WO2013129004A1 - 束状製品の製造方法および製造装置 - Google Patents
束状製品の製造方法および製造装置 Download PDFInfo
- Publication number
- WO2013129004A1 WO2013129004A1 PCT/JP2013/051850 JP2013051850W WO2013129004A1 WO 2013129004 A1 WO2013129004 A1 WO 2013129004A1 JP 2013051850 W JP2013051850 W JP 2013051850W WO 2013129004 A1 WO2013129004 A1 WO 2013129004A1
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- WIPO (PCT)
- Prior art keywords
- hollow fiber
- yarn
- fiber membrane
- yarns
- bundle
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H54/00—Winding, coiling, or depositing filamentary material
- B65H54/56—Winding of hanks or skeins
- B65H54/58—Swifts or reels adapted solely for the formation of hanks or skeins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D63/00—Apparatus in general for separation processes using semi-permeable membranes
- B01D63/02—Hollow fibre modules
- B01D63/021—Manufacturing thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D63/00—Apparatus in general for separation processes using semi-permeable membranes
- B01D63/02—Hollow fibre modules
- B01D63/021—Manufacturing thereof
- B01D63/0233—Manufacturing thereof forming the bundle
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D65/00—Accessories or auxiliary operations, in general, for separation processes or apparatus using semi-permeable membranes
- B01D65/10—Testing of membranes or membrane apparatus; Detecting or repairing leaks
- B01D65/102—Detection of leaks in membranes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H51/00—Forwarding filamentary material
- B65H51/015—Gathering a plurality of forwarding filamentary materials into a bundle
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H63/00—Warning or safety devices, e.g. automatic fault detectors, stop-motions ; Quality control of the package
- B65H63/06—Warning or safety devices, e.g. automatic fault detectors, stop-motions ; Quality control of the package responsive to presence of irregularities in running material, e.g. for severing the material at irregularities ; Control of the correct working of the yarn cleaner
- B65H63/062—Electronic slub detector
- B65H63/065—Electronic slub detector using photo-electric sensing means, i.e. the defect signal is a variation of light energy
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/95—Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
- G01N21/952—Inspecting the exterior surface of cylindrical bodies or wires
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2323/00—Details relating to membrane preparation
- B01D2323/42—Details of membrane preparation apparatus
Definitions
- the present invention relates to a method for producing a bundled product, which is produced by adjusting a winding amount so that a bundled product obtained by winding up continuously running yarns in the longitudinal direction is finally obtained in a predetermined amount or more. And an apparatus.
- Fibers, fibers, yarns represented by hollow fiber membranes, etc. have been manufactured from the past as yarn products alone, or yarns as main components.
- yarns As a final product, it has been used and utilized in various fields and applications.
- a yarn bundle obtained by bundling a plurality of yarns can greatly increase the performance as a product in comparison with a single yarn, and the yarn bundle itself can be used as a bundle product or a bundle product.
- a hollow fiber membrane filter used for water treatment such as sewage treatment or seawater desalination
- a bundle of hollow fiber membranes is stored in a resin or metal container called a case.
- the filtered water from which the raw water that has flowed into the container passes through the hollow fiber membrane from the outside (or the inside) to the inside (or the outside) and has a filtering effect on the raw water, and impurities are removed to the outside of the case. And the concentrated water enriched with impurities are separated and discharged.
- the amount of the hollow fiber membrane bundle is generally selected from at least one of the following physical quantities depending on the use of the module as the final product and the performance required by the customer. In other words, the number, outer diameter, surface area, weight, etc. for all hollow fiber membranes included in the module can be mentioned (hereinafter, some or all of these may be referred to as “control amount”) ). If this management amount is below a predetermined value, the module cannot exhibit sufficient filtration performance.
- a defective hollow fiber membrane there are scratches, defects, foreign matter, dents, bulges, huge holes, etc. on its surface, and the shape is excessively thick (thin film), excessively thin (thick film), crushed / flat, Examples thereof include twisting and blockage (hereinafter, some or all of these may be described as “bad”).
- defective hollow fiber membranes are included in the bundle of hollow fiber membranes constituting the module, the module is not only capable of exhibiting sufficient performance, but also because a small number of defective hollow fiber membranes are mixed in. There is a possibility that the product life of the entire module will be shortened (for example, mixing of raw water into filtered water due to breakage of defective parts during use of the module is exemplified).
- the yarn is wound up by, for example, a rotating cassette and wound up.
- a method of cutting all the strips at a predetermined position is common.
- it is very common to form multiple hollow fiber membranes simultaneously on one line and wind them up on the same rotating cassette. The more products that can be manufactured simultaneously on one line, the more This is an efficient manufacturing process (in addition, the method of collecting the hollow fiber membrane bundle is not limited to winding with a rotating cassette).
- the winding amount of the rotary cassette was finally incorporated into the module on the assumption that the outer diameter, surface area, and weight of the hollow fiber membrane are always as designed, and there is no defect in the hollow fiber membrane. In general, it is set so that a predetermined filtering ability can be exhibited. The reason for this is that it is difficult to predict how the outer diameter, surface area, and weight of the hollow fiber membrane will change under ever-changing manufacturing conditions, and where defects occur in the hollow fiber membrane. Moreover, since it cannot be predicted, an ideal state must be assumed as a provisional goal.
- the outer diameter, surface area, and weight of the hollow fiber membranes vary, and defects may occur.
- a specialized worker Adjust the amount of the bundle. Specifically, the worker first checks whether or not the hollow fiber membrane bundle contains a defective hollow fiber membrane, and when a defective hollow fiber membrane is found, removes it from the hollow fiber membrane bundle. Thereafter, several are randomly selected from the hollow fiber membranes remaining in the hollow fiber membrane bundle, and the outer diameter, surface area, or weight of a part thereof is measured, and each average value is obtained.
- the standard value of the management amount set to ensure the quality of the module as the final product is confirmed, and the management amount is measured in advance until the management amount exceeds this standard value, and no defects are included.
- the hollow fiber membrane that is also known is replenished to the bundle.
- Patent Documents 1, 2, and 3 have been proposed as means for solving such problems.
- Patent Document 1 a defect generated in the yarn during the running of the yarn in the manufacturing process is automatically detected, and the defect type is determined, and the length corresponding to the defect type is cut and removed during the running, It is stated that the disconnected parts are reconnected.
- Patent Document 2 when a yarn diameter abnormality is automatically detected when rewinding from a yarn bobbin on the unwinding side to a yarn cheese on the winding side, the length to be cut is calculated according to the degree, and the cheese is reversed. It is described that the target part is excised by rolling out the excision.
- Patent Document 3 when a visual worker discovers a defective part during paper sheet production (winding) and cuts out the defective part, the length automatically cut from the roll diameter before and after the defective part is deleted. It is described that the amount of winding is controlled so as to compensate for the deleted amount in order to detect the occurrence of the fixed length winding.
- Patent Documents 1 and 2 it is possible to cut out defective parts without using specialized workers by automatically carrying out measurement and inspection during yarn running. It is assumed that one yarn runs on the line. That is, when two or more yarns run on one line, if only a defective portion of a certain yarn is cut off, the length with other yarns changes, so that it cannot be wound on the same rotating cassette. If it is absolutely necessary to wind up the same cassette, when cutting out the defective part from a certain yarn, it is sufficient to cut out the normal part by the same length from the yarn that does not contain the defect manufactured at the same time. The method reduces the production yield. In addition, Patent Documents 1 and 2 do not propose a method for correcting the final management amount generated in the hollow fiber membrane bundle after cutting out the defective portion.
