a cutting process 22, a cutting process 24, and an accumulation process 26, and a packaging process 28 is provided on the downstream side of the accumulation process 26.

  In the cutting process 22, the raw fabric 20 produced through the film forming process 12 and the coating process 14 is loaded. In the cutting step 22, the web 18 is conveyed while being pulled out from the original fabric 20, and the web 18 is cut (slit) into a predetermined width.

  Thus, in the cutting step 22, a plurality of narrow webs 30 are produced from the wide web 18. At this time, the web 30 is cut so that the width dimension becomes the width dimension of the sheet 16 to be produced. Further, in the cutting step 22, each of the produced webs 30 is wound into a roll shape, and the number of slit rolls 32 corresponding to the number of slits of the web 18 is formed.

  The slit roll 32 produced in the cutting process 22 is conveyed to the cutting process 24. In the cutting step 24, for example, the web 30 is transported while being pulled out from the slit roll 32 loaded one by one, and the web 30 is cut into a length corresponding to the size of the sheet 16. Thereby, a sheet 16 having a predetermined size is produced.

  In the cutting step 24, the web 30 may be cut while being pulled out from the plurality of slit rolls 32 in parallel. In the production system 10 applied to the present embodiment, the slit roll 32 is produced in the cutting step 22 and the slit roll 32 is loaded into the cutting step 24. However, the present invention is not limited to this, and the cutting step 22 is performed. And the cutting step 24 may be continuously arranged, and the plurality of webs 30 produced in the cutting step 22 may be integrally cut into a predetermined length to produce a plurality of sheets 16 simultaneously. .

  The sheet 16 produced in the cutting process 24 is sent to the accumulation process 26. In the stacking step 26, the sheets 16 are sequentially stacked to create a book 34 in which a predetermined number of sheets 16 are bundled.

  The book 34 is sent to the packaging process 28 and sealed in a packaging bag or the like. As a result, a package 36 in which a predetermined number of sheets 16 are packaged is produced.

  The package 36 is shipped in a predetermined number of boxes in a cardboard box or the like. In addition, a conventionally well-known structure can be applied to the basic structure of each process of the production system 10 which produces such a sheet | seat 16, and detailed description is abbreviate | omitted in this Embodiment.

  Such a production system 10 is provided with a production management system for producing the raw fabric 20, producing the slit roll 32, producing the sheet 16 (packaging body 36) and the like, and managing production. Volumes and products are managed collectively. In addition, a conventionally well-known structure can be applied to the basic structure of such a production management system.

  On the other hand, as shown in FIG. 2, the production management system is provided with a production management computer 38, and a failure removal system 40 is formed in the production system 10 using this production management computer 38.

  The failure removal system 40 detects defects (hereinafter referred to as failures) such as defects and scratches generated during the production of the web 18 such as the film forming process 12 and the coating process 14, and discards the corresponding parts. Thus, the sheet 16 having no failure can be produced and shipped.

  The failure removal system 40 includes a surface inspection device 42 and a marking device 44 provided in the painting process 14.

  The surface inspection apparatus 42 detects a surface failure of the web 18 such as a coating abnormality by performing a surface inspection over the entire surface of the web 18 (not shown in FIG. 2). Further, when the surface inspection device 42 detects a surface failure on the web 18, the surface inspection longitudinal position and the web 18 width direction position of the surface failure can be detected together. That is, the surface inspection device 42 detects the position of the surface failure on the web 18 together with the surface failure.

  FIG. 3 shows an example of the surface inspection apparatus 42. In the coating process 14, an inspection roll 50 is disposed in the downstream portion, and the web 18 after the coating process is wound around the inspection roll 50 and conveyed, and thereafter, the raw fabric 20 (illustrated in FIG. 3). (Omitted).

  The surface inspection device 42 includes a laser irradiation unit 52 and a laser light receiving unit 54 provided to face the web 18 wound around the inspection roll 50.

  The laser irradiation unit 52 deflects the beam-shaped laser light oscillated by the laser oscillator 56 by the polygon mirror 60 that rotates at high speed by the scanning motor 58 and scans in the width direction of the web 18 while scanning in the width direction of the web 18. Irradiate the entire surface along.

  The laser light receiver 54 receives the laser light reflected by the surface of the web 18. At this time, since the laser light is reflected according to the surface state (planar shape) of the web 18, the amount of the laser light received by the laser light receiving portion 54 changes according to the surface state of the web 18.

