JP5734222B2 - Web winding apparatus, web roll manufacturing apparatus and method - Google Patents

Description

  The present invention relates to a web winding apparatus, a web roll manufacturing apparatus, and a method. More specifically, the present invention relates to a flexible belt-like support (hereinafter referred to as a web) that is continuously fed and wound around a new winding core. The present invention relates to a web winding apparatus, a web roll manufacturing apparatus, and a method.

  Various types of web winding devices have been proposed that wind a web such as paper or plastic film that is continuously fed around a winding core. In the web winding device, it is important from the viewpoint of time and production control that the web is wound without stopping the flow of the continuously fed web.

  The winding device rotates the turret arm when the web is wound around the winding core at the winding position and reaches a predetermined winding diameter, for example, full winding. As a result, the fully wound core is set at the core replacement position, and a new empty core is set at the winding position (see, for example, Patent Document 1). Thus, the winding device is used as a terminal device such as a film-forming facility that is continuously manufactured.

  Moreover, in the web winding device of Patent Document 2, a guide arm is provided between the turret arms to which the winding core is attached so that the web does not contact the turret shaft when the turret arm rotates. A roller capable of substantially releasing driving is disposed at the tip. As a roller that can be substantially released from driving, it has a clutch mechanism, and after contact with the traveling web, the clutch is released to make it a free roller, or at the same time as driving, free roller regardless of driving Tendency type rollers that work as described above are used. When these rollers are used, even if the web traveling speed fluctuates, no stress is generated between the roller surface and the web surface, so that the occurrence of scratches on the web surface can be suppressed.

JP 2005-89177 A JP-A-63-252857

  By the way, when a defect inspection of the wound roll web surface is performed in lot units, it has recently been observed that a lot of minute scratches are generated in a certain range on the web at a certain point before the end of winding. It has been found in precise inspection of defects on the surface. Since these scratches are very small, there is no particular problem with the end product that is intended, for example, LCD protective films and other applications, but there are defects when high-definition displays are required in the future. Therefore, countermeasures were desired.

  The present invention has been made in consideration of the above-mentioned problems, and is a web winding device and web that eliminates the occurrence of micro-scratches at a certain position near the winding end when rolled into a roll. An object is to provide a roll manufacturing apparatus and method.

  As a result of intensive studies on the cause of the occurrence of the above-mentioned frequent occurrence area of micro-scratches, the present inventors have found that there is a cause in the guide roller with which the web contacts when rotating the turret arm. Conventionally, if the guide roller is rotated at the same speed as the web winding speed, it is recognized that no scratches or the like will occur, and the guide roller is rotated at the same speed as the web winding speed. I was trying to receive the web with a guide roller. However, even if the web winding speed is set to the same speed as the web, the web is produced at a constant production speed from, for example, a film forming facility and sent at a constant traveling speed. Since the web needs to be wound around a new winding core after the winding of the web around the winding core, the turret arm is rotated 180 degrees, for example, in a type having two winding shafts, and a new winding core is wound. Set to the pick position. With the revolving operation of the winding core by the rotation of the turret arm, the web winding speed was changed, and it was found that the guide roller could not follow this change and a scratch was generated. In addition, as shown in Patent Document 2, it has also been proposed to suppress the generation of scratches on the web surface by using a roller that can be substantially released from driving, but winding at a high speed exceeding 100 m / min is proposed. In the case of performing the above, there is a limit to the countermeasures using only the tension type roller or the roller having the clutch mechanism, and a minute scratch is generated.

Based on the above knowledge, the web winding device of the present invention has a plurality of winding shafts on which a winding core for winding a web is set, and moves the winding core at the winding position to the winding core replacement position. An arm, a guide roller that is disposed between the plurality of winding shafts in the rotational direction of the turret arm, contacts the web when the turret arm rotates, and rotatably holds the guide roller, the turret arm wherein the guide arm which rotates together, the running speed of the web V0, the correction speed of rotation of the turret arm when the V1, when the rotation of the turret arm said web in contact with the guide roller and determined by the guide rollers of the peripheral speed V2 V0-V1, before in a state in which the guide roller in advance is rotated at a circumferential speed V2 And a guide roller speed controller contacting the guide roller to the web, the correction speed V1 by the rotation of the turret arm, the web running direction component of the revolution speed in the outermost periphery of the guide roller caused by the rotation of the turret arm characterized in that there.

The correction speed V1 is preferably obtained by V1 = V3 × cos α where the revolution speed at the outermost periphery of the guide roller 26 is V3 and the angle between the revolution speed V3 and the web 11 is α.

