WO2018029830A1

WO2018029830A1 - Inverter device, failure detection method, and failure detection program

Info

Publication number: WO2018029830A1
Application number: PCT/JP2016/073650
Authority: WO
Inventors: 育也奥村
Original assignee: 三菱電機株式会社
Priority date: 2016-08-10
Filing date: 2016-08-10
Publication date: 2018-02-15
Also published as: JPWO2018029830A1

Abstract

This inverter device is provided with: a converter unit (11) which converts alternating current from an AC power supply (20) into direct current; an inverter unit (12) which converts the direct current from the converter (11) into alternating current and outputs the alternating current to a motor (30); an inverter control unit (13) which controls the on-off positions of the switching element of the inverter unit (12); and a failure detection unit (14) which detects a failure in a roll-to-roll device (50) and outputs a failure signal. The failure detection unit (14) is provided with a torque-winding diameter estimation unit (143) that estimates the torque-winding diameter ratio, which is the ratio of motor torque (T) to winding diameter (r), and a comparison unit (145) that compares the estimated torque-winding diameter ratio with a torque-winding diameter ratio reference value measured in advance.

Description

Inverter device, abnormality detection method and abnormality detection program

The present invention relates to an inverter device that controls a motor that rotates a winding or unwinding shaft of a roll-to-roll device, an abnormality detection method, and an abnormality detection program.

A roll-to-roll apparatus applied to a paper mill or a wire drawing machine winds or unwinds a web by rotating a winding or unwinding shaft by a motor. The inverter device connected to such a motor controls the motor rotation speed of the winding or unwinding shaft of the roll-to-roll device by adjusting the voltage and frequency, and the line speed is controlled.

In a roll-to-roll apparatus, a detection device such as a tension sensor or a line speed detection device has been conventionally required to detect the occurrence of an abnormality typified by web breakage or mechanical failure. However, when such a detection device is installed, the size and cost of the device are increased.

Patent Document 1, which is an example of the prior art, stores a tension corresponding to a winding diameter in a normal state and compares the measured tension with a measurement result to determine a winding control of a yarn winding machine. An apparatus is disclosed.

JP 2003-285972 A

However, the above-described conventional technology is based on the relationship between the winding time and the tension in the operation pattern. For this reason, there has been a problem that it is impossible to cope with changes in driving patterns.

The present invention has been made in view of the above, and an object thereof is to obtain an inverter device capable of detecting an abnormality regardless of an operation pattern.

In order to solve the above-described problems and achieve the object, the present invention is an inverter device that controls a motor connected to an AC power source and connected to a winding or unwinding shaft of a roll-to-roll device. A converter unit that converts alternating current from the power source into direct current, an inverter unit that converts direct current from the converter unit into alternating current and outputs alternating current to the motor, and detects an abnormality in the roll-to-roll device and outputs an abnormal signal An abnormality detection unit. The abnormality detection unit includes a torque winding diameter ratio estimation unit that estimates a torque winding diameter ratio that is a ratio of motor torque to a winding diameter, and a comparison unit that compares the torque winding diameter ratio reference value and the torque winding diameter ratio. It is characterized by.

The inverter device according to the present invention has an effect that abnormality can be detected regardless of the operation pattern.

The figure which shows one structural example of the inverter apparatus and peripheral device which concern on Embodiment 1. The block diagram which shows the example of 1 structure of the abnormality detection part shown in FIG. The block diagram which shows one structural example of the abnormality detection part of a form different from the abnormality detection part shown in FIG. The figure which shows the torque winding diameter straight line which represents the torque winding diameter ratio at the time of normal operation | use with the winding diameter r as a horizontal axis and the motor torque T as a vertical axis | shaft. The figure which shows the torque winding diameter straight line which represents the torque winding diameter ratio at the time of occurrence of abnormality with the winding diameter r as the horizontal axis and the motor torque T as the vertical axis. The flowchart which shows the abnormality detection method which concerns on Embodiment 1. The block diagram which shows the example of 1 structure of the abnormality detection part with which the inverter apparatus which concerns on Embodiment 2 is provided. The block diagram which shows the example of 1 structure of the abnormality detection part of a form different from the abnormality detection part shown in FIG. The figure which shows the tension line showing the time change of the web tension at the time of normal operation which made time t horizontal axis and web tension F vertical axis. The figure which shows the tension line showing the time change of the web tension at the time of abnormality generation | occurrence | production which made time t the horizontal axis and web tension F the vertical axis | shaft. Flowchart showing an abnormality detection method according to the second embodiment The figure which shows one general structural example of the hardware which implement | achieves the abnormality determination part with which the inverter apparatus which concerns on Embodiment 1, 2 is provided.