  From here, in the surface inspection apparatus 42, abnormalities such as scratches and irregularities on the surface of the web 18 can be determined as surface failures from the amount of laser light received by the laser light receiving unit 54.

  The laser irradiation unit 52 and the laser light receiving unit 54 are connected to a detection control unit 62, and the detection control unit 62 determines the presence or absence of a surface failure of the web 18 from the amount of laser light received by the laser light receiving unit 54. . At this time, in the detection control unit 62, for example, when the amount of light received by the laser light receiving unit 54 is less than a preset threshold value, a surface failure has occurred at the corresponding laser light irradiation position. judge. Further, when the laser light receiving unit 54 condenses the scattered component of the laser light irradiated on the web 18 by the photomultiplier tube and the received light amount exceeds a preset threshold value, It may be determined that a surface failure has occurred at the corresponding position.

  A scanning motor 58 is connected to the detection control unit 62 together with the laser oscillator 56 and the laser light receiving unit 54. The detection control unit 62 controls the intensity of the laser beam, the scanning speed, the scanning width, and the like.

  Thereby, the detection control part 62 can judge the position along the web 18 width direction of the surface failure, when a surface failure is detected.

  Further, the inspection roll 50 is provided with a rotary encoder 64, and this rotary encoder 64 is connected to the detection control unit 62. The inspection roll 50 rotates according to the conveyance amount of the web 18, and the rotary encoder 64 rotates according to the rotation angle of the inspection roll 50 by rotating the rotating shaft 64 </ b> A integrally with the inspection roll 50. Output a pulse.

  The detection control unit 62 counts the pulses output from the rotary encoder 64 to determine the position along the longitudinal direction of the web 18 when the surface failure of the web 18 is detected.

  The detection control unit 62 assigns a serial number when a surface failure is detected from the head of the web 18 produced as a roll 20 of the roll, for example, and a failure that can specify a position along the width direction together with the serial number for each surface failure. Generate information. The surface inspection apparatus 42 outputs the failure information to the production management computer 38 (see FIG. 2).

  The surface inspection device 42 is not only a surface inspection of the web 18 using laser light, but also a color streak detector, a scratch detector that detects a color streak defect on the surface of the web 18 by a charge coupled device (CCD). Further, a gloss detector and a color detector may be included, and not only one surface (front surface) of the web 18 but also defect detection (surface inspection) on both the front and back surfaces may be performed.

  On the other hand, as shown in FIG. 2, the surface inspection device 42 is connected to the marking device 44, and outputs failure information to the marking device 44 every time a failure on the web 18 is detected. As shown in FIG. 1, the marking device 44 includes a marker 46 facing one end in the width direction of the web 18, and when the surface inspection device 42 detects a surface failure of the web 18, the web 18. The marking is applied to one end portion along the width direction of the surface of the substrate based on the determination result of the surface inspection device.

  At this time, the marking device 44 performs marking on the web 18 based on the longitudinal position of the web 18 with the surface failure detected by the surface inspection device 42, the width direction position of the web 18, and the serial number.

  That is, as shown in FIG. 4A, in the coating process 14, when a surface failure 66 is detected on the web 18, according to the surface failure 66, a failure mark 68 is recorded at a predetermined position on the web 18, The failure mark 68 makes it possible to identify individual surface failures 66 on the web 18. In FIG. 4A, the slit position along the width direction of the web 18 in the cutting step 22 is indicated by a two-dot chain line.

  In the present embodiment, the failure mark 68 is marked at the end in the width direction corresponding to the position of the surface failure 66 on the web 18 as a position set in advance for the detected surface failure 66. Further, the marking device 44 for marking the web 18 may be an ink jet system, and any conventionally known configuration such as a perforating process on the web 18 using a laser beam or the like can be applied.

  FIG. 5A shows an example of the failure mark 68 formed on the web 18 in the present embodiment. The failure mark 68 has a dot matrix of 10 rows × 5 columns.

  The failure mark 68 is a reference mark indicating that the mark 68A in the first and tenth rows is an information code for the surface failure 66, and the serial number of the surface failure 66 is indicated by a mark 68B in the second and third rows. Give.

