WO2011118495A1 - 吸収体の製造装置 - Google Patents
吸収体の製造装置 Download PDFInfo
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- WO2011118495A1 WO2011118495A1 PCT/JP2011/056371 JP2011056371W WO2011118495A1 WO 2011118495 A1 WO2011118495 A1 WO 2011118495A1 JP 2011056371 W JP2011056371 W JP 2011056371W WO 2011118495 A1 WO2011118495 A1 WO 2011118495A1
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Classifications
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/15577—Apparatus or processes for manufacturing
- A61F13/15617—Making absorbent pads from fibres or pulverulent material with or without treatment of the fibres
- A61F13/15658—Forming continuous, e.g. composite, fibrous webs, e.g. involving the application of pulverulent material on parts thereof
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/15577—Apparatus or processes for manufacturing
- A61F13/15707—Mechanical treatment, e.g. notching, twisting, compressing, shaping
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/15577—Apparatus or processes for manufacturing
- A61F13/15707—Mechanical treatment, e.g. notching, twisting, compressing, shaping
- A61F13/15723—Partitioning batts; Cutting
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/15577—Apparatus or processes for manufacturing
- A61F13/15772—Control
Definitions
- the present invention relates to an apparatus for producing an absorbent body of an absorbent article such as a sanitary napkin.
- sanitary napkins and the like are known as absorbent articles that absorb liquid such as excreta.
- This absorbent article has an absorber that absorbs liquid as its component.
- the absorbent body uses a base material obtained by molding an absorbent body material such as pulp fiber into a predetermined shape.
- Such an absorbent body is manufactured by a fiber stacking apparatus.
- the fiber stacking device has a rotating drum that is driven to rotate. On the outer peripheral surface of the rotating drum, concave molds are intermittently arranged at a predetermined arrangement pitch in the rotational direction.
- an absorber is manufactured by supplying an absorber raw material from a suitable duct toward the shaping
- Such a fiber stacking device is driven and rotated in synchronism with the other devices so as to manufacture a napkin in cooperation with other devices located on the upstream side or the downstream side.
- the synchronization signal is, for example, a signal indicating a rotation angle of 0 ° to 360 °, and this rotation angle of 0 ° to 360 ° is repeatedly assigned to a unit operation amount corresponding to a product pitch of another device. It is output.
- the rotary drum is provided with an encoder, and the input shaft of the encoder rotates once while the rotary drum rotates by a rotation angle corresponding to the arrangement pitch of the mold, so that the rotary drum is rotated by the arrangement pitch.
- a signal indicating a rotation angle of 0 ° to 360 ° is output from the encoder.
- an appropriate controller controls the drive rotation of the rotary drum so that the indicated value of the rotation angle from the encoder matches the indicated value of the rotation angle of the synchronization signal, so that the synchronous operation with other devices can be performed. It has been realized.
- the adjustment for rotating the input shaft of the encoder by one rotation with the rotation operation (rotation angle) of the rotary drum corresponding to the arrangement pitch is made through a rotation operation transmission mechanism that transmits the rotation operation of the rotation drum to the input shaft of the encoder.
- the rotational motion transmission mechanism is wound around, for example, a first pulley provided on the rotary shaft of the rotary drum, a second pulley provided on the input shaft of the encoder, and the first and second pulleys. And an endless belt. Therefore, the above adjustment is performed by appropriately setting the rotation ratio that is the ratio between the diameter of the pitch circle of the first pulley and the diameter of the pitch circle of the second pulley.
- the diameter of the pitch circle of the pulley is also simply referred to as the pulley diameter.
- the size of the napkin to be manufactured is periodically changed.
- the size change is also performed in the fiber stacking apparatus.
- a plurality of arc-shaped mold plates forming the outer peripheral surface are formed from the cylindrical drum body forming the base of the rotating drum. Remove.
- a molding die is provided on the molding plate.
- an L size mold plate is attached to the drum body. Thereby, the size change of the rotating drum itself is completed.
- the encoder since the arrangement pitch of the mold has changed for the L size, the encoder must also be set for the L size. That is, in the present state, when the rotary drum rotates by the rotation angle corresponding to the arrangement pitch of M size, the input shaft of the encoder is rotated once, which corresponds to the arrangement pitch of L size. It must be changed so that the input shaft of the encoder rotates once for each rotation angle.
- Such a change is made by changing the rotation ratio of the input shaft of the encoder to the rotation shaft of the rotating drum.
- the second pulley having the diameter for M size is removed from the input shaft of the encoder and replaced with the second pulley having the diameter for L size.
- the present invention has been made in view of the above-described conventional problems, and an object of the present invention is to reduce a work load when resizing an absorbent body manufacturing apparatus.
- the main invention for achieving the above object is: A driving source for driving and rotating the drum around the rotation axis while synchronizing with the other device based on a synchronization signal repeatedly output with the unit operation amount of the other device corresponding to the product pitch as one unit;
- the absorbent material is supplied to the outer peripheral surface of the drum from a duct disposed at a predetermined position in the rotation direction toward a plurality of recesses intermittently disposed at a predetermined arrangement pitch in the rotation direction, and the absorption is performed.
- An apparatus for producing an absorbent body by depositing body material in the recess A first pitch setting member for setting the arrangement pitch to a first pitch; A second pitch setting member for setting the arrangement pitch to a second pitch different from the first pitch; A first signal generator that repeatedly generates a first rotation angle signal based on rotation of the drum, with the rotation angle of the drum corresponding to the first pitch as one unit; A second signal generation unit that repeatedly generates a second rotation angle signal based on the rotation of the drum, with the rotation angle of the drum corresponding to the second pitch as one unit; A controller for controlling the driving rotation of the driving source, When the arrangement pitch is set to the first pitch, the controller controls driving rotation of the driving source based on the first rotation angle signal and the synchronization signal, When the arrangement pitch is set to the second pitch, the controller controls the drive rotation of the drive source based on the second rotation angle signal and the synchronization signal. It is a body manufacturing device.
- the workload when changing the size of the absorber manufacturing apparatus is reduced.
- FIG. 1 is a schematic side view of a production line 10 for a napkin 1.
- FIG. 2A is a plan view of the napkin 1
- FIG. 2B is a cross-sectional view taken along the line BB in FIG. 2A.
- It is a center sectional view of fiber stacking device 20 which is manufacturing device 20 of absorber 3.
- 3 is an exploded perspective view of a rotary drum 22.
- FIG. It is the schematic side view which looked at the rotating drum 22 of the reference example from the drive side.
- 2 is a schematic configuration diagram of a controller 60.
- FIG. It is the schematic side view which looked at the rotating drum 22 which concerns on this embodiment from the drive side. It is explanatory drawing of another example of the winding pattern of the timing belt of a rotational motion transmission mechanism.
- the absorbent material is supplied to the outer peripheral surface of the drum from a duct disposed at a predetermined position in the rotation direction toward a plurality of recesses intermittently disposed at a predetermined arrangement pitch in the rotation direction, and the absorption is performed.
- An apparatus for producing an absorbent body by depositing body material in the recess A first pitch setting member for setting the arrangement pitch to a first pitch; A second pitch setting member for setting the arrangement pitch to a second pitch different from the first pitch; A first signal generator that repeatedly generates a first rotation angle signal based on rotation of the drum, with the rotation angle of the drum corresponding to the first pitch as one unit; A second signal generation unit that repeatedly generates a second rotation angle signal based on the rotation of the drum, with the rotation angle of the drum corresponding to the second pitch as one unit; A controller for controlling the driving rotation of the driving source, When the arrangement pitch is set to the first pitch, the controller controls driving rotation of the driving source based on the first rotation angle signal and the synchronization signal, When the arrangement pitch is set to the second pitch, the controller controls the drive rotation of the drive source based on the second rotation angle signal and the synchronization signal.