  The web roll manufacturing apparatus of the present invention is a web manufacturing facility that continuously manufactures a web, and uses the above-described web winding apparatus to wind a web that is continuously manufactured in a roll shape around a winding core. It is characterized by manufacturing a roll.

The web roll manufacturing method of the present invention includes a plurality of winding shafts on which winding cores for winding a web are set, and a turret arm that moves a winding core at a winding position to a winding core replacement position; A guide roller that is disposed between the plurality of winding shafts in the rotation direction of the turret arm, contacts the web when the turret arm rotates, holds the guide roller rotatably, and rotates integrally with the turret arm. using a web winding apparatus having a guide arm, a web roll manufacturing method of the web roll by winding the web to be continuously produced in the winding core, the running speed of the web V0, and the correction rate a web running direction component of the revolution speed in the outermost periphery of the guide roller caused by the rotation of the turret arms and the V1 A, the guide determined by the peripheral speed V2 V0-V1 of rollers, said web in a state in which the guide roller in advance is rotated at the peripheral speed V2 of when the web by rotation of the turret arm is in contact with the guide roller characterized in that it comprises a guide roller speed control step of contacting said guide rollers.

  According to the present invention, when the web traveling speed is V0 and the correction speed by turret arm rotation is V1, the guide roller is rotated in advance at the guide roller peripheral speed V2 obtained by V0-V1. The web can be brought into contact with the guide roller by the rotation of the turret arm. Therefore, the traveling speed of the web that contacts the guide roller and the peripheral speed of the guide roller can be set to be approximately the same, so that no minute scratches are generated on the web contact surface of the guide roller.

It is the schematic which shows the film forming equipment which has the web winding apparatus of this invention. It is the schematic which shows the state which the turret arm rotated 180 degree | times from the state of FIG. It is the schematic which shows the state which the turret arm started rotation. It is the schematic which shows the state just before a guide roller contacts a web by rotation of a turret arm. It is a flowchart which shows the operation | movement of half rotation of the turret arm at the time of film rewinding.

  As shown in FIG. 1, a web 11 such as a cellulose acylate film sent from a film forming line 10 is wound into a roll shape by a web winding device 12 of the present invention to become a web roll 13. Although not shown, the film forming line 10 includes a casting machine, a tenter, and a dryer. For example, a solution (dope) in which a polymer is dissolved in a solvent is placed on a traveling support body that travels. The film is continuously produced by casting and peeling the dope formed into a film by casting, that is, the casting film from the casting support and drying. The film forming line 15 and the web winding device 12 constitute a film forming facility 15 as a web roll manufacturing apparatus. The web 11 is guided in a predetermined direction by a guide roller 16. As the guide roller 16, any of a free roller, a driving roller, a tender roller, and the like is used.

  The web winding device 12 is configured by attaching a turret arm 21 and a guide arm 22 to a gantry 20 through a turret shaft 23 so as to be rotatable. Winding shafts 24 are attached to both ends of the turret arm 21 so as to protrude perpendicularly from the arm body 21a. Winding cores 25 a and 25 b are detachably attached to the winding shaft 24.

  The guide arm 22 is integrated with the turret arm 21 so as to be orthogonal to the turret arm 21, and the whole is formed in a cross shape. Guide rollers 26 are attached to both ends of the guide arm 22 in parallel with the winding shaft 24.

  A turret motor 30 is connected to the turret shaft 23 of the turret arm 21. The turret motor 30 is connected to the controller 31 via a driver 30a. When the controller 31 rewinds the web 11 to the empty winding core 25a, the controller 31 controls the rotation of the turret motor 30, and intermittently rotates (half-rotates) the turret arm 21 by 180 degrees.

  A winding motor 32 is connected to the winding shaft 24. The take-up motor 32 is composed of a servo motor incorporating a motor driver and a rotary encoder, and drives the take-up shaft 24 to rotate. By the rotation of the winding shaft 24, the winding cores 25a and 25b rotate integrally with the winding shaft 24, and the web 11 is wound around the winding cores 25a and 25b. The winding motor 32 is connected to the controller 31, and the rotation is controlled by the controller 31. The controller 31 stores a predetermined winding tension pattern, and drives and controls the winding motor 32 so as to wind the web 11 while applying tension to the web 11 based on the winding tension pattern. The optimum winding tension pattern according to the product type and winding diameter of the web roll 13 is obtained in advance by experiments and the like. The optimum winding tension pattern according to the type and winding diameter of the web 11 is obtained. Is selected.

  The guide roller 26 is composed of a tendency roller. As is well known, the tendency roller is configured to perform the same function as the free roller at the same time as driving regardless of the driving. Therefore, even when the web winding speed fluctuates, the rotation of the guide roller 26 follows the web 11 winding speed.

