METHOD AND DEVICE FOR POSITIONALLY ACCURATE PROCESSING OF A MATERIAL WEB

Abstract

The invention relates to a method and an apparatus for positionally accurate processing of a material web in a web-processing process for the series production of products, in particular for producing membrane assemblies, wherein a shaped element (2) is introduced into the material web (1) or a shaped element (2) is applied to the material web (1), wherein multiple reference marks (3) per product are created when the shaped element (2) is being introduced into or when the shaped element (2) is being applied to the material web, and, in a subsequent process step for positionally accurate processing of the material web (1) relative to the shaped element (2) of a product, the position of at least one of the multiple reference marks (3) of this product and/or at least one of the multiple reference marks (3) of a following and/or a preceding product is detected.

Claims

1. A method for positionally accurate processing of a material web in a web-processing process for the series production of products, in particular for producing membrane assemblies, wherein, for each product, a shaped element is introduced into the material web or a shaped element is applied to the material web, wherein multiple reference marks per product are created when the shaped element is being introduced into or when the shaped element is being applied to the material web, and, in a subsequent process step for positionally accurate processing of the material web relative to the shaped element of a product, the position of at least one of the multiple reference marks of this product and/or at least one of the multiple reference marks of a following and/or at least one of the multiple reference marks of a preceding product is detected.

2. The method according to claim 1, wherein the shaped element is introduced into the material web or applied to the material web by means of a tool, wherein the reference marks are created by means of this tool when the shaped element is being introduced or when the shaped element is being applied.

3. The method according to claim 1, wherein the reference marks are created in or on an oversize region of the material web, in particular in or on an edge of the material web.

4. The method according to claim 1, wherein a constant sequence of equidistant reference marks is created, wherein an interval between the shaped elements is an integral multiple of an interval between the reference marks.

5. The method according to claim 1, wherein two sequences of reference marks are created in the material web along two tracks.

6. The method according to claim 1, wherein, in a process step following the creation of the reference marks, for each product an additional shaped element is introduced into the material web or an additional shaped element is applied to the material web, wherein, in a further process step, the position of the additional shaped element and of at least one reference mark are detected.

7. The method according to claim 1, wherein, in a process step following the creation of the reference marks, the material web is laminated with a second material web, wherein for each product a shaped element and at least one reference mark is introduced into the second material web before the laminating operation, wherein the position of at least one reference mark of the material web relative to the position of at least one reference mark of the second material web is detected.

8. An apparatus for positionally accurate processing of a material web in a web-processing process for the series production of products, in particular for producing membrane assemblies, comprising a shaped-element station, wherein the shaped-element station is designed to introduce, for each product, a shaped element into the material web or to apply a shaped element to the material web, wherein the shaping-element station is designed to create multiple reference marks per product when the shaped element is being introduced into or when the shaped element is being applied to the material web, wherein, for subsequent positionally accurate processing of the material web relative to the shaped element of a product, the position of at least one of the multiple reference marks of this product and/or at least one of the multiple reference marks of a following and/or at least one of the multiple reference marks of a preceding product can be detected.

9. The apparatus according to claim 8, wherein a tool for introducing or applying the shaped element is provided at the shaped-element station, wherein the tool is designed to create the reference marks when the shaped element is being introduced into the material web or when the shaped element is being applied to the material web.

10. The apparatus according to claim 8, wherein the shaped-element station, in particular the tool, is designed to create the reference marks on an oversize region of the material web, in particular on an edge of the material web.

11. The apparatus according to claim 8, wherein the shaped-element station, in particular the tool, is designed to create a constant sequence of equidistant reference marks on the material web, wherein an interval between the shaped elements is an integral multiple of an interval between the reference marks and/or to create two sequences of reference marks along two tracks in the material web.

12. A web-processing plant comprising an apparatus according to claim 8 and a process station, downstream of the shaped-element station, for processing the material web, wherein the process station has a sensor system, in particular an optical sensor system comprising a camera, by means of which the position of at least one of the reference marks of this product and/or at least one of the multiple reference marks of a following and/or a preceding product can be detected at the process station.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Further advantages and aspects of the invention will become apparent from the claims and from the description of exemplary embodiments of the invention, which are explained below on the basis of the figures. In the figures:

[0037] FIG. 1 shows a plan view of an apparatus for positionally accurate processing of a material web in a web-processing process;

[0038] FIG. 2 shows a plan view of the material web according to FIG. 1 during a first process step in a web-processing process;

[0039] FIG. 3 shows a plan view of the material web according to FIG. 1 during a second process step in a web-processing process;

[0040] FIG. 4 shows a plan view of a second exemplary embodiment of an apparatus for positionally accurate processing of a material web in a web-processing process;

[0041] FIG. 5 shows a plan view of the material web according to FIG. 4 during a subsequent process step in a web-processing process;

[0042] FIG. 6 shows a plan view of a third exemplary embodiment of an apparatus for positionally accurate processing of a material web in a web-processing process;

[0043] FIG. 7 shows a plan view of an alternatively processed material web during the second process step according to FIG. 3; and

[0044] FIG. 8 shows a plan view of an alternatively processed material web during the first process step according to FIG. 2.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0045] FIG. 1 shows a plan view of an apparatus 10 for positionally accurate processing of a material web 1 in a web-processing process for the series production of products. A transport direction of the material web 1 is illustrated schematically by an arrow here.