- Patent Document 3 deals with paper sheets instead of yarns, the length of the cut portion is obtained from the roll diameter before and after cutting the defective portion so that the length of the paper sheet included in the final product is as specified. The winding amount is corrected. However, similarly to Patent Documents 1 and 2, this method is difficult to apply when a plurality of products are manufactured simultaneously on one line.
- the management amount in Patent Document 3 is only the length of the paper sheet, but when manufacturing a highly functional final product such as a hollow fiber membrane bundle, values such as the outer diameter, the surface area, and the weight are also used as described above. It is essential to manage.
- An object of the present invention is to provide a bundled product manufacturing method and a manufacturing apparatus that improve inspection quality and production efficiency when a necessary amount is collected while inspecting two or more yarns continuously running in parallel. There is to do.
- the bundled product manufacturing method of the present invention is characterized by any one of the following configurations (1) to (9).
- the method further includes an exclusion step of removing the yarns determined to contain an abnormality in the inspection step from a bundle of a plurality of yarns, and configuring the bundled product after eliminating the yarn containing the abnormality by the exclusion step.
- the total number of multiple yarns to be processed, the total weight, the representative weight, the total outer diameter value, the representative outer diameter value, the total surface area, and the management amount of at least one multiple thread selected from the group consisting of the representative surface area exceeds a predetermined value
- the method for producing a bundle product according to any one of (1) to (8), wherein the amount of collection in the collection step is adjusted.
- the bundled product manufacturing apparatus of the present invention is characterized by any of the following configurations (10) to (13).
- An inspection unit that inspects two or more yarns that run continuously in parallel in the longitudinal direction, a collection unit that collects the yarn, and all the yarns that are collected after collection are cut at predetermined positions.
- a bundled product manufacturing apparatus having a cutting unit for obtaining a bundled product in which a plurality of yarns are bundled, based on the inspection result obtained by the inspection unit, the total of the plurality of yarns constituting the bundled product
- An apparatus for manufacturing a bundle product further comprising a collection amount adjustment unit capable of adjusting the collection amount.
- the bundled product is configured after the yarn containing the abnormality is eliminated.
- the total number of multiple yarns to be processed, the total weight, the representative weight, the total outer diameter value, the representative outer diameter value, the total surface area, and the management amount of at least one multiple thread selected from the group consisting of the representative surface area exceeds a predetermined value
- the bundled product manufacturing apparatus according to any one of (10) to (12), wherein the collection amount adjustment unit adjusts the collection amount of the collection unit.
- the manufacturing method of the bundled product of the present invention makes it possible to measure the total amount of the managed amount from the start to the end of the collection for all the plurality of running yarns. As a result, it is possible to control the amount of winding in the collection process so that the management amount exceeds the standard value, and the quality of the finally obtained bundled product can be reliably ensured. Therefore, it is not necessary to measure the amount of management by the worker after obtaining the bundled product and to replenish the bundled product with the normal yarn. Furthermore, since it is possible to measure the total amount of all of the multiple yarns that is impossible for the operator, the risk that the actual performance of the finally obtained bundled product will be insufficient can be minimized. it can.
- all the plurality of running yarns are inspected for defects, and if a defect is found, the defective portion is later removed from the yarn bundle, and collected. Since it is possible to control the number of times the process is wound, it is not necessary to inspect the yarn bundle and replenish the normal yarn to the bundle product by an operator after obtaining the bundle product.
- the elimination of the defective portion of the present invention is premised to be carried out after the yarn bundle is obtained once. Therefore, even if many defects occur, it is not necessary to stop the line, and the production efficiency is not lowered. .
- the bundled product manufacturing apparatus of the present invention is an apparatus that can suitably carry out the above-described bundled product manufacturing method of the present invention, wherein two or more yarns constituting the bundled product are continuously arranged in parallel. When traveling, it is possible to ensure the quality and improve the production efficiency.
- FIGS. 1A and 1B are schematic views showing an example of an embodiment (winding and collecting step) of the production apparatus of the present invention, where FIG. 1A is a side view and FIG. 1B is a top view.
- 2 (a) to 2 (c) are schematic views showing an example of an embodiment (cutting process) of the manufacturing apparatus of the present invention, and (a) to (c) illustrate the operation process over time.
- FIGS. 3A and 3B are schematic views illustrating images including images of hollow fiber membranes having different outer diameters.
- 4A to 4D are schematic views illustrating images including images of hollow fiber membranes that are defective yarns.
- FIG. 5 is a schematic diagram illustrating a flow for controlling the collection process based on the total amount of management amounts.
- FIG. 6 is a schematic diagram illustrating a flow for controlling the collection process based on the representative amount of the management amount.
- 7A and 7B are schematic views showing an example of another embodiment (cutting and collecting step) of the manufacturing apparatus of the present invention, where FIG. 7A is a side view and FIG. 7B is a top view.
- . 8 (a) and 8 (b) are schematic views showing an example of another embodiment (folding recovery step) of the production apparatus of the present invention, where (a) is a side view and (b) is a top view.
- . 9A and 9B are schematic views showing an example of an embodiment of the manufacturing apparatus of the present invention (a state in which a marker is provided in the winding and collecting step), where FIG. 9A is a side view, and FIG. ) Is a top view.
- the bundled product manufacturing apparatus of the present invention includes at least a bundled product inspection unit, a collection unit, a cutting unit, and a collection amount adjustment unit.
- the recovery unit and the cutting unit can be configured as units independent from each other, or as a cutting recovery unit having both a recovery function and a cutting function. Furthermore, it can have a marker unit.
- the inspection unit has a measurement / inspection means and an inspection control mechanism, and the total amount (total number, total weight, total outer diameter, total surface area) and two or more yarns continuously running in parallel in the longitudinal direction and It is a unit that measures and inspects a control amount selected from representative amounts (representative weight, representative outer diameter, representative surface area), and that can inspect for the presence or absence of defects on the yarn.
- the marker unit has a marker head and a marker control mechanism, and is a unit that performs marking on the yarn that is determined to be abnormal in cooperation with the inspection unit.
- the recovery unit is a unit that recovers the yarn while combining a plurality of continuously running yarns, and can adjust the amount recovered per bundled product in cooperation with the inspection unit and the recovery amount adjustment unit. It can.
- Examples of the independent recovery unit include a winding recovery device that recovers the yarn while rotating the yarn, and a return recovery device that recovers the yarn while returning the yarn to a predetermined length.
- the cutting unit is a unit that cuts all the yarns collected by the collecting unit at a predetermined position.
- the cutting and collecting unit is a unit having a collecting function for a plurality of yarns, a function for adjusting a collecting amount, and a cutting function.
- a cutting and collecting device that collects a yarn while cutting it to a certain length can be exemplified. .
- the recovery amount adjustment unit adjusts the recovery amount in the recovery unit so that the management amount of the plurality of yarns measured by the inspection unit exceeds a predetermined value in the bundled product, and is further determined to be abnormal by the inspection unit. It is a control unit that adjusts the yarn collection amount of the collection unit to supplement the management amount of the yarn that is excluded from the product.
- the manufacturing method of the bundle product of the present invention includes at least an inspection process, a recovery process, and a cutting process.
- the recovery step and the cutting step can be independent of each other, or can be a cutting and recovering step for performing both operations.
- the inspection process consists of a total amount (total number, total weight, total outer diameter, total surface area) and representative amount (representative weight, representative outer diameter, representative surface area) for yarns that run continuously in parallel in the longitudinal direction. ) Measure and inspect the management amount selected from
- the cutting and collecting step collects and cuts a plurality of yarns in one step.
- the method for manufacturing a bundle product of the present invention can stably manufacture a high-quality bundle product using the above-described bundle product manufacturing apparatus.
- bundle products include hollow fiber membrane bundles that are employed as ultrafiltration membranes, microfiltration membranes, gas separation membranes, pervaporation membranes, dialysis membranes, and the like.
