WO2007063927A1 - シートの製造方法およびシートの製造装置 - Google Patents
シートの製造方法およびシートの製造装置 Download PDFInfo
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- WO2007063927A1 WO2007063927A1 PCT/JP2006/323885 JP2006323885W WO2007063927A1 WO 2007063927 A1 WO2007063927 A1 WO 2007063927A1 JP 2006323885 W JP2006323885 W JP 2006323885W WO 2007063927 A1 WO2007063927 A1 WO 2007063927A1
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Definitions
- the present invention relates to a method for manufacturing a sheet such as a film and a sheet manufacturing apparatus.
- FIG. 1 is a diagram showing an overall schematic configuration of a general sheet manufacturing facility
- FIG. 2 is an enlarged perspective view of a main part of the die 4 shown in FIG.
- the sheet manufacturing equipment in FIG. 1 is (1) a sheet material such as a polymer extruded by an extruder 3 and a die 4 in which a number of sheet thickness adjusting means 10 are arranged in the sheet width direction. (2) Further processing, such as stretching the formed sheet 1 with a stretching machine 2, and (3) measuring the sheet thickness as a distribution in the sheet width direction after processing with a thickness measuring instrument 8 The measured thickness distribution in the width direction of the sheet is sometimes referred to as a thickness profile), and (4) Sheet 1 is wound up.
- the measured thickness profile file is brought close to a preset target thickness profile.
- FIG. 3 is a diagram for explaining the correspondence between the thickness adjusting means 10 in the die 4 and the thickness adjusting means at the position of the post-process thickness measuring instrument 8.
- the upper horizontal line in Fig. 3 represents the sheet at the die 4, and the lower horizontal line represents the sheet at the thickness gauge 8 after processing.
- each thickness adjusting means 10 in the die 4 is subjected to processing such as stretching in the sheet width direction, and passes through the sheet width direction positions 22a to 22d at the thickness measurement position. Therefore, for example, it is necessary to control the thickness adjusting means 10 at 21a so that the thickness measurement value at 22a approaches the target value. In such a sheet manufacturing method, it is important that the correspondence between each thickness adjusting means 10 and the sheet thickness measurement position is determined with high accuracy. Otherwise, for example, if the thickness adjusting means of 21b is operated to adjust the sheet thickness of 22a in FIG. Since the sheet thickness is changed, the thickness of the sheet cannot be accurately controlled, and the sheet quality is deteriorated.
- each thickness adjusting means and the position of the sheet thickness are measured except for the end in the sheet width direction where there is a neck-in when the polymer is extruded. Can be made to correspond more generally than the geometric positional relationship.
- the stretching ratio in the sheet width direction is not uniform with respect to the position in the sheet width direction due to temperature unevenness during the stretching process. With only a simple positional relationship, each thickness adjusting means cannot correspond to the measurement position of the sheet thickness after stretching.
- Patent Document 1 and Patent Document 2 have been proposed as methods utilizing the determination of the corresponding relationship between the thickness profile forces of the sheet after stretching. Both of the methods described in Patent Document 1 and Patent Document 2 make use of the fact that the corresponding position of each thickness adjusting means is generally required in the sheet before stretching.
- the thickness profile of the sheet before stretching is measured, the thickness profile of the sheet before stretching is divided into fixed sections, and the profile of each part of the divided unstretched sheet and after stretching.
- the corresponding position of each thickness adjusting means in the sheet after stretching is detected from the corresponding position in the sheet before stretching of each thickness adjusting means obtained by geometric calculation or empirical method. .
- the correspondence of the thickness adjusting means can be estimated without causing a loss during the manufacture of the sheet under a certain specific situation.
- Patent Document 1 JP-A 63-315221
- Patent Document 2 JP-A-9-164582
- Patent Document 1 and Patent Document 2 have the following problems of false detection and detection omission as described below.
- Patent Document 1 has the following problem in order to obtain the cross-correlation in a preliminarily set interval.
- a low-frequency bandpass filter in order to calculate cross-correlation, must be applied in order to remove thickness unevenness of a large pitch in the width direction within the section.
- each of the borders of the section set by force
- the shape of the unevenness could be greatly deformed.
- the method described in the patent document 2 does not use the feature of the profile shape. Instead, this method utilizes the property that the same mass of sheet material passes through the corresponding parts of the sheet before and after stretching. For this purpose, the thickness of the sheet before stretching, the thickness of the sheet after stretching, the longitudinal stretching ratio, and the density of the sheet before stretching and the sheet after stretching are taken into consideration.
- the correspondence is determined based only on the mass that passes through, the correspondence between at least one force point between the unstretched sheet and the stretched sheet is preliminarily strong. Must be. Therefore, the corresponding position is calculated from a pair of reference corresponding positions provided on the unstretched sheet and the stretched sheet, respectively. For this reason, there is no big error compared with the method described in Patent Document 1, but there is a case where an erroneous corresponding position is estimated due to the necessity of setting a reference corresponding position in advance.
- the reference corresponding position is good everywhere, for example, the reference corresponding position is set at the center of the sheet before stretching and the sheet after stretching. In the latter case, the center of the sheet before stretching must always correspond to the center of the sheet after stretching. Actually, if the ambient temperature is uneven in the stretching process, this correspondence will be shifted. In addition, there is an empirical fact that the temperature distribution changes as time passes rather than the atmospheric temperature distribution in the stretching process is always the same. According to the method described in Patent Document 2, it is not possible to obtain a correct correspondence relationship using a reference correspondence position for such fluctuations.
- the object of the present invention is to provide a sheet manufacturing method that eliminates the above-mentioned conventional drawbacks, that is, accurately adjusts the thickness by accurately estimating the correspondence after the stretching of the thickness adjusting means without causing loss during sheet manufacturing.
- Another object of the present invention is to provide a sheet manufacturing method, a program, a computer, and a sheet manufacturing apparatus that contribute to this.