  The mark 68C in the fourth row indicates the rank of the surface failure, and the 5 × 5 matrix mark 68D in the fifth to ninth rows indicates the position of the surface failure 66 along the width direction of the web 18. I am doing so. In the failure removal system 40, the web 18 is divided into a maximum of 25 blocks along the width direction, and the presence / absence of the surface failure 66 in each block is displayed by a 5 × 5 matrix.

  As shown in FIG. 1, in the production system 10, the raw fabric 20 produced in the coating process 14 is temporarily stored and conveyed to the cutting process 22 at a predetermined timing so that the cutting process is performed.

  At this time, the production management computer 38 provided in the production system 10 stores the failure information input from the surface inspection apparatus 42 as electronic data for each raw fabric 20 (see FIG. 2 for both). At this time, it may be stored in the storage means provided in the production management computer 38 together with the lot number set for each raw fabric 20, or the failure information is written together with the lot number in a storage medium (not shown) It may be stored together with the original fabric 20.

  On the other hand, on the production management computer 38, prior to the cutting process of the web 18, a failure map for each web 18 is created based on the failure information.

  As shown in FIG. 4 (A), the surface fault 66 occurring in the web 18 includes a fault that continues in a stripe shape along the longitudinal direction at the same position in the width direction of the web 18 (streaks fault 66A), and a web fault. It can be roughly classified into point-like faults (point faults 66B) that occur randomly on the surface of 18. For the streak fault 66A, fault marks 68 are formed at predetermined intervals along the longitudinal direction of the web 18.

  On the production management computer 38, when creating the failure map, it is determined whether the failure map 66A or the point failure 66B. This determination may be made automatically on the production management computer 38 using a defect classification system, and a failure map is displayed on a display device such as a CRT or a liquid crystal display, and an input such as a keyboard or a pointing device is used. A device or the like may be used to input a determination as to whether it is a streak fault 66A or a point fault 66B.

  In the production management computer 38 forming the failure removal system 40, whether or not the surface failure 66 on the web 18 is a failure that needs to be extracted, and when the extraction is necessary, a sampling method is set.

For example, if the failure requiring extraction is a point failure 66B, the extraction is performed in units of sheets 16. When it is a streak failure 66A, the cut sheet 16 is continuously extracted from the slit web 30 .

  As shown in FIG. 2, the failure removal system 40 is provided with a mark reading device 72 and a marking device 74 together with a cutting control device 70 that controls the processing in the cutting step 22.

  The production management computer 38 outputs the extraction information to the cutting control device 70 together with the failure information for the raw fabric 20 processed in the cutting step 22. Further, as shown in FIG. 1, the mark reading device 72 is provided with a mark sensor 76 facing the end in the width direction of the web 18 drawn out from the original fabric 20. The formed fault mark 68 (not shown in FIG. 1) is read.

  As shown in FIG. 2, the mark reading device 72 is connected to the cutting control device 70, and outputs failure information based on the failure mark 68 read by the mark sensor 76 to the cutting control device 70.

  The cutting control device 70 collates the failure information input from the mark reading device 72 with the sampling information input from the production management computer 38, and adds failure information to the surface failure 66 that needs to be extracted. And the failure information is output to the marking device 74.

  As shown in FIG. 1, the marking device 74 is provided with a marker 78, and marking based on failure information is possible at each widthwise end of the web 30 produced in the cutting step 22. .

  In addition, the marker 78 may be arrange | positioned facing each of the web 30, and may mark the some web 30 with one marker. As the marker 78, any configuration can be applied as long as desired marking is possible, such as an ink jet method or a laser method, in the same manner as the marker 46 described above.

  The marking device 74 performs marking based on the failure information input from the cutting control device 70. At this time, the marking device 74 specifies the web 30 where the surface fault 66 exists based on the position along the web 18 width direction of the surface fault 66 corresponding to the fault information, and the width direction of the specified web 30 is determined. A failure mark 80 (see FIGS. 4B and 4C) for identifying the surface failure 66 is marked at a predetermined position such as an end.

  That is, as shown in FIG. 4B, in the cutting step 22, a failure mark 80 opposite to the failure mark 68 recorded on the web 18 is formed on the web 30 where the corresponding surface failure 66 has occurred.

  As a result, as shown in FIG. 4C, the web 30 processed in the cutting step 24 has a failure mark 80 that can identify the surface failure 66 at the end in the width direction corresponding to the surface failure 66. It has come to be specified. In FIG. 4C, the cutting position of the web 30 in the cutting step 24 is shown.