[0046] In the material web 1 illustrated, for each product to be produced a shaped element 2 in the form of a window cutout is introduced. The illustrated window cutouts are rectangular. In other embodiments, differently shaped window cutouts and/or other shaped elements 2 and/or more than one shaped element per product are provided.

[0047] The shaped elements 2 in the form of window cutouts are introduced at a shaped-element station 40. In the exemplary embodiment illustrated, the shaped elements 2 in the form of window cutouts are introduced by means of a schematically illustrated punching device comprising a punching cylinder 4. In other embodiments, a lift punch or a cutting device for introducing the window cutouts is provided. Depending on the shaped element, in other embodiments, instead of the punching device other tools for introducing or applying the shaped element are provided.

[0048] The apparatus 1 introduces reference marks 3 into the material web 1 when the shaped elements 2 are being introduced. In the process, in the exemplary embodiment illustrated in FIG. 1, a sequence of reference marks 3 is also introduced by means of the punching cylinder 4 for introducing the shaped elements 2.

[0049] In the exemplary embodiment illustrated, the reference marks 3 are introduced equidistantly at an interval a. An interval A between the shaped elements 2 is an integral multiple of the interval a between the reference marks 3. In the exemplary embodiment illustrated, it is eight times the interval a, but the layout is only by way of example.

[0050] Multiple reference marks 3, which are introduced into the material web 1 together with the shaped element 2 and therefore have a geometric relationship, defined by the punching cylinder 4, with the associated shaped element 2, are thus provided for each shaped element 2.

[0051] In the exemplary embodiment illustrated, eight reference marks 3, all of which have a defined geometric relationship with the associated shaped element 2, are provided for each shaped element 2.

[0052] As described below on the basis of FIGS. 2 and 3, the respective position of at least one reference mark 3 can be detected for subsequent positionally accurate processing of the material web 1 relative to the shaped elements 2.

[0053] FIG. 2 schematically shows a plan view of the material web 1 according to FIG. 1 during a first process step for depositing blanks 5 onto the shaped elements 2 in the form of window cutouts.

[0054] In this case, in the exemplary embodiment illustrated, a position of a reference mark 3 that is upstream of a leading edge 20 of a shaped element 2 that is to be covered with the blank 5 is detected by means of a sensor device 6. This reference mark 3 has a defined geometric relationship with the associated shaped element 2. In the exemplary embodiment illustrated, the position of exactly one reference mark 3 relative to a stationary reference point 7 is detected. On the basis of this detected position of the reference mark 3, it is possibleas schematically indicated by two double-headed arrowsto correct a position of the blank 5 in the longitudinal direction and/or in the transverse direction of the material web 1, in order to enable positionally accurate deposition of the blank 5 on the associated shaped element 2 in the form of a window cutout.

[0055] FIG. 3 schematically shows a plan view of the material web 1 according to FIG. 1 during a second process step for introducing punched contours 80 by means of a schematically illustrated punching roller 8.

[0056] In this case, in the exemplary embodiment illustrated, the positions of two reference marks 2, which are upstream and downstream of the leading edge 20 (cf. FIG. 2) of the shaped element 2 relevant for the processing, are detected by means of a further sensor device 6. The two reference marks 3 have a defined geometric relationship with this shaped element 2. In the exemplary embodiment illustrated, the positions of the two reference marks 3 relative to a stationary reference point 7 are detected. On the basis of the detected positions of the two reference marks 3, it is possible to correct a position and orientation of the punching rollers 8 in a plane parallel to the plane of the material web 1, in order to enable positionally accurate introduction of the punched contours 80 relative to the associated shaped element 2. The positionally accurate processing relative to the shaped element 2 is possible here by means of a sensor device 6 disposed above the material web 1, even though the shaped element is concealed by the blank 5.

[0057] In the case of the embodiment illustrated in FIG. 3, the positions of the two reference marks 3 are detected by means of a single sensor device 6. Instead of a single sensor device 6, in other embodiments multiple sensor devices 6 are provided, the signals from which are analysed together for positionally accurate processing of the material web.

[0058] As can be seen in FIG. 3, the reference marks 3 are disposed on an oversize region of the material web 1, that is to say in a region which is not part of the product to be produced. In the exemplary embodiment illustrated in FIGS. 1 to 3, the reference marks 3 are disposed on an edge of the material web.

[0059] The detection of exactly one or two reference marks 3 in the process steps according to FIGS. 2 and 3 is merely exemplary. In other embodiments, more than one reference mark 3 is detected during the process step according to FIG. 2 or only one reference mark 3 is detected during the process step according to FIG. 3. In yet other embodiments, further or alternative process steps are provided.

