JP7451191B2 - Controls and roll-to-roll conveying systems - Google Patents

Description

The present invention relates to a control device for a roll-to-roll conveyance system.

In a roll-to-roll conveyance system, a long object (web) such as paper, film, or metal foil is unwound from a roll, moved through rollers, and various processes are applied to the web along the path of movement. Generally, the web is conveyed under tension set as production conditions so that it does not slacken on the moving path and is easy to process. To accomplish this, the web processing system includes a dancer mechanism or tension detector to control the web to maintain a set tension.

Japanese Patent Application Publication No. 2013-173598

Calibration is required before using the dancer mechanism. There is nothing better than being able to reduce the burden of this calibration work.

The present invention has been made in view of these circumstances, and one exemplary objective of a certain aspect of the present invention is to provide a technique that can reduce the burden of calibration work on a dancer mechanism.

In order to solve the above problems, a control device according to an aspect of the present invention is a control device for a roll-to-roll conveyance system that includes a dancer roller that applies tension to a web and a sensor that detects the position of the dancer roller. a first button for storing the detected value of the sensor as a first detected value indicating that the dancer roller is in the first position; and a second button for storing the detected value of the sensor as a first detected value indicating that the dancer roller is in the second position. a second button for storing the value as a value; a display control unit for displaying a screen including the button on a predetermined display unit; and a position specifying unit for specifying the position.

Another aspect of the invention is also a control device. This device is a control device for a roll-to-roll conveyance system that includes a dancer roller that applies tension to the web and an actuator that applies thrust to the dancer roller. A first button for storing the amount of operation applied to the actuator as the first amount of operation for applying the first thrust to the dancer roller, and a second button for storing the amount of operation applied to the actuator as the second amount of operation for applying the first thrust to the dancer roller. 1 button, a display control unit that displays a screen including a button on a predetermined display unit, and a first operation amount and a second operation amount to specify an operation amount for the actuator to apply a desired thrust to the dancer roller. An operation amount specifying section.

Note that arbitrary combinations of the above-mentioned components and mutual substitution of the components and expressions of the present invention among methods, devices, systems, etc. are also effective as aspects of the present invention.

According to the present invention, the load of calibrating the dancer mechanism can be reduced.

FIG. 1 is a schematic diagram showing the configuration of a roll-to-roll conveyance system according to an embodiment. FIG. 2 is a block diagram showing the functional configuration of the control device in FIG. 1. FIG. 3 is a diagram showing a sensor calibration screen displayed by the display control section of FIG. 2. FIG. 3 is a diagram showing an actuator calibration screen displayed by the display control section of FIG. 2. FIG.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below based on preferred embodiments with reference to the drawings. Identical or equivalent components, members, and processes shown in each drawing are designated by the same reference numerals, and redundant explanations will be omitted as appropriate. Further, the embodiments are illustrative rather than limiting the invention, and all features and combinations thereof described in the embodiments are not necessarily essential to the invention.

FIG. 1 is a schematic diagram showing the configuration of a roll-to-roll conveyance system (hereinafter simply referred to as a conveyance system) 2 according to an embodiment. The conveyance system 2 includes an unwinding unit 10 that unwinds the web 4, a first feed unit 14, a second feed unit 16, and a third feed unit 18 that convey the unwound web 4, and a winding unit that winds the web 4. It includes a take unit 12 and a control device 11 that controls them.

The web 4 is a band-like or sheet-like base material such as paper or film, and exists continuously along the moving path. The web 4 is subjected to predetermined processing along the moving route. The predetermined processing may be, for example, processing such as printing, stretching, shaping, coating, laminating, slitting, etc., or it may also be a process such as printing, stretching, forming, coating, laminating, slitting, etc., or also rolling the web from a large unwind roll to a plurality of smaller take-up rolls. 4 may be wound up. The web 4 is conveyed under a tension set as a production condition so that it does not slacken on the moving path and is easy to process.

The unwinding unit 10 includes an unwinding roll 20, a gear 22, a motor 24, and a tension detector 26. Motor 24 rotates unwinding roll 20 via gear 22. The unwinding roll 20 gives the web 4 unwound therefrom a speed that depends on the rotational speed and diameter of the unwinding roll 20.

