JP7238281B2 - Manufacturing method and manufacturing equipment - Google Patents

Description

TECHNICAL FIELD The present invention relates to a manufacturing method and manufacturing apparatus for manufacturing elongated materials.

2. Description of the Related Art In recent years, as a method of manufacturing green tires, a technique has been developed in which strip-shaped belt plies are attached to the outside of a core having an annular circumferential surface. As an example of such technology, an apparatus for inspecting the attachment state of belt plies has been disclosed. (See Patent Document 1, for example).

On the other hand, in a conventional method that does not use a core, strip-shaped material pieces are joined on a conveyor to form a long material used in tire manufacturing. However, the quality of the manufactured long material is left to the visual inspection of the operator.

JP 2015-45577 A

SUMMARY OF THE INVENTION The present invention has been devised in view of the actual situation as described above, and a main object of the present invention is to provide a manufacturing method and the like for inspecting the quality of long materials while manufacturing them.

A first aspect of the present invention is a method for manufacturing an elongated material, comprising the steps of supplying a piece of material to a predetermined position on a conveyor movable in a first direction; and moving the conveyer in the first direction by a feed amount smaller than the length of the material piece along the first direction, so that the material pieces are partially overlapped on the conveyor. of the material preparation step of forming a long material by joining to the conveyor, the feed amount of the conveyor, the thickness of the long material, and the position of the edge in the second direction orthogonal to the first direction of the long material a measuring step of measuring at least one; and a judging step of judging the quality of the long material based on the measured values measured in the measuring step.

In the manufacturing method according to the present invention, it is desirable that the determination step includes a step of calculating an overlap amount or a gap between the material pieces adjacent in the first direction based on the feed amount and the thickness. .

In the manufacturing method according to the present invention, the determining step calculates the width of the elongated material or the deviation amount of the edges of the material pieces adjacent in the first direction based on the positions of the edges. It is desirable to include steps.

A second invention of the present invention is an apparatus for manufacturing a long material, comprising: a conveyor movable in a first direction; a supply section for supplying material pieces to predetermined positions on the conveyor; The material pieces are partially overlapped on the conveyor by moving the conveyor supplied with the material pieces in the first direction by a feeding amount smaller than the length of the material pieces along the first direction. A material preparation unit that joints to form a long material, the feed amount of the conveyor, the thickness of the long material, and the position of the edge in the second direction orthogonal to the first direction of the long material a measuring unit that measures at least one of them; and a determining unit that determines the quality of the elongated material based on the measured value measured by the measuring unit.

In the manufacturing apparatus according to the present invention, it is preferable that the measurement section includes an encoder that measures the feed amount.

In the manufacturing apparatus according to the present invention, it is preferable that the measurement section includes a distance sensor that measures a distance from a predetermined reference position to the long material.

In the manufacturing apparatus according to the present invention, it is preferable that the distance sensors are arranged on the front side and the back side of the elongated material.

In the manufacturing apparatus according to the present invention, it is preferable that the distance sensors are arranged on both sides of the center line of the long material along the first direction.

In the manufacturing apparatus according to the present invention, it is preferable that the measurement section includes a calculation section that calculates the thickness based on the signal output from the distance sensor.

In the manufacturing apparatus according to the present invention, it is preferable that the distance sensor has a measurement area along the width direction of the long material.

In the manufacturing apparatus according to the present invention, it is preferable that the measurement section includes a calculation section that calculates the position of the edge based on the signal output from the distance sensor.

The first invention includes a material preparation step of joining material pieces on a conveyor to form a long material, a measuring step of measuring the long material, and a judgment process of judging the quality of the long material. In the measuring step, at least one of the feed amount of the conveyor, the thickness of the elongated material, and the position of the edge of the elongated material in the second direction is measured. Then, in the determining step, the quality of the elongated material is determined based on the measured values obtained in the measuring step. As a result, it is possible to automatically inspect the quality of long materials while manufacturing them without imposing a burden on workers.

The second aspect of the invention includes a material preparation section that forms a long material by joining material pieces on a conveyor, a measuring section that measures the long material, and a determination section that determines the quality of the long material. The measurement unit measures at least one of the feed amount of the conveyor, the thickness of the elongated material, and the position of the edge of the elongated material in the second direction. Then, the judging section judges the quality of the elongated material based on the measured value measured by the measuring section. As a result, it is possible to automatically inspect the quality of long materials while manufacturing them without imposing a burden on workers.

