PAPER WINDER AND PAPER WINDING METHOD

Abstract

A paper winder includes a first winding core that is provided in a first arm turning centering on a rotating shaft and on which the paper should be wound, a first motor that drives the first winding core, a second winding core that is provided in a second arm turning centering on the rotating shaft and on which the paper should be wound next to the first winding core, and a controller that performs rotation control for the first motor and a second motor. In the rotation control, after, according to the turning of the second arm, completion of the winding of the paper by the first winding core and after a position of the second winding core has reached a position where the paper should be wound, during an operation of a traverse cutter that cuts the paper near the second winding core, when a torque value of the second motor is equal to or larger than a torque reference value, the controller switches a control mode of the second motor from speed control to torque control and perform tension correction control for adjusting the torque value of the second motor such that tension of the paper falls within a target range.

Claims

1. A paper winder that winds a paper, the paper winder comprising: a first winding core that is provided in a first arm turning centering on a rotating shaft and on which the paper should be wound; a first motor that drives the first winding core; a second winding core that is provided in a second arm turning centering on the rotating shaft and on which the paper should be wound next to the first winding core; a second motor that drives the second winding core; and a controller that performs rotation control for the first motor and the second motor, wherein the controller is configured to, in the rotation control, after completion of the winding of the paper by the first winding core and after, according to the turning of the second arm, a position of the second winding core has reached a position where the paper should be wound, during an operation of a traverse cutter that cuts the paper near the second winding core, when a torque value of the second motor is equal to or larger than a torque reference value, switch a control mode of the second motor from speed control to torque control and perform tension correction control for adjusting the torque value of the second motor such that tension of the paper falls within a target range.

2. The paper winder according to claim 1, wherein the torque reference value is a torque value of the first motor at a time when the tension of the paper at a time of the winding of the paper by the first winding core immediately before the paper is wound by the second winding core is within the target range.

3. The paper winder according to claim 1, wherein the torque reference value is a value obtained by adding at least a mechanical loss of the second motor to the torque value of the first motor immediately before the paper is wound by the second winding core.

4. The paper winder according to claim 3, wherein the mechanical loss is periodically updated during the driving of the second motor.

5. The paper winder according to claim 1, wherein the controller is further configured to, in the rotation control, after switching the control mode of the second motor from the speed control to the torque control and after completion of the operation of the traverse cutter, set a control mode of the first motor to stop the driving of the first motor.

6. A paper winding method for winding a paper, comprising: determining, after completion of winding of the paper by a first winding core that is provided in a first arm turning centering on a rotating shaft and on which the paper should be wound and after a position of a second winding core that is provided in a second arm turning centering on the rotating shaft and on which the paper should be wound next to the first winding core has reached a position where the paper should be wound, during an operation of a traverse cutter that cuts the paper near the second winding core, whether a torque value of a second motor that drives the second winding core is equal to or larger than a torque reference value; switching a control mode of the second motor from speed control to torque control when it is determined that the torque value of the second motor is equal to or larger than the torque reference value; and performing tension correction control for adjusting the torque value of the second motor such that tension of the paper falls within a target range.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0008] FIG. 1 is a diagram for explaining an outline of a paper winder according to an embodiment.

[0009] FIG. 2 is a diagram for explaining an outline of the paper winder according to the embodiment.

[0010] FIG. 3 is a diagram for explaining a specific example of the paper winder according to the embodiment.

[0011] FIG. 4 is a diagram for explaining a specific example of the paper winder according to the embodiment.

[0012] FIG. 5 is a flowchart showing a processing example of the paper winder according to the embodiment.

DESCRIPTION OF EMBODIMENTS

[0013] A paper winder and a paper winding method according to an embodiment of the present disclosure are explained with reference to the accompanying drawings. Elements common in the figures are denoted by the same reference numerals and signs and redundant explanation of the elements is omitted.

1. Overview

1-1. Configuration of a Paper Winder

[0014] FIG. 1 is a diagram for explaining an overview of a paper winder 1 according to an embodiment. The paper winder 1 is a turret-type device that continuously winds paper 50 with a plurality of winding cores. The paper 50 is, for example, thick paper having thickness of 800 m or the like. The paper winder 1 includes a paper winding mechanism unit 2, a paper cutting unit 3, and a controller 100.