The tension detector 26 is configured to be able to detect the tension of the web 4 unwound from the unwinding roll 20, that is, the tension of the web 4 between the unwinding roll 20 and a feed roller 30 (described later). The control device 11 controls the speed of the motor 24 and the speed difference between the motor 24 and the motor 34 (described later) so that the tension of the web 4 between the unwinding roll 20 and the feed roller 30 is maintained at a predetermined target value. control.

The first feed unit 14 includes a feed roller 30, a gear 32, a motor 34, and a dancer mechanism 36. Motor 34 rotates feed roller 30 via gear 32. The feed roller 30 provides the web 4 with a speed corresponding to its rotational speed and diameter.

The dancer mechanism 36 is provided downstream of the feed roller 30 in the movement path of the web 4 . Dancer mechanism 36 includes a dancer roller 70, an actuator 72, and a sensor 76. Dancer roller 70 is supported movably in the vertical direction in this embodiment, although it is not particularly limited. The actuator 72 applies thrust to the dancer roller 70. The actuator 72 of this embodiment has a rod 74 connected to the dancer roller 70 and applies thrust to the dancer roller 70 via the rod 74. The dancer roller 70 receiving the thrust presses the web 4. Thereby, tension is applied to the web 4. The control device 11 controls the actuator 72 to maintain the tension of the web 4 between the feed roller 30 and the feed roller 40 at a predetermined target value.

The sensor 76 detects the position of the dancer roller 70. The sensor 76 of this embodiment detects the position of the dancer roller 70 by detecting the position of the rod 74. The sensor 76 outputs a detected value indicating the position of the dancer roller 70 to the control device 11 at a predetermined period.

The second feed unit 16 includes a feed roller 40, a gear 42, and a motor 44. Motor 44 rotates feed roller 40 via gear 42 . The feed roller 40 provides the web 4 with a speed corresponding to its rotational speed and diameter. In this example, the second feed unit 16 is a unit that serves as a speed reference. Therefore, the control device 11 rotates the motor 44 and thus the feed roller 40 at a constant reference speed.

The third feed unit 18 includes a feed roller 50, a gear 52, a motor 54, and a tension detector 56. Motor 54 rotates feed roller 50 via gear 52. The feed roller 50 provides the web 4 with a speed corresponding to its rotational speed and diameter. The tension detector 56 is configured to be able to detect the tension of the web 4 between the feed roller 40 and the feed roller 50. The control device 11 controls the speed of the motor 54 and the speed difference between the motors 54 and 44 so that the tension of the web 4 between the feed rollers 40 and 50 is maintained at a predetermined target value.

The winding unit 12 includes a winding roll 60, a gear 62, a motor 64, and a tension detector 66. It is configured to be able to detect the tension of the web 4 between the webs 4 and 4. Motor 64 rotates take-up roll 60 via gear 62. A take-up roll 60 takes up the web 4. The control device 11 controls the speed of the motor 64 and the speed difference between the motors 64 and 54 so that the tension of the web 4 between the feed roller 50 and the take-up roll 60 is maintained at a predetermined target value. .

FIG. 2 is a block diagram showing the functional configuration of the control device 11. As shown in FIG. Each block shown here can be realized in terms of hardware using elements such as a computer's CPU or mechanical devices, and in terms of software, it can be realized by computer programs, etc., but here, they are realized by their cooperation. The functional blocks are drawn. Therefore, those skilled in the art will understand that these functional blocks can be realized in various ways by combining hardware and software.

The control device 11 includes a display control section 102, a calibration support section 104, a unit control section 106, a dancer position specifying section 108, a manipulated variable specifying section 110, and a storage section 112. The storage unit 112 stores data referenced and updated by each unit. The display control unit 102 displays various screens on a predetermined display unit. The display control unit 102 displays, for example, a sensor calibration screen and an actuator calibration screen, which will be described later.

The calibration support unit 104 supports calibration of the sensor 76 and actuator 72. The dancer position specifying unit 108 specifies the position of the dancer roller 70 at a predetermined period based on the detected value from the sensor 76. The operation amount specifying unit 110 specifies the operation amount for the actuator 72 to apply a desired thrust to the dancer roller 70. Details of the calibration support section 104, dancer position specifying section 108, and operation amount specifying section 110 will be described later.