1 is a plan view showing one embodiment of a manufacturing apparatus according to the first aspect of the present invention; FIG. It is a flowchart which shows the procedure of the manufacturing method of 1st invention of this invention. FIG. 2 is a side view of the measuring section of the manufacturing apparatus showing the arrangement of the distance sensors of FIG. 1; FIG. 2 is a front view of a measuring section of the manufacturing apparatus showing the arrangement of the distance sensors in FIG. 1; FIG. 10 is a plan view showing a length of material including pieces of material displaced in a third direction;

An embodiment of the present invention will be described below with reference to the drawings.
FIG. 1 is a plan view showing a schematic configuration of a manufacturing apparatus 1 of this embodiment. As shown in FIG. 1, the manufacturing apparatus 1 of this embodiment is an apparatus for manufacturing a long material 100. As shown in FIG. The manufacturing apparatus 1 includes a material preparation section 2 that forms the long material 100 , a measuring section 3 that measures the long material 100 and the like, and a determination section 4 that determines the quality of the long material 100 .

A long material 100 is formed by joining a plurality of strip-shaped material pieces 101 . In the elongated material 100 of this embodiment, an array of a plurality of cords is covered with a topping rubber. Such a long material 100 is suitably used for tire carcass plies and belt plies. The elongated material 100 of the present invention is not limited to the cord-containing ply material described above, and may be configured only from rubber.

The material preparation unit 2 includes a conveyor 21 that can move in the first direction D1, a supply unit 22 that supplies the material pieces 101 to the conveyor 21, and a joint unit 23 that joints the material pieces 101 together.

The conveyor 21 is driven by rollers 24 or the like, and conveys the long material 100 (material piece 101) in the first direction. The feed amount of the conveyor 21 is controlled by the rotation speed of the roller 24 or a motor (not shown) that drives the roller 24 .

The supply section 22 supplies the material piece 101 to a predetermined position P on the conveyor 21 . The supply unit 22 supplies the material piece 101 in a third direction D3 having a predetermined angle θ with respect to the first direction D1. The angle θ is determined according to the use of the elongated material 100 and the like.

The joint part 23 presses the rear end in the first direction D1 of the material piece 101 conveyed by the conveyor 21 and the front end in the first direction D1 of the material piece 101 next supplied by the supply part 22. , to joint. By sequentially repeating the supply of the material piece 101 by the supply unit 22, the jointing of the material piece 101 by the joint unit 23, and the conveying of the long material 100 by the conveyor 21, the long material 100 extending in the first direction D1 is formed.

The measurement unit 3 measures the feed amount X of the conveyor 21, the thickness T of the long material 100 (see FIG. 4 described later), and the edges 100a and 100b of the long material 100 in a second direction D2 perpendicular to the first direction D1. Measure at least one of the positions of In this embodiment, the measuring unit 3 includes an encoder 31 for measuring the feed amount X of the conveyor 21, and a distance sensor 32 for measuring the thickness T of the long material 100 and the positions of the edges 100a and 100b. contains. The measurement unit 3 also includes a calculation unit 33 that calculates the feed amount X of the conveyor 21 , the thickness T of the long material 100 and the positions of the edges 100 a and 100 b of the long material 100 .

The encoder 31 is provided, for example, on the side of the conveyor 21 and outputs a pulsed electric signal corresponding to the feed amount X of the conveyor 21 to the calculator 33 . The encoder 31 may be, for example, a linear encoder that measures the amount of movement of the conveyor 21 in the first direction, or a rotary encoder that measures the rotation angle of the roller 24 or the motor that drives the roller 24 .

The distance sensor 32 is provided above or downstream of the conveyor 21 to face the elongated material 100 .

A two-dimensional laser displacement sensor, for example, is used for the distance sensor 32 of the present embodiment. The two-dimensional laser displacement sensor irradiates the subject with laser light L (see FIGS. 3 and 4, which will be described later) and detects the reflected light. It is a non-contact displacement sensor that measures the distance between The reference position can be, for example, the exit port of the laser beam L, but can be any position inside or outside the distance sensor 32 .

