JP2020001861A - Method and apparatus for production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method or the like for inspecting the quality of a long material while manufacturing it. SOLUTION: The manufacturing method includes a step S1 of supplying a material piece to a predetermined position on a conveyor movable in a first direction, and a conveyor to which the material piece is supplied along a first direction of the material piece. By repeating the step S2 of moving the material pieces in the first direction with a feed amount less than the length, the material making step of forming a long material by joining the material pieces so as to partially overlap on the conveyor, the feed of the conveyor. Judgment to determine the quality of the long material based on the measurement step S3 for measuring at least one of the quantity, the thickness of the long material, and the edge position of the long material, and the measured value measured in the measurement step. The step S4 is included. [Selection diagram] Fig. 1

Description

  The present invention relates to a manufacturing method and a manufacturing apparatus for manufacturing a long material.

  2. Description of the Related Art In recent years, as a method of manufacturing a green tire, a technique of attaching a strip-shaped belt ply to the outside of a core having an annular circumferential surface has been developed. As an example of such a technique, an apparatus for inspecting an attached state of a belt ply is disclosed. (For example, see Patent Document 1).

  On the other hand, in the conventional method without using a core, a strip-shaped material piece is joined on a conveyor to form a long material used for manufacturing a tire. However, the quality of the manufactured long material is left to an inspection such as visual inspection by an operator.

JP 2015-45577 A

  The present invention has been devised in view of the above situation, and has as its main object to provide a production method and the like for inspecting the quality of a long material while producing it.

  According to a first aspect of the present invention, there is provided a method for manufacturing a long material, comprising: supplying a material piece to a predetermined position on a conveyor movable in a first direction; Moving the conveyed conveyor in the first direction with a feed amount smaller than the length of the material pieces along the first direction, so that the material pieces partially overlap on the conveyor. A material forming step of forming a long material by joining the long material, the feeding amount of the conveyor, the thickness of the long material, and the position of the edge of the long material in a second direction orthogonal to a first direction. A measuring step of measuring at least one; and a determining step of determining the quality of the long material based on the measured value measured in the measuring step.

  In the manufacturing method according to the present invention, it is preferable that the determining step includes a step of calculating an overlapping amount or a gap between the material pieces adjacent in the first direction based on the feed amount and the thickness. .

  In the manufacturing method according to the present invention, the determining step calculates a width of the long material or a shift amount of the edge of the material piece adjacent in the first direction based on the position of the edge. It is desirable to include a step.

  A second invention of the present invention is an apparatus for producing a long material, a conveyor movable in a first direction, a supply unit for supplying a piece of material to a predetermined position on the conveyor, By moving the conveyor to which the material pieces are supplied in the first direction with a feed amount smaller than the length of the material pieces along the first direction, the material pieces partially overlap on the conveyor. Forming section that forms a long material by jointing, the feed amount of the conveyor, the thickness of the long material, and the position of the edge of the long material in the second direction orthogonal to the first direction. A measuring unit that measures at least one of them; and a determining unit that determines the quality of the long material based on a measurement value measured by the measuring unit.

  In the manufacturing apparatus according to the present invention, it is preferable that the measuring unit includes an encoder that measures the feed amount.

  In the manufacturing apparatus according to the present invention, it is preferable that the measurement unit includes a distance sensor that measures a distance from a predetermined reference position to the long material.

  In the manufacturing apparatus according to the present invention, it is preferable that the distance sensor is disposed on a front side and a back side of the long material.

  In the manufacturing apparatus according to the present invention, it is preferable that the distance sensors are arranged on both sides of a center line of the long material along the first direction.

  In the manufacturing apparatus according to the present invention, it is preferable that the measurement unit includes a calculation unit that calculates the thickness based on a signal output from the distance sensor.

  In the manufacturing apparatus according to the present invention, it is preferable that the distance sensor has a measurement area along a width direction of the long material.

  In the manufacturing apparatus according to the present invention, it is preferable that the measurement unit includes a calculation unit that calculates the position of the edge based on a signal output from the distance sensor.

  The first invention includes a material forming step of joining long pieces of material on a conveyor to form a long material, a measuring step of measuring the long material, and a determining step of determining the quality of the long material. In the measuring step, at least one of the feed amount of the conveyor, the thickness of the long material, and the position of the edge of the long material in the second direction is measured. Then, in the determination step, the quality of the long material is determined based on the measurement value measured in the measurement step. This makes it possible to automatically inspect the quality of the long material while producing the long material without imposing a burden on the operator.