The unit control section 106 controls the unwinding unit 10, the winding unit 12, the first feed unit 14, the second feed unit 16, and the third feed unit 18. Specifically, the unit control section 106 controls the motors 24, 34, 44, 54, and 64 of each unit and the dancer mechanism 36 so that the tension of the web 4 reaches a predetermined target value. The unit control section 106 particularly controls the actuator 72 using the position of the dancer roller 70 specified by the dancer position specifying section 108 and the operation amount specified by the operation amount specifying section 110.

FIG. 3 is a diagram showing a dancer position calibration screen displayed on a predetermined display section by the display control section 102. The latest detected value (voltage value in this example) from the sensor 76 is displayed in the detected value display column 126.

The user clicks the first set button 120 while moving the dancer roller 70 to the +100% position. Then, the calibration support unit 104 stores the latest detected value (voltage value in this example) from the sensor 76 at this time in the storage unit 112 as the first detected value indicating that the dancer roller 70 is at the +100% position. The "+100% position" is the position of the dancer roller 70 where the path of the web 4 is the shortest, and in the example of FIG. 1 is the upper end position in the stroke range of the dancer roller 70.

Further, the user clicks the second set button 122 while moving the dancer roller 70 to the -100% position. Then, the calibration support unit 104 stores the latest detection value from the sensor 76 at this time in the storage unit 112 as a second detection value indicating that the dancer roller 70 is at the -100% position. The "-100% position" is the position of the dancer roller 70 where the path of the web 4 is the longest, and in the example of FIG. 1 is the lower end position in the stroke range of the dancer roller 70.

The dancer position specifying unit 108 specifies the position of the dancer roller 70 indicated by the detected value of the sensor 76 by linear interpolation using the first detected value and the second detected value.

The dancer position display field 124 displays the position of the dancer roller 70, which is specified from the sensor detection value by linear interpolation using the first detection value and the second detection value. For example, the user moves the dancer roller 70 to around the 0% position (the middle position of the stroke range) and checks whether the value displayed in the dancer position display column 124 is close to 0%. This makes it possible to confirm whether the sensor 76 has been correctly calibrated.

FIG. 4 is a diagram showing a dancer thrust calibration screen displayed on a predetermined display section by the display control section 102. A thrust force is input into the first thrust input field 130. Hereinafter, the thrust input into the first thrust input field 130 will be referred to as a first thrust. As the first thrust, a thrust that is within the range that can be applied to the web 4 by the dancer roller 70 and that is greater than or equal to the thrust that is scheduled to be applied is adopted. The first thrust may be the maximum thrust that can be applied, that is, the maximum thrust according to the specifications of the dancer mechanism 36.

When the first set button 132 is clicked, the calibration support unit 104 calculates the operation amount (driving voltage in this example) of the actuator 72 for applying the first thrust based on a predetermined calculation formula. The calibration support unit 104 displays the calculated operation amount in the operation amount display column 146, and drives the actuator 72 using the operation amount.

If a thrust lower than the first thrust is applied to the dancer roller 70, the Up button 148 is clicked. Then, the calibration support unit 104 increases the operation amount displayed in the operation amount display column 146 by a predetermined value, and drives the actuator 72 with the increased operation amount.

If a thrust higher than the first thrust is applied to the dancer roller 70, the Down button 150 is clicked. Then, the calibration support unit 104 lowers the manipulated variable displayed in the manipulated variable display field 146 by a predetermined value, and drives the actuator 72 with the lowered manipulated variable.

The user clicks on the Up button 148 and/or the Down button 150 until the first thrust is actually applied to the dancer roller 70.

If the first thrust is actually applied to the dancer roller 70, the first save button 136 is clicked. Then, the calibration support unit 104 stores the operation amount at this time in the storage unit as the first operation amount for applying the first thrust to the dancer roller 70, and displays it in the first operation amount display column 134.