- the hollow fiber membrane bundle is used for water treatment, artificial kidney, or concentration of valuable materials in various industrial processes.
- the bundled product is not limited to the hollow fiber membrane as described above, and a plurality of yarns such as clothing fibers, carbon fibers, optical fibers, steel wires, medical catheters and the like are substantially parallel at the same time. Any bundle product can be used as long as it is a yarn product having a structure that can be manufactured by the above method.
- the first embodiment of the bundled product manufacturing apparatus of the present invention includes an inspection unit, a winding recovery unit, a cutting unit, and a recovery amount adjustment unit.
- 1A and 1B illustrate an embodiment of an inspection unit, a winding recovery unit and a recovery amount adjustment unit
- FIGS. 2A, 2B and 2C illustrate an embodiment of a cutting unit.
- 10 is a single yarn of a hollow fiber membrane
- 11 is a composite hollow fiber membrane comprising a plurality of single yarns
- 12 is a recovered composite hollow fiber membrane bundle
- 20 is a Inspection head
- 21 is a measurement / inspection control mechanism
- 22 is a winding / collecting device
- 23 is a cassette
- 231, 232, and 233 are a cassette 1 position, a cassette 2 position, a cassette 3 position
- 24 is a winding recovery control.
- the mechanism, 25 is a combined yarn guide
- 26 is a roll
- 37 is a yarn path guide.
- the inspection unit includes at least a measurement / inspection head 20 and a measurement / inspection control mechanism 21.
- the collection unit includes at least a winding collection device 22, a cassette 23, a combined yarn guide 25, a roll 26, and a yarn path guide 37.
- the recovery amount adjustment unit is configured by a winding recovery control mechanism 24.
- FIG. 1A is a side view
- FIG. 1B is a top view.
- the measurement / inspection head 20, the measurement / inspection control mechanism 21, and the winding recovery control mechanism 24 related to the control signal are shown in FIG. Only described in (a).
- 13 is a hollow fiber membrane bundle
- 40 is a cutter
- 401 is a cutter in a cutting position
- 41 is a binding tool
- 42 is a hanging rope
- 43 is A crane rail 44 is a crane.
- the hollow fiber membrane to be manufactured in the present invention is basically obtained by combining the single yarn 10 of the hollow fiber membrane and collecting it as the combined hollow fiber membrane 11 as shown in FIG. There is no particular problem even if it is recovered as it is.
- the combined hollow fiber membrane 11 or the single yarn 10 may be recovered simultaneously or sequentially by a plurality of recovery means (for example, a plurality of cassette positions). The following description will be made on the assumption that the composite hollow fiber membrane 11 is used for easy understanding.
- Examples of the material of the hollow fiber membrane include polycarbonate, polyolefin, polyamide, polyimide, cellulose, polysulfone, polyethersulfone, polymethacrylic acid, polyacrylonitrile, polyvinylidene fluoride, and polyetherketone.
- Examples thereof include organic polymers and ceramics such as alumina, zirconia, titania, and silicon carbide.
- a plurality of hollow fiber membrane single yarns 10 conveyed from the upstream process are defined in traveling position by a yarn path guide 37, and single yarns are separated by a yarn guide 25. It becomes the combined yarn hollow fiber membrane 11 and is wound by the cassette 23 of the winding / collecting device 22 while being pressed against the roll 26 to form the combined yarn hollow fiber membrane bundle 12 (in the description of the present invention, three fibers are used).
- the cassette 23 may have a plurality of winding positions as shown in the cassette No.
- the combined hollow fiber membrane 11 can be wound up (as already described above, not only the combined hollow fiber membrane 11 but also the single yarn 10 of the hollow fiber membrane).
- the cassette 23 is configured to be movable in the same direction as the rotation axis, and by this movement, the yarn is uniformly hollow in the cassette 1 position 231 (casset 2 position 232, cassette 3 position 233) in the width direction. In order to wind the yarn film 11 or to continue winding after the winding is completed, the cassette position is moved to the next.
- the number of cassette positions is not necessarily limited to three.
- the example which moves the cassette 23 in the same direction as a rotating shaft was shown, the same effect is acquired even if the cassette 23 is fixed and the system which moves the combined yarn guide 25 is obtained.
- the winding / recovery control mechanism 24 performs operations such as rotation start / stop of the winding / recovery device 22, rotational speed, movement in the same direction as the rotation axis of the cassette 23, movement of the cassette position after completion of winding, and the like.
- the rotational speed of the cassette 23 is controlled so that the hollow fiber membrane bundle 12 is obtained in a predetermined amount, and the cassette is stopped after the predetermined amount is obtained, or It controls completion operations such as automatically moving the cassette position.
- the inspection unit of the present invention is a measurement / inspection head 20 that monitors the single yarn of the hollow fiber membrane, and processes the information obtained by the measurement / inspection head 20 to actually measure the yarn outer diameter and check for defects.
- a measurement / inspection control mechanism 21 for inspection is provided.
- the measurement / inspection control mechanism 21 and the take-up collection control mechanism 24 are configured to be able to communicate with each other.
- the measurement / inspection head 20 may be a general-purpose digital camera or analog camera, a general-purpose camera lens, a shape measurement sensor using LED illumination or laser light, or the like.
- the measurement / inspection control mechanism 21 may be a system constructed by installing an image capture board, signal processing board, communication board, signal processing software, system control software, etc. on a general-purpose PC, or a commercially available image inspection system. .
- the winding recovery control mechanism 24 and the measurement / inspection control mechanism 21 may be configured as an integrated type. The operation of the parts related to these control signals will be described in detail later.
- the composite hollow fiber membrane bundle 12 After winding the composite hollow fiber membrane bundle 12 by a predetermined amount around the cassette 23, the composite hollow fiber membrane bundle 12 is cut at a portion connected to the composite hollow fiber membrane 11, and the entire cassette 23 is taken out to the next step. Is done. If the combined hollow fiber membrane 11 is continuously conveyed from the upstream thereafter, a new empty cassette 23 is immediately set and winding of the combined hollow fiber membrane 11 is started. continue.
- FIG. 2A first, the cassette 23 is fixed to the cutter 40. Thereafter, in the collecting step near the cutter 40, the position corresponding to the upstream is bound with the lifting rope 42 by the binding tool 41.
- the lifting rope 42 is configured to be wound up by a crane 44 provided on the crane rail 43. Thereafter, as shown in FIG. 2 (b), the combined yarn hollow fiber membrane bundle 12 is cut together by moving the cutter 40 to the cutting position 401, and the hollow fiber membrane bundle 13 is obtained.
- an exclusion process is a process which excludes from the hollow fiber membrane bundle 13 the thread
- the management amount of the hollow fiber membrane bundle 13 is determined by the use of the module as the final product and the performance required by the customer. This management amount is included in the hollow fiber membrane bundle 13 to be incorporated in the module in the future.
- the recovery amount of the recovery process is determined from the quality standard value, There is no need to compensate during manufacturing.
- manufacturing variations occur, and when a defective yarn is generated due to a disturbance generated in the manufacturing process, the defective yarn must be excluded from the hollow fiber membrane bundle 13. Therefore, in the present invention, on the assumption that these manufacturing variations and defective yarns occur, the hollow fiber membrane bundle 13 exceeds a predetermined standard value after passing through the collection step and the exclusion step. The collection process is controlled during production.
- the management amount of the hollow fiber membrane bundle 13 needs to exceed at least the standard value, controlling to complete the recovery process at the time when the standard value is exceeded will eliminate useless production, More preferred.
- the manufacturing variation of the hollow fiber membrane and the presence or absence of defective yarn are monitored by the measurement / inspection head 20 and the measurement / inspection control mechanism 21 as shown in FIG.