  The second aspect of the present invention includes a material producing unit that forms a long material by joining material pieces on a conveyor, a measuring unit that measures the long material, and a determination unit that determines the quality of the long material. In the measuring unit, at least one of the feed amount of the conveyor, the thickness of the long material, and the position of the edge of the long material in the second direction is measured. Then, the determination unit determines the quality of the long material based on the measurement value measured by the measurement unit. This makes it possible to automatically inspect the quality of the long material while producing the long material without imposing a burden on the operator.

It is a top view showing one embodiment of the manufacturing device of the 1st invention of the present invention. 3 is a flowchart showing a procedure of the manufacturing method according to the first invention of the present invention. FIG. 2 is a side view of a measuring unit of the manufacturing apparatus, showing an arrangement of the distance sensor in FIG. 1. It is a front view of the measuring part of the manufacturing apparatus which shows arrangement | positioning of the distance sensor of FIG. It is a top view showing the long material containing the piece of material supplied shifted in the 3rd direction.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is a plan view illustrating a schematic configuration of a manufacturing apparatus 1 according to the present embodiment. As shown in FIG. 1, a manufacturing apparatus 1 according to the present embodiment is an apparatus for manufacturing a long material 100. The manufacturing apparatus 1 includes a material creating unit 2 that forms the long material 100, a measuring unit 3 that measures the long material 100, and the like, and a determination unit 4 that determines the quality of the long material 100.

  The long material 100 is formed by joining a plurality of strip-shaped material pieces 101. In the long material 100 of the present embodiment, an array of a plurality of cords is covered with topping rubber. Such a long material 100 is suitably used for a carcass ply or a belt ply of a tire. The long material 100 of the present invention is not limited to the cord-containing ply material described above, but may be a form composed of only rubber.

  The material preparation unit 2 includes a conveyor 21 that can move in the first direction D1, a supply unit 22 that supplies the material pieces 101 to the conveyor 21, and a joint unit 23 that joins the material pieces 101.

  The conveyor 21 is driven by rollers 24 and the like, and conveys the long material 100 (material piece 101) in the first direction. The feed amount of the conveyor 21 is controlled by the rotation speed of the roller 24 or a motor (not shown) for driving the roller 24.

  The supply unit 22 supplies the material pieces 101 to a predetermined position P on the conveyor 21. The supply unit 22 supplies the material piece 101 in a third direction D3 at a predetermined angle θ with respect to the first direction D1. The angle θ is determined according to the use of the long material 100 and the like.

  The joint 23 presses the rear end of the material piece 101 conveyed by the conveyor 21 in the first direction D1 and the front end of the material piece 101 supplied next by the supply unit 22 in the first direction D1. To join. By successively repeating the supply of the material pieces 101 by the supply unit 22, the joint of the material pieces 101 by the joint unit 23, and the conveyance of the long material 100 by the conveyor 21, the long material 100 extending in the first direction D1 is formed.

  The measuring unit 3 includes a feed amount X of the conveyor 21, a thickness T of the long material 100 (see FIG. 4 described later), and edges 100 a and 100 b in a second direction D2 orthogonal to the first direction D1 of the long material 100. At least one of the positions is measured. In the present embodiment, the measuring unit 3 includes an encoder 31 for measuring the feed amount X of the conveyor 21 and a distance sensor 32 for measuring the thickness T of the long material 100 and the positions of the edges 100a and 100b. Contains. The measuring unit 3 includes a calculating unit 33 that calculates the feed amount X of the conveyor 21, the thickness T of the long material 100, and the positions of the edges 100 a and 100 b of the long material 100.

  The encoder 31 is provided, for example, on the side of the conveyor 21, and outputs a pulse-like electric signal corresponding to the feed amount X of the conveyor 21 to the calculation unit 33. As the encoder 31, for example, a linear encoder that measures the amount of movement of the conveyor 21 in the first direction, a rotary encoder that measures the rotation angle of the roller 24 or a motor that drives the roller 24, or the like is applied.

  The distance sensor 32 is provided above or downstream of the conveyor 21 so as to face the long material 100.