- a sheet manufacturing method including the following steps (1) to (5):
- a desired sheet is formed by performing predetermined processing with dimensional changes in the sheet width direction.
- the thickness adjusting means is operated according to the operation amount to control the sheet thickness.
- the position corresponding to the sheet width direction after the completion of the processing with respect to the thickness adjusting means is determined by the method of the following steps A and B, and the determined correspondence to the sheet width direction
- a sheet manufacturing method is provided in which thickness control is performed based on the position.
- the mass of the sheet material that passes each part in the sheet width direction before the completion of the processing per unit time and the sheet after the completion of the processing there is provided a sheet manufacturing method using a sheet corresponding to the sum of differences from the mass of the sheet passing through each part in the width direction per unit time.
- the unknown parameter is determined so as to minimize or maximize the evaluation function using the following expression ⁇ 1> or a mathematically equivalent expression as the evaluation function: A sheet manufacturing method is provided.
- Tf (xf) sheet thickness at the position xf in the sheet width direction after completion of the force
- Ts (xs) the sheet thickness at the position xs in the sheet width direction before the completion of the force
- mapping function g (xf, 0) Mapping function, sheet width direction position xs before processing is completed Function in the width direction position xf and a function equation when modeled by the parameter ⁇ vf: velocity in the sheet flow direction after completion of the processing
- Ds Density of the sheet before completion of the processing
- xfO Sheet width direction position after completion of the above processing, which is the starting point when calculating the error of the mapping function
- a preliminary evaluation function of the mapping function prior to step A of step (4), a preliminary evaluation function of the mapping function, the thickness distribution in the sheet width direction before completion of the processing Measured value of thickness distribution after completion of the processing, density of the sheet material in each part in the sheet width direction before completion of the processing and / or density after completion of the processing, or a ratio thereof.
- the unknown parameter is preliminarily obtained so that a preliminary evaluation function including the corresponding one as the unknown parameter becomes an extreme value, and thus the sheet width before the completion of the machining among the previously obtained unknown parameters.
- the mapping function is determined as a known parameter that corresponds to the density of the sheet material in each part in the sheet width direction before the completion of the determined processing and / or the density after the processing or the ratio thereof.
- the density of the sheet material at each part in the sheet width direction before the completion of the processing and / or the density after the completion of the processing or a ratio thereof there is provided a sheet manufacturing method characterized by using a material including an unknown parameter corresponding to the above.
- the evaluation function uses only the region included in the center as the region in the sheet width direction for obtaining the sum of errors.
- a sheet manufacturing method is provided.
- the evaluation function uses a region substantially included at both ends of the sheet as the region in the sheet width direction for obtaining the sum of errors.
- a method for producing a sheet is provided.
- sheet areas positioned at both ends of the center part and the center part are obtained. There is provided a sheet manufacturing method using an area included in a rising portion of a wedge.
- the following equation ⁇ 2> or a mathematically equivalent equation is used as the evaluation function, and the evaluation function is unknown so as to minimize or maximize the evaluation function.
- a method of manufacturing a sheet is provided that is characterized by determining a parameter.
- Tf (xf) sheet thickness at the position xf in the sheet width direction after completion of the force
- Ts (xs) the sheet thickness at the position xs in the sheet width direction before the completion of the force
- mapping function g (xf, 0) Mapping function, sheet width direction position xs before completion of force force is completion of Karoe Function expressed by xf and parameter ⁇
- h (xf, ⁇ ) a function composed of the position xf in the width direction of the sheet after the completion of the force included in the evaluation function and the parameter ⁇
- xfl Sheet width direction position after completion of the above processing, which is the end point when calculating the mapping function error It is.
- g (xf, ⁇ ) is a polynomial related to xf, and the coefficient of each term of the polynomial is the parameter vector ⁇
- the thickness distribution measurement value is a value obtained by performing an averaging process including a temporally weighted average. Is done.
- a sheet material is extruded into a sheet shape using a die provided with a plurality of thickness adjusting means.
- a desired sheet is formed by performing predetermined processing with dimensional changes in the sheet width direction.
- the thickness adjusting means is operated according to the operation amount to control the sheet thickness.
- the position corresponding to the sheet width direction after the completion of the processing with respect to the thickness adjusting means was determined using a computer by the program of the following steps A and B, and determined.
- a program is provided that performs thickness control based on the position corresponding to the sheet width direction.
- a computer-readable recording of the program is performed. Possible recording media are provided.
- a sheet manufacturing apparatus having the following means (1) to (6):
- Processing apparatus for performing predetermined processing including stretching or foaming of the sheet-like material
- a computer that calculates the operation amount to be applied to the thickness adjusting means corresponding to each measurement position based on the measured value of the processed thickness measuring instrument!
- a control device that adds the operation amount calculated by the computer to the thickness adjusting means.
- the computer of (5) calculates the operation amount by calculating the thickness adjusting means by the following steps A and B.
- the sheet manufacturing apparatus is characterized in that a position corresponding to the sheet width direction after completion of the processing is determined, and thickness control is performed based on the determined position corresponding to the sheet width direction.
- the present invention is configured as described above, the correspondence relationship between the sheet width direction and the thickness profile of the sheet before stretching is obtained from the thickness profile of the sheet before stretching and the thickness profile of the sheet after stretching. The position in the width direction of the sheet after stretching can be determined.
- the “thickness adjusting means” is provided corresponding to each part in the width direction of the sheet.
- This means means for adjusting the discharge amount of the sheet material in each part.
- die bolts in a die that changes the discharge amount of sheet material by changing the gap between the die mechanically or thermally or electrically (particularly, the type that controls the length of the die bolt by thermal expansion is heated.
- a lip heater in a heater-type die that changes the discharge rate by changing the flow velocity by changing the viscosity of the sheet material at that location by changing the heat generated by the heater).
- the adjustable discharge range is relatively large!