- a case where a general-purpose digital camera type image inspection system is used for the measurement / inspection head 20 and the measurement / inspection control mechanism 21 will be described as an example.
- the digital camera as the measurement / inspection head 20 repeatedly captures a plurality of hollow fiber membrane single yarns 10 conveyed in parallel without taking a part of the hollow fiber membrane while keeping a predetermined interval in time. Then, the captured image is transmitted to the measurement / inspection control mechanism 21. Examples of captured and transmitted images are shown in FIGS. 3A, 3B, 4A, 4B, 4C, and 4D.
- 50 is an image
- 51, 52, 53, and 55 are images of a hollow fiber membrane having an outer diameter ⁇
- 54 is an image of a hollow fiber membrane having an outer diameter ⁇
- 56 is an outer diameter.
- the relationship of the outer diameter is ⁇ ⁇ ⁇
- ⁇ is the outer diameter as designed by the manufacture
- ⁇ is the lower limit value of the outer diameter
- ⁇ is the upper limit value of the outer diameter.
- the hollow fiber membrane When the wall thickness is thin, the hollow fiber membrane is easily ruptured while being used as a filtration membrane. On the contrary, when the wall thickness is thick, excessive pressure is required for filtration or the hollow interior Therefore, it is difficult to secure a flow rate necessary for filtration, and clogging is likely to occur.
- 57 is an image of a defective hollow fiber membrane (scratch)
- 58 is an image of a defective hollow fiber membrane (defect)
- 59 is a defective hollow fiber membrane (foreign matter).
- 60 is an image of a defective hollow fiber membrane (dent)
- 61 is an image of a defective hollow fiber membrane (bulge)
- 62 is an image of a defective hollow fiber membrane (giant hole)
- 63 is a defective hollow fiber membrane (excessively thinned; outside)
- 64 is an image of a defective hollow fiber membrane (overweight; exceeds the upper limit value ⁇ of the outer diameter)
- 65 is an image of a defective hollow fiber membrane (crushed)
- 66 is a defective hollow fiber.
- 67 is an image of a defective hollow fiber membrane (clogging)
- 68 is a state in which a thread breakage occurs and an image of the hollow fiber membrane is not captured.
- the imaging resolution in the width direction (XD direction) of the hollow fiber membrane of the image is X ⁇ m / pix
- the imaging resolution is defined as an amount in which pixels (pix) constituting an image correspond to the actual size of the three-dimensional world, and the unit is determined by the size ( ⁇ m / pix) per pixel (pix).
- the control amount of the hollow fiber membrane is the total amount (total number, total weight, total outer diameter, total surface area) and representative amount (representative weight, representative outer diameter, Two types are possible when the representative surface area is used as an index.
- the former adjusts the collection amount of the hollow fiber membrane bundle based on all the information on the management amount during the production of the hollow fiber membrane, and is more ideal in terms of quality control.
- the measurement / inspection control mechanism 21 is subjected to a very large burden, there is a need to use a high-speed and expensive computer, and there are also disadvantages in equipment installation such as sharing of the system by a plurality of computers.
- the measurement / inspection control mechanism 21 measures a specific portion of the hollow fiber membrane being manufactured once or a plurality of times according to a predetermined condition, and collects the representative amount calculated based on these as an index. The amount is adjusted and can be configured with simple equipment.
- the quality variation of the manufactured hollow fiber membrane is required to be sufficiently small. That is, it is preferable to employ the former when the quality variation of the manufactured hollow fiber membrane is expected to be large, and the latter when it is expected to be small.
- the program in the measurement / inspection control mechanism 21 is first initialized in Step 11. At this time, the type and standard value of the management amount used for quality control set in advance are read into the program.
- the measurement / inspection control mechanism 21 commands the winding / recovery control mechanism 24 to rotate the cassette 23, and the cassette 23 starts to rotate.
- Step 13 the management amount total value is calculated for each single yarn 10 of the plurality of hollow fiber membranes conveyed in parallel while the cassette 23 makes one round, and then the management amount total value is calculated based on the defective yarn determination result. Correction is made (details will be described later).
- Step 14 all the management amount total values up to the current lap are added together to obtain the total amount of management amounts.
- Step 15 it is determined whether or not the total management amount exceeds the standard value. If the total amount of the management amount does not exceed the standard value, the process returns to Step 12, and if it exceeds, the process proceeds to Step 16 (if it exceeds, the predetermined winding of the composite hollow fiber membrane bundle 12 is performed at the cassette position. Completed).
- Step 16 it is determined whether or not to move the winding of the hollow fiber membrane to another cassette position. When moving, the winding and collecting apparatus 22 is operated to move the hollow fiber membrane to the adjacent cassette position, and the process returns to Step 11, and when not moving, the process proceeds to Step 17. Next, in Step 17, the cassette is stopped, and the winding of the predetermined combined hollow fiber membrane bundle 12 at all cassette positions is completed.
- Step 13a a plurality of images 50 of hollow fiber membrane single yarns 10 conveyed in parallel by a digital camera are taken at time intervals, and the images are sent to the signal processing unit of the digital camera type image inspection system. 50 is transmitted.
- the timing of imaging the single yarn 10 of the hollow fiber membrane with a time interval is determined so that all of the conveyed hollow fiber membranes are imaged and there is no imaging omission in a part thereof.
- the imaging timing can be determined in consideration of the width of the image covered by one imaging and the conveyance speed of the hollow fiber membrane.
- Step 13b the signal processing unit individually recognizes a plurality of single-fiber hollow fiber membrane images 51 to 67 in the image 50. Even when yarn breakage has occurred, the occurrence 68 of yarn breakage is recognized by confirming the location where the image of the hollow fiber membrane should be taken.
- Step 13c the management amount is calculated for each single yarn 10 of the hollow fiber membrane. Although the calculation method of the management amount will be described later, for the yarn breakage, all the management amounts are calculated as 0 (zero).
- Step 13d all the management amounts up to the present of the measurement performed based on the images transmitted with a time interval are added, and the total management amount for each single yarn 10 of the hollow fiber membrane is obtained.
- the addition of the management amount in step 13d is based on the premise that the image for one turn of the casket is captured in multiple times. Not as long.
- Step 13e the presence or absence of defective hollow fiber membranes 57 to 67 is inspected in the image. If the defective hollow fiber membranes 57 to 67 do not exist, the process proceeds directly to the next Step 13h. On the other hand, if the defective hollow fiber membranes 57 to 67 exist, the process proceeds to the next Step 13f. In Step 13f, an extraction flag is generated in the information on the defective yarn. A method of using the extraction flag will be described later. Next, in Step 13g, the management amount total value calculated in Step 13d is corrected. That is, since the defective yarn in which an abnormality is found is eliminated in the elimination process, the management amount must be excluded from the management amount total value during the round of the cassette.
- Step 13h it is determined whether or not one round of the cassette has been completed. For the determination, a completion signal may be received from the winding recovery control mechanism 24. If the first round of the cassette is not completed, the process returns to Step 13a, and if completed, the process proceeds to Step 14.
- the program in the measurement / inspection control mechanism 21 is first initialized in Step 21. At this time, the type and standard value of the management amount used for quality control set in advance are read into the program, and the provisional value of the rotation speed of the cassette 23 is set.
- the measurement / inspection control mechanism 21 instructs the winding / collection control mechanism 24 to rotate the cassette 23, and the cassette 23 starts to rotate.
- the total amount of management amounts is calculated for the single yarns 10 of the plurality of hollow fiber membranes conveyed in parallel, and the target rotational speed is determined according to the condition for obtaining the representative amount, and then the defective yarn The target rotational speed is corrected based on the determination result (details will be described later).