  As the distance sensor 32 of the present embodiment, for example, a two-dimensional laser displacement sensor is used. The two-dimensional laser displacement sensor irradiates the subject with laser light L (see FIGS. 3 and 4 described later) and detects the reflected light, so that the subject moves from a predetermined reference position to a subject over a predetermined measurement area. This is a non-contact type displacement sensor that measures the distance of the object. The reference position may be, for example, an emission port of the laser light L, but may be an arbitrary position inside or outside the distance sensor 32.

  The calculation unit 33 is realized by, for example, a calculation processing unit 5 including a CPU (Central Processing Unit) that executes various calculation processes, information processing, and the like, a program that controls the operation of the CPU, a memory that stores various information, and the like. . The program may be stored in a hard disk device or the like. The arithmetic processing unit 5 also functions as a determination unit 4 described later. That is, the calculation unit 33 and the determination unit 4 may be configured by the same CPU, memory, and the like.

  The calculation unit 33 calculates the feed amount X of the conveyor 21 based on the electric signal output from the encoder 31. Further, the calculation unit 33 calculates the thickness T of the long material 100 and the positions of the edges 100a and 100b based on the electric signal output from the distance sensor 32. Information regarding the feed amount X of the conveyor 21, the thickness T of the long material 100, and the positions of the edges 100 a and 100 b calculated by the calculation unit 33 are output to the determination unit 4.

  The determination unit 4 converts the measurement values measured by the measurement unit 3, that is, information on the feed amount X of the conveyor 21, the thickness T of the long material 100, and the positions of the edges 100 a and 100 b output from the calculation unit 33. Based on this, the quality of the long material 100 is determined. For example, the determination unit 4 compares the feed amount X of the conveyor 21, the thickness T of the long material 100 and the positions of the edges 100 a and 100 b measured by the measurement unit 3 with predetermined standard values. The quality of the long material 100 is determined.

  When the feed amount X of the conveyor 21, the thickness T of the long material 100, and the positions of the edges 100 a and 100 b exceed predetermined standard values, the arithmetic processing unit 5 stops the operation of the manufacturing apparatus 1. Further, in this case, the arithmetic processing unit 5 may be configured to issue an alarm to that effect and to notify the worker and the administrator.

  According to the manufacturing apparatus 1, it is possible to automatically inspect the quality of the long material 100 while manufacturing the long material 100 without imposing a burden on an operator.

  FIG. 2 is a flowchart illustrating a procedure of a method for manufacturing the long material 100. The method for manufacturing the long material 100 includes a material preparation process S1 and S2 for forming the long material 100, a measurement process S3 for measuring the long material 100 and the like, and a determination process S4 for determining the quality of the long material 100. Contains.

  The material creation steps S1 and S2 are performed by the material creation unit 2. That is, by repeating the step S1 in which the supply unit 22 supplies the material pieces 101 and the step S2 of moving the conveyor 21 to which the material pieces 101 are supplied in the first direction, the material pieces 101 are joined on the conveyor 21. Thus, the long material 100 is formed.

  The measurement step S3 is performed by the measurement unit 3. That is, in the measuring step S3, the measuring unit 3 measures at least one of the feed amount X of the conveyor 21, the thickness T of the long material 100, and the positions of the edges 100a and 100b.

  The determining step S4 is performed by the determining unit 4. That is, in the determination step S4, the determination unit 4 determines the quality of the long material 100 based on the measurement value measured in the measurement step S3.

  The quality of the long material 100 is automatically inspected while the long material 100 is manufactured by repeatedly performing the above steps S1 to S4.

  3 and 4 show the arrangement of the distance sensor 32. FIG. A plurality of distance sensors 32 of the present embodiment are provided downstream of the conveyor 21.

  The distance sensors 32 include distance sensors 32A and 32B arranged on the front side of the long material 100 and distance sensors 32C and 32D arranged on the back side of the long material 100. The distance sensors 32A and 32C are arranged on one side of the center line C of the long material 100 along the first direction D1, and the distance sensors 32B and 32D are arranged on the other side of the center line C, respectively. That is, the distance sensors 32 are arranged on both sides of the center line C.

  FIG. 3 shows a state where the joint portions of the material pieces 101 and 101 pass through the measurement area of the distance sensor 32. As shown in FIG. 3, the distance sensors 32A and 32B measure the distance L1 from the reference position to the surface of the long material 100. On the other hand, the distance sensors 32C and 32D measure the distance L2 from the reference position to the back surface of the long material 100. The thickness T of the long material 100 is calculated based on the distances L1 and L2.