- Body manufacturing equipment When the arrangement pitch is set to the first pitch, the controller controls driving rotation of the driving source based on the first rotation angle signal and the
- the first signal generator used when the arrangement pitch of the recesses is the first pitch and the second signal generator used when the arrangement pitch is the second pitch are separately provided. Have. Therefore, it is not necessary to reset the first signal generation unit and the second signal generation unit in accordance with the size change to change the arrangement pitch to the first pitch or the second pitch, and the work load related to the size change is reduced. be able to.
- the controller can synchronize the drive rotation of the drive source with another device by associating the first rotation angle signal with the synchronization signal
- the controller can synchronize the drive rotation of the drive source with another device by associating the second rotation angle signal with the synchronization signal. Therefore, it is possible to synchronize the rotational operation of the drum with other devices for both the first pitch and the second pitch.
- the first rotation angle signal and the second rotation angle signal are preferably signals having the same specifications as the synchronization signal. According to such an absorber manufacturing apparatus, since both the first rotation angle signal and the second rotation angle signal have the same specifications as the synchronization signal, each drum rotation is synchronized with another apparatus. When the rotation angle signal is associated with the synchronization signal, the association becomes easy.
- the first rotation angle signal is a signal indicating a phase of 0 ° to 360 °
- the second rotation angle signal is a signal indicating a phase of 0 ° to 360 °
- the synchronization signal is preferably a signal having a phase of 0 ° to 360 °. According to such an absorber manufacturing apparatus, any of the first rotation angle signal, the second rotation angle signal, and the synchronization signal is a signal having a phase of 0 ° to 360 °. Therefore, when each rotation angle signal is associated with the synchronization signal in order to synchronize the rotation of the drum with another device, the association becomes easy.
- the first signal generation unit and the second signal generation unit are signal generation units having the same specifications,
- the first signal generation unit has a first input shaft and generates the first rotation angle signal by rotation of the first input shaft.
- the second signal generation unit has a second input shaft and generates the second rotation angle signal by the rotation of the second input shaft.
- the rotating shaft of the drum rotates integrally with the drum;
- the rotation operation of the drum is input from the rotation shaft to the first input shaft and the second input shaft through a rotation operation transmission mechanism,
- the rotational motion transmission mechanism so that the rotation ratio RL of the second input shaft to the rotation shaft becomes NL while the rotation ratio RM of the first input shaft to the rotation shaft becomes the NM.
- the first signal generation unit and the second signal generation unit use the same signal generation unit. Therefore, when synchronizing the rotation operation of the drum with the operation of another device, it is possible to reliably associate the signal generation units with the synchronization signals.
- the rotation ratio is as described above, the size change between the first pitch PM and the second pitch PL can be handled without any problem.
- the rotational motion transmission mechanism has at least one relay shaft, The rotation operation of the drum is transmitted from the rotation shaft to the first input shaft and the second input shaft via the relay shaft,
- the rotation ratio RM is divided into a plurality of rotation ratios having a value smaller than the rotation ratio RM by the relay shaft,
- It is desirable that the rotation ratio RL is divided into a plurality of rotation ratios having a smaller value than the rotation ratio RL by the relay shaft.
- the rotation ratios RM and RL of the rotation operation transmitted from the rotation shaft to the first and second input shafts are each divided into small rotation ratios by using the relay shaft. Therefore, the rotation operation of the drum can be accurately transmitted to the first and second input shafts. Details will be described later.
- An apparatus for manufacturing such an absorber In order to transmit the rotation operation of the drum to the first input shaft and the second input shaft, the rotation shaft is connected to the rotation operation transmission mechanism at a predetermined portion of the rotation shaft, It is desirable that the predetermined portion is shared for both the case where the arrangement pitch is the first pitch and the case where the arrangement pitch is the second pitch. According to such an absorber manufacturing apparatus, the predetermined portion of the rotation shaft is shared by both the first pitch and the second pitch. Therefore, when the size is changed, it is not necessary to use the rotational motion transmission mechanism at all, and the work load required for the size change can be reduced.
- An apparatus for manufacturing such an absorber The discharge port of the duct that discharges and supplies the absorber material is disposed to face the outer peripheral surface of the drum,
- the diameter of the drum formed by the first pitch setting member and the diameter of the drum formed by the second pitch setting member are preferably equal to each other.
- the diameter of the drum having the arrangement pitch of the first pitch and the diameter of the drum having the arrangement pitch of the second pitch are equal to each other. It is not necessary to exchange, that is, it can be shared. Therefore, the work load related to the size change can be reduced.
- FIG. 1 is a schematic side view of a production line 10 for an absorbent article 1.
- a sanitary napkin 1 is produced as an example of an absorbent article 1 that absorbs excretory fluid.
- FIG. 2A is a plan view of the napkin 1
- FIG. 2B is a cross-sectional view taken along the line BB in FIG. 2A.
- the napkin 1 includes, for example, an absorbent body 3 having a pulp fiber 5 as a main material between a liquid-permeable top sheet 2 such as a nonwoven fabric and a liquid-impermeable back sheet 4 such as a film. It is interposed together with a carrier sheet 6 (not shown in FIGS. 2A and 2B).
- an embossed groove 7 is formed in the center of the napkin 1 in the longitudinal direction and in the width direction by embossing or the like, so that the parts 2, 3, 4 and 6 constituting the napkin 1 are integrated. ing.
- the production line 10 of the napkin 1 has a plurality of transport mechanisms 12, 12... For transporting the semi-finished products 1a, 1b, etc. of the napkin 1 in the transport direction.
- suction belt conveyors 12 having a suction function on the mounting surface are used, and each is driven using a motor (not shown) as a drive source. In some cases, a conveyance roller may be used.
- the semi-finished products 1a, 1b, etc. are conveyed in the conveying direction by the conveying mechanisms 12, 12,...
- Various processes such as pressing and punching and hot-melt adhesives (hereinafter referred to as the semi-finished products 1a, 1b,. , Also referred to as HMA), adhesion of other components, and the like are sequentially performed to complete the napkin 1.
- HMA pressing and punching and hot-melt adhesives
- adhesion of other components and the like are sequentially performed to complete the napkin 1.
- CD direction orthogonal to the transport direction in FIG. 1, the direction penetrating the paper surface
- the production line 10 has a plurality of reels 15, 15.
- the reel 15 is installed on each of the top sheet 2, the back sheet 4, and the carrier sheet 6.
- the sheet is carried into the production line 10 in the form of a sheet roll formed by winding the sheet.
- Each of the sheet rolls 2r, 4r, and 6r is mounted on the corresponding reel 15 and fed out in the form of a continuous sheet.
- the production line 10 includes a fiber stacking device 20, an absorber rotary cutter device 70, an embossing press device 80, a rotary die cutter device 90, and the like as main processing devices, and a plurality of locations in the transport direction. HMA coating devices 85 and 85 are provided.
- the fiber stacking device 20 forms pulp fibers 5 as an example of an absorbent raw material into a predetermined shape such as a substantially rectangular parallelepiped to generate the absorbent body 3 (FIG. 3), and the produced absorbent body 3 is a product pitch in the transport direction. Place it on the carrier sheet 6 with P.
- an absorber rotary cutter device 70 Downstream of this, an absorber rotary cutter device 70 is arranged.
- the apparatus 70 includes a cutter roll 71 and an anvil roll 72 that are driven and rotated to face each other. Then, when the carrier sheet 6 on which the absorbent body 3 as the semi-finished product 1a at this time is passed through the gap between the rolls 71 and 72, the carrier sheet 6 is cut at a position between the absorbent bodies 3 and 3 ( FIG. 3). Thereby, the semi-finished product 1b is generated.