- Step 25 it is determined whether or not the actual rotational speed has exceeded the target rotational speed. If the actual rotational speed does not exceed the target rotational speed, the process returns to Step 22, and if it exceeds, the process proceeds to Step 26 (if the actual rotational speed exceeds, the predetermined winding of the composite hollow fiber membrane bundle 12 is performed at the cassette position. Completed).
- Step 26 it is determined whether or not to move the winding of the hollow fiber membrane to another cassette position.
- the winding and collecting apparatus 22 is operated to move the hollow fiber membrane to the adjacent cassette position, and the process returns to Step 21, and when not moving, the process proceeds to Step 27.
- step 27 the cassette is stopped, and the winding of the predetermined combined hollow fiber membrane bundle 12 at all cassette positions is completed.
- Step 23a an image 50 of a single yarn 10 of a hollow fiber membrane that is conveyed in parallel by a digital camera is imaged, and the image is transmitted to the signal processing unit of the digital camera type image inspection system.
- Step 23b the signal processing unit individually recognizes the plurality of single-fiber hollow fiber membrane images 51 to 67 in the image 50. Even when yarn breakage has occurred, the occurrence 68 of yarn breakage is recognized by confirming the location where the image of the hollow fiber membrane should be taken.
- Step 23c it is confirmed whether or not the target rotational speed has been determined. If it has been established, the process proceeds to Step 23g. If it has not been completed yet, the process proceeds to Step 23d.
- Step 23d the management amount is calculated for each single yarn 10 of the hollow fiber membrane, and the value is stored in the numerical buffer. Although the calculation method of the management amount will be described later, for the thread breakage, all the management amounts are calculated as 0 (zero).
- Step 23e it is confirmed whether or not the management amount data sufficient for calculating the representative amount is prepared. If they are aligned, the process proceeds to Step 23f. If they are not aligned, the process proceeds to Step 23g.
- Step 23f the target rotational speed is determined by processing and calculating the management amount data according to the representative amount calculation condition and the standard value, and the temporary rotational speed is rewritten to the target rotational speed.
- Step 23g the presence or absence of defective hollow fiber membranes 57 to 67 is inspected in the image. If the defective hollow fiber membranes 57 to 67 do not exist, the process proceeds directly to the next Step 23j. On the other hand, if the defective hollow fiber membranes 57 to 67 exist, the process proceeds to the next Step 23h. In Step 23h, an extraction flag is generated in the information on the defective yarn. A method of using the extraction flag will be described later. Next, in Step 23i, the target rotational speed calculated in Step 23f is corrected. That is, since the defective yarn in which an abnormality is found is eliminated in the exclusion process, there is a possibility that the standard value cannot be finally cleared at the current target rotational speed.
- Step 23j it is determined whether or not one round of the cassette has been completed. For the determination, a completion signal may be received from the winding recovery control mechanism 24. If the first round of the cassette is not completed, the process returns to Step 23a, and if completed, the process proceeds to Step 24.
- Step 23f is supplemented.
- the representative amount calculation conditions used in Step 23 should be set appropriately depending on the degree of variation in the manufacturing process, the quality control of the type to be manufactured, or the quality requirements of the customer. As an example, it is preferable to use the average value of the management amounts of all the plurality of yarns in the first turn of the cassette 23, the average value of a specific single yarn, or the average value of these multiple turns.
- the method of determining the conditions is not limited to these.
- the common feature of the two methods when the total amount and the representative amount are used as the management amount of the hollow fiber membrane is, first of all, the characteristic of how to obtain the management amount.
- the management amount is basically obtained with fine performance up to the limit of the imaging resolution (X ⁇ m / pix, Y ⁇ m / pix) described above (primary management amount), but is generally used for the purpose of eliminating disturbance factors from the data.
- the secondary management amount may be obtained from a plurality of primary management amounts by performing correction using a typical image processing method. As a general image processing method, averaging, normalization, and other methods are used.
- a method for detecting defects in the hollow fiber membrane there is a method for detecting defects in the hollow fiber membrane. That is, a general image processing technique can be applied to the inspection of the defective hollow fiber membrane.
- the normal hollow fiber membrane images 51 to 56 in FIGS. 3 (a) and 3 (b) are registered in advance in the data buffer of the measurement / inspection control mechanism as master patterns in the normal state, and FIGS. (C) After obtaining the defective hollow fiber membrane images 57 to 67 shown in (d), the two may be compared. As a result, the difference in luminance can be detected with the defective hollow fiber membrane images 57, 59, 62, and 67, and the defective hollow fiber membrane images 58, 60, 61, 63, 64, 65, and 66 can be detected.
- a difference in the difference between the planar areas can be detected.
- simply counting the number of pixels in the XD direction in the image of the hollow fiber membrane and multiplying the imaging resolution X ⁇ m / pix to measure the outer diameter value is repeated in the YD direction.
- You may determine with a bad hollow fiber membrane by detecting the part which exceeds an outer diameter allowable value.
- the defective hollow fiber membrane images 58, 60, 61, 63, 64, 65, and 66 can be detected as abnormalities exceeding the allowable value of the outer diameter.
- control amount number, weight, outer diameter value, surface area
- the number is the number, but the number is handled only as a total amount as a management amount, and is calculated by Step 13 in FIG.
- Step 13c it is calculated as “1” for each hollow fiber membrane at the beginning of the round of the casket, and the number is always maintained within the same lap of the casserole (from the second round, Step 13d is ignored. Configure the program).
- the weight can be used as a control amount in both the total amount and the representative amount.
- the raw material of a hollow fiber membrane is generally supplied with a sufficient precision.
- the outer diameter value becomes thicker or thinner than the design value due to variations in forming the raw material into the shape of the hollow fiber membrane, but in the former case, the wall thickness is thin, and in the latter case, the meat thickness is reduced.
- the amount of the raw material per unit length of the hollow fiber membrane is constant only by increasing the thickness.
- the outer diameter R ⁇ m as the management amount obtained by the above formula (2) is obtained in Step 13c or Step 23d in the processing flow, and naturally, a plurality of images can be obtained in one image, and a plurality of values can be obtained in one round of the case. It is obtained.
- the surface area S ⁇ m 2 as the management amount obtained by the above equation (3) is obtained as the outer circumference as the minimum measurement unit in Step 13c and Step 23d in the processing flow, and naturally, a plurality of images can be obtained in one image. In addition, a plurality of pieces can be obtained even in one round of the cassette, and the information is added as the surface area by adding information in the conveyance direction.
- the second embodiment of the bundled product manufacturing apparatus of the present invention includes an inspection unit, a cutting collection unit, and a collection amount adjustment unit.
- FIGS. 7A and 7B illustrate the second embodiment.
- the inspection unit includes the measurement / inspection head 20 and the measurement / inspection control mechanism 21 as in the first embodiment.
- the recovery amount adjustment unit is configured by a cutting recovery control mechanism 32, and a cutting recovery unit that recovers the yarn while cutting the yarn into a certain length is configured as the cutting recovery unit.
- a cutting and collecting device can be used as the collecting means instead of the winding and collecting device of the first embodiment.
- the combined hollow fiber membrane 11 is cut into a predetermined length by a cutter 31 and collected in a collection tray 28 of a cutting and collecting device 27 to form a combined yarn hollow fiber membrane bundle 12 ′ (not only the combined hollow fiber membrane 11).
- a combined yarn hollow fiber membrane bundle 12 ′ not only the combined hollow fiber membrane 11.
- the combined hollow fiber membrane 11 is fixed by a clip 29.
- the clips 291 to 296 rotate at the same speed as the combined hollow fiber membrane 11 while maintaining a specific distance on the clip rail 30, and the combined hollow fiber membrane 11 is moved to the position of the clip 292.