The calculation unit 33 is realized by, for example, a CPU (Central Processing Unit) that executes various kinds of arithmetic processing, information processing, etc., and an arithmetic processing unit 5 that includes a memory that stores a program that controls the operation of the CPU and various types of information. . The program may be stored in a hard disk device or the like. The arithmetic processing unit 5 also functions as a determination unit 4, which will be described later. That is, the calculation unit 33 and the determination unit 4 may be configured by the same CPU, memory, and the like.

The calculator 33 calculates the feed amount X of the conveyor 21 based on the electrical signal output from the encoder 31 . Further, the calculation unit 33 calculates the thickness T of the elongated material 100 and the positions of the edges 100a and 100b based on the electrical signal output from the distance sensor 32. FIG. Information regarding the feed amount X of the conveyor 21 , the thickness T of the elongated material 100 and the positions of the edges 100 a and 100 b calculated by the calculation unit 33 is output to the determination unit 4 .

The determination unit 4 determines the measurement values measured by the measurement unit 3, that is, information regarding the feed amount X of the conveyor 21, the thickness T of the long material 100, and the positions of the edges 100a and 100b output from the calculation unit 33. Based on this, the quality of the long material 100 is determined. For example, the determination unit 4 compares the feed amount X of the conveyor 21, the thickness T of the long material 100, and the positions of the edges 100a and 100b measured by the measurement unit 3 with predetermined standard values. , to determine the quality of the strip of material 100 .

When the feed amount X of the conveyor 21, the thickness T of the long material 100, and the positions of the edges 100a and 100b exceed predetermined standard values, the processing unit 5 stops the operation of the manufacturing apparatus 1. FIG. Further, in this case, the arithmetic processing unit 5 may be configured to issue an alarm to that effect and contact the operator, manager, and the like.

According to the manufacturing apparatus 1 described above, it is possible to automatically inspect the quality of the long material 100 while manufacturing it, without imposing a burden on the operator.

FIG. 2 is a flow chart showing the procedure of the method for manufacturing the elongated material 100. As shown in FIG. The method for manufacturing the long material 100 includes material preparation steps S1 and S2 for forming the long material 100, a measurement step S3 for measuring the long material 100, and a determination step S4 for determining the quality of the long material 100. contains.

Material preparation steps S1 and S2 are performed by the material preparation section 2 . That is, by repeating the step S1 of supplying the material piece 101 by the supply unit 22 and the step S2 of moving the conveyor 21 supplied with the material piece 101 in the first direction, the material piece 101 is jointed on the conveyor 21. to form a strip of material 100 .

The measurement step S3 is performed by the measurement section 3 . That is, in the measuring step S3, the measuring unit 3 measures at least one of the feed amount X of the conveyor 21, the thickness T of the long material 100, and the positions of the edges 100a and 100b.

The determination step S4 is performed by the determination unit 4 . That is, in the determination step S4, the determination unit 4 determines the quality of the elongated material 100 based on the measured values measured in the measurement step S3.

By repeatedly performing the steps S1 to S4, the quality of the long material 100 is automatically inspected while it is being manufactured.

3 and 4 show the placement of the distance sensor 32. FIG. A plurality of distance sensors 32 of this embodiment are provided downstream of the conveyor 21 .

The distance sensor 32 includes distance sensors 32A and 32B arranged on the front side of the long material 100 and distance sensors 32C and 32D arranged on the back side of the long material 100 . The distance sensors 32A, 32C are arranged on one side of the center line C of the long material 100 along the first direction D1, and the distance sensors 32B, 32D are arranged on the other side of the center line C, respectively. That is, the distance sensors 32 are arranged on both sides of the center line C. As shown in FIG.

FIG. 3 shows the joint of the material pieces 101 , 101 passing through the measurement area of the distance sensor 32 . As shown in FIG. 3, the distance sensors 32A, 32B measure the distance L1 from their reference position to the surface of the elongate material 100. As shown in FIG. On the other hand, the distance sensors 32C and 32D measure the distance L2 from the reference position to the back surface of the elongated material 100. FIG. Based on the distances L1 and L2, the thickness T of the strip of material 100 is calculated.