- the “sheet material” refers to a raw material constituting the sheet.
- paper pulp slurry and materials such as plastic that is melted or melted are used.
- any material such as polypropylene, polyethylene terephthalate, polyethylene naphthalate, or pulp of papermaking material can be considered. Since these materials are discharged from the die, they are often brought into a fluid state by heating the materials, dissolving the resin with an organic solvent, or slurrying the materials with water. Therefore, during the sheet manufacturing process, the sheet material may contain water and organic solvents.
- the “operation amount” refers to the amount of energy applied to each thickness adjusting unit or a numerical value corresponding to this in order to change the discharge amount of the sheet material in the thickness adjusting unit.
- this corresponds to the amount of power input via the power unit.
- the thickness adjusting means is usually operated by supplying power.
- predetermined processing refers to processing in which the flow of the sheet material has a component in the sheet width direction in any processing step in manufacturing the sheet. Typical examples include a stretching process and a foaming process in the width direction and / or the flow direction.
- “before completion of predetermined processing” means that the sheet material discharged from the die moves at least in the sheet width direction at a position in the sheet width direction to be controlled by the thickness adjusting means. Or the flow in the sheet width direction is relatively small Therefore, it is a stage where each thickness adjusting means and the corresponding position in the sheet width direction can estimate the geometrical relational force. Even when a neck-in phenomenon occurs in which the sheet material slightly shrinks in the width direction when discharging from the die, the amount of force reduction is usually small, so each thickness adjustment means after neck-in and the sheet width direction are relatively easy. Can be obtained geometrically. On the other hand, when the above-mentioned “predetermined processing” is performed, the deformation in the width direction of the sheet is large, and the deformation due to the location in the width direction is not uniform. Often not available.
- “after completion of predetermined processing” means a stage after the completion of the processing process in which the movement of the sheet material has a component in the sheet width direction in the manufacture of the sheet.
- the "mapping function” is a mathematical expression that models the relationship between the sheet width direction position of the predetermined processed sheet and the sheet width direction position of the predetermined processed sheet. Is a function.
- the mapping function can be any function such as a first-order or higher-order polynomial, various functions included in the category of trigonometric functions, exponential functions, or the sum of listed functions.
- the structure of the force function is determined, but the coefficients such as the coefficient of the polynomial, the angular frequency of the trigonometric function, and the base part of the exponential function are used when estimating the corresponding position.
- the mapping function g (xf, 0) is expressed by the following formula ⁇ 3>.
- the “evaluation function” is a function for evaluating the error of the mapping function.
- the mapping function is determined by the structure of the function.
- the force coefficient is an unknown parameter. Therefore, specifically, the evaluation function is a function related to unknown parameters, and the mass or volume that flows per time at the corresponding position before and after the completion of processing of the sheet matches in a predetermined region in the sheet width direction. It is usually expressed to express the degree to which it is done. If the error of the mapping function is small, it may be set so that the value of the evaluation function is large. If the error of the mapping function is small V, it may be set so that the evaluation function is small! ,.
- the “extreme value” means that when an unknown parameter is obtained so as to reduce the error of the mapping function using the evaluation function, the value of a certain set of unknown parameters is approximate.
- the value of the evaluation function that locally maximizes or minimizes the evaluation function.
- matrix equivalent means that the evaluation function in the evaluation function is Each evaluation function is called mathematically equivalent if it differs by a constant, or when the above evaluation function is changed slightly, the result of obtaining an unknown parameter for which the evaluation function has an extreme value is almost unchanged.
- it goes without saying that it is considered mathematically equivalent to undergo various conversions that accompany the physical quantity, which is originally a continuous quantity, in order to make it easier to use on a computer.
- the mass force that flows per time at the corresponding position before and after the completion of processing of the sheet coincides with a corresponding predetermined region in the sheet width direction.
- a mapping function may be determined.
- the “parameter corresponding to the density” means the density before and after the completion of machining, which is difficult to measure with high accuracy, the thickness measuring instrument before the completion of machining, and after the completion of machining.
- the volume force of the sheet material flowing per time obtained from the measurement result is the mass of the true sheet material. This is a correction coefficient for calculation. In this case as well, if the evaluation function is considered mathematically equivalent, it is not necessarily close to the actual density and need to be a value.
- it may be a ratio of the density of the sheet material before processing and the density after casting.
- the "central portion" is a position in the sheet width direction before or after processing in a sheet manufacturing facility having a predetermined processing process such as stretching or foaming. An area with a width of 80% centered on the center of the sheet.
- "rising of the sheet edge” means that the thickness increases as it moves from the center in the sheet width direction to both ends in the vicinity of the sheet edge outside the center and thicker than the center. The point where it gradually grows thick.
- the processed sheet is evaluated, and before processing, the corresponding position is obtained by using the fact that the mass flowing per time at the corresponding position before completion of processing and after processing is equal.
- FIG. 12 shows an example in which the rising region of the sheet is a region having a thickness of 1.2 times or less with respect to the average thickness of the central portion.
- the normal thickness is often near the average thickness
- the thickness of the sheet is A location that exceeds a certain threshold times the average thickness (1.2 times in this example) is the sheet edge, and the area between the center and the sheet edge
- the rising edge of the edge is calculated by averaging the thickness profile at the center of the sheet when the thickness distribution is measured with a thickness meter in the sheet width direction.
- the average thickness may be updated every time it is measured with a thickness meter, and may take a certain value (for example, the average value until then) for a predetermined period.
- the correspondence between the thickness adjusting means and the thickness measurement position can be estimated more accurately without causing a large loss during product manufacture. Therefore, when a sheet is manufactured, the thickness can be adjusted accurately using the determined correspondence, so that the yield is improved and the productivity is improved.
- FIG. 1 is a schematic explanatory diagram of a conventional film forming process.
- FIG. 2 is an enlarged perspective view of a main part of the die shown in FIG.