  When the long material 100 is conveyed by the conveyor 21 in the first direction D1, a portion where the distance L1 measured by the distance sensors 32A and 32B suddenly decreases (a portion where the thickness T of the long material 100 sharply increases) is a material. It can be determined that it is the front edge 101a of the piece 101. On the other hand, when the long material 100 is conveyed by the conveyor 21 in the first direction D1, a portion where the distance L2 measured by the distance sensors 32C and 32D rapidly increases (a portion where the thickness T of the long material 100 sharply decreases) is Can be determined to be the rear edge 101b of the material piece 101.

  Therefore, the distance L3 between the rear edge 101b of a certain material piece 101 and the front edge 101a of the material piece 101 supplied next by the supply unit 22 is determined by the amount of overlap of the material pieces 101, 101 in the first direction D1 ( Joint length). The determination unit 4 calculates the time from when the front edge 101a is detected by the distance sensors 32A and 32B to when the rear edge 101b is detected by the distance sensors 32C and 32D, and based on the electric signal output from the encoder 31. By calculating the feed amount X of the conveyor 21 within the above time, the overlap amount of the material pieces 101, 101 is calculated. The determination unit 4 determines the quality of the long material 100, particularly the joint quality, by comparing the calculated amount of overlap with a predetermined standard value. The joint quality can be more accurately evaluated by calculating the overlap amount L3 · sin θ in the direction orthogonal to the front edge 101a and the rear edge 101b of the material pieces 101, 101.

  If the feed amount X of the conveyor 21 is excessive with respect to the length of the material pieces 101 in the first direction D1, a gap is generated between the adjacent material pieces 101. When detecting the rear edge 101b by the distance sensors 32C and 32D before detecting the front edge 101a by the distance sensors 32A and 32B, the determination unit 4 does not joint the material pieces 101 and 101 and Can be determined to have a gap. Such a gap can be more accurately determined by the determination unit 4 monitoring the transition of the distances L1 and L2.

  That is, the determination step S4 includes a step of calculating an overlap amount or a gap between the material pieces 101, 101 adjacent in the first direction D1, based on the feed amount X and the thickness T measured in the measurement step S3. . Thereby, among the quality of the long material 100, especially the joint quality of the material pieces 101, 101 can be accurately determined. Further, it is possible to determine the length abnormality of the material piece 101 supplied from the supply unit 22 in the first direction D1.

  In this embodiment, based on the feed amount X and the thickness T, the amount of overlap or the gap between the material pieces 101 adjacent in the first direction D1 is calculated, so that the cause of the joint failure can be easily specified. it can. For example, if the feed amount X is abnormal, the cause is the conveyor 21; if the feed amount X is normal, the cause is the length of the material piece 101 in the first direction D1 or the supply angle θ. Can be estimated.

  In the present embodiment, the distance sensors 32A and 32C are arranged on one side of the center line C of the long material 100, and the distance sensors 32B and 32D are arranged on the other side of the center line C. By calculating and comparing the amount of overlap or the gap between the material pieces 101, 101 on both sides of the line C, the quality such as the symmetry of the long material 100 can be determined in detail.

  As shown in FIG. 4, each of the distance sensors 32A, 32B, 32C, and 32D has its own measurement area SA, SB, along the second direction D2 orthogonal to the first direction D1, that is, along the width direction of the long material 100. It has SC and SD. The distance sensors 32A, 32B, 32C, 32D are arranged so as to include the edges 100a, 100b in the second direction D2 which is the width direction of the long material 100 in the respective measurement areas SA, SB, SC, SD. I have.

  The calculation unit 33 calculates the positions of the edges 100a and 100b (that is, the center lines) based on the distances from the center line C to the reference positions of the distance sensors 32A and 32B and the electric signals output from the distance sensors 32A and 32B. The distance from C to the edges 100a and 100b) is calculated. The edges 100a, 100b are located at locations where the distance L1 (see FIG. 3) suddenly increases from the reference position toward the outside in the width direction of the long material 100 from the center line C (the thickness T of the long material 100 decreases rapidly). Is determined by detecting the location where the Electric signals output from the distance sensors 32C and 32D may be used for calculating the positions of the edges 100a and 100b.