[0015] The paper winding mechanism unit 2 includes an arm unit 10 (a first arm 10a, a second arm 10b, a third arm 10c, and a fourth arm 10d). Each of the arms has a mechanism of turning in at least one direction centering on a rotating shaft 10e provided at one end of the arm. These arms may have cross-shaped structure as shown in FIG. 1(A).

[0016] Each of the arms repeatedly performs turning at a predetermined angle at every predetermined timing after an operation start of the paper winder 1. Alternatively, the arm receives a turning instruction by the controller 100 explained below and performs the turning at the predetermined angle.

[0017] A first winding core 11 is provided at the other end of the first arm 10a. A second winding core 12 is provided at the other end of the second arm 10b. A guide roller 13 is provided at the other end of the third arm 10c. A guide roller 14 is provided at the other end of the fourth arm 10d.

[0018] The first winding core 11 is a winding core on which the paper 50 should be wound. The second winding core 12 is a winding core on which the paper 50 should be wound next to the first winding core 11. For example, as shown in FIG. 1(A), the second winding core 12 is located on the opposite side of the first winding core 11 via the rotating shaft 10e. When the position of one winding core of the first winding core 11 and the second winding core 12 is a position where the paper 50 should be wound, the paper 50 is wound by the winding core. The position where the paper 50 should be wound is, for example, the position of the first winding core 11 shown in FIG. 1(A).

[0019] After completion of the winding of the paper 50 by the first winding core 11 and in a period from when, according to the turning of the second arm 10b, the position of the second winding core 12 has reached the position where the paper 50 should be wound until the paper 50 is cut, the guide roller 14 guides the paper 50 to be wound by the first winding core 11. Although not illustrated, after the completion of the winding of the paper 50 by the second winding core 12 and in a period from when, according to the turning of the first arm 10a, the position of the first winding core 11 has reached again the position where the paper 50 should be wound until the paper 50 is cut, the guide roller 13 guides the paper 50 to be wound by the second winding core 12.

[0020] The paper winding mechanism unit 2 further includes a first motor 21 and a second motor 22. The first motor 21 is a motor that drives the first winding core 11. The first motor 21 is fixed and attached to the first winding core 11. The second motor 22 is a motor that drives the second winding core 12. The second motor 22 is fixed and attached to the second winding core 12. The first motor 21 and the second motor 22 receive a command by the controller 100 explained below and perform a driving start or a driving stop.

[0021] When the position of one winding core of the first winding core 11 and the second winding core 12 is the position where the paper 50 should be wound, the winding of the paper 50 by the winding core is realized by driving a motor corresponding to the winding core.

[0022] The paper cutting unit 3 includes a first touch arm 30 and a second touch arm 40. The first touch arm 30 is a mechanical device for, such that the second winding core 12 can wind the cut paper 50, pressing the paper 50 against the outer circumferential surface of the second winding core 12 when the paper 50 is cut.

[0023] The first touch arm 30 includes a mechanism that turns based on a rotating shaft 30a provided at one end of the first touch arm 30. Here, a motion of the first touch arm 30 turning in the clockwise direction at the viewpoint of FIG. 1 is referred to as forward movement and a motion of the first touch arm 30 turning in the counterclockwise direction at the viewpoint of FIG. 1 is referred to as backward movement. The first touch arm 30 moves forward before the paper 50 is cut and moves backward after the paper 50 is cut.

[0024] Specifically, as shown in FIG. 1(B), the first touch arm 30 moves forward simultaneously with completion of an operation of the paper winding mechanism unit 2. The first touch arm 30 moves backward simultaneously with completion of cutting of the paper 50 by a traverse cutter 40c explained below.

[0025] When moving forward, the first touch arm 30 presses the paper 50 against the outer circumferential surface of the second winding core 12 with a nip roll 30b provided at the other end of the first touch arm 30. Consequently, the second winding core 12 can wind the cut paper 50.

[0026] The second touch arm 40 is a mechanical device that cuts the paper 50. The second touch arm 40 includes a mechanism that turns based on a rotating shaft 40a provided at one end of the second touch arm 40. A motion of the second touch arm 40 turning in the counterclockwise direction at the viewpoint of FIG. 1 is referred to as forward movement and a motion of the second touch arm 40 turning in the clockwise direction at the viewpoint of FIG. 1 is referred to as backward movement. The second touch arm 40 moves forward before the paper 50 is cut and moves backward after the paper 50 is cut.