- FIG. 3 is a diagram showing the relationship between the position of the thickness adjusting means on the die and the corresponding position on the stretched thickness measuring instrument.
- FIG. 4 is a schematic explanatory diagram of a film forming process in one embodiment of the present invention.
- FIG. 5 is an example of a weight to each measurement value subjected to a temporal weighted averaging process used for smoothing a measured thickness profile in an embodiment of the present invention.
- FIG. 6 is a diagram showing a calculation flow in one embodiment of the present invention.
- FIG. 7 is a diagram showing the relationship between the position of the thickness adjusting means in the die, the corresponding position in the thickness measuring instrument before stretching, and the corresponding position in the thickness measuring instrument after stretching in an embodiment of the present invention. .
- FIG. 8 is a schematic explanatory diagram in one embodiment of the present invention.
- FIG. 9 is a view showing thickness profiles of the sheet before stretching and the sheet after stretching shown in FIG. 4.
- FIG. 10 is a diagram showing a transition of thickness unevenness when an embodiment of the present invention is applied during sheet manufacture and a transition of thickness unevenness when a conventional technique is applied during sheet manufacture.
- FIG. 11 is a flowchart of an algorithm for estimating a density ratio before and after stretching of a sheet according to another embodiment of the present invention.
- FIG. 12 is a diagram for explaining a rising portion of a sheet edge used in an embodiment of the present invention.
- FIG. 13 is a diagram showing a flowchart of an algorithm for estimating a density ratio before and after stretching from a sheet thickness profile after stretching in which a sheet edge is trimmed according to an embodiment of the present invention.
- FIG. 4 is a diagram showing an overall schematic configuration of a facility in which a sheet thickness measuring device before stretching is added to the general sheet manufacturing facility shown in FIG. 1, and FIG. FIG.
- the sheet manufacturing equipment includes an extruder 3 for extruding a polymer, and a sheet of the extruded polymer.
- a die 4 for forming a sheet, a cooling roll 5 for cooling a polymer (hereinafter referred to as sheet 1) formed in the above sheet shape, a stretching machine 2 for stretching sheet 1 at least in the sheet width direction, and stretched A take-up machine 6 for winding the sheet 1 is provided.
- the die 4 includes a number of thickness adjusting means 10 arranged in the width direction of the sheet 1 (direction perpendicular to the paper surface of FIG. 4) and a gap 11 for discharging the polymer.
- this sheet manufacturing facility includes a post-stretching thickness measuring device 8 that measures the thickness distribution of the stretched sheet in the width direction of the sheet, and the amount of operation given to the thickness adjusting means based on the above thickness distribution!
- the control unit 9 is provided with the operation amount given to the computing computer 14 and the thickness adjusting means, and updated every time the operation amount given to the thickness adjusting means is computed by the computer 14.
- a thickness measuring device 12 before stretching that measures the thickness distribution in the width direction of the sheet before stretching is provided.
- the thickness measuring device 8 after stretching and the thickness measuring device 12 before stretching generally measure the thickness distribution in the width direction of the sheet by scanning the thickness of the sheet 1 in the sheet width direction. It is also possible to use a device that optically scans in the sheet width direction instead of scanning, or a device in which a large number of small thickness measuring devices are arranged in the sheet width direction. Thickness measuring instrument 8 and thickness measuring instrument 12 can be any thickness measuring instrument such as those using absorption of
- the control unit 9 calculates an operation amount based on the difference value between the thickness measurement value of the sheet 1 and the target thickness value, and adds the operation amount to the thickness adjustment unit 10.
- a plurality of thickness adjusting means 10 are arranged on the die 4 at equal intervals in the sheet width direction.
- heat bolts are used for the thickness adjusting means 10, and the bolt 11 is thermally expanded and contracted by changing the temperature of these bolts to adjust the gap 11 of the die 4.
- a lip heater in Fig. 10 to change the temperature of the polymer.
- a lip heater type that adjusts the thickness of the sheet 1 by changing the discharge amount of the polymer discharged from the die 4 by changing the viscosity of the polymer can be used.
- the average thickness value in the entire sheet width can also be adjusted by the output of the extruder 3 or the like.
- the thickness adjusting means 10 may not be given the role of adjusting the average thickness value over the entire sheet width.
- control means 9 calculates the manipulated variable, an average value in the sheet width direction of the deviation data is obtained for the deviation data of the difference between the thickness measurement value and the target thickness, and the deviation data force sheet It is preferable to subtract the average value in the width direction.
- the control means 9 calculates the manipulated variable, it is preferable to perform conversion processing such as filter processing on the deviation data that is the difference between the thickness measurement value of the sheet 1 and the target thickness value.
- Filter processing may include filtering in the sheet width direction that performs moving average processing in the sheet width direction, and filtering in the time direction including temporally weighted averages with past deviation data.
- the weighted averaging process the transverse stretching ratio (lateral deformation ratio in the case of arbitrary processing) includes, for example, the following averaging process.
- the current time is 0, the filter output of the current time is y (0), the measured value of the current time is x (0), and N is a natural number of 1 or more.
- x (—N) is expressed as follows.
- y (0) ax (0) + a (la) x (-l) + a (la) 2 x (-2) + --- + a (la) N x (-N) +-Further control means 9 calculates the manipulated variable based on the deviation data thinned out from the number of thickness adjusting means with respect to the above-mentioned deviation data after filtering, which has an element of the number of thickness measurement points in the width direction. To control.
- each thickness The method using deviation data at the thickness measurement point at the position corresponding to the thickness adjustment means or the method using the average value of the deviation data at the thickness measurement points within a certain range from the position corresponding to each thickness adjustment means be able to.
- the control method can be modern control using PID control or mathematical model.
- the mathematical model is a good method to include that the change in thickness as a result of the operation of each thickness adjusting means affects each other in the width direction.