- the merging position of the top sheet 2 is set. That is, at the same position, the top sheet 2 is supplied and bonded to the carrier sheet 6 so as to cover the lower side of the carrier sheet 6 of the semi-finished product 1b.
- a hot melt adhesive is previously applied to the top sheet 2 by the HMA coating device 85 as a pretreatment for the bonding.
- the merging position of the back seat 4 is set downstream of the merging position. Therefore, at the same position, the back sheet 4 is supplied from above to the semi-finished product 1c in which the carrier sheet 6 and the absorber 3 are sequentially placed on the top sheet 2, and the semi-finished product 1c is taken from above. Affixed to cover. Incidentally, in the supply route of the back sheet 4 before this joining position, a hot melt adhesive is previously applied to the back sheet 4 by the HMA coating device 85 as a pretreatment for the bonding.
- the embossing press device 80 includes an embossing roll 81 and an anvil roll 82 that are driven and rotated to face each other.
- the embossing roll 81 has a convex portion having a shape corresponding to the above-described embossing groove 7 (FIG. 2). Therefore, when the semi-finished product 1d passes through the gap between the rolls 81 and 82, the semi-finished product 1d is embossed by the convex portion, and the embossed groove 7 is formed.
- the apparatus 90 includes a cutter roll 91 and an anvil roll 92 that are driven and rotated to face each other. Then, when the semi-finished product 1 d passes through the gap between the rolls 91 and 92, the rolls 91 and 92 punch the semi-finished product 1 d into the product shape of the napkin 1. Thereby, the sanitary napkin 1 is completed.
- FIG. 3 is a central cross-sectional view of the fiber stacking device 20 that is the manufacturing device 20 of the absorbent body 3.
- the fiber stacking device 20 includes, for example, a rotating drum 22 (corresponding to a drum) that continuously rotates in one direction of the rotation direction Dc (for example, clockwise) around a rotation shaft 21 along the CD direction, and a predetermined position in the rotation direction Dc.
- a spraying duct 51 (corresponding to a duct) that discharges mixed air 5a containing pulp fibers 5 from a spraying opening 51a (corresponding to a discharge port) disposed toward the outer peripheral surface 22a of the rotary drum 22.
- the rotary drum 22 is a substantially cylindrical body, and a concave molding die 23 (corresponding to a concave portion) corresponding to the shape of the absorbent body 3 to be molded is provided on the outer peripheral surface 22a thereof at a predetermined arrangement pitch P in the rotational direction Dc. It is provided intermittently.
- a breathable member 24 is provided as a bottom surface of each mold 23, and the inside of the mold 23 communicates with the inside of the rotary drum 22 through the vent holes 24 h of the breathable member 24 so as to allow ventilation.
- a donut-shaped substantially closed space S is partitioned between the rotary drum 22 and the rotary shaft 21.
- the substantially closed space S is divided into zones in the rotation direction Dc by a plurality of unillustrated partition walls.
- the first zone Z1 is maintained in a negative pressure state lower than the external air pressure by the intake air of the intake duct 53.
- the second zone Z2 on the downstream side is maintained at the same or slightly higher pressure than the external pressure.
- a spray opening 51a of the spray duct 51 is disposed corresponding to the first zone Z1, and a suction belt conveyor 12 serving as the transport mechanism 12 is disposed corresponding to the second zone Z2. .
- the absorber 3 is shape
- a polymer charging pipe (not shown) may be provided in the spray duct 51, and the superabsorbent polymer may be discharged from the charging port toward the rotary drum 22.
- FIG. 4 is an exploded perspective view of the rotary drum 22.
- FIG. 5 is a schematic side view of the rotary drum 22 of the reference example as viewed from the drive side.
- the rotary drum 22 includes a drum body 25 and a plurality of mold plates 29, 29... Detachably attached to the outer peripheral surface of the drum body 25.
- the drum body 25 has a cylindrical portion 26 and a rotating shaft 21 arranged concentrically with each other, and the cylindrical portion 26 and the rotating shaft 21 are integrally connected by a plurality of spoke-like members 28, 28.
- a bearing member (not shown) is provided at one end of the rotating shaft 21, and the drum body 25 is rotatably supported by a base (not shown) of the fiber stacking device 20 via the bearing member.
- a driving rotational force is input to the rotating shaft 21 from a motor 30 described later, whereby the rotating drum 22 is driven to rotate.
- openings 26h, 26h,... That are slightly larger than the molding die 23 are formed at portions where the molding dies 23 are to be located.
- both end edges 26e, 26e in the CD direction of the cylindrical portion 26 are closed by circular fixing walls 27, 27, respectively. As a result, the aforementioned substantially closed space S is defined inside the cylindrical portion 26.
- the mold plate 29 has, for example, an arc-shaped plate 29a having a length obtained by equally dividing the circumference of the outer peripheral surface 22a of the rotary drum 22 by the number of molds 23 to be provided (six in FIG. 4).
- An opening 29h having a shape corresponding to the shape of the absorbent body 3 to be molded is formed at the center of the arc-shaped plate 29a.
- this opening part 29h is covered with the air permeable member 24 from the inner peripheral surface side of the circular arc-shaped plate 29a, and the said air permeable member 24 makes the bottom face of the shaping
- one opening 29h forming the mold 23 is formed for each mold plate 29.
- the opening 29h per one mold plate 29 is provided. Two or more may be formed. Then, the mold plate 29 is attached to a predetermined position of the outer peripheral surface 26a of the cylindrical portion 26 by bolting or the like sequentially using a benchmark provided in advance in the cylindrical portion 26 of the drum body 25 as a mark. Such a benchmark is provided for each size such as M size or L size in order to cope with the size change described later. Also, the mold plate 29 is prepared for each of an M size mold plate 29M (corresponding to a first pitch setting member) and an L size mold plate 29L (corresponding to a second pitch setting member). ing.
- M size mold plate 29M corresponding to a first pitch setting member
- L size mold plate 29L corresponding to a second pitch setting member
- the rotating drum 22 is driven to rotate by using a motor 30 as a driving source. Further, a rotary encoder 35 for detecting the rotation angle of the rotary drum 22 is also provided in order to synchronize this driving rotation with other devices 70 of the production line 10 and the like. And in this reference example, it is comprised so that it may synchronize with the cutting
- the cutter roll 71 of the absorber rotary cutter device 70 has only one flat blade 71c along the CD direction in a part of the outer peripheral surface 71a in the circumferential direction. Then, the cutter roll 71 is controlled to rotate once while one semi-finished product 1a arranged at the product pitch P is conveyed in the conveying direction, and thus the absorber 3 as the semi-finished product 1a at this time is on the board.
- the carrier sheet 6 is divided at a product pitch P at a portion between the absorbers 3 and 3.
- the cutter roll 71 is also provided with a rotary encoder 74, which detects the rotation angle of the cutter roll 71 and outputs a detection signal.
- a signal indicating a phase of 0 ° to 360 ° with one rotation as a unit operation amount of the cutter roll 71 as one unit is repeatedly output in proportion to the rotation angle of the cutter roll 71. Then, this detection signal is transmitted as a synchronization signal to the controller 60 that controls the driving rotation of the rotary drum 22.
- the input shaft 35 a of the encoder 35 of the rotary drum 22 of this reference example rotates the rotary drum 22 by a rotation angle ⁇ P corresponding to the arrangement pitch P of the mold 23 as the product pitch P. Accordingly, a signal indicating a phase of 0 to 360 ° is output in proportion to the rotation angle of the input shaft 35a.