[0027] Specifically, as shown in FIG. 1(B), the second touch arm 40 moves forward simultaneously with the completion of the operation of the paper winding mechanism unit 2. The second touch arm 40 moves backward simultaneously with the completion of the cutting of the paper 50 by the traverse cutter 40c explained below.

[0028] The second touch arm 40 includes a winding core fixture 40b in which the second winding core 12 provided at the other end of the second touch arm 40 can be fit and fixed. The second winding core 12 is fixed by the winding core fixture 40b when the paper 50 is cut.

[0029] The second touch arm 40 includes the traverse cutter 40c provided between one end of the second touch arm 40 and the other end of the second touch arm 40. The traverse cutter 40c is a cutting machine that cuts the paper 50. The traverse cutter 40c is housed in the second touch arm 40 except when cutting the paper 50 and is used only when cutting the paper 50. An image during the use of the traverse cutter 40c is represented, for example, as shown in FIG. 1(B).

[0030] The traverse cutter 40c cuts the paper 50 near the second winding core 12 after the second winding core 12 has reached the position where the paper 50 should be wound. For example, as shown in FIG. 1(B), a position where the paper 50 is cut is a position between one end (the rotating shaft 40a) of the second touch arm 40 and the other end (the winding core fixture 40b) of the second touch arm 40 and near the second winding core 12. An overview of a method of cutting the paper 50 by the traverse cutter 40c is explained below.

[0031] The controller 100 is a controller that performs rotation control for the first motor 21 and the second motor 22. The controller is, for example, a PLC (Programmable Logic Controller). The controller 100 includes a driver that drives the first motor 21 and the second motor 22. Further, the controller 100 stores a paper winding program (not shown). The controller 100 executes the paper winding program, whereby a function of the rotation control for the first motor 21 and the second motor 22 is realized.

[0032] The controller 100 is connected to each of the first motor 21, the second motor 22, the arm unit 10, the first touch arm 30, and the second touch arm 40. The controller 100 and the respective kinds of equipment are respectively connected by, for example, cables.

[0033] The controller 100 receives at least a turning start flag of the second arm 10b from the arm unit 10. The controller 100 receives at least a forward movement start flag of the first touch arm 30 from the first touch arm 30. Further, the controller 100 receives at least a backward movement start flag of the second touch arm 40 from the second touch arm 40. Details of the rotation control for the first motor 21 and the second motor 22 by the controller 100 are explained below.

1-2. Operation Example of the Traverse Cutter

[0034] FIG. 2 is a diagram for explaining an overview of a method of cutting by the traverse cutter 40c in the paper winder 1 according to the embodiment. Specifically, in FIG. 2, an operation example of the traverse cutter 40c that cuts the paper 50 near the second winding core 12 after the completion of the winding of the paper 50 by the first winding core 11 and after, according to the turning of the second arm 10b, the position of the second winding core 12 has reached the position where the paper 50 should be wound is shown in time series.

[0035] As shown in FIG. 2, the traverse cutter 40c cuts the paper 50 in a direction (a cutting direction) orthogonal to the longitudinal direction of the paper 50 in a state in which the paper 50 is pressed against the outer circumferential surface of the second winding core 12 by the nip roll 30b. Since cutting speed of the traverse cutter 40c is adjusted to winding speed of the paper 50, the paper 50 being wound by the first winding core 11 is cut by the traverse cutter 40c at a slant angle of 45 degrees with respect to a winding direction.

[0036] In the traverse cutter 40c, a movable range 60 is provided with respect to the cutting direction. As shown in FIG. 2, the traverse cutter 40c cuts the paper 50 according to the movable range 60. Note that, when the width of the paper 50 is represented as W [m] and the speed of the paper 50 being wound by the first winding core 11 is represented as V [m/min], a cutting time of the traverse cutter 40c is represented by the following Expression (1).

[00001]$\begin{array}{cc}\left[\mathrm{Math}.1\right]& \\ \frac{W}{V}& \left(1\right)\end{array}$

[0037] For example, when the width of the paper 50 is 2.01 [m] and the speed of the paper 50 is set to 20 [m/min], the cutting time of the traverse cutter 40c is 6.03 [s].

[0038] After the cutting of the paper 50 by the traverse cutter 40c, two separated pieces of the paper 50 are respectively wound by the first winding core 11 and the second winding core 12. Consequently, the winding roll after the completion of the winding of the paper 50 by the first winding core 11 can be replaced in a state in which the paper winder 1 is continuously operated.