- the operation amount given to each thickness adjustment means is leveled in the width direction to prevent the difference in the operation amount given to the thickness adjustment means between adjacent thickness adjustment means. It is also possible to use such an operation.
- each thickness adjusting means In the sheet manufacturing facility, the correspondence between each thickness adjusting means and each thickness measurement position is about a force. To accurately control the thickness of the sheet, the correspondence is always estimated with high accuracy. However, it is desirable to control the thickness using the correspondence.
- “always estimate” means to estimate the correspondence of the thickness adjusting means each time the thickness gauge before completion of drawing or after the completion of drawing measures the thickness distribution in the sheet width direction during sheet manufacture.
- the correspondence of the thickness adjusting means may be estimated only when the thickness unevenness of the thickness profile after stretching is large, or the correspondence of the thickness adjusting means may be estimated intermittently. It is also possible to perform a test run to estimate the correspondence before sheet manufacturing, which is not always estimated, and to estimate the correspondence and start manufacturing the sheet again based on the result. ).
- the shape of the function of the mapping function is determined by modeling the relationship between the sheet width direction position of the stretched sheet and the sheet width direction position of the unstretched sheet.
- the mapping function can be any function such as a first-order or higher-order polynomial, various functions included in the category of trigonometric functions, exponential functions, or the sum of listed functions.
- This mapping function represents a positional change in the sheet width direction with a predetermined processing including stretching and foaming, and there is an experimental fact that the positional relationship changes smoothly in the above processing. Is a smooth function, that is, the mapping function is It is also possible to make the first-order differentiable with respect to the position.
- mapping function To determine the mapping function, compare the thickness profiles of the unstretched sheet and the stretched sheet during film formation, and consider what function the stretch ratio in the width direction can be modeled. After that, it is also a good method to adopt a function obtained by first-order integration of the function with respect to the position in the width direction as the mapping function. Also, for example, a method of modeling the mapping function for the phenomenon force of the predetermined processing is also good, for example, the temperature is higher at the center and the edge in the width direction of the sheet.
- mapping function When the mapping function is modeled by a polynomial, most of the modeling function can be modeled by a first-order term. In practice, higher accuracy is usually required, so it is desirable to approximate with a polynomial of 5th order or higher. Note that the first-order differentiation of the mapping function at the position in the sheet width direction is called the transverse draw ratio. However, as the number of parameter elements corresponding to the coefficients of each term increases, the model becomes easier to describe the true relationship, but the amount of parameters estimated from the same amount of information increases, so the variation in estimated parameters tends to increase. It is in.
- mapping function has the following problems in addition to the large variation in the estimated parameters.
- fine pitch thickness unevenness in the sheet before stretching remains as fine pitch thickness unevenness in the stretched sheet, while fine thickness unevenness in the stretching process does not occur. Often does not occur.
- the transverse draw ratio changes smoothly in each part in the sheet width direction, it can often be approximated by a 1 to 9th order polynomial for the position in the sheet width direction.
- an approximate draw ratio is obtained from the relationship of mass, and a mapping function is determined using an algorithm that uses a fine pitch thickness unevenness for high-precision fitting. If this order is made to match the number of thickness measurement points on the stretched sheet or the unstretched sheet, this calculation becomes a defect setting problem and the solution cannot be determined uniquely.
- the mass passing per unit time in the minute region Sf of the width ⁇ at the width direction position xf of the stretched sheet is expressed by the following formula ⁇ 5>. .
- Tf (xf) Sheet thickness at the position xf in the sheet width direction after completion of stretching
- the mass passing per unit time in the sheet micro-region Ss before stretching corresponding to the micro-region Sf of the stretched sheet is obtained.
- the width of the minute region Ss is expressed by (dxsZdxf) X ⁇ ,
- the mass corresponding to the micro area Ss of the sheet before stretching is expressed by the following formula ⁇ 6>.
- Ts (xs) Sheet thickness at the position xs in the sheet width direction before completion of stretching
- the mass passing per unit time passing through the corresponding minute region is equal, and therefore the evaluation function can be determined so that the sum of the differences between the two is minimized. .
- the density change is small even when stretched or foamed, for example, 1% or less.
- the evaluation function can also be determined using a relational expression for volume conservation, which is not a relational expression for mass conservation, that is, a relational expression without a density term.
- the area for calculating the total sum of errors may be only the central portion excluding the sheet edge or the like, or the entire width including the sheet edge.
- the sheet edge is an end portion in the sheet width direction of the unstretched sheet or the stretched sheet, and the influence of neck-in is great or the sheet is gripped in the stretching process.
- the thickness of the central portion of the sheet is significantly different from that of the central portion of the sheet.
- the sheet edge is included, the correspondence of each thickness adjustment means in the sheet before stretching is affected by the neck-in and cannot be determined geometrically, so experimental detection may be required. .
- the area for calculating the sum of errors may be an area sandwiched between rising edges of the sheet edge where the film becomes thicker as the sheet edge is approached when the area is expanded from the center to the sheet edge.
- the region is expanded from the central region in either direction of the width, and the thickness becomes 1.05 times or more and 2.0 times or less the thickness of the center portion after stretching.
- An area expanded to the position in the width direction may be used. As described above, this uses the rising edge of the sheet edge to be evaluated in the processed sheet, so that the evaluation includes parts where the thickness shape changes relatively at both ends in the width direction of the sheet. Accuracy may increase.
- the absolute value of force error using the sum of squares of errors as an evaluation function or the sum of errors even-numbered powers may be used as an evaluation function, and the weight of an abnormal thickness measurement value may be used as an evaluation function.
- the sum of errors whose weights are changed according to values, such as the sum of logarithms of errors may be used as an evaluation function.
- an approximate relationship is obtained as an initial value used in estimating the correspondence between each thickness adjusting means 10 and each thickness measurement position.