When the long material 100 is conveyed in the first direction D1 by the conveyor 21, the location where the distance L1 measured by the distance sensors 32A and 32B sharply decreases (the location where the thickness T of the long material 100 rapidly increases) It can be determined that it is the front edge 101 a of the piece 101 . On the other hand, when the long material 100 is conveyed in the first direction D1 by the conveyor 21, the location where the distance L2 measured by the distance sensors 32C and 32D sharply increases (the location where the thickness T of the long material 100 rapidly decreases) is , the trailing edge 101b of the piece 101 of material.

Therefore, the distance L3 between the rear edge 101b of a given material piece 101 and the front edge 101a of the next material piece 101 supplied by the supply unit 22 is the amount of overlap of the material pieces 101, 101 in the first direction D1 ( joint length). The determination unit 4 calculates the time from the detection of the leading edge 101a by the distance sensors 32A and 32B to the detection of the trailing edge 101b by the distance sensors 32C and 32D, based on the electrical signal output from the encoder 31. By calculating the feeding amount X of the conveyor 21 within the above time, the overlapping amount of the material pieces 101, 101 is calculated. The judging unit 4 judges the quality of the elongated material 100, particularly the joint quality, by comparing the calculated overlapping amount with a predetermined standard value. The joint quality can be evaluated more accurately by calculating the overlapping amount L3·sin θ in the direction orthogonal to the front edge 101a and the rear edge 101b of the material pieces 101, 101. FIG.

When the feed amount X of the conveyor 21 is excessive with respect to the length of the material piece 101 in the first direction D1, a gap is generated between the adjacent material pieces 101,101. If the distance sensors 32C and 32D detect the trailing edge 101b before the distance sensors 32A and 32B detect the leading edge 101a, the judging section 4 determines that the material pieces 101 and 101 are not jointed and there is a gap between them. It can be determined that there is a gap in Such a gap can be determined more accurately by the determination unit 4 monitoring transitions of the distances L1 and L2.

That is, the determination step S4 includes a step of calculating the amount of overlap or gap between the material pieces 101, 101 adjacent in the first direction D1 based on the feed amount X and the thickness T measured in the measurement step S3. . As a result, among the qualities of the elongated material 100, particularly the joint quality of the material pieces 101, 101 can be accurately determined. Further, it is possible to determine whether the length of the material piece 101 supplied from the supply unit 22 in the first direction D1 is abnormal.

In this embodiment, the amount of overlap or the gap between the material pieces 101 adjacent to each other in the first direction D1 is calculated based on the feed amount X and the thickness T, so that the cause of joint failure can be easily identified. can. For example, if the feed amount X is abnormal, the cause is the conveyor 21, and if the feed amount X is normal, the length of the material piece 101 in the first direction D1 or the feed angle θ is the cause. can be estimated.

Further, in this embodiment, the distance sensors 32A and 32C are arranged on one side of the center line C of the elongated material 100, and the distance sensors 32B and 32D are arranged on the other side of the center line C. By calculating and comparing the amount of overlap or gap between the pieces of material 101, 101 on both sides of the line C, the quality such as symmetry of the elongated material 100 can be determined in detail.

As shown in FIG. 4 , each of the distance sensors 32A, 32B, 32C, 32D has respective measurement areas SA, SB, It has SC and SD. Distance sensors 32A, 32B, 32C, and 32D are arranged so that respective measurement areas SA, SB, SC, and SD include edges 100a and 100b in second direction D2, which is the width direction of long material 100. there is

The calculator 33 calculates the positions of the edges 100a and 100b (that is, the centerline C to edges 100a and 100b). The edges 100a and 100b are located at locations where the distance L1 (see FIG. 3) from the reference position sharply increases (the thickness T of the long material 100 sharply decreases) from the center line C toward the outside in the width direction of the long material 100. It is identified by detecting the location where the Electrical signals output from the distance sensors 32C and 32D may be used to calculate the positions of the edges 100a and 100b.

Then, the determination unit 4 calculates the width W of the long material based on the positions of the edges 100a and 100b. That is, the determination step S4 includes a step of calculating the width W of the long material 100 based on the positions of the edges 100a and 100b. This makes it possible to determine the quality of the long material 100 in detail.