Hereinafter, an inverter device, an abnormality detection method, and an abnormality detection program according to an embodiment of the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited to the embodiments.

Embodiment 1 FIG.
FIG. 1 is a diagram illustrating a configuration example of an inverter device and peripheral devices according to Embodiment 1 of the present invention. An inverter device 10 shown in FIG. 1 includes a converter unit 11, an inverter unit 12, an inverter control unit 13, and an abnormality detection unit 14. The converter unit 11 is connected to an AC power supply 20, and the inverter unit 12 is a motor 30. It is connected to the.

The converter unit 11 converts alternating current from the alternating current power source 20 into direct current. The inverter unit 12 converts the direct current from the converter unit 11 into an alternating current and outputs an alternating current to the motor 30. The inverter control unit 13 controls on / off of a switching element (not shown) included in the inverter unit 12. The abnormality detection unit 14 stores an abnormality detection program, performs a winding diameter calculation, and detects an abnormality in the roll-to-roll device 50. Then, the abnormality detection unit 14 outputs an abnormality signal to the outside including the host controller.

The motor 30 is connected to a speed reducer 40, and the speed reducer 40 is connected to a winding or unwinding shaft 54. In addition, the reduction gear 40 should just be provided as needed, and is not an essential structure.

The roll-to-roll device 50 includes a dancer roll 51,

guide rolls

52 and 53 arranged on both sides of the dancer roll 51, a winding or unwinding shaft 54, and a web 55. The take-up or unwinding shaft 54 is connected to the speed reducer 40 and is rotated by the motor 30 to wind or unwind the web 55.

FIG. 2 is a block diagram showing a configuration example of the abnormality detection unit 14 shown in FIG. The abnormality detection unit 14 illustrated in FIG. 2 includes a winding diameter calculation unit 140, a parameter storage unit 141, a motor torque calculation unit 142, a torque winding diameter ratio estimation unit 143, a normal torque winding diameter ratio storage unit 144, And a comparison unit 145.

2 calculates the winding diameter r, which is the current radius of the winding or unwinding shaft 54. The winding diameter calculation section 140 shown in FIG. Here, the winding diameter calculation unit 140 calculates the winding diameter r by an actual line speed calculation method based on the line speed.

In the actual line speed calculation method, using the line speed v [mm / min] and the motor rotation speed wfb [r / min], the winding diameter r [mm] which is the radius of the winding or unwinding shaft 54 is expressed by the following formula. Calculated according to (1). In the following formula (1), z is a gear ratio.

As the line speed v, a line speed command output from the inverter control unit 13 or a detection speed of a line speed detector (not shown) is used. When the line speed command is used, the line speed detector is not necessary. A line speed detector (not shown) is provided in the inverter device 10.

The motor rotation speed wfb uses a motor rotation speed detected by an encoder (not shown) or a speed estimation value from the inverter control unit 13. An encoder (not shown) is provided in the motor 30.

The gear ratio z is a fixed value determined by the device configuration, in particular, the speed reducer 40, and thus is preset and stored in the parameter storage unit 141.

FIG. 3 is a block diagram showing a configuration example of the abnormality detection unit 14a having a different form from the abnormality detection unit 14 shown in FIG. The abnormality detection unit 14a illustrated in FIG. 3 is different in that a winding diameter calculation unit 140a is provided instead of the winding diameter calculation unit 140, and a parameter storage unit 141a is provided instead of the parameter storage unit 141. The winding diameter calculation unit 140a shown in FIG. 3 calculates the winding diameter r by a thickness calculation method based on the integration of the material thickness.

In the thickness calculation method, the winding thickness r [mm], which is the radius of the winding or unwinding shaft 54, is calculated by the following equation (2) using the material thickness d [mm] of the web 55 that has been wound or unwound. To do. In the following formula (2), r1 [mm] is the initial radius of the winding or unwinding shaft 54, that is, the initial winding diameter that is the radius of the winding or unwinding shaft 54 before winding or unwinding. , N is the roll rotation speed, and z is the gear ratio.

The material thickness d is a known fixed value determined by the material of the web 55, and is stored in the parameter storage unit 141a in advance.

The initial winding diameter r1 is a known fixed value determined by the apparatus configuration, particularly the winding or unwinding shaft 54, and is stored in advance in the parameter storage unit 141a.

The roll rotation speed N is output from an encoder (not shown) attached to the winding or unwinding shaft 54.

The gear ratio z is set in advance and stored in the parameter storage unit 141a as in FIG.

