JPH08245056A - Failure data correcting device and failure processing control device - Google Patents

Abstract

PURPOSE: To reduce work load and improve work reliability by correcting failure data on the basis of a status parameter to obtain corrected failure data, and obtaining control data from the corrected failure data obtained by correcting the failure data on the basis of the status parameter. CONSTITUTION: A failure data correcting device 1 reads a status parameter 11 from a production control system 4 or the like and stores it in a storage means 8. The failure data correcting device 1 also reads failure detection data from a failure detecting device 6 and web transfer data at the failure detecting time from a web transfer distance measuring device 5 and stores these failure data 12 in the storage means 8. On the basis of the status parameter 11, corrected failure data is further obtained through corrective processing routine 14. On the other hand, a failure processing control device 2 stores corrected failure data 17 in a storage means 15, reads the web transfer distance data from a web transfer distance measuring device 7 to perform relative operation to the failure position data through control data generation and processing routine 19, and outputs specified control data to a production machine control device 8.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for correcting defective data and an apparatus for generating control data for a manufacturing / processing apparatus based on the corrected data. In particular, in a web manufacturing and processing apparatus such as an offset printing machine, a gravure printing machine, a coating machine, a papermaking machine, a plastic sheet manufacturing machine, etc., the defective data relating to the web which is wound after the manufacturing processing and becomes a winding body is acquired and corrected. The present invention relates to a device and a device that generates control data in a defect processing process.

[0002]

2. Description of the Related Art In a web manufacturing and processing apparatus such as an offset printing machine, a gravure printing machine, a coating machine, a papermaking machine and a plastic sheet manufacturing machine, the web after the manufacturing and processing is wound around a core such as a paper tube. Since it is a winding body, it is not possible to judge from the appearance which is a good product and which is a defective product. Therefore, the operator of the manufacturing and processing machine attaches a label to the start position of the normal paper (non-defective product) or the edge of the web of the defective part when a defect occurs, inserts a piece of paper or tape, and puts the label on the outside of the winding body. In some cases, a piece of paper or a tape is exposed so that a defective portion can be extracted in a later process as a mark. In addition, for each web winding body, enter the start position and end position of the defect as data relating to the defect position, and the defect name as data relating to the content of the defect in the slip (for example, refer to the winding quality communication card in FIG. 8). In the terminal of the production management system (for example, refer to the screen display of FIG. 9), data is automatically or manually input and referred to when necessary.

[0003]

However, since the reliability (accuracy) of the defect position data is unknown, when the process of removing the defect or the work of confirming the defect is performed, only the worst possible position error is considered. It is necessary for the operator to visually check whether there is any defect from the position in front. In addition, if the defect is mild, it may not be necessary to perform a process for removing the defect. However, since the defect level (necessity of processing) cannot be determined from the data transmitted from the previous process, the operator in the subsequent process cannot omit the visual confirmation work.

Therefore, an object of the present invention is to correct defective data appropriately to obtain corrected defective data, and
An object of the present invention is to provide a device that generates control data for performing device control of a subsequent process based on the corrected defective data.

[0005]

The above object can be achieved by the present invention described below. That is, the present invention is a defect data correction device having a correction operation unit that performs an operation for correcting defect data based on a situation parameter to obtain corrected defect data. Further, the present invention is a defect processing control device having a control data generation unit that obtains control data from corrected defective data obtained by performing a calculation for correcting defective data based on a situation parameter.

[0006]

According to the defective data correcting apparatus of the present invention, the correction calculating means performs the calculation for correcting the defective data based on the situation parameter indicating the situation at the time of acquiring the defective data, and the corrected defective data is obtained. Since this corrected defective data is the data obtained by proper correction, the processing in the subsequent process may be performed based on this data, and it is necessary to perform the work in comparison with the case of processing based on the worst possible error. The load is greatly reduced. Further, according to the defect processing control device of the present invention, the control data generation means can obtain the control data from the corrected defect data obtained by performing the operation for correcting the defect data based on the situation parameter. Since the automatic control is performed based on the corrected defective data described above, the work load is further reduced and the work reliability is high.

[0007]

Next, the present invention will be described based on preferred embodiments. FIG. 1 is a diagram showing the configurations of a defective data correction device, a defective processing control device, and peripheral devices according to the present invention. FIG.
In FIG. 1, the part surrounded by the solid line frame 1 is the defective data correction device of the present invention, and the part surrounded by the solid line frame 2 is the defect processing control device of the present invention, and 3 is the LAN (Lo
cal area network), 4 is a production management system capable of mutually transferring data with the defective data correction device 1 and the defective processing control device 2 through the LAN 2, and storing and managing data relating to production. 5 is a web transfer on a production machine. A web transfer distance measuring device that measures a distance and outputs data to the defect data correction device 1, 6 is a defect detection device that performs quality inspection of the web on the production machine and outputs data to the defect data correction device 1, 7 is a production machine The web transfer distance measuring device 8 measures the web transfer distance and outputs data to the defect processing control device 2, and 8 is a production machine control device to which the defect processing control device 2 outputs control data.