- it should be set by an arbitrary method such as the correspondence obtained empirically, the final result at the previous production, the correspondence obtained geometrically, or the method described in Patent Literature 1 and Patent Literature 2. Can do. Since it is better that the relationship between the initial value and the true value is not greatly deviated, it is considered that the empirical correspondence and the method described in Patent Document 2 are better than the method described in Patent Document 1. However, unlike the method described in Patent Document 2, the initial value need not be set with absolute accuracy.
- select multiple thickness adjustment means that are not far apart from each other and operate the selected thickness adjustment means to determine and select the location where the thickness changes most as the corresponding position.
- select multiple thickness adjustment means that are not, it is possible to use a method of determining by interpolating the correspondence of the selected thickness adjustment means.
- the thickness profile before stretching is completed and the thickness profile force after stretching
- the positions corresponding to the sheet width direction before and after stretching are calculated.
- an average profile of thickness profiles obtained by scanning a plurality of times can be obtained.
- a thickness profile using an exponential filter that gradually reduces the influence of past thickness measurement values as shown in Fig. 5 according to a predetermined rule such as a certain ratio is used to obtain the position corresponding to the width direction of the sheet. May be.
- a predetermined rule such as a certain ratio
- the influence of thickness unevenness in the flow direction can be reduced from the thickness measurement value.
- an average profile is calculated from a thickness profile scanned 100 times or more, and the calculated average thickness profile is used to compare the sheet width direction. It is preferable to calculate the response position.
- the sheet in order to add functions to the sheet, fine particles are mixed with cavities called voids, and the sheet may intentionally create concaves that are much larger than the normal thickness distribution. It is also a good method to obtain a simple average or a weighted average after removing a portion where the thickness variation measured from the time series data is exceptionally large.
- the measured thickness distribution values of the sheet before stretching and the sheet after stretching are given as measurement information to the evaluation function, and the unknown parameter ⁇ is determined so as to minimize this evaluation function.
- the evaluation function of Equation 1> is calculated.
- an arbitrary method such as the two-utton method, the quasi-Euton method, or the steepest descent method can be used.
- the initial force value set to determine the minimum value of the evaluation function is appropriate, the value is usually the minimum value.
- the maximum value maximum value
- the absolute value of the thickness profile of the sheet before stretching As described above, the absolute value of the thickness profile of the sheet after stretching, and the density of the sheet before stretching and the sheet after stretching are important, but in reality the calibration of the thickness meter is inaccurate or the density is measured. There are many problems such as poor accuracy. A similar problem occurs in the method described in Patent Document 2, and a skilled worker sometimes manually changes this density.
- the density of the sheet after stretching relative to the density of the sheet before stretching, the inaccuracy of the calibration of the thickness measuring instrument, and the density distributed in the width direction of the sheet The correction coefficient for correcting the distribution can be estimated as an unknown parameter, and it is also a good method to use the evaluation function of Eq. 2> where h (xf, ⁇ ) is the correction coefficient. Is).
- h (xf, ⁇ ) is the correction coefficient. Is).
- the density is estimated as an unknown parameter only at the beginning of film formation, and then estimated after that. Resulting power It is also a good method to estimate other unknown parameters using the most probable density as known information.
- the parameter related to density is estimated to estimate the parameter using the thickness unevenness as information. It can be difficult.
- the thickness changes greatly, and the characteristic portions at both ends in the width direction of the sheet are included in the evaluation region, and the density-related Parameter estimation is robust.
- all unknown parameters including parameters related to density may be estimated only in the region including the rising region of the sheet edge thickness.
- the manipulated variable is determined based on the mapping function thus determined.
- Equation 2> a preliminary evaluation function that includes a parameter related to density as an unknown parameter in the above method
- the force includes a region including the rising region of the sheet edge thickness or the region included at both ends.
- the final density function e.g., Equation ⁇ 1>
- the density-related parameters thus obtained are known values and other unknown parameters are unknown is used in the sheet width direction. It is also a good method to determine the final mapping function by obtaining the error only in the region included in the center of the.
- the density can be easily estimated by approximating the density constant in the width direction in the sheet before stretching / after stretching.
- FIG. 13 shows the flowchart.
- the width direction position to be trimmed after stretching within a conceivable range and the corresponding width direction position before stretching are preliminarily determined.
- estimation is performed based on the density, and the error in the mapping function that reduces the error is obtained.
- the parameters related to density can be estimated. This means that robust estimation is possible by limiting the corresponding range at the position for trimming. However, since the accuracy of estimation is lower than when using the edge rising region, it is also a good method to temporarily stop the estimation when the thickness unevenness is small.
- the standard may be applied to the position in the width direction of the sheet before or after stretching.
- the evaluation function For example, when calculating the evaluation function using Equation 1 or Equation ⁇ 2>, if xf is directly obtained as the position in the width direction on the actual sheet, the position in the width direction of the sheet after stretching is large as an absolute value.
- the 5th-order term overflows in numerical calculations, so it may not be possible to perform optimization calculations correctly.
- the above standard method is mathematically equivalent to the case of directly obtaining the position in the width direction on an actual sheet.
- the influence of reducing the accuracy of the corresponding result estimated due to the small thickness unevenness can be reduced.
- the corresponding position in the sheet width direction thickness profile of the sheet after stretching by each thickness adjusting means can be constantly monitored and corrected.
- a biaxially stretched polyethylene terephthalate film for a magnetic storage tape film having a thickness of 6 ⁇ m was manufactured using the sheet manufacturing facility shown in FIG.
- the thickness adjusting means 10 used was a heat bolt system in which a bolt 11 with a built-in force cartridge heater was thermally expanded and contracted to adjust the gap 11.
- the thickness measuring device 8 is a ⁇ -ray thickness measuring device using the ⁇ -ray absorption phenomenon
- the thickness measuring device 12 is an X-ray thickness measuring device using the X-ray absorption phenomenon. Using this, the thickness distribution in the width direction of the sheet was measured while scanning in the sheet width direction. Each time the thickness measuring device 8 scans the width direction of the sheet once, the thickness control was performed using PID control.