As described with reference to FIGS. 2 and 3, by the winding diameter r [m] calculated by the actual line speed calculation method or the thickness calculation method, the motor torque T [N · m] of the motor 30, and the gear ratio z, The web tension F is represented by the following formula (3).

From the above equation (3), when the web tension F is controlled to be constant, the gear ratio z is a fixed value, so the relationship between the motor torque T and the winding diameter r is uniquely determined.

The motor torque calculation unit 142 outputs a motor torque T estimated using the excitation current and the torque component current calculated by performing coordinate conversion between the output current of the motor 30 and the motor constant stored in the parameter storage unit 141a. . The output current of the motor 30 is output from a current detector (not shown) provided on the output side of the inverter unit 12.

The torque winding diameter ratio estimation unit 143 uses the motor torque T and the winding diameter r estimated by the above formula (1) or (2) to estimate the torque winding that is the ratio of the motor torque T to the winding diameter r. Estimate the diameter ratio.

The normal torque winding diameter ratio storage unit 144 stores, as a reference, a normal torque winding diameter ratio that is a relationship between the motor torque T and the winding diameter r measured in advance during normal operation. Since the normal torque winding diameter ratio is a reference value for determining abnormality, it is also described as a torque winding diameter ratio reference value.

The comparison unit 145 compares the estimated torque winding diameter ratio with the normal torque winding diameter ratio. When the comparison unit 145 determines that there is an abnormality based on the comparison result between the normal torque winding diameter ratio and the estimated torque winding diameter ratio and the abnormality determination setting value, the comparison unit 145 outputs an abnormality signal. Specifically, when the normal torque winding diameter ratio and the estimated torque winding diameter ratio are separated from the stored abnormality determination setting value, an abnormality signal is output. This abnormality signal is output to the outside, typically to the host controller, and the user grasps the occurrence of the abnormality. The abnormality determination set value is set in advance and stored in the comparison unit 145.

FIG. 4 is a diagram showing a torque winding diameter straight line representing a torque winding diameter ratio during normal operation with the winding diameter r as the horizontal axis and the motor torque T as the vertical axis. In FIG. 4, the normal measurement value straight line stored in advance is represented by a solid line, and the current estimated value straight line is represented by a broken line, which are not separated from each other. Therefore, in FIG. 4, it is determined that the operation is normal, and no abnormal signal is output.

FIG. 5 is a diagram showing a torque winding diameter straight line representing a torque winding diameter ratio when an abnormality occurs, with the winding diameter r as the horizontal axis and the motor torque T as the vertical axis. In FIG. 5, the normal measurement value straight line stored in advance is represented by a solid line, the current estimated value straight line is represented by a broken line, and they are separated from each other. Therefore, in FIG. 5, it is determined that an abnormality has occurred, and an abnormal signal is output.

Note that the first embodiment includes the above-described abnormality detection method. FIG. 6 is a flowchart showing the abnormality detection method according to the first embodiment. The abnormality detection method according to the first embodiment is an abnormality detection method for a roll-to-roll device 50 including a winding or unwinding shaft 54 connected to a motor 30 or a speed reducer 40 controlled by an inverter device 10. The winding diameter r of the winding or unwinding shaft 54 is calculated (S11), the motor torque T of the motor 30 is calculated (S12), and the torque winding diameter ratio that is the ratio of the motor torque T to the winding diameter r is estimated. (S13) The torque winding diameter ratio during normal operation measured in advance is compared with the estimated torque winding diameter ratio (S14). If there is an abnormality, that is, if the separation between the two is equal to or greater than the abnormality determination set value, an abnormality signal is output (S15). Here, the calculation of the winding diameter r of the winding or unwinding shaft 54 is performed by the above-described actual line speed calculation method or thickness calculation method. An abnormality detection program for causing a computer to execute this abnormality detection method is also included in the present invention.

As described above, the inverter device according to the first embodiment including the abnormality detection unit can detect an abnormality only with the motor torque and the winding diameter, and thus can detect an abnormality independent of the operation pattern. Therefore, the adjustment work for the initial value, which is necessary in the prior art depending on the operation pattern, is unnecessary.

Further, according to the first embodiment, when the roll-to-roll device controls the air cylinder using the tension of the dancer roll as a command from the inverter device, it is possible to detect an abnormality regardless of the material of the web.

In the present embodiment, since the winding diameter calculation unit 140 and the motor torque calculation unit 142 are provided in the inverter device, there is an effect that abnormality detection is possible with the inverter device alone. However, the present invention is not limited to this, and values calculated by an external host controller may be used for the winding diameter and the motor torque. Even when the calculated value is used, an effect that abnormality detection is possible regardless of the operation pattern can be obtained.