- the controller 60 controls the driving rotation of the motor 30 of the rotating drum 22 based on the above-described synchronization signal and the rotation angle signal from the encoder 35 of the rotating drum 22. That is, the controller 60 outputs the drive current I to the motor 30 while controlling the deviation ⁇ between the rotation angle instruction value ⁇ a indicated by the synchronization signal and the rotation angle instruction value ⁇ r indicated by the detection signal to be small. To do.
- FIG. 6 is a schematic configuration diagram of the controller 60.
- the controller 60 includes a position comparator 61, a speed command calculator 62, a speed comparator 63, and a drive current calculator 64.
- the position comparator 61 the rotation angle instruction value ⁇ a indicated by the synchronization signal is compared with the rotation angle instruction value ⁇ r indicated by the encoder 35, and a deviation ⁇ (angle deviation ⁇ ) between them is calculated.
- the angle deviation ⁇ is input to the speed command calculator 62.
- the speed command calculator 62 performs a predetermined calculation based on the angle deviation ⁇ , calculates a command value ⁇ a of angular velocity (rotational speed), and transmits the command value ⁇ a to the speed comparator 63. Then, the speed comparator 63 compares the command value ⁇ a of the angular velocity with the actual value ⁇ r of the angular velocity sent from the encoder 35 of the rotary drum 22, and calculates the difference ⁇ (angular velocity deviation ⁇ ) between them. Then, the angular velocity deviation ⁇ is transmitted to the drive current calculator 64.
- the drive current calculator 64 performs a predetermined calculation based on the angular velocity deviation ⁇ , and obtains a value of the drive current I so that the angular velocity deviation ⁇ becomes small. Then, the obtained drive current I is supplied to the motor 30 to drive the motor 30.
- the transmission of the rotational motion of the rotary drum 22 to the encoder 35 is performed by an appropriate rotational motion transmission mechanism as shown in FIG.
- a so-called winding transmission mechanism having pulleys 21p, 42p, 42p, 35p and timing belts 37, 38 is used.
- the adjustment of the rotation ratio R of the input shaft 35a of the encoder 35 with respect to the rotary drum 22 described above, that is, while the rotary drum 22 rotates by the rotation angle ⁇ P corresponding to the arrangement pitch P, the input shaft 35a of the encoder 35 is 1
- the adjustment to rotate is performed, for example, by adjusting the ratio between the diameter of the pulley 21p of the rotating shaft 21 of the rotating drum 22 (the diameter of the pitch circle) and the diameter of the pulley 35p of the input shaft 35a (the diameter of the pitch circle). Is called.
- ⁇ Resize of fiber pile device 20 >>>
- the size of the napkin 1 that is produced periodically is changed.
- size change is also performed in the fiber stacking apparatus 20.
- the product pitch P in the transport direction, the length of the absorber 3, and the like change. Therefore, in the rotary drum 22, the arrangement pitch P of the mold 23, the length of the mold 23, and the like are changed.
- the size is changed from the M size to the L size will be described as an example.
- the M size mold plate 29M is removed from the drum body 25 of the rotary drum 22 shown in FIG. 4, and instead, an L size mold plate 29L (not shown) is used. It is made by attaching. At this time, using the benchmark (or key and keyway) formed on the drum body 25 as a mark, the mold plate 29L is attached at a predetermined fixed position. This is a position where the relative positional relationship necessary for synchronization with the cutter roll 71 is guaranteed. Therefore, if the mold plate 29L is attached to this fixed position, the relative positional relationship necessary for synchronization between the rotary drum 22 and the cutter roll 71 is ensured.
- the number N of the molds 23 formed on the rotary drum 22 changes from, for example, 6 to 5 by exchanging with the mold plate 29L for L size.
- the arrangement pitch P of the mold 23 in the rotation direction Dc of the rotary drum 22 also changes from the arrangement pitch PM for the M size to the arrangement pitch PL for the L size.
- the drum body 25 having the rotating shaft 21 and the motor 30 as a driving source for driving the drum body 25 are used without being replaced at all.
- the mold plate 29 (29M ⁇ 29L) is exchanged, the outer diameter of the rotary drum 22 does not substantially change when changing from the M size to the L size. Therefore, the spraying duct 51 disposed to face the rotating drum 22 is also used as it is.
- the reason why the correspondence relationship is maintained in this way is that the absorber rotary cutter device 70 that should generate the synchronization signal is changed from the M size cutter roll 71 to the L size cutter roll 71 as the size is changed. This is because the relationship that the cutter roll 71 rotates once to cut the semi-finished product 1a with the L size product pitch PL is maintained.
- 1.2 rotations are performed, and as a result, the encoder 35 outputs a signal exceeding the phase range of 0 ° to 360 °.
- the encoder 35 of the above-described reference example is an M size encoder 35M
- an L size encoder 35L is additionally provided. . That is, dedicated encoders 35M and 35L are provided for each of the M size and the L size (FIG. 7).
- the encoders 35M and 35L to be used are selectively switched according to the size to be manufactured, thereby eliminating the adjustment work of the encoders 35M and 35L accompanying the size change and reducing the workload of the size change. I am trying.
- the configuration will be described in detail.
- FIG. 7 is a schematic side view of the rotary drum 22 according to this embodiment as viewed from the drive side.
- an M size encoder 35M (corresponding to the first signal generating unit) and an L size encoder 35L (corresponding to the second signal generating unit) are located near the rotary drum 22.
- Each of the encoders 35M and 35L has the same specification, and has input shafts 35aM and 35aL, respectively.
- Each of the input shafts 35aM and 35aL is provided with a winding transmission mechanism as an example of a rotational operation transmission mechanism. Rotational operations are input from the rotary shaft 21 of the rotary drum 22 at predetermined rotation ratios RM and RL, respectively.
- the input shaft 35aM rotates once, so that the encoder 35M for the M size outputs a signal having a phase range of 0 ° to 360 ° for the rotation operation corresponding to the arrangement pitch PM of the rotary drum 22.
- the shaft 35aL rotates once, so that the encoder 35L for the L size outputs a signal having a phase range of 0 ° to 360 ° for the rotation operation corresponding to the arrangement pitch PL of the rotary drum 22.
- a signal input to the controller 60 is connected to the controller 60 by a selector switch provided by an electric circuit or the like outside the controller 60 or a selector switch configured by a program or the like that can be executed by the processor in the controller 60.
- the size change of the encoder 35 is completed by appropriately switching between the size encoder 35M and the L size encoder 35L.
- the winding transmission mechanism which has the relay shaft 42 as shown in FIG. 7 is used as a rotational motion transmitter which transmits rotational motion with said rotational ratio RM, RL.
- one relay shaft 42 is rotatably disposed around the axis at a fixed position between the rotary drum 22 and the encoders 35M and 35L.
- the pulleys 21p, 35pM, and 35pL are concentric and integral with a predetermined portion of the rotary shaft 21 of the rotary drum 22, the input shaft 35aM of the encoder 35M for M size, and the input shaft 35aL of the encoder 35L for L size.
- three pulleys 42p, 42p, and 42p having the same diameter are concentrically and integrally fixed to the relay shaft 42.
- the three pulleys 42p, 42p, 42p of the relay shaft 42 correspond to any of the pulley 21p of the rotating shaft 21, the pulley 35pM of the input shaft 35aM, and the pulley 35pL of the input shaft 35aL, respectively.
- the timing belts 37, 38M, and 38L are wound around the corresponding pulleys 21p, 35pM, and 35pL in the 42p, 42p, and 42p, respectively, so that the rotation operation of the rotary drum 22 is performed via the relay shaft 42.