  A guide motor 35 is connected to the guide roller 26. The guide motor 35 is composed of a servo motor incorporating a motor driver and a rotary encoder. The guide motor 35 is connected to the controller 31 and its rotation is controlled by the controller 31 so as to have an arbitrary peripheral speed V2.

  Due to the half rotation of the turret arm 21, the state shown in FIG. 1 is shifted to the state shown in FIG. In FIG. 2, the empty winding core 25b set on the winding shaft 24 is set at the normal winding position. Moreover, the winding core 25a close to the fully wound state just before the completion of winding on the opposite side is set at the winding core replacement position. In the present embodiment, when the winding shaft 24 is positioned on the upper left side, it is the normal winding position, and when the winding shaft 24 is positioned on the lower right side on the opposite side, it is the winding core replacement position.

  At the core replacement position, the cores 25a and 25b are replaced. Specifically, the web roll 13 fully wound on the winding core 25a is removed from the winding shaft 24 together with the winding core 25a, and an empty winding core 25b is set on the removed winding shaft 24. The cores 25a and 25b are exchanged. A double-sided adhesive tape piece (not shown) is attached in advance to the empty winding core 25b, and the web 11 can be attached to the winding core 25b by this adhesive tape piece.

  When the web roll 13 is nearly fully wound at the normal winding position, as shown in FIG. 3, the turret arm 21 starts to rotate, rotates 180 degrees as shown in FIG. 2, and stops rotating. As a result, the positions of the winding core 25a around which the web 11 is wound and the empty winding core 25b are switched.

  The full winding is a state in which the web roll 13 formed by winding the web 11 around the winding core 25 a has a predetermined diameter, and is determined by the controller 31. In the controller 31, the diameter of the web roll 13 is calculated from the diameter of the winding core 25 a and the thickness of the web 11 input in advance and the rotational speed acquired from the rotary encoder of the winding motor 32, for example.

  As shown in FIG. 1, a known web rewinding device 40 is provided in the vicinity of the winding core 25a at the normal winding position. As the web rewinding device 40, for example, those described in JP-A-2005-89177 and JP-A-2008-230723 are used. Specifically, although not shown, it has a cutting drum arranged on one surface side of the web 11 so as to sandwich the web 11 and a receiving drum arranged on the other surface side, and both are opposed to each other. The web 11 is cut by rotating once. And the front-end | tip of the cut | disconnected web 11 is wound around the winding core 25b with the adhesive tape of the new winding core 25b, and the rear end of the other cut | disconnected web 11 is wound up by the winding core 25a near full winding, and the web roll 13 It becomes.

  As shown in FIG. 1, in a state immediately before the end of full winding, the web 11 is wound around the winding core 25 a at the normal winding position, and the web roll 13 is configured. When full winding approaches, as shown in FIG. 2, the turret arm 21 rotates 180 degrees, and the web roll 13 is switched from the normal winding position to the winding core replacement position. By the rotation of 180 degrees, the empty winding core 25b that was in the winding core replacement position is set to the normal winding position.

  As shown in FIG. 3, when the turret arm 21 starts to rotate, the guide roller 26 of the guide arm 22 contacts the web 11 so that the web 11 does not contact the turret shaft 23 as shown in FIG. Then, the web 11 is supported. After that, as shown in FIG. 2, the web 11 is wound around the web roll 13 which is close to a full roll while being in contact with the guide roller 26. At this time, the web roll 13 revolves around the turret shaft 23 by the rotation of the turret arm 21. By this revolution, the web take-up speed changes and becomes a speed different from the web running speed V0.

Conventionally, as shown in Patent Document 2, the rotation of the guide roller 26 is set to the same speed as the winding speed, which causes a speed difference between the web surface and the guide roller surface. The actual web traveling speed V0 and the circumferential speed V2 of the guide roller 26 are different, and this speed difference causes minute scratches on the contact surface of the web 11. In order to prevent the occurrence of this scratch, the peripheral speed V2 of the guide roller 26 is determined based on the following equation (1).
V2 = V0−V1 (1)

  V 0 is a web traveling speed sent from the film forming line 10, and V 1 is a correction speed caused by the rotation of the turret arm 21. The correction speed V1 corrects the amount by which the position of the guide roller 26 is changed by the rotation of the turret arm 21 and the rotational speed is increased or decreased by the peripheral speed of the guide roller.