- the initial value of the correspondence between each thickness adjustment means and the thickness measurement position required at the beginning is the position where the thickness change is greatest in the stretched sheet by operating the specific thickness adjustment means greatly.
- h ( ⁇ ) A function that corrects the ratio of the density of the sheet after stretching to the density of the sheet before stretching in the evaluation function that evaluates the error of the correction function and mapping function.
- ⁇ Unknown in the evaluation function One of the parameters, the density of the sheet before stretching
- the unknown parameter is unknown only in terms of the density ratio of the unstretched sheet to the unstretched sheet. Added as a parameter.
- the area on the sheet after stretching when calculating the total sum of errors is the central part that is 80% of the total width of the sheet centered on the center of the sheet in the width direction that does not include the edge of the sheet after stretching.
- the xf of the part was set from 1 to 1.
- the center part of the sheet after stretching and the sheet before stretching described in Patent Document 2 The reference positions corresponding to each other were set, and the corresponding positions were set so that the mass conservation of the thickness profile of the sheet before stretching and the thickness profile of the sheet after stretching was satisfied.
- the density ratio parameter used was 1.04 as a general value for biaxially stretched polyethylene terephthalate films.
- the thickness distribution is measured using a ⁇ -ray thickness measurement device using the ⁇ -ray absorption phenomenon as the thickness measuring device 8 and an X-ray thickness measurement using the X-ray absorption phenomenon as the thickness measurement device 12.
- the thickness distribution of the sheet in the width direction was measured while scanning in the sheet width direction using each of the instruments.
- the thickness profile used in the subsequent process is measured by the thickness gauge in one hour.
- a thickness distribution before and after stretching was obtained using an average thickness profile of the thickness profile. • For the calculation of unknown parameters that minimize the difference between the thickness profile of the unstretched sheet and the stretched sheet.
- the initial value was updated so that the unknown parameter that minimizes the evaluation function obtained in (5) becomes the initial value used in the next numerical calculation.
- Fig. 7 is a diagram showing the relationship between positions 21a to 21d of the thickness adjusting means on the die and corresponding positions 20a to 20d of the thickness measuring instrument before stretching, and corresponding positions 22a to 22d of the thickness measuring instrument after stretching. It is.
- the mapping function of the position in the width direction of the sheet before and after stretching and the force of both the thickness adjusting means and the position corresponding to the width direction of the sheet before stretching was calculated by the thickness adjusting means. • Feedback of the results of thickness adjustment to thickness control
- Feedback to the control is performed when the difference between the maximum value and the minimum value of the average thickness profile for 1 hour exceeds 0.08 ⁇ m after 1 hour or more has passed since the response result of the thickness adjustment means was fed back. Only feedback.
- FIG. 10 is a diagram showing a transition of thickness unevenness when one embodiment of the present invention is applied during sheet manufacturing and a transition of thickness unevenness when the conventional technique is applied during sheet manufacturing.
- the density ratio is changed from 0.99 to 1.09 in increments of 0.01, while the sheet position after stretching corresponding to the center position in the width direction of the sheet before stretching is changed in the width direction.
- the mapping function was determined using the law of conservation of mass by the method described in Example 1, (3), with the center being changed to ⁇ 50 mm, ⁇ 40 mm,..., +50 mm.
- the expected thickness profile after stretching was calculated based on the mapping function and the sheet thickness profile before stretching. Then, the sum of the expected thickness profile after stretching, the average thickness at the center of the measured thickness profile after stretching, and the error in the rising position of the thickness edge was determined. Next, the density ratio with the smallest error was taken as the estimation result.
- the present invention can be applied not only to the production of plastic films but also to the production of paper, etc., but the scope of application is not limited to these.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Algebra (AREA)
- General Physics & Mathematics (AREA)
- Mathematical Analysis (AREA)
- Mathematical Optimization (AREA)
- Mathematical Physics (AREA)
- Pure & Applied Mathematics (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN2006800520616A CN101365571B (zh) | 2005-11-30 | 2006-11-30 | 薄片制造方法及薄片制造装置 |
EP06833688A EP1964659A1 (en) | 2005-11-30 | 2006-11-30 | Method of producing sheet and sheet producing device |
CA002631557A CA2631557A1 (en) | 2005-11-30 | 2006-11-30 | Sheet manufacturing method and sheet manufacturing device |
US12/095,419 US7813829B2 (en) | 2005-11-30 | 2006-11-30 | Sheet manufacturing method and sheet manufacturing device |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2005-345354 | 2005-11-30 | ||
JP2005345354 | 2005-11-30 |
Publications (1)