- the rotation ratios RM and RL described above are determined by the ratio between the diameter of the pulley 21p of the rotary drum 22 and the diameters of the pulleys 35pM and 35pL of the encoders 35M and 35L. Therefore, in this embodiment, when the diameter of the pulley 21p of the rotating drum 22 is Dp, the diameter of the M-size pulley 35pM is 1/6 ⁇ Dp, and the diameter of the L-size pulley 35pL is 1 / 5 ⁇ Dp.
- the reason why the relay shaft 42 is used is to increase the degree of freedom of the arrangement position of the encoder 35M (35L) and to transmit the rotational operation of the rotary drum 22 to the input shafts 35aM and 35aL with high accuracy. is there.
- the reason for the latter will be described. If the relay shaft 42 is used, the rotation ratio RM (RL) of the rotation operation transmitted from the rotation shaft 21 to the input shaft 35aM (35aL) is divided into two rotation ratios having a value smaller than the rotation ratio RM (RL). be able to. Thereby, conversion of a rotation ratio can be performed gently.
- each timing belt 37 and 38M (37 and 38L) since there are two timing belts 37 and 38M (37 and 38L), the length of each timing belt 37 and 38M (37 and 38L) can be shortened. As a result, the slack of each timing belt 37, 38M (37, 38L) is also reduced, so that the tension to be applied to each timing belt 37, 38M (37, 38L) in order to remove the slack can be reduced. As a result, the load acting on the rotating shaft 21 and the input shaft 35aM (35aL) can be reduced, and the rotating operation of each of the shafts 21 and 35aM (35aL) is stabilized. With the above, the rotating operation of the rotating drum 22 is changed to the input shaft 35aM. (35aL) can be accurately transmitted.
- the relay shaft 42 is not necessarily used.
- a single timing belt is directly wound around the pulley 21p of the rotating shaft 21 of the rotating drum 22 and the pulley 35pM (35pL) of the input shaft 35aM (35aL) of the encoder 35M (35L) to transmit the rotating operation. Also good.
- the motor 30 for driving and rotating the rotary drum 22 inputs the driving torque to the rotary drum 22 via the relay shaft 42 described above. That is, the relay shaft 42 is further provided with a pulley 43p integrally and concentrically, and the timing belt 39 is wound around the pulley 43p and the pulley 30p of the drive rotation shaft 30a of the motor 30.
- the driving rotational force is transmitted to the relay shaft 42, and the driving rotational force is transmitted from the relay shaft 42 to the rotary drum 22 via the timing belt 37 and the rotational shaft 21.
- the drive torque transmission method of the motor 30 is not limited to this.
- the relay shaft 42 may not be used. That is, the driving rotational force may be transmitted by directly winding a single timing belt around the pulley 21p of the rotating shaft 21 of the rotating drum 22 and the pulley 30p of the driving rotating shaft 30a of the motor 30.
- FIG. 8 is an explanatory diagram of another example of the timing belt wrapping pattern of the rotational motion transmission mechanism.
- the relay shaft is used in the same manner as described above, but two relay shafts 42 and 44 are used as an example instead of one.
- the input shaft 35aM of the M size encoder 35M is also used as a relay shaft.
- first, the first relay shaft 42 and the second relay shaft 44 are disposed at a fixed position between the rotary shaft 21 of the rotary drum 22 and the encoders 35M and 35L with a gap therebetween.
- the first relay shaft 42 closer to the rotating shaft 21 of the rotating drum 22 has a pair of pulleys 42p, 42p having the same diameter and are concentric with each other.
- the second relay shaft 44 closer to the encoders 35M and 35L also has a pair of pulleys 44p and 44p having the same diameter as a single body and concentric with each other.
- One pulley 42p of the first relay shaft 42 is connected to the pulley 21p of the rotating shaft 21 of the rotary drum 22 via the timing belt 37, and the other pulley 42p is connected to the first pulley 42p via the timing belt 46.
- the two relay shafts 44 are connected to one pulley 44p.
- the other pulley 44p of the second relay shaft 44 is connected to the pulley 35pM of the input shaft 35aM of the M size encoder 35M by the timing belt 45. Accordingly, the rotation operation of the rotary drum 22 is input to the M size encoder 35M via the first relay shaft 42 and the second relay shaft 44.
- the input shaft 35aM of the M-size encoder 35M further includes another pulley 35aM having the same diameter as that of the pulley 35pM described above, which is integrated and concentric.
- the pulley 35aM is connected to the pulley 35pL of the input shaft 35aL of the L size encoder 35L via the timing belt 47. Therefore, the rotation operation of the rotary drum 22 is input to the L size encoder 35L via the input shaft 35aM of the M size encoder 35M.
- the pulp fiber 5 is exemplified as the main material of the absorbent material.
- the present invention is not limited to this, and a superabsorbent polymer may be used as the main material.
- the “main material” referred to here is a raw material most often contained in the absorbent body 3 in terms of weight percent (or volume percent).
- the size change between the M size and the L size is exemplified.
- the size change is not limited to this, and the three sizes of S, M, and L, and the four sizes including the LL in the size are included.
- the concept of the above-described embodiment can also be applied to the size change.
- an S-size encoder 35S is additionally provided in the configuration of the above-described embodiment.
- the rotary drum 22 includes a total of three encoders 35S, 35M, 35L will be provided.
- the winding transmission mechanism including the pulleys 21p, 42p, 35pM, and 35pL and the timing belts 37, 38M, and 38L is shown as an example of the rotational operation transmission mechanism.
- This is not a limitation.
- a gear train having a plurality of gears meshing with each other may be used.
- the size of the rotary drum 22 is changed only by replacing the mold plate 29 in FIG. 4 and the drum body 25 is not replaced. However, in some cases, the mold plate 29 is attached.
- the size of the rotating drum 22 may be changed by exchanging the drum body 25 in the state.
- the rotating shaft 21 of the rotating drum 22 is detachably connected to a rotating shaft portion on the rotating drum 22 side and a rotating shaft portion on the motor 30 side, for example.
- a connecting structure for connecting in a separable manner an appropriate shaft joint may be mentioned.
- the rotating shaft part by the side of the motor 30 is supported by the base of the fiber stacking apparatus 20 via the bearing member so that rotation is possible.
- the above-described pulley 21p that transmits the rotation operation to the encoders 35M and 35L is provided on a rotation shaft portion (corresponding to a predetermined portion) on the motor 30 side.
- the rotating drum 22 is removed at the connecting structure and carried out of the production line 10. Then, instead, the rotating drum 22 corresponding to the napkin 1 of the next size to be manufactured was carried in, and the rotating shaft portion on the rotating drum 22 side included in the rotating drum 22 was left in the manufacturing line 10. It is connected to the rotating shaft portion on the motor 30 side.
- the connection is made on the basis of benchmarks, key members, and the like that the rotary shaft portions have.
- the correspondence between the position in the rotation direction Dc of the mold 23 that is the rotation position of the rotary drum 22 and the rotation angle instruction value ⁇ r indicated by the encoders 35M and 35L is maintained at a predetermined relationship necessary for the synchronous operation.
- the M-size rotating drum 22 itself corresponds to the “first pitch setting member”
- the L-size rotating drum 22 itself corresponds to the “second pitch setting member”.
- the size of the rotary drum 22 may be changed by replacing the cylindrical portion 26 with the mold plate 29 attached thereto.
- the connecting portion between the spoke-like member 28 of the drum main body 25 and the cylindrical portion 26 is configured in advance by a separable connecting structure such as a bolt.
- the cylindrical portion 26 When changing the size, the cylindrical portion 26 is removed at the connecting portion and is carried out of the production line 10. That is, the spoke-like member 28 and the rotating shaft 21 remain in the production line 10 in the state before the cylindrical portion 26 is removed. Then, as an alternative, the cylindrical portion 26 corresponding to the napkin 1 of the next size to be manufactured is carried in with the mold plate 29 attached, and the cylindrical portion 26 remains in the manufacturing line 10. It is connected to the shaped member 28. The connection is made based on a mark such as a benchmark that the cylindrical portion 26 and the spoke-like member 28 have.