FIG. 5 shows a length of material 100 including a piece of material 101 displaced in the third direction D3. In the present embodiment, the calculation unit 33 calculates the positions of the edges 100a and 100b, so that the edges 100c and 100d of the material piece 101 that is displaced in the third direction D3 are shifted from the edges 100a and 100b. fluctuate. Based on the positions of the edges 100a, 100b, 100c, and 100d, the determination unit 4 calculates the displacement amount Z of the edges 100c and 100d. That is, the determination step S4 includes a step of calculating the displacement amount Z of the edges 100c and 100d based on the positions of the edges 100a, 100b, 100c and 100d. This allows the quality of the elongated material 100 to be determined in greater detail.

Although the manufacturing apparatus 1 and the manufacturing method of the present invention have been described in detail above, the present invention is not limited to the above-described specific embodiments and can be modified in various aspects.

1: Manufacturing device 2: Material preparation unit 3: Measurement unit 4: Judgment unit 21: Conveyor 22: Supply unit 23: Joint unit 31: Encoder 32: Distance sensor 33: Calculation unit 100: Long material 100a: Edge 100b: Edge 100c: Edge 100d: Edge 101: Material piece 101a: Front edge 101b: Rear edge C: Center line D1: First direction D2: Second direction D3: Third direction L: Laser beams S1, S2: Material preparation process S3 : Measurement process S4 : Judgment process SA : Measurement area SB : Measurement area SC : Measurement area SD : Measurement area Z : Deviation amount

Claims (11)

A method for manufacturing a length of material, comprising:
supplying a piece of material to a predetermined position on a conveyor movable in a first direction; a material preparation step of forming the long material by repeating the step of moving in the first direction by a feed amount and jointing the material pieces so that they partially overlap on the conveyor;
a measuring step of measuring at least one of the feed amount of the conveyor, the thickness of the long material, and the position of the edge of the long material in a second direction orthogonal to the first direction ;
a determination step of determining the quality of the long material based on the measured values measured in the measurement step ;
A cause identification step of identifying the cause of joint failure based on the feed amount of the conveyor and the thickness of the long material,
A method for manufacturing the long material. 2. The manufacturing method according to claim 1, wherein said determining step includes a step of calculating an overlapping amount or a gap between said material pieces adjacent in said first direction based on said feed amount and said thickness. 3. The determining step includes calculating a width of the elongated material or a deviation amount of the edges of the material pieces adjacent in the first direction based on the positions of the edges. The manufacturing method described in . An apparatus for manufacturing elongated material, comprising:
a conveyor movable in a first direction; a supply unit for supplying a piece of material to a predetermined position on the conveyor; a material preparation unit that moves in the first direction at a feed amount less than the length of the material to form the long material by jointing the material pieces so that the material pieces partially overlap on the conveyor;
a measuring unit that measures at least one of the feed amount of the conveyor, the thickness of the long material, and the position of the edge of the long material in a second direction orthogonal to the first direction;
a determination unit that determines the quality of the long material based on the measured values measured by the measurement unit; and
A cause identification unit that identifies the cause of joint failure based on the feed amount of the conveyor and the thickness of the long material,
A manufacturing apparatus for the elongated material. 5. The manufacturing apparatus according to claim 4, wherein said measuring unit includes an encoder for measuring said feed amount. 6. The manufacturing apparatus according to claim 4, wherein said measuring unit includes a distance sensor that measures a distance from a predetermined reference position to said long material. 7. The manufacturing apparatus according to claim 6, wherein said distance sensors are arranged on the front side and the back side of said elongated material. 8. The manufacturing apparatus according to claim 6, wherein said distance sensors are arranged on both sides of a center line of said elongated material along said first direction. 9. The manufacturing apparatus according to any one of claims 6 to 8, wherein said measurement unit includes a calculation unit that calculates said thickness based on a signal output from said distance sensor. 7. The manufacturing apparatus according to claim 6, wherein said distance sensor has a measurement area along the width direction of said elongated material. 11. The manufacturing apparatus according to claim 10, wherein said measurement unit includes a calculation unit that calculates the position of said edge based on the signal output from said distance sensor.

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