The correction speed V1 is obtained from the following equation (2) as the web traveling direction component of the revolution speed V3 at the outermost periphery of the guide roller 26. V3 is the revolution speed of the guide roller 26, and α is the angle formed between the revolution speed V3 and the web 11.
V1 = V3 × cos α (2)

  Scratches due to the contact of the guide roller 26 are caused by a speed difference between the web traveling speed V0 when the guide roller 26 contacts the web 11 and the peripheral speed V2 of the guide roller 26. Therefore, as shown in FIG. 4, when the guide roller 26 contacts the web 11, the guide roller 26 contacts the web 11 using the correction speed V <b> 1 so that the speed difference between the two approaches 0. The guide roller peripheral speed V2 is obtained from the web running speed V0, and the guide roller 26 is rotated at this speed V2 and brought into contact with each other. Thus, according to the web winding diameter, the actual web traveling speed at the time of contact of the web 11 with the guide roller 26 is obtained in advance, and the guide roller 26 is rotated at this web traveling speed. Since the web 11 is brought into contact with the guide roller 26, the speeds of the two at the time of contact substantially coincide with each other, and the generation of scratches is suppressed. When the web 11 comes into contact with the guide roller 26, the contact roller is brought into a free roller state by the action of the tendency roller, the speed difference between the web 11 and the guide roller 26 is eliminated, and the subsequent scratches are also generated. Disappear.

  Next, the operation of this embodiment will be described with reference to the flowchart of FIG. The web 11 manufactured by the film forming line 10 is sent out in the direction of the arrow in FIG. The web 11 is wound around the winding core 25a at the normal winding position via the guide roller 26 and the web rewinding device 40.

  As shown in FIG. 1, while the web 11 is being wound around the winding core 25a, the controller 31 causes the web roll 13 to rotate according to the number of rotations of the winding core 25a measured from the time when the web 11 is wound around the winding core 25a. The diameter is calculated. When winding of the web 11 proceeds and the diameter of the web roll 13 reaches a predetermined value, it is recognized that the web roll 13 is almost fully wound, and a web rewinding signal is output from the controller 31, and the turret motor 30 is turned on based on this. Thus, the turret arm 21 starts to rotate. The time until the guide roller 26 comes into contact with the web 11 by the rotation of the turret arm 21 and the rotation angle of the turret arm 21 can be obtained in advance based on the web winding diameter and the specifications of the apparatus. Therefore, the peripheral speed V2 of the guide roller 26 immediately before the guide roller 26 contacts the web 11 is controlled so as to be the same speed as the actual web traveling speed.

  The contact timing between the web 11 and the guide roller 26 does not need to be determined strictly, and when the turret arm 21 starts to rotate, the circumferential speed of the guide roller 26 may be controlled to be V2. Therefore, even if the web 11 comes into contact with the guide roller 26 by the rotation of the turret arm 21, the peripheral speed V2 of the guide roller 26 at the time of contact and the web running speed V0 substantially coincide with each other. The occurrence of is suppressed.

  When the turret arm 21 rotates 180 times, the turret motor 30 is turned off. Further, the peripheral speed of the guide roller 26 is switched from V2 to V0. Thereafter, when the web roll 13 reaches a predetermined winding length and a winding completion signal is issued, the web 11 is cut by the web rewinding device 40, and the leading end of the cut web 11 is set at the normal winding position. Winding of the new web roll 13 is started around the wound core 25b.

  In addition, the rear end of the cut web 11 is wound on the web roll 13 at the winding core replacement position, and the winding is finished. Thereafter, the rear end of the web 11 is fixed to the peripheral surface of the web roll 13 with a tape or the like, and the web roll 13 is completed. Further, after the web 11 is cut, the rotation of the guide motor 35 is stopped when the rear end of the web 11 passes the guide roller 26.

  In the above-described embodiment, the tension roller is used as the guide roller 26. However, instead of this, a clutch mechanism is provided, and after coming into contact with the running web 11, the clutch is released to be a free roller. May be used. Furthermore, it does not have such a clutch mechanism, and a drive roller that is simply driven to rotate may be used. In this case, the fluctuation of the actual web traveling speed V0 when the turret arm 21 is rotated is obtained in advance by simulation or the like, and the guide roller 26 is rotationally driven according to the actual web traveling speed V0 obtained by this simulation. To do. The control of the circumferential speed V2 of the guide roller 26 is made to be the same as the actual web traveling speed.

  In the said embodiment, although the web winding apparatus 12 was provided in the film forming line 10, the web winding apparatus 12 is used also for coating lines other than the film forming line 10, for example.