- the M-size cylindrical portion 26 to which the mold plate 29 is attached corresponds to the “first pitch setting member”
- the L-size cylindrical portion 26 to which the mold plate 29 is attached is the “second pitch setting member”. Corresponds to “member”.
- the drive rotation of the rotary drum 22 is synchronized with the cutting operation of the absorber rotary cutter device 70, but the present invention is not limited to this.
- the driving rotation of the rotary drum 22 may be synchronized with the emboss press device 80 or the rotary die cutter device 90.
- a synchronization signal is output from an encoder that detects the operation of these devices 80 and 90.
- the drive rotation of the embossing press device 80 or the rotary die cutter device 90 as another device may be synchronized based on the synchronization signal of the cutter device 70.
- the transport mechanism 12 may also be controlled to perform a transport operation in synchronization with the cutter device 70, or the transport mechanism so as to have the same transport speed as the peripheral speed of the flat blade 71c of the cutter device 70. 12 may be controlled.
- the encoder 35M is exemplified as the first signal generation unit, and the signal indicating the phase of 0 ° to 360 ° is exemplified as the first rotation angle signal.
- the rotation corresponding to the arrangement pitch PM as the first pitch is exemplified.
- the signal is not limited to this as long as it is a signal repeatedly generated with the rotation angle ⁇ PM of the drum 22 as one unit and has the same specifications as the synchronization signal.
- the first rotation angle signal may be a signal composed of 8192 digital values from 0 to 8191 equally allocated to the rotation angle ⁇ PM of the rotary drum 22, and It may be a signal made up of a predetermined number of pulses evenly allocated to the rotation angle ⁇ PM.
- the encoder 35L is exemplified as the second signal generation unit, and the signal indicating the phase of 0 ° to 360 ° is exemplified as the second rotation angle signal.
- the rotation corresponding to the arrangement pitch PL as the second pitch is exemplified. It is a signal that is repeatedly generated with the rotation angle ⁇ PL of the drum 22 as one unit, and is not limited to this as long as it has the same specifications as the synchronization signal.
- the second rotation angle signal may be a signal composed of 8192 digital values from 0 to 8191 equally allocated to the rotation angle ⁇ PL of the rotary drum 22, and further, It may be a signal made up of a predetermined number of pulses evenly allocated to the rotation angle ⁇ PL.
- the encoder 74 is exemplified as the one that generates the synchronization signal, and the signal indicating the phase of 0 ° to 360 ° is exemplified as the synchronization signal.
- the unit operation amount of another device corresponding to the product pitch P is exemplified.
- the signal is not limited to this.
- the synchronization signal may be a signal composed of 8192 digital values from 0 to 8191 that are equally allocated to the rotation angle of one rotation as the unit operation amount of the cutter roll 71, and further May be a signal composed of a predetermined number of pulses evenly allocated to the same rotation angle.
- 1 sanitary napkin (absorbent article), 1a semi-finished product, 1b semi-finished product, 1c semi-finished product, 1d semi-finished product, 1e semi-finished product, 2 top sheet, 2r sheet roll, 3 absorbent, 4 back sheet, 4r sheet roll, 5 pulp fiber (absorber raw material), 5a mixed air, 6 carrier sheet, 6r sheet roll, 7 embossed groove, 10 production line, 12 suction belt conveyor (conveyance mechanism), 15 reel, 20 fiber stacking device (absorber production) Equipment), 21 rotary shaft, 21p pulley, 22 rotary drum (drum), 22a outer peripheral surface, 23 molding die (concave), 24 breathable member, 24h vent hole, 25 drum body, 26 cylindrical portion, 26a outer peripheral surface, 26e Both edges, 26h opening, 27 circular fixed wall, 28 spoke-shaped member, 29 Mold plate, 29M Mold plate (first pitch setting member), 29L Mold plate (second pitch setting member), 29a arc plate, 29h opening, 30 motor (drive source), 30a drive rotating shaft, 30