- the cutter 31 cuts the composite hollow fiber membrane 11 with the three clips 291, 292, and 296. Immediately after that, the combined yarn hollow fiber membrane bundle 11 is stored in the collection tray 28 by opening the clips 291 and 296, but the clip 292 continues moving while holding the combined yarn hollow fiber membrane 11. This operation is repeated to continuously collect the combined hollow fiber membrane bundle 12 '.
- the cutting and collecting control mechanism 32 controls the number of times of cutting of the cutter 31 in addition to the start / stop of the cutting and collecting device 27, the clip moving speed, the cutting operation, and the like.
- the number of times of cutting is controlled so that only a predetermined amount can be obtained, and after the predetermined amount has been obtained, the cutting and clip are stopped, or the recovery tray 28 and an empty recovery tray (not shown) are replaced. Is what you do.
- the measurement / inspection control mechanism 21 and the cutting / recovery control mechanism 32 are configured to be able to communicate with each other.
- the combined hollow fiber membrane bundle 12' After collecting the combined hollow fiber membrane bundle 12 'by a predetermined amount on the recovery tray 28, the combined hollow fiber membrane bundle 12' is bound at one end by a binding tool (not shown), and suspended by a crane to remove it. It is carried out to. Therefore, when cutting and collecting are employed as the collecting means, the step of cutting the hollow fiber membrane bundle in the cutting step is not necessary.
- the third embodiment of the bundled product manufacturing apparatus of the present invention includes an inspection unit, a turn-back collection unit, a cutting unit, and a collection amount adjustment unit.
- FIGS. 8A and 8B illustrate the third embodiment.
- the inspection unit includes the measurement / inspection head 20 and the measurement / inspection control mechanism 21 as in the first embodiment.
- the collection amount adjusting unit is constituted by a folding collection control mechanism 36, and a folding collection means for collecting the yarn while folding the yarn to a fixed length is constructed as the folding collection unit.
- a return collecting device can be used instead of the winding collecting device of the first embodiment.
- the combined yarn hollow fiber membrane 11 is collected while being turned back to a rotating folding gear 34 by a moving guide 35 at a predetermined length to form a combined yarn hollow fiber membrane bundle 12 ′′ (not only the combined yarn hollow fiber membrane 11 but also the hollow fiber membrane). This is also applicable to the single yarn 10 as described above.)
- the turn-back recovery device 33 uses the fulcrum ligature guide 251 as a fulcrum to move the synthetic yarn hollow.
- the yarn film 11 is swung to positions 351, 352, and 353, and the combined yarn hollow fiber membrane 11 is hung on the predetermined teeth of the folding gears 341 and 342 that rotate in synchronization with the movement guide 35 to form a combined yarn hollow fiber membrane bundle 12 ′′. Continue to collect.
- the return recovery control mechanism 36 controls the number of times of return of the return gear 34 in addition to the start / stop of the return recovery device 33, the moving guide moving speed, the return gear rotation speed, and the like. Completion operations such as stopping the folding operation and the gear rotation operation, or exchanging the folding gear 34 and an empty folding gear (not shown) are performed.
- the measurement / inspection control mechanism 21 and the loopback collection control mechanism 36 are configured to be able to communicate with each other.
- the combined hollow fiber membrane bundle 12 ′′ After collecting the combined hollow fiber membrane bundle 12 ′′ by a predetermined amount in the turning gear 34, the combined hollow fiber membrane bundle 12 ′′ is bound at one end by a binding tool (not shown) and both ends are cut by a cutting tool (not shown). In the cut state, it is suspended by a crane and carried out to the exclusion process.
- the fourth embodiment of the bundled product manufacturing apparatus of the present invention includes an inspection unit, a marker unit, a winding recovery unit, and a recovery amount adjustment unit.
- FIGS. 9A and 9B illustrate the fourth embodiment.
- the inspection unit, take-up recovery unit, and recovery amount adjustment unit are configured in the same manner as in the first embodiment.
- the marker unit includes at least a marker head 70 and a marker control mechanism 71.
- a marker head 70 that can mark the single yarn 10 of the hollow fiber downstream of the measurement / inspection head 20 and upstream of the winding / collecting device 22.
- the marker head 70 is controlled by a marker control mechanism 71 configured to be able to communicate with the measurement / inspection control mechanism 21, and marks the single yarn 10 of the hollow fiber membrane that the measurement / inspection control mechanism 21 has determined to be defective. Since the defective yarn is marked, the removal operation of the defective yarn in the exclusion process mainly relying on manpower is improved, which is preferable.
- the extraction flags of Step 13f and Step 23h shown in FIGS. 5 and 6 may be used.
- the marking position may be in the vicinity of the defect, but it is more preferable that the length position is substantially the same with respect to the longitudinal direction of the bundle after obtaining the hollow fiber membrane bundle 13. This is because the worker only needs to confirm the predetermined position with respect to the longitudinal direction of the hollow fiber membrane bundle 13 and remove only the defective yarn from the hollow fiber membrane bundle 13 when the marking is found. is there.
- the collection amount of the collection process is controlled so that the management amount exceeds the standard value.
- Example 1 A hollow fiber membrane bundle was manufactured with the configuration shown in FIGS. 1 and 2. That is, a rotating unit was adopted as the recovery unit. In addition, the number of single yarns combined for winding is three, and the total amount is managed by adopting the surface area as the quality control amount of the hollow fiber membrane bundle. As the cassette, one with a circumference of 1.4 m was used. As the inspection unit, commercially available LED lighting, digital line sensor camera, general-purpose camera lens, image capture board, signal processing board, general-purpose PC and system control software created using C language are used. We used a commercially available programmable controller and control software that we created using a ladder language.
- the design value of the outer diameter was set to 1425 ⁇ m. That is, the design value of the outer periphery is 0.0044745 m, and the design value of the surface area of one hollow fiber membrane is 0.0062643 m 2 considering one turn of the case.
- the hollow fiber membrane bundle is finally incorporated into a water treatment module as a final product, and the standard value of the total surface area required for the hollow fiber membrane bundle is 4 to guarantee the performance of the module.
- a .02M 2 ideally assuming could produce hollow fiber membranes designed values, the total surface area when constituting the hollow fiber membrane bundle with a single filament of 642 this is 4.0216806M 2 become so standard value Will be satisfied.
- the management width of the outer diameter abnormality of the hollow fiber membrane alone is set to 1350 to 1500 ⁇ m so as not to cause any adverse effects during the use of the module by the customer as already described.
- the outer diameter of the hollow fiber membrane swings to the side thicker than the design value (median value is about 1488 ⁇ m), and the total surface area of the hollow fiber membrane is 4.
- the standard value was cleared to 023 m 2 (the number of hollow fiber membranes was 615).
- the outer diameter of the hollow fiber was able to be manufactured in a state close to the design value (median value is about 1422 ⁇ m), but immediately after completing the rotation of 186 times, the three single yarns were completed. One of them has run out. Therefore, after that, only the two single yarns were collected, and when the cassette was rotated up to 229 times, the total surface area of the hollow fiber membranes was 4.026 m 2 , which cleared the standard value (note that the number of hollow fiber membranes was 644). It became a book).
- Example 2 In some types of hollow fiber membrane bundles, it is known that the manufacturing state is sufficiently stable and the initial state is maintained, so the surface area as the management amount is controlled as the representative amount.
- the representative amount calculation condition is a method in which the outer diameter is measured once for each of the three single yarns up to three times, and the number of rotations of the cassette is calculated based on the average value of nine outer diameter data. Setting was performed and manufacturing was performed (other conditions are the same as in Example 1).
- the rotation speed of the cassette was 210 rotations, and a hollow fiber membrane bundle was composed of 630 single yarns.