Embodiment 2. FIG.
In the first embodiment, the torque winding diameter ratio is compared, but the abnormality can be detected by comparing the tension command value and the estimated tension value. In the second embodiment, an inverter device that detects an abnormality by comparing a tension command value and a tension estimated value will be described. In the second embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted.

The inverter device according to the second embodiment is simply omitted from the configuration shown in FIG. 1 because the abnormality detection unit 14 is replaced with the abnormality detection unit 14b.

FIG. 7 is a block diagram illustrating a configuration example of the abnormality detection unit included in the inverter device according to the second embodiment. The abnormality detection unit 14b illustrated in FIG. 7 includes a winding diameter calculation unit 140, a parameter storage unit 141, a motor torque calculation unit 142, a tension calculation unit 146, and a tension comparison unit 147 that is a comparison unit. In addition, the same code | symbol is attached | subjected to the structure same as Embodiment 1. FIG.

The tension calculator 146 receives the winding diameter r and the motor torque T and outputs the estimated tension value calculated by the above equation (3). The tension comparison unit 147 constantly compares the estimated tension value output from the tension calculation unit 146 with the tension command value output from the inverter control unit 13, and the estimated tension value and the tension command value are stored in the abnormality determination. When the set value is exceeded, an abnormal signal is output.

FIG. 8 is a block diagram illustrating a configuration example of the abnormality detection unit 14c having a different form from the abnormality detection unit 14b illustrated in FIG. The abnormality detection unit 14c illustrated in FIG. 8 includes a winding diameter calculation unit 140a, a parameter storage unit 141a, a motor torque calculation unit 142, a tension calculation unit 146, and a tension comparison unit 147. Since all the configurations shown in FIG. 8 have already been described, the above description is incorporated.

FIG. 9 is a diagram showing a tension line representing the time change of the web tension during normal operation with the time t as the horizontal axis and the web tension F as the vertical axis. In FIG. 9, the tension command value is represented by a solid line and the estimated tension value is represented by a broken line, and the two are not separated. Therefore, in FIG. 9, it is determined that the operation is normal, and no abnormal signal is output.

FIG. 10 is a diagram showing a tension line representing the time change of the web tension at the time of occurrence of an abnormality with the time t as the horizontal axis and the web tension F as the vertical axis. In FIG. 10, the tension command value is represented by a solid line, the estimated tension value is represented by a broken line, and the two are separated from each other. Therefore, in FIG. 10, it is determined that an abnormality has occurred, and an abnormal signal is output.

The second embodiment includes an abnormality detection method. FIG. 11 is a flowchart showing the abnormality detection method according to the second embodiment. The abnormality detection method according to the second embodiment is an abnormality detection method for a roll-to-roll device 50 including a winding or unwinding shaft 54 connected to the motor 30 or the speed reducer 40 controlled by the inverter device 10. The winding diameter r of the winding or unwinding shaft 54 is calculated (S21), the motor torque T of the motor 30 is calculated (S22), and the web tension F is estimated from the winding diameter r and the motor torque T (S23). The tension command value is compared with the estimated estimated tension value (S24). If there is an abnormality, that is, if the separation between the two is equal to or greater than the abnormality determination set value, an abnormality signal is output (S25). Here, the calculation of the winding diameter r of the winding or unwinding shaft 54 is performed by the above-described actual line speed calculation method or thickness calculation method. An abnormality detection program for causing a computer to execute this abnormality detection method is also included in the present invention.

As described in the second embodiment, the abnormality can be detected without depending on the operation pattern and the web material even by comparing the tension command value and the estimated tension value.

In the above-described embodiment, the

abnormality determination units

14, 14a, 14b, and 14c include at least a processor, a memory, a receiver, and a transmitter, and the operation of each device is realized by software. be able to. FIG. 12 is a diagram illustrating a general configuration example of hardware that realizes the abnormality determination unit included in the inverter device according to the first and second embodiments. The apparatus illustrated in FIG. 12 includes a processor 201, a storage circuit 202, a receiver 203, and a transmitter 204. The processor 201 performs calculation and control by software using received signals and parameters, and the storage circuit 202 receives Data or software necessary for the calculation or control of the data or the processor 201 is stored. The receiver 203 is an interface that receives a signal or information input to the abnormality determination unit. The transmitter 204 is an interface that transmits a signal or information output from the abnormality determination unit. Note that a plurality of processors 201, storage circuits 202, receivers 203, and transmitters 204 may be provided.