  FIG. 5B shows an example of the failure mark 80 formed on the web 30 in the cutting step 22. The failure mark 80 displays desired information depending on the presence or absence of dots arranged in a 5 × 5 matrix. At this time, in the failure mark 80, the first first row and the last fifth row mark 80A serve as a reference mark indicating that the failure mark 80 is present, and 2 × 5 dots in the second row and the third row. The serial number of the surface fault 66 is represented by the mark 80B.

  In the fault mark 80, the mark 80C in the fourth row clearly indicates whether the corresponding surface fault 66 is a single fault such as a point fault 66B or a continuous fault such as a streak fault 66A, and is a continuous fault. Sometimes, the start (start) or end of a continuous fault is clearly indicated.

That is, as shown in FIG. 5C, when there is a single failure such as a point defect 66B to be discarded in units of sheets, the first row of marks 80C is marked. In addition, when the surface failure 66 is a continuous surface failure (slit rejection) such as a streak failure 66A, as shown in FIG. marking the third column of the mark 80C in 80 on the mark, as shown in FIG. 5 (E), with respect to the surface faults 66 of the last (end), so that marking the fifth column of the mark 80C .

  For the surface faults 66 other than the first and last consecutive faults, the fault mark 80 may be omitted or the fault marks 80 may be formed at a predetermined interval.

  In this way, in the failure removal system 40, when the web 18 is slit in the cutting step 22 to produce the narrow web 30, the surface is determined based on the failure mark 68 given to the web 18. A failure mark 80 is transferred to the web 30 where the failure 66 has occurred.

  As a result, a failure mark 80 corresponding to the surface failure 66 is formed on each of the webs 30 forming the slit roll 32.

  As shown in FIG. 1, the slit roll 32 produced in the cutting process 22 is cut in a cutting process 24 in roll units to produce a sheet 16, and the sheet 16 is collected in a collecting process 26 to form a book 34. Produced.

  As shown in FIG. 2, the cutting step 24 and the stacking step 26 are provided with a cutting and stacking control device 82 and a mark reading device 84 and a discarding device 86 that form the failure removal system 40. In this embodiment, as an example, a discarding device 86 that discards in units of sheets is used.

  The cutting and accumulating control device 82 is connected to the production management computer 38, and the production management computer 38 outputs failure information including extraction information for the web 30 of the slit roll 32 to be cut to the cutting and accumulating control device 82.

  As shown in FIG. 1, the mark reading device 84 includes a mark sensor 88 that faces the end of the web 30 in the width direction, and the mark sensor 88 reads a failure mark 80 formed on the web 30. .

  Further, as shown in FIG. 2, the mark reading device 84 is connected to the cutting / integrating control device 82, and outputs failure information based on the failure mark 80 read by the mark sensor 88 to the cutting / integrating control device 82. I have to.

  The cutting and integration control device 82 collates the sampling information and failure information input from the production management computer 38 with the failure information input from the mark reading device 84, and controls the operation of the discarding device 86 based on the comparison result. Then, the sheet 16 having the surface failure 66 is discarded.

  As shown in FIG. 6, the stacking process 26 is provided with a stacking apparatus 90, and the sheets 16 produced in the cutting process 24 are stacked by being sent to the stacking apparatus 90. As a result, a book 34 in which a predetermined number of sheets 16 are collected is produced. Note that any known configuration can be applied to the integration device 90, and detailed description thereof is omitted in this embodiment.

  Conveyors 92 and 94 are provided between the cutting step 24 and the stacking device 90. The conveyors 92 and 94 convey the sheet 16 between the upper conveyors 92A and 94A and the lower conveyors 92B and 924B, for example.

  Further, a gate conveyor 96 that forms a disposal device 86 is provided between the conveyors 92 and 94. The gate conveyor 96 is formed by an upper conveyor 96A and an oscillating conveyor 98 facing the upper conveyor 96A.

  The sheet 16 is conveyed by the conveyance conveyor 92, the gate conveyor 96, and the conveyance conveyor 94 and sent to the stacking device 90.

  The swing conveyor 98 can swing so as to be inclined (indicated by a two-dot chain line in FIG. 6) at a predetermined angle with the roller 98A on the transport conveyor 92 side (upstream side) as an axis and the downstream side downward. Yes.