- the filtration performance of the module was sufficient.
- Example 3 A hollow fiber membrane bundle was manufactured by adopting the configuration shown in FIG. 9 instead of the configuration of FIG.
- a marker is provided in addition to the configuration of FIG. 1, and this marker marks a defective yarn based on the inspection result by the measurement / inspection unit (other conditions are the same as in the second embodiment). The same).
- a commercially available laser marker manufactured by Keyence Corporation was used as the marker.
- the measurement / inspection unit has six defective hollow fiber membranes (scratches) that are included in the hollow fiber membrane bundle finally obtained by the cutting process. 17 yarn membranes (foreign matter) and 8 defective hollow fiber membranes (bulges) were detected.
- the recovery amount adjusting unit increased the number of rotations of the casket to 221 rotations by 11 times from 210 when there was no defective hollow fiber membrane.
- the marker was marked by firing with laser irradiation within a range of 100 to 250 mm away from these defective hollow fiber membranes when the hollow fiber membrane bundle was obtained in the cutting process, with the position of the binding tool as a reference.
- the bundle of hollow fiber membranes contained 663 single yarns at the time of completion of production, but the operator confirmed the marking through the removal process, and 31 defective hollow fiber membranes determined as defective by the measurement / inspection unit. As a result, the number of hollow fiber membranes was finally 632. When a final inspection prior to module shipment was performed on the module incorporating the hollow fiber membrane bundle, the filtration performance of the module was sufficient. Further, since the defective hollow fiber membrane was excluded with high accuracy, the module did not cause an abnormality even when the module was used by a customer.
- Example 4 A hollow fiber membrane bundle was manufactured by adopting the configuration shown in FIG. 7 instead of the configuration of FIG. That is, a cutting and collecting unit was adopted as the collecting unit, and in the cutting process, the cutting operation was eliminated and only the operation of hanging the hollow fiber membrane bundle was performed. The outer diameter was adopted as the quality control amount of the hollow fiber membrane bundle. (Other conditions are the same as in Example 1).
- the design value of the outer diameter of the hollow fiber membrane is 1425 ⁇ m.
- the standard value of the total outer diameter required for the hollow fiber membrane bundle is 1.28 m. If a hollow fiber membrane bundle is formed with 642 single yarns even if the yarn membrane can be manufactured, the total outer diameter is 1.28079 m, which satisfies the standard value. In other words, it is sufficient to rotate the cassette 214 times under the manufacturing conditions for three synthetic yarns.
- the production of the hollow fiber membrane bundle was performed under such conditions. Then, in the production state of a certain lot, the outer diameter of the hollow fiber membrane swings to the side thicker than the design value (the median is about 1467 ⁇ m), and when the rotation is 208 times, the total outer diameter of the hollow fiber membrane is 1.282 m. The standard value was cleared (the number of hollow fiber membranes was 624). When a final inspection prior to module shipment was performed on the module incorporating the hollow fiber membrane bundle, the filtration performance of the module was sufficient.
- a hollow fiber membrane bundle was produced in the same production state as in Example 1 without adjusting the recovery amount of the hollow fiber membrane constituting the present invention, and the effect of the present invention was confirmed.
- the rotation of the cassette was stopped at 214 times based on the design value, so if the outer diameter of the hollow fiber membrane was swung to the side thinner than the design value The total surface area of the hollow fiber membrane bundle could not satisfy the standard value. Therefore, the module was discarded as a defective product because the filtration performance of the module was insufficient in the final inspection before shipping the module.
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Abstract
Description
本発明の束状製品の製造装置の第1の実施形態は、検査ユニット、巻取回収ユニット、切断ユニットおよび回収量調整ユニットを含む。図1(a)(b)は検査ユニット、巻取回収ユニットおよび回収量調整ユニット、図2(a)(b)(c)は切断ユニットの実施形態を例示するものである。
W = Wm × L ・・・式(1)
R = X × Xn ・・・式(2)
S = π × R ・・・式(3)
本発明の束状製品の製造装置の第2の実施形態は、検査ユニット、切断回収ユニット、および回収量調整ユニットを含む。図7(a)(b)は第2の実施形態を例示するものである。検査ユニットは、第1の実施例と同じく、計測・検査ヘッド20、計測・検査制御機構21で構成さる。また後述の通り、回収量調整ユニットは切断回収制御機構32で構成され、切断回収ユニットとして、糸条を一定長に切断しながら回収する切断回収手段が構成される。
本発明の束状製品の製造装置の第3の実施形態は、検査ユニット、折返し回収ユニット、切断ユニットおよび回収量調整ユニットを含む。図8(a)(b)は第3の実施形態を例示するものである。検査ユニットは、第1の実施例と同じく、計測・検査ヘッド20、計測・検査制御機構21で構成さる。また後述の通り、回収量調整ユニットは折返し回収制御機構36で構成され、折返し回収ユニットとして、糸条を一定長に折り返しながら回収する折返し回収手段が構成される。