The inverter devices described in the first and second embodiments can detect a tension abnormality alone. Therefore, the roll-to-roll device can be downsized. It is also possible to reduce the manufacturing cost of the roll-to-roll apparatus.

The configuration described in the above embodiment shows an example of the contents of the present invention, and can be combined with another known technique, and can be combined with other configurations without departing from the gist of the present invention. It is also possible to omit or change the part.

10 inverter device, 11 converter unit, 12 inverter unit, 13 inverter control unit, 14, 14a, 14b, 14c abnormality detection unit, 20 AC power supply, 30 motor, 40 speed reducer, 50 roll-to-roll device, 51 dancer roll, 52 , 53 guide roll, 54 winding or unwinding shaft, 55 web, 140, 140a winding diameter calculation unit, 141, 141a parameter storage unit, 142 motor torque calculation unit, 143 torque winding diameter ratio estimation unit, 144 normal torque winding Diameter ratio storage unit, 145 comparison unit, 146 tension calculation unit, 147 tension comparison unit, 201 processor, 202 storage circuit, 203 receiver, 204 transmitter.

Claims

An inverter device for controlling a motor connected to an AC power source and connected to a winding or unwinding shaft of a roll-to-roll device,
A converter unit for converting alternating current from the alternating current power source into direct current;
An inverter unit that converts direct current from the converter unit into alternating current and outputs an alternating current to the motor;
An abnormality detection unit that detects an abnormality of the roll-to-roll device and outputs an abnormality signal,
The abnormality detection unit
A torque winding diameter ratio estimation unit that estimates a torque winding diameter ratio that is a ratio of a motor torque to a winding diameter;
An inverter device comprising: a torque winding diameter ratio reference value and a comparison unit that compares the torque winding diameter ratio.
An inverter device for controlling a motor connected to an AC power source and connected to a winding or unwinding shaft of a roll-to-roll device,
A converter unit for converting alternating current from the alternating current power source into direct current;
An inverter unit that converts direct current from the converter unit into alternating current and outputs an alternating current to the motor;
An abnormality detection unit that detects an abnormality of the roll-to-roll device and outputs an abnormality signal,
The abnormality detection unit
A tension calculator that estimates and outputs an estimated tension value from the winding diameter and motor torque;
The inverter apparatus provided with the comparison part which compares the said tension estimated value and the said tension command value.
A winding diameter calculation unit for calculating and outputting the winding diameter;
The inverter device according to claim 1, further comprising: a motor torque calculation unit that calculates and outputs the motor torque.
The winding diameter calculation unit calculates the winding diameter by an actual line speed calculation method using a line speed of the roll-to-roll device, a motor rotation speed of the motor, and a gear ratio of the roll-to-roll device. The inverter device according to claim 3.
The winding diameter calculation unit includes a web material thickness of the roll-to-roll device, an initial radius of the winding or unwinding shaft, a roll rotational speed of the winding or unwinding shaft, and the roll-to-roll device. The inverter device according to claim 3 or 4, wherein the winding diameter is calculated by a thickness calculation method using a gear ratio.
The inverter device according to any one of claims 1 to 5, wherein the comparison unit outputs an abnormality signal when it is determined to be abnormal based on a comparison result and an abnormality determination set value.
A roll-to-roll device abnormality detection method comprising a winding or unwinding shaft connected to a motor controlled by an inverter device,
Calculating a winding diameter of the winding or unwinding shaft;
Calculating a motor torque of the motor;
Estimating a torque winding diameter ratio that is a ratio of the motor torque to the winding diameter;
A method for detecting an abnormality, comprising: comparing a torque winding diameter ratio reference value with the torque winding diameter ratio.
A roll-to-roll device abnormality detection method comprising a winding or unwinding shaft connected to a motor controlled by an inverter device,
Calculating a winding diameter of the winding or unwinding shaft;
Calculating a motor torque of the motor;
Estimating the web tension of the roll-to-roll device from the winding diameter and the motor torque;
And a step of comparing the tension command value with the estimated tension.
The calculation of the winding diameter is performed by an actual line speed calculation method using a line speed of the roll-to-roll device, a motor rotation speed of the motor, and a gear ratio of the roll-to-roll device. The abnormality detection method according to claim 7 or claim 8.
The calculation of the winding diameter includes the web material thickness of the roll-to-roll device, the initial radius of the winding or unwinding shaft, the number of roll rotations of the winding or unwinding shaft, and the roll-to-roll device. The abnormality detection method according to claim 7, wherein the abnormality detection method is performed by a thickness calculation method using a gear ratio.
An abnormality detection program that causes a computer to execute the abnormality detection method according to any one of claims 7 to 10.