  In a state where the swinging conveyor 98 swings in the direction away from the upper conveyor 96 </ b> A (downward), the sheet 16 fed from the transporting conveyor 92 to the gate conveyor 96 is guided and transported downward by the swinging conveyor 98.

  An accumulation box 100 for accumulating the sheets 16 to be discarded is provided below the gate conveyor 96 and the transfer conveyor 94. When the swinging conveyor 98 swings downward, the sheets 16 are stored in the stacking box. Sent to 100 and collected.

  In the discarding device 86, the swinging conveyor 98 is swung at the timing when the sheet 16 set to be extracted in units of sheets reaches the gate conveyor 96 (the swinging conveyor 98). As a result, the sheet 16 is discarded in units of sheets.

  In the production system 10 provided with the defect removal system 40 configured as described above, the raw web 20 is formed by winding the wide web 18 produced through the film forming process 12 and the coating process 14 into a roll shape. . The original fabric 20 is stored until the next processing is performed.

  When the sheet 16 is produced using the stored original fabric 20, the original fabric 20 is loaded into the cutting step 22. In the cutting step 22, the web 18 is transported while being pulled out from the original fabric 20, and a web 30 having a predetermined width is produced by slitting, and a slit roll 32 is formed by winding the produced web 30 into a roll.

  The slit roll 32 is loaded into the cutting step 24. In the cutting step 24, the web 30 is conveyed while being pulled out from the slit roll 32, and is cut to a predetermined length, thereby producing a sheet 16 having a predetermined size.

  The sheet 16 is conveyed from the cutting process 24 to the stacking process 26. In the stacking step 26, a predetermined number of sheets 16 are stacked to form a book 34. The booklet 34 is sent out from the stacking process 26 one by one, and sealed in the packaging process 28 to produce a package 36 that is a product of the sheet (X-ray film) 16.

  Incidentally, the production system 10 is formed with a failure removal system 40 that removes the sheet 16 on which the surface failure 66 has occurred. The failure removal system 40 detects a surface failure 66 such as a surface abnormality of the web 18 that has been subjected to the coating process, using a failure detection means such as a surface inspection device 42 provided in the coating process 14.

  Further, in the failure removal system 40, the disposal device 86 is used to discard the sheet 16 in which the surface failure 66 has occurred. At this time, the discarding device 86 discards the sheet 16 in units of sheets. As a result, the failure removal system 40 enables reliable and efficient disposal of the sheet 16.

  Here, the disposal of the sheet 16 in the failure removal system 40 in the production system 10 will be described with reference to FIGS. 7 and 8.

  FIG. 7 shows an outline of the surface inspection process of the failure removal system 40 in the coating process 14.

  This flowchart confirms whether or not production of a new original fabric 20 has been started in the first step 200. Thus, when production of a new raw fabric 20 is started, an affirmative determination is made in step 200 and the process proceeds to step 202. In this step 202, the surface failure 66 is detected using the surface inspection device 42 and the like while counting the transport amount from the tip of the web 18.

  In the next step 204, it is confirmed whether or not the surface failure 66 has been detected. If the surface failure 66 is detected, an affirmative determination is made in step 204 and the routine proceeds to step 206. In this step 206, the position of the detected surface failure 66 in the longitudinal direction and width direction of the web 18 is determined, and failure information is generated based on the determination result. For example, a serial number for each web 18 is given to the failure information at this time so that the surface failure 66 on the web 18 can be specified.

  In the next step 208, the failure information is output to the marking device 44 together with the production management computer 38. In step 210, the marking device 44 records the failure mark 68 on the web 18 based on the failure information. Accordingly, the failure information is read from the failure mark 68 of the web 18 so that the position of the corresponding surface failure 66 on the web 18 becomes clear. In addition, the production management computer 38 records failure information for each raw fabric 20.

  In this way, when the fault inspection is completed over the entire length of the web 18, an affirmative determination is made at step 212 and the routine proceeds to step 214. In this step 214, a failure map of the web 18 for each raw fabric 20 is created based on the failure information input from the surface inspection apparatus 42, and it is determined whether or not to dispose of each of the surface failures 66.

  In the next step 216, the failure information for each raw fabric 20 and the disposal method set for each surface failure 66 are recorded on a recording medium or the like and stored as failure information. The creation of the failure map and the setting of the disposal method may be performed as long as the slit process for the corresponding original fabric 20 is started.