本発明の束状製品の製造装置の第4の実施形態は、検査ユニット、マーカーユニット、巻取回収ユニット、および回収量調整ユニットを含む。図9(a)(b)は第4の実施形態を例示するものである。検査ユニット、巻取回収ユニットおよび回収量調整ユニットは、第1の実施例と同様に構成される。また後述の通り、マーカーユニットはマーカーヘッド70、マーカー制御機構71を少なくとも含む。
図1および図2に示す構成で中空糸膜束の製造を行った。すなわち、回収ユニットとしては回転ユニットを採用した。また巻取の単糸合糸数は3本とし、中空糸膜束の品質の管理量としては表面積を採用して総量を管理することとした。またカセとしては1周が1.4mのものを使用した。なお検査ユニットとしては市販のLED照明、デジタルラインセンサカメラ、汎用カメラ用レンズ、画像取込ボード、信号処理ボード、汎用PCとC言語を用いて自作したシステム制御ソフトウェアを用い、回収量調整ユニットとしては市販のプログラマブルコントローラーとラダー言語を用いて自作した制御ソフトウェアを用いた。
ある品種の中空糸膜束においては、製造状態が充分に安定して初期状態を保つことがわかっているため、管理量としての表面積は代表量を管理することとした。代表量算出条件としては、カセの回転が3回まで、3本の単糸それぞれについて1回ずつ外径を測定し、9つの外径データの平均値を基準にカセの回転数を求める方法を設定し、製造を実行した(なお他の条件は実施例1と同様とする)。
図1の構成に変えて図9に示す構成を採用して中空糸膜束の製造を行った。図9の構成では図1の構成に加えてマーカーが備えられており、このマーカーは計測・検査ユニットによる検査結果に基づいて不良糸にマーキングを施すものである(なお他の条件は実施例2と同様とする)。なおマーカーとしては市販のレーザーマーカー(キーエンス社製)を使用した。
図1の構成に変えて図7に示す構成を採用して中空糸膜束の製造を行った。すなわち回収ユニットとして切断回収ユニットを採用し、切断工程においては切断作業を排して中空糸膜束を吊り下げる作業のみとした。また中空糸膜束の品質の管理量としては外径を採用した。(なお他の条件は実施例1と同様とする)。
一方、実施例1と同様の製造状態において本発明を構成する中空糸膜の回収量調整を行うことなく中空糸膜束を製造し、本発明の効果を確認した。その結果、中空糸膜の製造状態によらず、カセの回転は設計値を基準とした214回で停止させたため、中空糸膜の外径が設計値より細い側に振れてしまった場合には中空糸膜束における総表面積が規格値を満たすことはできなかった。よってモジュール出荷前の最終検査においてモジュールの濾過性能が不十分であったため該モジュールは不良品として廃棄された。逆に中空糸膜の外径が設計値より太い側に振れてしまった場合には中空糸膜束における総表面積は規格値をクリアしたものの、中空糸膜束の嵩高が必要以上に大きくなり、モジュールに中空糸膜束を挿入できなかった。よって中空糸膜束をモジュールに挿入できる状態とするまで中空糸膜束から単糸を排除するという手間が生じてしまった。
11 単糸が複数本あわさった合糸中空糸膜
12 回収された合糸中空糸膜束
12′ 切断後に回収された合糸中空糸膜束
12″ 折り返して回収された合糸中空糸膜束
13 中空糸膜束
20 計測・検査ヘッド
21 計測・検査制御機構
22 巻取回収装置
23 カセ
231 カセ1番位置
232 カセ2番位置
233 カセ3番位置
24 巻取回収制御機構
25 合糸ガイド
251 支点合糸ガイド
26 ロール
27 切断回収装置
28 回収トレー
29 クリップ
291、292、293、294、295、296 クリップ(個別)
30 クリップレール
31 カッター
32 切断回収制御機構
33 折返し回収装置
34、341、342 折返し歯車
35 移動ガイド
351、352、353 移動ガイドのポジション
36 折返し回収制御機構
37 糸道ガイド
40 カッター
401 切断ポジションのカッター
41 結束具
42 吊り下げロープ
43 クレーンレール
44 クレーン
50 画像
51、52、53、55 外径がβの中空糸膜の像
54 外径がαの中空糸膜の像
56 外径がγの中空糸膜の像
57 不良中空糸膜(キズ)の像
58 不良中空糸膜(欠損)の像
59 不良中空糸膜(異物)の像
60 不良中空糸膜(凹み)の像
61 不良中空糸膜(膨らみ)の像
62 不良中空糸膜(巨大穴)の像
63 不良中空糸膜(過細り;上限値αを超過)の像
64 不良中空糸膜(過太り;上限値γを超過)の像
65 不良中空糸膜(つぶれ)の像
66 不良中空糸膜(ねじれ)の像
67 不良中空糸膜(閉塞)の像
68 糸切れが発生した様子
70 マーカーヘッド
71 マーカー制御機構
Claims (13)
- 長手方向に2本以上並列して連続走行する糸条を検査する検査工程、前記糸条を回収する回収工程、回収完了後に回収された糸条全てを予め定められた位置で切断して複数糸条を束とした束状製品を得る切断工程、を有する束状製品の製造方法において、前記検査工程で得られた検査結果に基づき、前記束状製品を構成する複数糸条の総本数、総重量、代表重量、総外径値、代表外径値、総表面積および代表表面積からなる群から選ばれる少なくともひとつの複数糸条の管理量が所定の値を超えるよう、前記回収工程における回収量を調整することを特徴とする束状製品の製造方法。
- 前記回収工程が、糸条を回転しながら回収する巻取回収工程であることを特徴とする請求項1に記載の束状製品の製造方法。
- 前記回収工程が、糸条を一定長に切断しながら回収する切断回収工程であることを特徴とする請求項1に記載の製造方法。
- 前記回収工程が、糸条を一定長に折り返しながら回収する折返し回収工程であることを特徴とする請求項1に記載の製造方法。
- 前記糸条が中空糸膜であることを特徴とする請求項1~4のいずれかに記載の束状製品の製造方法。
- 前記複数糸条の管理量が、束状製品を構成する複数糸条の総表面積であることを特徴とする請求項1~5のいずれかに記載の束状製品の製造方法。
- 前記複数糸条の管理量が、束状製品を構成する複数糸条の代表表面積であることを特徴とする請求項1~5のいずれかに記載の束状製品の製造方法。
- 前記検査工程において糸条の外径を計測し、得られた外径計測値から糸条の表面積を算出することを特徴とする請求項6または7に記載の束状製品の製造方法。
- 前記検査工程によって異常を含むと判定された糸条を複数糸条の束から排除する排除工程を更に有し、該排除工程によって異常を含む糸条を排除した後に束状製品を構成する複数糸条の総本数、総重量、代表重量、総外径値、代表外径値、総表面積および代表表面積からなる群から選ばれる少なくともひとつの複数糸条の管理量が所定の値を超えるよう、前記回収工程における回収量を調整することを特徴とする請求項1~8のいずれかに記載の束状製品の製造方法。
- 長手方向に2本以上並列して連続走行する糸条を検査する検査ユニット、前記糸条を回収する回収ユニット、回収完了後に回収された糸条全てを予め定められた位置で切断して複数糸条を束とした束状製品を得る切断ユニット、を有する束状製品の製造装置において、前記検査ユニットで得られた検査結果に基づき、前記束状製品を構成する複数糸条の総本数、総重量、代表重量、総外径値、代表外径値、総表面積および代表表面積からなる群から選ばれる少なくともひとつの複数糸条の管理量が所定の値を超えるよう、前記回収ユニットにおける回収量を調整し得る回収量調整ユニットを更に有することを特徴とする束状製品の製造装置。
- 前記糸条が中空糸膜であることを特徴とする請求項10に記載の束状製品の製造装置。
- 前記検査ユニットが糸条の外径を計測して得られた外径計測値から糸条の表面積を算出し得る手段を有することを特徴とする請求項10または11に記載の束状製品の製造装置。
- 前記検査ユニットによって異常を含むと判定された糸条が製品出荷前に複数糸条の束から排除されることを前提とし、異常を含む糸条が排除された後に束状製品を構成する複数糸条の総本数、総重量、代表重量、総外径値、代表外径値、総表面積および代表表面積からなる群から選ばれる少なくともひとつの複数糸条の管理量が所定の値を超えるよう、前記回収量調整ユニットが回収ユニットの回収量を調整することを特徴とする請求項10~12のいずれかに記載の束状製品の製造装置。
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JP2014502077A JP6128114B2 (ja) | 2012-02-29 | 2013-01-29 | 束状製品の製造方法および製造装置 |
US14/380,258 US20150034755A1 (en) | 2012-02-29 | 2013-01-29 | Manufacturing method and manufacturing device for bundle product |
KR1020147021280A KR101929277B1 (ko) | 2012-02-29 | 2013-01-29 | 다발형상 제품의 제조 방법 및 제조 장치 |
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WO2021065755A1 (ja) * | 2019-09-30 | 2021-04-08 | 株式会社京都製作所 | 線材束製造装置 |
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SG11201810648YA (en) * | 2016-06-02 | 2018-12-28 | Applied Materials Inc | Qualification and repair station |
US9863875B1 (en) * | 2016-10-19 | 2018-01-09 | International Business Machines Corporation | In-situ detection of hollow glass fiber formation |
EP3493004A1 (en) * | 2017-12-01 | 2019-06-05 | Zappala´ SPA | Plant |
CN109850676B (zh) * | 2018-12-25 | 2021-09-03 | 台州派申印业有限公司 | 一种用于食品包装袋的边料回收装置 |
CN113928667B (zh) * | 2020-07-13 | 2023-05-12 | 泰科电子(上海)有限公司 | 线缆盘绕系统 |
KR102452901B1 (ko) * | 2020-11-13 | 2022-10-12 | (주)선진환경 | 중공사 제조 장치 |
CN114387269B (zh) * | 2022-03-22 | 2022-06-03 | 南京矩视科技有限公司 | 一种基于激光的纤维丝缺损检测方法 |
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CN104136351B (zh) | 2016-09-07 |
US20150034755A1 (en) | 2015-02-05 |
JPWO2013129004A1 (ja) | 2015-07-30 |
KR20140131913A (ko) | 2014-11-14 |
KR101929277B1 (ko) | 2018-12-14 |
JP6128114B2 (ja) | 2017-05-17 |
CN104136351A (zh) | 2014-11-05 |
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