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Abstract
Description
かかる吸収体は、積繊装置によって製造される。積繊装置は駆動回転する回転ドラムを有する。回転ドラムの外周面には回転方向に所定の配置ピッチで凹状の成形型が間欠的に配置されている。そして、回転ドラムの外周面の成形型に向けて適宜なダクトから吸収体原料を供給して成形型に堆積することにより吸収体を製造する(特許文献1)。
製品ピッチに相当する他の装置の単位動作量を1単位として繰り返し出力される同期信号に基づいて、前記他の装置と同期しながら、ドラムを回転軸周りに駆動回転する駆動源を有し、
前記ドラムの外周面に、回転方向に所定の配置ピッチで間欠的に配置された複数の凹部に向けて、前記回転方向の所定位置に配されたダクトから吸収体原料を供給して、前記吸収体原料を前記凹部に堆積させて吸収体を製造する装置であって、
前記配置ピッチを第1ピッチに設定する第1ピッチ設定部材と、
前記配置ピッチを前記第1ピッチとは異なる第2ピッチに設定する第2ピッチ設定部材と、
前記ドラムの回転に基づいて、前記第1ピッチに相当する前記ドラムの回転角度を1単位として第1回転角度信号を繰り返し生成する第1信号生成部と、
前記ドラムの回転に基づいて、前記第2ピッチに相当する前記ドラムの回転角度を1単位として第2回転角度信号を繰り返し生成する第2信号生成部と、
前記駆動源の駆動回転を制御するコントローラと、を有し、
前記配置ピッチが前記第1ピッチに設定された場合には、前記コントローラは、前記第1回転角度信号と前記同期信号とに基づいて、前記駆動源の駆動回転を制御し、
前記配置ピッチが前記第2ピッチに設定された場合には、前記コントローラは、前記第2回転角度信号と前記同期信号とに基づいて、前記駆動源の駆動回転を制御することを特徴とする吸収体の製造装置である。
製品ピッチに相当する他の装置の単位動作量を1単位として繰り返し出力される同期信号に基づいて、前記他の装置と同期しながら、ドラムを回転軸周りに駆動回転する駆動源を有し、
前記ドラムの外周面に、回転方向に所定の配置ピッチで間欠的に配置された複数の凹部に向けて、前記回転方向の所定位置に配されたダクトから吸収体原料を供給して、前記吸収体原料を前記凹部に堆積させて吸収体を製造する装置であって、
前記配置ピッチを第1ピッチに設定する第1ピッチ設定部材と、
前記配置ピッチを前記第1ピッチとは異なる第2ピッチに設定する第2ピッチ設定部材と、
前記ドラムの回転に基づいて、前記第1ピッチに相当する前記ドラムの回転角度を1単位として第1回転角度信号を繰り返し生成する第1信号生成部と、
前記ドラムの回転に基づいて、前記第2ピッチに相当する前記ドラムの回転角度を1単位として第2回転角度信号を繰り返し生成する第2信号生成部と、
前記駆動源の駆動回転を制御するコントローラと、を有し、
前記配置ピッチが前記第1ピッチに設定された場合には、前記コントローラは、前記第1回転角度信号と前記同期信号とに基づいて、前記駆動源の駆動回転を制御し、
前記配置ピッチが前記第2ピッチに設定された場合には、前記コントローラは、前記第2回転角度信号と前記同期信号とに基づいて、前記駆動源の駆動回転を制御することを特徴とする吸収体の製造装置。
前記第1回転角度信号及び前記第2回転角度信号は、前記同期信号と同じ仕様の信号であるのが望ましい。
このような吸収体の製造装置によれば、第1回転角度信号及び第2回転角度信号のどちらの信号も、同期信号と同じ仕様の信号なので、ドラムの回転を他の装置に同期させるべく各回転角度信号を同期信号と対応付ける際に、その対応付けが容易となる。
前記第1回転角度信号は、0°~360°の位相を示す信号であり、
前記第2回転角度信号は、0°~360°の位相を示す信号であり、
前記同期信号は、0°~360°の位相を示す信号であるのが望ましい。
このような吸収体の製造装置によれば、第1回転角度信号、第2回転角度信号、及び同期信号の何れの信号も、0°~360°の位相を示す信号である。よって、ドラムの回転を他の装置に同期させるべく各回転角度信号を同期信号と対応付ける際に、その対応付けが容易となる。
前記第1信号生成部と前記第2信号生成部とは、互いに同仕様の信号生成部であり、
前記第1信号生成部は、第1入力軸を有するとともに、前記第1入力軸の回転によって前記第1回転角度信号を生成し、
前記第2信号生成部は、第2入力軸を有するとともに、前記第2入力軸の回転によって前記第2回転角度信号を生成し、
前記ドラムの前記回転軸は前記ドラムと一体に回転し、
回転動作伝達機構を介して、前記回転軸から前記第1入力軸及び前記第2入力軸へと前記ドラムの回転動作が入力され、
前記ドラムに前記第1ピッチPMで配置される前記凹部の数をNMとし、前記ドラムに前記第2ピッチPLで配置される前記凹部の数をNLとした場合に、
前記回転軸に対する前記第1入力軸の回転比RMが、前記NMとなるようにしつつ、前記回転軸に対する前記第2入力軸の回転比RLが、前記NLとなるように、前記回転動作伝達機構が設定されるのが望ましい。
このような吸収体の製造装置によれば、第1信号生成部と第2信号生成部とで同仕様の信号生成部を用いる。よって、ドラムの回転動作を他の装置の動作に同期させる際に、これら信号生成部の同期信号に対する対応付けを確実に行うことができる。
前記回転動作伝達機構は少なくとも1本の中継軸を有し、
前記中継軸を介して、前記回転軸から前記第1入力軸及び前記第2入力軸へと前記ドラムの回転動作が伝達され、
前記中継軸によって、前記回転比RMが、当該回転比RMよりも小さい値の複数の回転比に分割されているとともに、
前記中継軸によって、前記回転比RLが、当該回転比RLよりも小さい値の複数の回転比に分割されているのが望ましい。
このような吸収体の製造装置によれば、中継軸を用いているので、第1及び第2信号生成部の配置位置の自由度を高めることができる。
また、回転軸から第1及び第2入力軸へ伝達される回転動作の各回転比RM,RLを、中継軸を用いることにより、それぞれ、小さな回転比に分割している。よって、ドラムの回転動作を第1及び第2入力軸に対して精度良く伝達可能となる。詳細には後述する。
前記ドラムの回転動作を前記第1入力軸及び前記第2入力軸へと伝達すべく、前記回転軸における所定部位において、前記回転軸は前記回転動作伝達機構に連結され、
前記配置ピッチが前記第1ピッチの場合、及び前記配置ピッチが前記第2ピッチの場合の両者に対して、前記所定部位は共用されるのが望ましい。
このような吸収体の製造装置によれば、回転軸における前記所定部位は、第1ピッチ及び第2ピッチの両者に対して共用される。よって、サイズ替えに際して、回転動作伝達機構を全くさわらずに済み、もって、サイズ替えに要する作業負荷を軽減することができる。
前記吸収体原料を吐出供給する前記ダクトの吐出口は、前記ドラムの前記外周面に対向して配置されており、
前記第1ピッチ設定部材によって形成されたドラムの直径と、前記第2ピッチ設定部材によって形成されたドラムの直径とは、互いに等しいのが望ましい。
このような吸収体の製造装置によれば、配置ピッチが第1ピッチのドラムの直径と、配置ピッチが第2ピッチのドラムの直径とは互いに等しいので、吸収体原料を吐出供給する前記ダクトを交換せずに済み、つまり共用可能である。よって、サイズ替えに係る作業負荷を軽減することができる。
<<<製造ライン10の概略構成>>>
図1は、吸収性物品1の製造ライン10の概略側面図である。この製造ライン10では、排泄液を吸収する吸収性物品1の一例として生理用ナプキン1を製造する。
このナプキン1は、例えば、不織布等の液透過性のトップシート2とフィルム等の液不透過性のバックシート4との間に、パルプ繊維5を主材とする吸収体3がティッシュペーパー等のキャリアシート6(図2A及び図2B中では不図示)と共に介装されたものである。
ちなみに、ナプキン1の長手方向及び幅方向の略中央には、エンボス溝7が型押し等で形成されており、これによりナプキン1を構成する部品2,3,4,6の一体化が図られている。
図3は、吸収体3の製造装置20たる積繊装置20の中心断面図である。なお、同図3中では、一部の構成を側面視で示している。
積繊装置20は、例えばCD方向に沿う回転軸21を回転中心として回転方向Dcの一方向に(例えば時計回りに)連続回転する回転ドラム22(ドラムに相当)と、回転方向Dcの所定位置に配置された散布開口部51a(吐出口に相当)から回転ドラム22の外周面22aに向けてパルプ繊維5を含んだ混入空気5aを吐出する散布ダクト51(ダクトに相当)と、を有する。
ちなみに、散布ダクト51内に不図示のポリマー投入管を設け、その投入口から回転ドラム22に向けて高吸収性ポリマーを吐出しても良い。
図4は、回転ドラム22の分解斜視図である。また、図5は、参考例の回転ドラム22を駆動側から見た概略側面図である。
図4に示すように、回転ドラム22は、ドラム本体25と、ドラム本体25の外周面に着脱自在に装着される複数の成形型プレート29,29…と、を有する。