  FIG. 8 shows an outline of the process of the failure removal system 40 in the cutting step 22. In the failure removal system 40, failure information is transferred in the cutting step 22. That is, the failure information is marked for the surface failure 66 on each web 30 formed by slitting.

  This flowchart is executed at the cutting step 22 in accordance with the start of processing for a new original fabric 20. In the first step 220, failure information for the original fabric 20 to be processed is read. Note that the failure information includes a discard setting based on the failure map, and the discard setting may be performed prior to the slit process in the cutting step 22.

  Thereafter, when the drawing of the web 18 from the original fabric 20 and the slit process for the drawn web 18 are started in the cutting step 22, the failure mark 68 is read in step 222 in accordance with the conveyance of the web 18.

  In the next step 224, it is confirmed whether or not the failure mark 68 formed on the web 18 is detected by the mark sensor 76. When the failure mark 68 is detected, an affirmative determination is made in step 224, and the flow proceeds to step 226. The failure information is read from the failure mark 68.

  At this time, the failure mark 68 includes a serial number that identifies the surface failure 66 and a position along the longitudinal direction of the surface 18 of the surface failure 66 and a position along the width direction. Is read from.

  In the next step 228, collation of the read failure information is collated with failure information including the disposal method, the surface failure 66 for the detected failure mark 68 is specified, and the disposal method is set.

  In the next step 230, marking based on the failure information is performed so that the surface failure 66 and the processing for the surface failure 66 are clarified on the slit web 30.

  Here, the marking device 74 provided in the cutting step 22 identifies the web 30 in which the corresponding surface failure 66 appears from the position along the web 18 width direction of the surface failure 66 based on the input failure information. Then, a failure mark 80 based on the failure information is marked on the end of the identified web 30 in the width direction.

  In the failure mark 80, whether the surface failure 66 is a point failure 66B or a continuous stripe failure 66A in the longitudinal direction so that the disposal method is clarified together with a serial number that can identify the surface failure 66. Is included, and when the surface failure 66 is continuous in the longitudinal direction (for example, the streak failure 66A), the failure start position or the end position is included.

  The marking of the failure mark 80 may be performed prior to cutting the web 18 or may be performed on the web 30 after the web 18 is cut.

  As described above, in the failure removal system 40, the processing for the entire length of the web 18 is completed in step 232 while the failure information is transferred so that the failure mark 68 on the web 18 becomes the failure mark 80 on the web 30. Confirm.

  The slit roll 32 produced in this way is loaded into the cutting step 24 and used for production of the sheet 16.

  The cutting / stacking control device 82 that controls the cutting process 24 and the stacking process 26 reads the failure mark 80 from the web 30 to be cut, and determines the surface failure 66 based on the disposal method set by the failure mark 80. The generated sheet 16 is discarded.

  At this time, when the failure mark 80 is recorded as the point failure 66B, the corresponding sheet 16 (in units of the sheet 16) is discarded using the discarding device 86. Further, when a failure mark 80 is recorded as a continuous surface failure 66 such as a streak failure 66A, the disposal device 86 continuously discards the leading sheet 16 to the last sheet 16 of the corresponding surface failure 66. Reject.

  As described above, in the failure removal system 40, when the sheet 16 is produced by cutting each slit roll 32 using the slit roll 32 of the web 30 formed by slitting the web 18 of the raw fabric 20, the sheet 16 is slit. A fault mark 80 that allows the surface fault 66 to be specified on the web 30 is formed.

  As a result, even when the web 30 is cut in units of slit rolls 32 and the sheet 16 is produced, the sheet 16 in which the surface failure 66 has occurred can be accurately and efficiently discarded.

  Therefore, the production system 10 provided with the failure removal system 40 can produce the high-quality sheet 16 in which the surface failure 66 does not occur and the package 36 in which the sheet 16 is packaged.

  In the present embodiment, the failure mark 68 is formed on the web 18 and the failure mark 80 is formed on the web 30. However, the failure information formed on the web 18 and the web 30 is not limited to this, and surface failure Any display can be applied as long as the position and processing method of 66 are clear.

  Further, in the present embodiment, the sheet 16 which is an X-ray film is described as an example of the sheet body. The present invention can be applied to the production of various sheet bodies in which a web-shaped sheet material, such as various recording papers such as paper, is processed into a predetermined size sheet.