In FIG. 1, the defective data correction device 1 is further configured in detail, 9 is a storage means, 10 is a calculation means, and these are the main body of a computer such as a personal computer or an engineering workstation, or the calculation. It is a control device such as a sequence control device having a function. In the storage means 9, 11 is a situation parameter, 12 is defective data, 13 is corrected defective data, and in the arithmetic means 10, 14 is a correction arithmetic processing routine. Further, in FIG. 1, the defect processing control device 2 is further configured in detail, 15 is a storage means, 16 is a calculation means, and these are the main body part of a computer such as a personal computer or an engineering workstation, or a calculation function. It is a control device such as a sequence control device. And the storage means 15
In FIG. 17, reference numeral 17 is corrected defective data, 18 is control data, and in the calculating means 16, 19 is a control data generation processing routine.

FIG. 2 is a flow chart showing the processing steps in the defective data correction apparatus of the present invention. Further, FIG. 3 is a flow chart showing a processing process in the defect processing control device of the present invention. The operation of the defective data correction device and the defective processing control device of the present invention will be described with reference to FIGS. First, the defective data correction device 1 will be described. In the defective data correction device 1, the situation parameter 11 is read from the production management system 4 or the like and stored in the storage means 9. The situation parameter has the following items, and is composed of data of at least one item of those data (S1). Work process (factory, production machine etc.) Inspection machine performance Production machine setting Workers (proficiency level, number of people etc.) Presence or absence of visual confirmation Material used (web material, ink type etc.) Difficulty in product processing Details of defects (This status parameter is read from the defect detection device.) Acceptable product range

Next, the defect detection data is read from the defect detection device 6 and the web transfer data (defect position data) at the time of the defect detection from the web transfer distance measuring device 5, and the defect data 12 composed of these data is read. It is stored in the storage means 9. The defect detection data includes not only the presence / absence of a defect and the position of the defect but also detailed data of the degree of the defect and the content of the defect. The detailed data of the defect content is also stored in the situation parameter 11 (S2). Next, the correction calculation processing routine 14 performs a calculation for correcting the defective data based on the situation parameter 11 to obtain corrected defective data. The calculation for correcting the defective data differs depending on the item of the situation parameter 11. A specific example will be described later (S3).

Next, the defect processing control device 2 will be described. The corrected defective data 17 obtained by performing the calculation for correcting the defective data based on the situation parameter is read from the defective data correcting device 1 or the production management system 4 into the defective processing control device 2 and stored in the storage means 15 (S11). Next, by the control data generation processing routine 19, the web transfer distance data is constantly read from the web transfer distance measuring device 7 (at a sampling period considered to be substantially continuous), and the defect position data included in the corrected defect data 17 is read. Is calculated and compared with. This defective position data is corrected defective data 17
Needless to say, defective data 1
It is different from the data included in 2 (raw data). If the result that the defective position is near is obtained by the comparison calculation,
Control data is generated such that the web transfer speed is reduced and the web transfer is stopped when the defective position of the web reaches a predetermined position of the production machine, and the control data is output to the production machine control device 8 (S12). .

Next, the present invention will be described with reference to more specific examples. FIG. 4 is a diagram schematically showing a state in which the defective data correction device and the defective processing control device of the present invention are installed in a production machine. In FIG. 4, reference numeral 20 denotes the transfer distance data of the web 27 output by the web transfer distance measuring device, the defect data output by the defect detecting device, and the situation parameters stored in the production management system. machine)
The input device 21 for inputting from the device has a correction operation means for performing an operation for correcting defective data based on the situation parameter to obtain corrected defective data, and a control data generating means for obtaining control data from the corrected defective data. A storage / arithmetic device (device of the present invention), 22 is an information acquisition device for acquiring control data, and 23 is a signal control device for controlling transfer of the web 31 to perform processing such as defect removal based on the control data. Is.

Further, 24 is a first production machine and 25 is a first production machine.
Of the first production machine 24, 26 is a paper discharge section of the first production machine 24, and 27 is a web that is transported in the direction of the arrow.
28 is a second production machine, 29 is a second production machine 28
Of the second production machine 28, 31 is a web, and is conveyed in the direction of the arrow.