[Evaluation test]
The material of the web 11 is TAC (triacetyl cellulose), the web thickness is 60 μm, the web width is 1500 mm, the tension applied to the web 11 is 100 N / web width, the web running speed V0 is 100 m / min, the winding core 25 a and the winding core 25 b. The web roll 13 was manufactured with the film forming equipment 15 shown in FIG. The web roll 13 is manufactured by changing the correction speed V1 with respect to the peripheral speed V2 of the guide roller 26 as shown in Table 1, and each web roll 13 is passed through a film surface inspection device to determine the number of defects appearing on the film surface. Asked.

When the web traveling speed V0 is 100 m / min, the tip of the guide roller 26 turns at the tip turning speed 3.44 m / min, and the contact angle between the web 11 and the guide roller 26 is α, the guide roller The peripheral speed V2 of the
V2 = 100-3.44 × cos α (m / min)
= 100-3.44 × 0.99 (m / min) = 96.6 (m / min)
It becomes. Note that cos α varies little depending on the equipment layout, and can be approximated as a constant of about 0.99.

  When the number of detected defects in the area where the guide roller 26 contacts the web 11 was counted in units of 300 mm in the web running direction, the number of detected defects was 103 in Example 2 in which the correction speed V1 was 3.4 m / min. Thus, the number of defects was the smallest. In addition, in order of the third embodiment in which the correction speed V1 is 4.5 m / min, the fourth embodiment in which the correction speed V1 is 6.0 m / min, and the first embodiment in which the correction speed V1 is 2.1 m / min. It turned out that the number increases. In Comparative Example 1 in which the correction speed V1 is 8.0 m / min and Comparative Example 3 in which the correction speed V1 is 0 m / min, the number of defects is increased to 180 and 186. When it is used for a protective film for fine applications, there may be a problem. Further, in Comparative Example 2 in which the correction speed V1 is 10.0 m / min, the number of defects is 259, and there is a problem with the current product standard, and the determination is x.

DESCRIPTION OF SYMBOLS 10 Film forming line 11 Web 12 Web winding device 13 Web roll 15 Film forming equipment 21 Turret arm 22 Guide arm 24 Winding shaft 25a, 25b Winding core 26 Guide roller 30 Turret motor 31 Controller 32 Winding motor 35 Guide motor 40 Web Rewinding device

Claims (5)

A turret arm having a plurality of winding shafts on which a winding core for winding a web is set, and moving the winding core at the winding position to the winding core replacement position;
A guide roller disposed between the plurality of winding shafts in the rotation direction of the turret arm and contacting the web when the turret arm rotates;
A guide arm that rotatably holds the guide roller and rotates integrally with the turret arm;
The running speed of the web V0, the correction speed of rotation of the turret arm is taken as V1, the peripheral speed V2 of the guide roller when the web by rotation of the turret arm is in contact with the guide roller V0- determined by V1, and a guide roller speed control section in a state in which the guide roller in advance is rotated at a circumferential speed V2 contacting the guide roller to the web,
The correction speed V1 due to the rotation of the turret arm is a web traveling direction component of the revolution speed at the outermost periphery of the guide roller due to the rotation of the turret arm . The correction speed V1 is obtained by V1 = V3 × cos α where the revolution speed on the outermost periphery of the guide roller 26 is V3, and the angle between the revolution speed V3 and the web 11 is α. Item 5. A web winding device according to Item 1. In a web manufacturing facility for continuously manufacturing a web, using the web winding device according to claim 1 or 2, a web roll is manufactured by winding a continuously manufactured web in a roll shape around a winding core. A web roll manufacturing apparatus characterized by the above. A turret arm having a plurality of winding shafts on which a winding core for winding a web is set, and moving the winding core at the winding position to the winding core replacement position;
A guide roller disposed between the plurality of winding shafts in the rotation direction of the turret arm and contacting the web when the turret arm rotates;
Rotatably holds the guide rollers, using a web winding apparatus having a guide arm which rotates integrally with the turret arm, and the web roll wound the web to be continuously produced in the winding core In the web roll manufacturing method to
The running speed of the web V0, the correction rate a web running direction component of the revolution speed in the outermost periphery of the guide roller caused by the rotation of the turret arm when the V1, the web by rotation of the turret arm said guide the peripheral speed V2 of the guide rollers when contacting the rollers determined by V0-V1, includes a guide roller speed control step while rotating the guide rollers advance at a peripheral velocity V2 contacting the guide roller to the web The web roll manufacturing method characterized by the above-mentioned. The correction speed V1 is obtained by V1 = V3 × cos α where the revolution speed on the outermost periphery of the guide roller 26 is V3, and the angle between the revolution speed V3 and the web 11 is α. Item 5. A method for producing a web roll according to Item 4.

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