It is a schematic block diagram of the production system applied to this Embodiment. It is a block diagram which shows schematic structure of the failure elimination system provided in a production system. It is a schematic block diagram of the principal part which shows an example of a surface inspection apparatus. (A) is a schematic diagram of a web produced in the coating process, (B) is a schematic diagram of a web (slit web) produced by cutting in the cutting process, and (C) is an outline of the web cut in the cutting process. FIG. (A) is a schematic diagram illustrating an example of a failure mark used as a first index, (B) is a schematic diagram illustrating an example of a failure mark used as a second index, and (C) is an index mark used as a second index. (D) is an index mark used as a second index indicating the start of a continuous fault, and (E) is an index mark used as a second index indicating the end of the continuous fault. . It is a schematic block diagram which shows an example of the integration process which provided the discard apparatus. It is a flowchart which shows the outline of the process in an application | coating process. It is a flowchart which shows the outline of the process in a cutting process.

Explanation of symbols

10 Production system 14 Coating process (raw fabric production process)
16 sheet (sheet body)
18 Web 20 Raw Material 22 Cutting Process 24 Cutting Process 26 Stacking Process 30 Web (Slit Web)
32 Slit Roll 34 Volume 38 Production Management Computer 40 Fault Removal System (Defect Removal System)
42 Surface inspection equipment (surface inspection means)
44 Marking device (first marking means)
66 (66A, 66B) Surface failure 68 Failure mark (first index)
70 Cutting control device 72 Mark reading device (first reading means)
74 Marking device (second marking means)
80 Failure mark (second indicator)
82 Cutting integration control device 84 Mark reading device (second reading means)
86 Disposal device (Disposal means)

Claims (4)

In the raw fabric production process, the web is rolled up into a roll ,
In cutting process, the web drawn from the original is an original counterproductive in counter-productive step, the respective slit web of plural rows which produced and cut into a predetermined width, in the cutting step, cut into a predetermined length A sheet body production method for producing a sheet body ,
Said detecting surface faults on the web by the surface inspection device in raw production process, the first index in the width direction及beauty length side direction of the position on the web of the detected said surface faults are identified Marking the web,
Detecting the first index from the web cut in the cutting step, and includes a surface failure identified from the first index among the plurality of slit webs cut and formed from the web wherein only slit web, marking the second index at least the position in the longitudinal direction of the slit web of the surface fault is identified to be,
Production of a sheet body that produces a sheet body that does not include a surface failure by discarding the sheet body that includes the surface failure based on the second index from the sheet body that is produced in the cutting step. Way . A raw material production process for producing a raw material obtained by winding a web into a roll,
A cutting step of producing a plural rows of slits the web to pull out by said web from raw produced in raw production process and cut into a predetermined width,
A cutting step of producing a sheet body by cutting each of the slit webs to a predetermined length;
A defect removal system that is disposed in a production system including a sheet body in which a surface failure has occurred,
Surface inspection means that is provided in the raw fabric production process and detects a surface failure on the web by specifying the position in the web longitudinal direction and the web width direction;
A first marking means for forming a first index position is specified on the web of said detected surface faults in the surface sensing device to the web,
Reading failure information on the web, including a position along the width direction及beauty length side direction of the web relative to the surface faults in question detects the first index formed on the web is provided on the cutting process First reading means;
Longitudinal least surface faults on the first exist surface failure answer from the slit web of said plural rows formed by the cutting process on the basis of the failure information on the web read by the reading means away Rittouebu and second marking means for forming a second index position along the direction is identified,
A second indicator that is provided in the cutting step and detects the second index formed on the slit web and reads failure information on the slit web including a position along the longitudinal direction of the slit web with respect to the corresponding surface failure. Reading means of
The cutting based on the failure information on the slit web read by said second reading means from among the sheet produced in step Cie over preparative body contains surface faults identified by the fault information A means of decommissioning,
The including defect removal system. The second index to be marked on the slit web by said second marking means, as the failure information on the slit web, whether the surface faults applicable to continuous in a longitudinal direction of the slit web and, wherein the surface failure include information ends it is identified along the longitudinal direction of the slit web when continuous in the longitudinal direction of the slit web, defect removal system of claim 2. A fault map indicating the position of the surface fault on the web is created based on the detection result of the surface detection means, and fault information on the web including each type of the surface fault is set based on the fault map. Including setting means,
The defect removal system according to claim 2 or 3, wherein the second marking unit forms the second index including failure information on the web set by the setting unit on the slit web. .

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