The operation of the above structure will be described below.
In the first production machine 24, from the paper feed unit 25 to the web 27
Is fed, processed, and subjected to quality inspection by a defect detection device (not shown), and then wound as a winding body in the paper discharge unit 26. When a defect occurs, the input device 20 inputs the web transfer distance data from the web transfer distance measuring device (not shown) to the storage / calculation device 21 in order to identify the defective position of the web. Further, the input device 20 firstly sets the failure data output by the failure detection device (not shown) and the situation parameter stored in the production management system (not shown).
Input from the production machine 21.

FIG. 5 is a diagram showing the relationship between the defective position of defective data and the defective position of corrected defective data with respect to the occurrence of defects on the web 27. In FIG. 5, the defective position of the defective data is between 3000 m and 3100 m, and the defective position of the corrected defective data is between 2910 m and 3194 m. As shown in FIG. 5, it is assumed that the input device 20 now obtains defective data "the defective position is between 3000 m and 3100 m". The defective data is raw data that does not take into consideration the expansion and contraction of the web due to the web tension in the first production machine 24, the measurement error of the transfer distance measuring device (not shown), and the like. The expansion and contraction of these webs and the measurement error are obtained as situation parameters. Input device 20
When the production machine ID and the winding body ID are input, the amount of error corresponding to the input ID is stored in the database of the storage operation device 21.

FIG. 6 is a diagram showing the contents of the defect position data accuracy parameter and the defect position data in the database of the storage operation device 21. In the table defective position data accuracy parameter of FIG. 6, for the production machine ID A, there are items of tension and input device error as error factors, and the error amounts are described respectively. These items are examples of situation parameters. Since these two items are independent error factors, the error amount (correction parameter) of the total amount due to both is given by the product. If the error width due to tension is 99% to 101% and the error width due to input device error is 98% to 102%, the error width due to both is 97. It becomes 02% to 103.02%.

When the storage / calculation unit 21 executes the calculation for correcting the defective data based on the result, as shown in the defective position data in the table of FIG. 6, for the input defective position (defective data) of 3000 m to 3100 m, The correction parameter 0.9702 is multiplied by 1.0302 to obtain the product (correction defect position), that is, 291 as corrected defect data.
0.6 m to 3193.62 m is obtained. 2910m to 3194 which are the defective positions of the corrected defective data shown in FIG.
m can thus be obtained from the bad data using the situation parameters.

In the second production machine 28 shown in FIG. 4, the corrected defective data (positional data of a region where a defect may exist) shown in the table defective position data of FIG.
Is input to the information acquisition device 22. Based on the data, the signal control device 23 outputs a control signal to the second production machine 28, and the second production machine 28 slows down the web transfer and stops at the defective start position, for example.
Defect processing such as driving a defect removal device is performed.

Here, an example of a method of determining the value of the situation parameter will be described. As a method of determining the value of the situation parameter, it can be determined by statistical data. In the above example, the error range due to the accuracy of the defect input device is set sufficiently large (for example, ± 10%) and the actual work is performed to collect the error between the defect position of the corrected defect data and the actual defect position for a certain period. To do. When the numerical value that can be judged as the maximum error that can occur is obtained (for example, the error is always within ± 1%), the value of the situation parameter is corrected based on that value (for example ± 10% → ± 1%).

Next, the present invention will be described with reference to another example. Manufacturing processes such as laminating a plurality of films into a single film on a web of a transparent (semi-transparent) film such as a plastic film, coating for uniformly providing a coating layer on the film surface, and the like are performed. The web thus obtained is used for various purposes such as different printings as raw materials.
And, depending on the application, the required standard for the quality of the raw material web is different. In this example, a case will be described in which defective data output by a quality inspection device that detects the light transmittance of the web in the manufacturing process as described above is corrected by a situation parameter to obtain corrected defective data.

FIG. 7 is a graph showing the position of the web on the horizontal axis and the light transmittance (%) of the web on the vertical axis. As shown in FIG. 7, the target light transmittance was 20%, the allowable range of non-defective products when used for product A was 20 ± 5%, and the allowable range of non-defective products when used for product B was 20 ± 15%. To do. Figure 7
The defect 1 part exceeds 20 ± 5% of the acceptable range of non-defective products and is defective for product A, but 20% of the acceptable range of non-defective products.
Since it is within ± 15%, it is a good product for the product B.
Further, the defect 2 portion exceeds 20 ± 15% of the acceptable range of non-defective products, and both product A and product B are defective.