2. Specific Example

2-1. An Example of Rotation Control for the Motors

[0039] FIG. 3 is a diagram for explaining a specific example of the paper winder 1 according to the embodiment. Specifically, FIG. 3 shows an example of rotation control for the first motor 21 and the second motor 22 in the controller 100 of the paper winder 1. Note that, in processing of a portion shown in FIG. 3(A), a mechanical operation is performed in a chain reaction manner and control by the controller 100 is not performed. Based on this, an example of rotation control for the first motor 21 and the second motor 22 by the controller 100 is explained below.

[0040] At timing shown in FIG. 3(B), the controller 100 receives, from the arm unit 10, the turning start flag of the second arm 10b after the completion of the winding of the paper 50 by the first winding core 11.

[0041] The controller 100 sets a control mode of the second motor 22 to drive the second motor 22. Specifically, the controller 100 sets the control mode of the second motor 22 to speed control. The speed control means controlling rotating speed of a motor to drive the motor within a target speed range.

[0042] When the control mode of the second motor 22 is set to the speed control, a driving state of the second motor 22 is transitioned in the order of a stop state and an acceleration state. Consequently, the second motor 22 can be driven. Thereafter, the second motor 22 is controlled such that the second motor 22 is driven at speed within the target speed range.

[0043] The controller 100 switches the control mode of the second motor 22 from speed control to torque control at timing during the operation of the traverse cutter 40c and when a torque value of the second motor 22 satisfies a predetermined condition. The torque control means controls a motor to drive at generated torque within a range of target torque.

[0044] The timing during the operation of the traverse cutter 40c and when the torque value of the second motor 22 satisfies the predetermined condition is, for example, a position shown in FIG. 3(C). The predetermined condition means a condition that the torque value of the second motor 22 is equal to or larger than a torque reference value. Details of setting of the torque reference value are explained below.

[0045] Here, a method of the controller 100 grasping the timing during the operation of the traverse cutter 40c is conceived. A time period during the operation of the traverse cutter 40c is calculated by Expression (1) described above. Therefore, the controller 100 has to grasp only operation start time of the traverse cutter 40c. The operation start time of the traverse cutter 40c is, for example, time obtained by adding a predetermined time period (a first time period) to turning start time (timing shown in FIG. 3(B)) of the second arm 10b after the completion of the winding of the paper 50 by the first winding core 11. Alternatively, the operation start time of the traverse cutter 40c is time obtained by adding a predetermined time period (a second time period) to forward movement start time (timing shown in FIG. 3(D)) of the first touch arm 30.

[0046] Note that the first time period and the second time period may be information concerning predetermined time periods or may be information concerning time periods acquired by measurement.

[0047] Based on this, the controller 100 sets, as the turning start time of the second arm 10b, the turning start flag of the second arm 10b received from the second arm 10b. Alternatively, the controller 100 sets, as the forward movement start time of the first touch arm 30, the forward movement start flag of the first touch arm 30 received from the first touch arm 30. The controller 100 adds the first time period to the turning start time of the second arm 10b. Alternatively, the controller 100 adds the second time period to the forward movement start time of the first touch arm 30. Consequently, the controller 100 can grasp the operation start time of the traverse cutter 40c.

[0048] Further, the controller 100 performs tension correction control for the second motor 22 at the timing during the operation of the traverse cutter 40c and when the torque value of the second motor 22 satisfies the predetermined condition explained above. That is, at the timing, the controller 100 switches the control mode of the second motor 22 from the speed control to the torque control and performs the tension correction control for the second motor 22. The tension correction control means adjusting a torque value of a motor such that the tension of the paper 50 falls within a target range.

[0049] After switching the control mode of the second motor 22 from the speed control to the torque control and after the completion of the operation of the traverse cutter 40c, the controller 100 sets a control mode of the first motor 21 to stop the driving of the first motor 21. Specifically, the controller 100 switches the control mode of the first motor 21 from torque control to stop. When the control mode of the first motor 21 is set to the stop, a driving state of the first motor 21 is transitioned in the order of a deceleration state and a stop state. Consequently, the driving of the first motor 21 can be stopped.