  Then, the determination unit 4 calculates the width W of the long material based on the positions of the edges 100a and 100b. That is, the determination step S4 includes a step of calculating the width W of the long material 100 based on the positions of the edges 100a and 100b. Thereby, the quality of the long material 100 can be determined in detail.

  FIG. 5 shows a long material 100 including a material piece 101 supplied in a shifted manner in the third direction D3. In the present embodiment, since the calculation unit 33 calculates the positions of the edges 100a and 100b, the positions of the edges 100c and 100d are shifted from the edges 100a and 100b in the material pieces 101 supplied in the third direction D3. fluctuate. The determination unit 4 calculates a shift amount Z between the edges 100c, 100d based on the positions of the edges 100a, 100b, 100c, 100d. That is, the determination step S4 includes a step of calculating the shift amount Z between the edges 100c, 100d based on the positions of the edges 100a, 100b, 100c, 100d. Thereby, the quality of the long material 100 can be determined in more detail.

  As described above, the manufacturing apparatus 1 and the manufacturing method of the present invention have been described in detail, but the present invention is not limited to the above specific embodiments, but may be implemented in various modes.

1: Manufacturing apparatus 2: Material creation unit 3: Measurement unit 4: Judgment unit 21: Conveyor 22: Supply unit 23: Joint unit 31: Encoder 32: Distance sensor 33: Calculation unit 100: Long material 100a: Edge 100b: Edge 100c: Edge 100d: Edge 101: Piece of material 101a: Front edge 101b: Rear edge C: Center line D1: First direction D2: Second direction D3: Third direction L: Laser beams S1, S2: Material creation step S3: Measurement step S4: Judgment step SA: Measurement area SB: Measurement area SC: Measurement area SD: Measurement area Z: Shift amount

Claims (11)

A method for producing a long material, comprising:
Supplying a piece of material to a predetermined position on a conveyor that is movable in a first direction, and moving the conveyor supplied with the piece of material to a length less than a length of the material piece along the first direction. Repeating the step of moving in the first direction by a feed amount, thereby forming a long material by joining the material pieces on the conveyor so as to partially overlap,
A measuring step of measuring at least one of the feed amount of the conveyor, the thickness of the long material, and the position of an edge in a second direction orthogonal to the first direction of the long material, and
Based on the measurement value measured in the measurement step, including a determination step of determining the quality of the long material,
A method for producing the long material.   The manufacturing method according to claim 1, wherein the determining step includes a step of calculating an overlap amount or a gap between the material pieces adjacent in the first direction based on the feed amount and the thickness.   The said determination process includes the process of calculating the width | variety of the said elongate material or the deviation | shift amount of the said edge of the said material piece adjacent to the said 1st direction based on the position of the said edge. The method according to 1. An apparatus for producing a long material,
A conveyor that can move in a first direction, a supply unit that supplies a piece of material to a predetermined position on the conveyor, and a conveyor that is supplied with the material piece, along the first direction of the material piece. By moving the material piece in the first direction with a feed amount of less than the length, the material forming unit that forms the long material by joining the material pieces so as to partially overlap on the conveyor,
A measuring unit that measures at least one of the feed amount of the conveyor, the thickness of the long material, and the position of an edge in a second direction orthogonal to the first direction of the long material, and
Based on the measurement value measured by the measurement unit, including a determination unit that determines the quality of the long material,
An apparatus for manufacturing the long material.   The manufacturing device according to claim 4, wherein the measuring unit includes an encoder that measures the feed amount.   The manufacturing apparatus according to claim 4, wherein the measuring unit includes a distance sensor that measures a distance from a predetermined reference position to the long material.   The manufacturing apparatus according to claim 6, wherein the distance sensor is disposed on a front side and a back side of the long material.   The manufacturing device according to claim 6, wherein the distance sensors are arranged on both sides of a center line of the long material along the first direction.   The manufacturing apparatus according to claim 6, wherein the measurement unit includes a calculation unit that calculates the thickness based on a signal output from the distance sensor.   The manufacturing device according to claim 6, wherein the distance sensor has a measurement region along a width direction of the long material.   The manufacturing apparatus according to claim 10, wherein the measurement unit includes a calculation unit that calculates the position of the edge based on a signal output from the distance sensor.

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