Whether or not the first thrust is actually applied to the dancer roller 70 may be determined by installing a tension detector, for example. Alternatively, for example, the same load as the first thrust may be applied to the dancer roller 70 using a weight or the like, and the determination may be made based on whether or not the dancer roller 70 is balanced at the 0% position.

In the second thrust input field 138, a thrust lower than the first thrust is input. Hereinafter, the thrust input into the second thrust input field 138 will be referred to as a second thrust. As the second thrust, a thrust within a range that can be applied to the web 4 by the dancer roller 70 and less than or equal to the thrust to be applied is adopted. The second thrust may be the lowest thrust that can be applied, that is, the lowest thrust according to the specifications of the dancer mechanism 36.

When the second set button 140 is clicked, the operation amount of the actuator 72 for applying the second thrust is calculated based on the above-mentioned calculation formula. The calibration support unit 104 displays the calculated operation amount in the operation amount display column 146, and drives the actuator 72 using the operation amount.

If the second thrust is not applied to the dancer roller 70, click the Up button 148 and/or the Down button 150 until the second thrust is actually applied to the dancer roller 70, as in the case of the first thrust.

If the second thrust is actually applied to the dancer roller 70, the second save button 144 is clicked. Then, the calibration support unit 104 stores the operation amount at this time in the storage unit as the second operation amount for applying the second thrust to the dancer roller 70, and displays it in the second operation amount display field 142.

Whether or not the first thrust is actually applied to the dancer roller 70 may be determined in the same manner as in the case of the first thrust.

The manipulated variable specifying unit 110 identifies the manipulated variable for the actuator 72 to apply a desired thrust to the dancer roller 70 by linear interpolation using the first manipulated variable and the second manipulated variable.

According to the control device 11 described above, the first detection value and the second detection value are stored by operating a button on the screen, and based on them, the position of the dancer roller 70 indicated by the detection value of the sensor 76 is automatically specified. . This reduces the load on the user.

Further, according to the control device 11, the first operation amount and the second operation amount are stored by operating a button on the screen, and based on these, the operation amount for applying a desired thrust to the dancer roller 70 is automatically determined. be identified. This reduces the load on the user.

The present invention has been described above based on the embodiments. Those skilled in the art will understand that this embodiment is merely an example, and that various modifications can be made to the combinations of these components and processing processes, and that such modifications are also within the scope of the present invention. be.

2 roll-to-roll conveyance system, 4 web, 11 control device, 102 display control section, 106 unit control section, 108 dancer position specifying section, 110 operation amount specifying section.

Claims (3)

A control device for a roll-to-roll conveyance system, comprising a dancer roller that applies tension to a web, and a sensor that detects the position of the dancer roller,
a first button for storing the detection value of the sensor as a first detection value indicating that the dancer roller is in a first position; and a first button for storing the detection value of the sensor as a first detection value indicating that the dancer roller is in a second position. a second button for storing as a second detected value; a display control unit that causes a predetermined display unit to display a screen including
The position of the dancer roller indicated by the detection value of the sensor is determined by linear interpolation using the first detection value stored by operating the first button and the second detection value stored by operating the second button. a dancer position identification unit for identifying the dancer ;
The control device is characterized in that the display control section causes the position of the dancer roller specified by the dancer position specifying section to be displayed on the predetermined display section . A control device for a roll-to-roll conveyance system comprising a dancer roller that applies tension to a web, and an actuator that applies thrust to the dancer roller,
a first button for storing the amount of operation applied to the actuator as a first amount of operation for applying a first thrust to the dancer roller; and a second button for storing the amount of operation applied to the actuator as a first amount of operation for applying a first thrust to the dancer roller; a second button for storing a second operation amount for applying thrust; and a display control unit that displays a screen including a second button on a predetermined display unit;
The actuator applies a desired thrust to the dancer roller by linear interpolation using the first operation amount stored by operating the first button and the second operation amount stored by operating the second button. a manipulated variable identification unit that identifies a manipulated variable for
The display control unit displays a screen including an Up button for increasing the amount of operation applied to the actuator by a predetermined value, and a Down button for decreasing the amount of operation applied to the actuator by a predetermined value. A control device characterized by displaying information on a display unit . A roll-to-roll conveyance system comprising the control device according to claim 1 or 2 .

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