Publication Number | Publication Date |
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WO2007063927A1 true WO2007063927A1 (ja) | 2007-06-07 |
Family
ID=38092261
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/JP2006/323885 WO2007063927A1 (ja) | 2005-11-30 | 2006-11-30 | シートの製造方法およびシートの製造装置 |
Country Status (6)
Country | Link |
---|---|
US (1) | US7813829B2 (ja) |
EP (1) | EP1964659A1 (ja) |
KR (1) | KR20080071178A (ja) |
CN (1) | CN101365571B (ja) |
CA (1) | CA2631557A1 (ja) |
WO (1) | WO2007063927A1 (ja) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11999091B2 (en) | 2018-05-16 | 2024-06-04 | Windmöller & Hölscher Kg | Method for automatically regulating the size of a slot of a nozzle assembly and control and/or regulation system |
Families Citing this family (10)
Publication number | Priority date | Publication date | Assignee | Title |
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JP6127992B2 (ja) * | 2014-01-23 | 2017-05-17 | セイコーエプソン株式会社 | シート製造装置及びシート製造方法 |
DE102018111765A1 (de) * | 2018-05-16 | 2019-11-21 | Windmöller & Hölscher Kg | Verfahren zur automatisierten Regelung der Größe eines Spaltes einer Düsenanordnung und Steuer- und/oder Regelsystem |
DE102018111764A1 (de) * | 2018-05-16 | 2019-11-21 | Windmöller & Hölscher Kg | Verfahren zur automatisierten Regelung der Größe eines Spaltes einer Düsenanordnung und Steuer- und/oder Regelsystem |
DE102018111763A1 (de) * | 2018-05-16 | 2019-11-21 | Windmöller & Hölscher Kg | Verfahren zur automatisierten Regelung der Größe eines Spaltes einer Düsenanordnung und Steuer- und/oder Regelsystem |
DE102018124175A1 (de) * | 2018-10-01 | 2020-04-02 | Sikora Ag | Verfahren und Vorrichtung zum Steuern einer Produktionsanlage für plattenförmige oder strangförmige Körper |
DE102018127671A1 (de) | 2018-11-06 | 2020-05-07 | Windmöller & Hölscher Kg | Verfahren für die Kontrolle eines Dickenprofils einer Folienbahn |
DE102018127670A1 (de) | 2018-11-06 | 2020-05-07 | Windmöller & Hölscher Kg | Stellvorrichtung für eine Kontrolle einer Austrittsdicke eines Düsenaustrittsspaltes einer Flachfolienmaschine |
CN109624187B (zh) * | 2018-11-13 | 2021-03-05 | 梦百合家居科技股份有限公司 | 一种记忆海绵发泡过程的质量监控方法 |
US11426914B2 (en) * | 2019-03-15 | 2022-08-30 | The Japan Steel Works, Ltd. | Resin film manufacturing device and resin film manufacturing method |
FR3101568B1 (fr) | 2019-10-03 | 2022-08-05 | Aleph Sas | Procede de fabrication d’un film comportant des cavites avec determination de profils d’etirage, de masse volumique, d’epaisseur et/ou de porosite du film |
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JPH1044231A (ja) * | 1996-07-31 | 1998-02-17 | Teijin Ltd | 延伸フィルムの厚み調整方法 |
JP2002086539A (ja) * | 2000-09-19 | 2002-03-26 | Toray Ind Inc | シートの製造方法 |
JP2003089146A (ja) * | 2000-09-21 | 2003-03-25 | Toray Ind Inc | シートの製造方法およびシート厚み制御装置 |
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JP2612244B2 (ja) * | 1988-12-29 | 1997-05-21 | 王子油化合成紙株式会社 | 延伸樹脂フィルムの肉厚制御方法 |
JP3828950B2 (ja) * | 1995-12-15 | 2006-10-04 | 東芝機械株式会社 | 2軸延伸フィルム上のダイボルト対応位置算出方法および同算出方法を用いた2軸延伸フィルムの厚さ制御方法 |
DE60138121D1 (de) * | 2000-09-19 | 2009-05-07 | Toray Industries | Verfahren zur herstellung von folie |
US6856855B2 (en) * | 2000-09-21 | 2005-02-15 | Toray Industries, Inc. | Method of manufacturing sheet, device and program for controlling sheet thickness, and sheet |
US6862179B2 (en) * | 2002-11-26 | 2005-03-01 | Hewlett-Packard Development Company, L.P. | Partition for varying the supply of cooling fluid |
DE10300375B4 (de) * | 2003-01-06 | 2013-06-13 | Windmöller & Hölscher Kg | Verfahren zur Regelung der Dicke extrudierter Folie I |
US6983889B2 (en) * | 2003-03-21 | 2006-01-10 | Home Comfort Zones, Inc. | Forced-air zone climate control system for existing residential houses |
US6964174B2 (en) * | 2004-01-20 | 2005-11-15 | Carrier Corporation | Method and system for determining relative duct sizes by zone in an HVAC system |
US7200021B2 (en) * | 2004-12-10 | 2007-04-03 | Infineon Technologies Ag | Stacked DRAM memory chip for a dual inline memory module (DIMM) |
US7354005B2 (en) * | 2005-02-23 | 2008-04-08 | Emerson Electric Co. | Variable capacity climate control system for multi-zone space |
-
2006
- 2006-11-30 EP EP06833688A patent/EP1964659A1/en not_active Withdrawn
- 2006-11-30 WO PCT/JP2006/323885 patent/WO2007063927A1/ja active Application Filing
- 2006-11-30 CA CA002631557A patent/CA2631557A1/en not_active Abandoned
- 2006-11-30 CN CN2006800520616A patent/CN101365571B/zh not_active Expired - Fee Related
- 2006-11-30 US US12/095,419 patent/US7813829B2/en not_active Expired - Fee Related
- 2006-11-30 KR KR1020087014325A patent/KR20080071178A/ko not_active Application Discontinuation
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
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JPH1044231A (ja) * | 1996-07-31 | 1998-02-17 | Teijin Ltd | 延伸フィルムの厚み調整方法 |
JP2002086539A (ja) * | 2000-09-19 | 2002-03-26 | Toray Ind Inc | シートの製造方法 |
JP2003089146A (ja) * | 2000-09-21 | 2003-03-25 | Toray Ind Inc | シートの製造方法およびシート厚み制御装置 |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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US11999091B2 (en) | 2018-05-16 | 2024-06-04 | Windmöller & Hölscher Kg | Method for automatically regulating the size of a slot of a nozzle assembly and control and/or regulation system |
Also Published As
Publication number | Publication date |
---|---|
CN101365571B (zh) | 2011-05-04 |
KR20080071178A (ko) | 2008-08-01 |
US20090045536A1 (en) | 2009-02-19 |
US7813829B2 (en) | 2010-10-12 |
CN101365571A (zh) | 2009-02-11 |
CA2631557A1 (en) | 2007-06-07 |
EP1964659A1 (en) | 2008-09-03 |
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