[0060] In a further embodiment, in addition to the sensor device 6 illustrated in FIG. 2 or FIG. 3, a further sensor device, not illustrated in the figures, is provided, which is designed to detect the position of the blank 5. In this respect, in one embodiment it is provided that the position of the blank 5 and the position of at least one reference mark 3 are detected between the process steps illustrated in FIGS. 2 and 3, in order to check the correct positioning of the blank 5 on the material web.

[0061] FIG. 4 shows a plan view of a second exemplary embodiment of an apparatus 10 for positionally accurate processing of a material web 1 in a web-processing process. The apparatus 10 according to FIG. 4 is similar to the apparatus 10 according to FIG. 1 and the same reference signs are used for elements that are the same or similar.

[0062] By contrast to the design according to FIG. 1, two sequences of reference marks 3 are provided on the material web 1 according to FIG. 4 along two tracks 31, 32. The reference marks 3 of the two tracks 31, 32 have the same interval in the exemplary embodiment illustrated. In other embodiments, the intervals between the reference marks 3 of the two tracks are different. In the exemplary embodiment illustrated, the tracks 31, 32 are offset in the transport direction, illustrated by an arrow, of the material web. In other embodiments, the reference marks of the two tracks 31, 32 are disposed at the same level in the transport direction.

[0063] To align the material web 1 and/or the process station for a process step, in this case the positions of at least one reference mark 3 from one of the two tracks can be detected.

[0064] As illustrated schematically in FIG. 5, in this case in some embodiments the positions of in each case at least one reference mark 3 of each of the two tracks 31, 32 are detected by means of a first sensor device 6 relative to a first reference point 7 and by means of a second sensor device 11 relative to a reference point 12.

[0065] In the exemplary embodiment illustrated in FIGS. 4 and 5, the tracks 31, 32 are disposed on opposite web edges. This makes it possible to maximize an interval between reference marks 3 of which the position is detected for alignment, with the result that high accuracy can be achieved for positionally accurate processing of the material web relative to the shaped element. In other embodiments (not illustrated), the tracks 31, 32 are disposed on a common edge of the material web.

[0066] FIG. 6 shows a plan view of a third exemplary embodiment of an apparatus 10 for positionally accurate processing of a material web 1 in a web-processing process.

[0067] By contrast to the design according to FIG. 1, only three reference marks 3 per product are created on the material web 1 according to FIG. 6. A shaped element 2 is provided for each product, wherein the reference marks 3 in the exemplary embodiment illustrated are disposed in the region of a leading edge 20 of the shaped element 2. This arrangement is, however, merely exemplary.

[0068] The three reference marks 3 form a pattern, wherein the pattern repeats in a constant sequence in the longitudinal direction of the material web 1. An interval between the patterns is the same as an interval between the shaped elements in this case.

[0069] FIG. 7 shows a plan view of an alternatively processed material web 1 during the second process step according to FIG. 3.

[0070] By contrast to the design according to FIG. 3, only two reference marks 3 per product are provided on the material web 1 according to FIG. 7. In the exemplary embodiment illustrated in FIG. 6, the reference marks 3 are not introduced in the edge region but between the shaped elements 2 in an oversize region of the products that are to be created.

[0071] FIG. 8 schematically shows a plan view of a material web 1 during the first process step according to FIG. 2 for depositing blanks 5 onto the shaped elements 2 in the form of window cutouts. The products produced in the case of the exemplary embodiment according to FIG. 8 differ from the products produced in the case of the exemplary embodiment according to FIG. 2 in terms of a product size, wherein a shaped element 2 is provided for each product.

[0072] In this case, in the exemplary embodiment illustrated in FIG. 8, for positionally accurate deposition of the blank 5 on the shaped element 2 of a product, a position of a reference mark 3 that is downstream of a trailing edge 22 of an already covered shaped element 2 of a preceding product is detected by means of a sensor device 6.

[0073] The exemplary embodiments illustrated are merely exemplary and numerous modifications are conceivable.

[0074] The apparatuses illustrated and methods described can be used advantageously in particular during the production of a membrane assembly, such as an MEA.

[0075] In this case, in one embodiment the material web 1 is a material web of a frame material, into which shaped elements 2 in the form of window cutouts are introduced by means of a punching tool. The CCM is deposited onto the window cutouts. For exact positioning of a CCM relative to a window cutout, a position of at least one reference mark 3 is detected. On the basis of the detected position of the reference mark 3, the CCM and the material web 1 are aligned relative to one another and the CCM is deposited on the window cutout. After being transferred to the material web 1, the CCM conceals the window cutout, but not the reference marks 3.

[0076] Correct positioning of the CCM on the material web relative to the concealed window cutout can in this case be checked by detecting the position of at least one reference mark 3 and at the same time detecting the position of the CCM.

[0077] After the CCM has been transferred to the material web 1, cutouts which form channel structures or openings for connections in the finished MEA are made in the material web. For exact positioning of the cutouts relative to the window cutout concealed by the CCM, in one embodiment a position of at least one reference mark 3 is detected. On the basis of the detected position of the reference mark 3, a tool for making the cutouts and the material web 1 are aligned relative to one another. As an alternative, for this purpose the position of the CCM is detected, wherein the correct positioning of the CCM was checked preferably on the basis of the reference marks 3.