そして、かかる成形型プレート29は、ドラム本体25の円筒部26に予め設けられたベンチマークを目印として、円筒部26の外周面26aの予め決められた位置に順次ボルト止め等で取り付けられる。なお、かかるベンチマークは、後述するサイズ替えに対処すべく、MサイズやLサイズ等のサイズ毎に設けられている。また、成形型プレート29も、Mサイズ用の成形型プレート29M(第1ピッチ設定部材に相当)と、Lサイズ用の成形型プレート29L(第2ピッチ設定部材に相当)とのそれぞれについて用意されている。そして、ベンチマークに基づいて成形型プレート29を取り付ければ、基本的には、MサイズやLサイズによらず、この後で説明するカッターロール71との同期に必要な相対位置関係が確保されるようになっている。なお、図4には、Mサイズの成形型プレート29Mが示されている。
製造ライン10では、定期的に製造するナプキン1のサイズ替えを行う。これに対応させて、積繊装置20でもサイズ替えが行われる。そして、このサイズ替に伴い、搬送方向の製品ピッチPや吸収体3の長さ等が変化する。そのため、回転ドラム22においては、成形型23の配置ピッチPや成形型23の長さ等を変更する。なお、以下では、MサイズからLサイズへとサイズ替えをする場合を例に説明する。
詳しく説明すると、図5に示すように、サイズ替え前の現時点では、Mサイズの配置ピッチPMに相当する回転角度θPM(60°(=360°/6))だけ回転ドラム22が回転した場合に、エンコーダ35の入力軸35aが1回転するようになっている。そのため、Lサイズの配置ピッチPLに相当する回転角度θPL(72°(=360°/5))だけ回転ドラム22が回転した場合には、エンコーダ35の入力軸35aは、1回転よりも多く回転してしまい、具体的には1.2回転してしまい、その結果、エンコーダ35は、0°~360°の位相の範囲を超える信号を出力してしまうのである。
図7に示すように、回転ドラム22の近傍位置には、Mサイズ用のエンコーダ35M(第1信号生成部に相当)と、Lサイズ用のエンコーダ35L(第2信号生成部に相当)とが配置されている。各エンコーダ35M,35Lは、どちらも同仕様のものであり、それぞれ入力軸35aM,35aLを有し、各入力軸35aM,35aLには、回転動作伝達機構の一例としての巻き掛け伝動機構を介して回転ドラム22の回転軸21から回転動作が、それぞれ所定の回転比RM,RLで入力される。
詳しくは、回転ドラム22とエンコーダ35M,35Lとの間の定位置に、一本の中継軸42がその軸芯周りに回転自在に配置されている。また、回転ドラム22の回転軸21の所定部位、Mサイズ用のエンコーダ35Mの入力軸35aM、及びLサイズ用のエンコーダ35Lの入力軸35aLには、それぞれ同芯且つ一体にプーリ21p,35pM,35pLが固定されており、更に、中継軸42には、互いに同径の三つのプーリ42p,42p,42pが同芯且つ一体に固定されている。
以上、本発明の実施形態について説明したが、本発明は、かかる実施形態に限定されるものではなく、以下に示すような変形が可能である。
前述の実施形態では、吸収体原料の主材としてパルプ繊維5を例示したが、何等これに限るものではなく、高吸収性ポリマーを主材としても良い。なお、ここで言う「主材」とは、重量パーセント(又は体積パーセント)表記で、吸収体3に最も多く含まれる原料のことである。
その場合には、回転ドラム22の回転軸21は、例えば、回転ドラム22側の回転軸部分とモータ30側の回転軸部分とに分離可能に連結されてなる。この分離可能に連結するための連結構造としては、適宜な軸継ぎ手が挙げられる。そして、モータ30側の回転軸部分がベアリング部材を介して回転自在に積繊装置20の基台に支持されている。また、同モータ30側の回転軸部分(所定部位に相当)に、エンコーダ35M,35Lへ回転動作を伝達する前述のプーリ21pが設けられている。
また、他の装置としてのエンボスプレス装置80やロータリーダイカッター装置90の駆動回転についても、カッター装置70の同期信号に基づいて同期させても良い。
更には、搬送機構12も、カッター装置70に同期して搬送動作をするように制御しても良いし、又は、カッター装置70の平刃71cの周速と同じ搬送速度になるように搬送機構12を制御しても良い。
例えば、第1回転角度信号としては、回転ドラム22の前記回転角度θPMに対して均等に割り振られた0から8191までの8192個のデジタル値からなる信号であっても良いし、更には、同回転角度θPMに均等に割り振られた所定数のパルスからなる信号であっても良い。
例えば、第2回転角度信号としては、回転ドラム22の前記回転角度θPLに対して均等に割り振られた0から8191までの8192個のデジタル値からなる信号であっても良いし、更には、同回転角度θPLに均等に割り振られた所定数のパルスからなる信号であっても良い。
例えば、同期信号としては、カッターロール71の単位動作量としての1回転の回転角度に対して均等に割り振られた0から8191までの8192個のデジタル値からなる信号であっても良いし、更には、同回転角度に均等に割り振られた所定数のパルスからなる信号であっても良い。
Claims (7)
- 製品ピッチに相当する他の装置の単位動作量を1単位として繰り返し出力される同期信号に基づいて、前記他の装置と同期しながら、ドラムを回転軸周りに駆動回転する駆動源を有し、
前記ドラムの外周面に、回転方向に所定の配置ピッチで間欠的に配置された複数の凹部に向けて、前記回転方向の所定位置に配されたダクトから吸収体原料を供給して、前記吸収体原料を前記凹部に堆積させて吸収体を製造する装置であって、
前記配置ピッチを第1ピッチに設定する第1ピッチ設定部材と、
前記配置ピッチを前記第1ピッチとは異なる第2ピッチに設定する第2ピッチ設定部材と、
前記ドラムの回転に基づいて、前記第1ピッチに相当する前記ドラムの回転角度を1単位として第1回転角度信号を繰り返し生成する第1信号生成部と、
前記ドラムの回転に基づいて、前記第2ピッチに相当する前記ドラムの回転角度を1単位として第2回転角度信号を繰り返し生成する第2信号生成部と、
前記駆動源の駆動回転を制御するコントローラと、を有し、
前記配置ピッチが前記第1ピッチに設定された場合には、前記コントローラは、前記第1回転角度信号と前記同期信号とに基づいて、前記駆動源の駆動回転を制御し、
前記配置ピッチが前記第2ピッチに設定された場合には、前記コントローラは、前記第2回転角度信号と前記同期信号とに基づいて、前記駆動源の駆動回転を制御することを特徴とする吸収体の製造装置。 - 請求項1に記載の吸収体の製造装置であって、
前記第1回転角度信号及び前記第2回転角度信号は、前記同期信号と同じ仕様の信号であることを特徴とする吸収体の製造装置。 - 請求項2に記載の吸収体の製造装置であって、
前記第1回転角度信号は、0°~360°の位相を示す信号であり、
前記第2回転角度信号は、0°~360°の位相を示す信号であり、
前記同期信号は、0°~360°の位相を示す信号であることを特徴とする吸収体の製造装置。 - 請求項1乃至3の何れかに記載の吸収体の製造装置であって、
前記第1信号生成部と前記第2信号生成部とは、互いに同仕様の信号生成部であり、
前記第1信号生成部は、第1入力軸を有するとともに、前記第1入力軸の回転によって前記第1回転角度信号を生成し、
前記第2信号生成部は、第2入力軸を有するとともに、前記第2入力軸の回転によって前記第2回転角度信号を生成し、
前記ドラムの前記回転軸は前記ドラムと一体に回転し、
回転動作伝達機構を介して、前記回転軸から前記第1入力軸及び前記第2入力軸へと前記ドラムの回転動作が入力され、
前記ドラムに前記第1ピッチPMで配置される前記凹部の数をNMとし、前記ドラムに前記第2ピッチPLで配置される前記凹部の数をNLとした場合に、
前記回転軸に対する前記第1入力軸の回転比RMが、前記NMとなるようにしつつ、前記回転軸に対する前記第2入力軸の回転比RLが、前記NLとなるように、前記回転動作伝達機構が設定されることを特徴とする吸収体の製造装置。 - 請求項4に記載の吸収体の製造装置であって、
前記回転動作伝達機構は少なくとも1本の中継軸を有し、
前記中継軸を介して、前記回転軸から前記第1入力軸及び前記第2入力軸へと前記ドラムの回転動作が伝達され、
前記中継軸によって、前記回転比RMが、当該回転比RMよりも小さい値の複数の回転比に分割されているとともに、
前記中継軸によって、前記回転比RLが、当該回転比RLよりも小さい値の複数の回転比に分割されていることを特徴とする吸収体の製造装置。 - 請求項4又は5に記載の吸収体の製造装置であって、
前記ドラムの回転動作を前記第1入力軸及び前記第2入力軸へと伝達すべく、前記回転軸における所定部位において、前記回転軸は前記回転動作伝達機構に連結され、
前記配置ピッチが前記第1ピッチの場合、及び前記配置ピッチが前記第2ピッチの場合の両者に対して、前記所定部位は共用されることを特徴とする吸収体の製造装置。 - 請求項1乃至6の何れかに記載の吸収体の製造装置であって、
前記吸収体原料を吐出供給する前記ダクトの吐出口は前記ドラムの前記外周面に対向して配置されており、
前記第1ピッチ設定部材によって形成されたドラムの直径と、前記第2ピッチ設定部材によって形成されたドラムの直径とは、互いに等しいことを特徴とする吸収体の製造装置。
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