When the unevenness of the light transmittance is detected, not only the presence or absence of the unevenness but also the light transmittance is acquired and stored. In this case, the light transmittance is data indicating details of the defect content,
This data "light transmittance" is stored as a situation parameter that can be read by the winding body ID. Production machine I
Examples of "tension" and "input device error" as situation parameters that can be read by D have been shown above.
In addition to this, the "good product allowable range" is included as a situation parameter that can be read by the production item ID. In this way, even if there are defects 1 and 2 in the defective data, the defective data is corrected and calculated from the situation parameters that can be read by the winding body ID and the production item ID to determine the production item ID. In the case of the product B, the corrected defective data is only the defect 2.

[0023]

As described above, according to the present invention, the defective data is properly corrected to obtain the corrected defective data, and the device control of the subsequent process is performed based on the corrected defective data. An apparatus for generating control data is provided. With the device of the present invention, it is possible to obtain corrected defective data by performing correction calculation on the defective data using the situation parameters, and it is possible to reduce the work load of the defective portion identification and processing in the subsequent process. Further, it is possible to digitize and rank the reliability evaluation of each work unit (process, worker, etc.). For example, when a worker who inputs defective data is regarded as a situation parameter, a worker with a small error range has a higher technical level.

[Brief description of drawings]

FIG. 1 is a diagram showing a configuration of a defect data correction device, a defect processing control device, and a peripheral device of the present invention.

FIG. 2 is a flowchart showing a processing process in the defective data correction device of the present invention.

FIG. 3 is a flowchart showing a processing process in the defect processing control device of the present invention.

FIG. 4 is a diagram schematically showing a state in which a defect data correction device and a defect processing control device of the present invention are installed in a production machine.

FIG. 5 is a diagram showing a relationship between a defective position of defective data and a defective position of corrected defective data regarding occurrence of a defect on a web.

FIG. 6 is a diagram showing the contents of defective position data accuracy parameters and defective position data in the database of the storage operation device 21.

FIG. 7: Web position on the horizontal axis, web light transmittance (%)
Is a graph in which the vertical axis represents.

FIG. 8 is a diagram showing an example of a slip for recording defective data.

FIG. 9 is a diagram showing an example of a terminal screen display for inputting defective data.

[Explanation of symbols]

 1 Defect Data Correction Device 2 Defect Processing Control Device 3 LAN 4 Production Management System 5, 7 Web Transfer Distance Measuring Device 6 Defect Detection Device 8 Production Machine Control Device 9, 15 Storage Means 10, 16 Calculation Means 11 Status Parameter 12 Defect Data 13 , 17 Corrected defective data 14 Correction calculation processing routine 18 Control data 19 Control data generation processing routine 20 Input device 21 Storage calculation device 22 Information acquisition device 23 Signal control device 24 First production machine 25, 29 Paper feeding unit 26, 30 Paper output section 27,31 Web 28 Second production machine

[Procedure amendment]

[Submission date] June 1, 1995

[Procedure Amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0007

[Correction method] Change

[Correction content]

[0007]

Next, the present invention will be described based on preferred embodiments. FIG. 1 is a diagram showing the configurations of a defective data correction device, a defective processing control device, and peripheral devices according to the present invention. FIG.
In FIG. 1, the part surrounded by the solid line frame 1 is the defective data correction device of the present invention, and the part surrounded by the solid line frame 2 is the defect processing control device of the present invention, 3 is the LAN (L
ocal Area Network), 4 is LAN3
The production management system 5 is capable of mutually transferring data with the defective data correction device 1 and the defective processing control device 2 and stores and manages data related to production. Reference numeral 5 is a defective data correction device for measuring a web transfer distance on a production machine. 1 is a web transfer distance measuring device that outputs data, 6 is a defect detection device that performs a web quality inspection on a production machine and outputs data to a defect data correction device 1, 7 is a web transfer distance that is measured on a production machine A web transfer distance measuring device that outputs data to the defective processing control device 2, and a production machine control device 8 to which the defective processing control device 2 outputs control data.

[Procedure Amendment 2]

[Document name to be corrected] Drawing

[Name of item to be corrected] Figure 1

[Correction method] Change

[Correction content]

FIG.

[Procedure 3]

[Document name to be corrected] Drawing

[Name of item to be corrected] Figure 3

[Correction method] Change

[Correction content]

[Figure 3]

Claims (2)

[Claims] 1. A defect data correction apparatus comprising a correction operation unit for performing an operation for correcting defect data based on a situation parameter to obtain corrected defect data. 2. A defect processing control device comprising control data generating means for obtaining control data from corrected defective data obtained by performing a calculation for correcting defective data based on a situation parameter.