[0050] Here, a method of the controller 100 grasping operation completion time of the traverse cutter 40c is conceived. The operation completion time of the traverse cutter 40c may be, for example, backward movement start time (timing shown in FIG. 3(E)) of the second touch arm 40. The controller 100 sets, as the backward movement start time of the second touch arm 40, the backward movement start flag of the second touch arm 40 received from the second touch arm 40. Consequently, the controller 100 can grasp the operation completion time of the traverse cutter 40c.

2-2. Setting Example of the Torque Reference Value

[0051] As shown in FIG. 4, the controller 100 sets the torque reference value after a driving start of the second motor 22. The torque reference value is a torque value of the first motor 21 at the time when the tension of the paper 50 at the time of winding of the paper 50 by the first winding core 11 is within the target range. The torque value of the first motor 21 used for the setting of the torque reference value may be predetermined data or may be data acquired from the first winding core 11 immediately before the paper 50 is wound by the second winding core 12.

[0052] Further, the torque reference value may be a value obtained by adding at least a mechanical loss of the second motor 22 to the torque value of the first motor 21. The mechanical loss means a mechanical loss that depends on rotating speed of a motor. The mechanical loss is different depending on an individual difference of the second motor 22 and is periodically calculated during the driving of the second motor 22. The mechanical loss used for the setting of the torque reference value is periodically updated

[0053] The controller 100 determines whether the torque value of the second motor 22 is equal to or larger than the torque reference value during the operation of the traverse cutter 40c. When determining that the torque value of the second motor 22 is equal to or larger than the torque reference value, as shown in FIG. 4, the controller 100 switches the control mode of the second motor 22 from the speed control to the torque control. Further, as shown in FIG. 4, the controller 100 switches the control mode of the second motor 22 from the speed control to the torque control and performs the tension correction control for the second motor 22.

2-3. Effects

[0054] As explained above, in the paper winder 1 according to the embodiment, when the torque value of the second motor 22 is equal to or larger than the torque reference value during the operation of the traverse cutter 40c, the control mode of the second motor 22 is switched from the speed control to the torque control and the tension correction control for adjusting the torque value of the second motor 22 such that the tension of the paper 50 falls within the target range is performed. Consequently, it is possible to improve stability of winding of the paper 50 by a new winding core at a replacement time of a winding roll.

3. Processing Example

[0055] FIG. 5 is a flowchart showing a processing example of the controller 100 in the paper winder 1 according to the embodiment.

[0056] In step S100, the controller 100 sets the control mode of the second motor 22 to the speed control based on the turning start flag of the second arm 10b. Thereafter, the processing proceeds to step S110.

[0057] In step S110, the controller 100 sets the torque reference value for performing the rotation control for the second motor 22. Thereafter, the processing proceeds to step S120.

[0058] In step S120, the controller 100 determines whether the traverse cutter 40c is operating. When it is determined that the traverse cutter 40c is operating (step S120; Yes), the processing proceeds to step S130. Otherwise (step S120; No), the processing returns to step S120.

[0059] In step S130, the controller 100 determines whether the torque value of the second motor 22 is equal to or larger than the torque reference value. When it is determined that the torque value of the second motor 22 is equal to or larger than the torque reference value (step S130; Yes), the processing proceeds to step S140. Otherwise (step S130; No), the processing returns to step S130.

[0060] In step S140, the controller 100 switches the control mode of the second motor 22 from the speed control to the torque control. Thereafter, the processing proceeds to step S150.

[0061] In step S150, the controller 100 executes the tension correction control for the second motor 22. Thereafter, the processing proceeds to step S160. Note that the processing in step S150 is performed simultaneously with the processing in step S140 explained above.

[0062] In step S160, the controller 100 switches the control mode of the first motor 21 from the torque control to the stop.

REFERENCE SIGNS LIST

[0063] 1 . . . paper winder, 2 . . . paper winding mechanism unit, 3 . . . paper cutting unit, 10 . . . arm unit, 10a . . . first arm, 10b . . . second arm, 10c . . . third arm, 10d . . . fourth arm, 11 . . . first winding core, 12 . . . second winding core, 13 . . . guide roller, 21 . . . first motor, 22 . . . second motor, 30 . . . first touch arm, 30a . . . rotating shaft, 30b . . . nip roll, 40 . . . second touch arm, 40a . . . rotating shaft, 40b . . . winding core fixture, 40c . . . traverse cutter, 50 . . . paper, 60 . . . movable range, 100 . . . controller