Apparatus of manufacturing resin film, and method of controlling the same

Abstract

To provide an apparatus of manufacturing a resin film capable of automatically starting winding of the resin film by a winding machine when manufacturing the resin film is started.SOLUTION: An apparatus of manufacturing a resin film according to one embodiment is provided with a film passage sensor for winding, provided on the inlet side of a winding machine to detect passage of the conveyed resin film. When manufacturing the resin film is started, after passage of the resin film is detected by the film passage sensor for winding, driving of the winding machine is started.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a resin film manufacturing apparatus and a control method thereof. [Background technology]

[0002] As disclosed in Patent Documents 1 and 2, the inventors have developed a resin film manufacturing apparatus and a control method thereof. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2022-092768 A [Patent Document 2] JP 2023-082321 A Summary of the Invention [Problem to be solved by the invention]

[0004] For example, when starting to wind up a resin film using a winding machine at the start of resin film production, the leading end of the resin film transported from the upstream side was manually fixed to the winding machine by an operator, and then the operator manually started operating the winding machine. Therefore, the inventors aim to develop a technique for automatically starting winding of a resin film by a winding machine when production of the resin film starts. Other objects and novel features will become apparent from the description of this specification and the accompanying drawings. [Means for solving the problem]

[0005] In one embodiment, the resin film production apparatus includes a winding film passage sensor that is provided on the inlet side of a winding machine and detects the passage of the transported resin film. When the production of the resin film is started, the winding film passage sensor detects the passage of the resin film, and then starts driving the winding machine.

[0006] In one embodiment of a control method for a resin film manufacturing apparatus, when production of a resin film is started, a computer executes a step of (a) detecting that the resin film has passed by a winding film passing sensor provided on the inlet side of the winding machine, and then starting the operation of the winding machine. Effect of the Invention

[0007] According to the embodiment, it is possible to provide a resin film production apparatus that can automatically start winding up the resin film by the winder when the production of the resin film starts. [Brief description of the drawings]

[0008] [Figure 1] 1 is a schematic perspective view showing an overall configuration of a resin film manufacturing apparatus according to a first embodiment. [Diagram 2] 1 is a schematic cross-sectional view showing an overall configuration of a resin film manufacturing apparatus according to a first embodiment. [Diagram 3] FIG. [Figure 4] FIG. 2 is a partial perspective view of the lower side (lip side) of the T-die 20. [Diagram 5] 4 is a flowchart showing the overall configuration of a method for controlling the resin film production apparatus according to the first embodiment at the start of resin film production. [Figure 6] 6 is a schematic cross-sectional view showing the resin film manufacturing apparatus in a control mode MD1 in FIG. 5. [Figure 7] 6 is a schematic cross-sectional view showing the resin film manufacturing apparatus in a control mode MD2 in FIG. 5. [Figure 8] 6 is a schematic cross-sectional view showing the resin film manufacturing apparatus in a control mode MD3 in FIG. 5. [Figure 9] 6 is a schematic cross-sectional view showing the resin film manufacturing apparatus in a control mode MD4 in FIG. 5. [Figure 10] 6 is a flowchart showing details of a control mode MD1 in FIG. 5. [Figure 11]6 is a flowchart showing details of a control mode MD2 in FIG. 5. [Figure 12] 12 is a schematic cross-sectional view showing the casting machine 30 in step S21 in FIG. 11. [Figure 13] 6 is a flowchart showing details of a control mode MD3 in FIG. 5. [Figure 14] 14 is a schematic cross-sectional view showing the casting machine 30 and the winding machine 40 in step S31 in FIG. 13. [Figure 15] 6 is a flowchart showing details of a control mode MD4 in FIG. 5. [Figure 16] 6 is a flowchart showing details of a control mode MD5 in FIG. 5. [Figure 17] FIG. 4 is a schematic perspective view showing the overall configuration of a resin film manufacturing apparatus according to a second embodiment. [Figure 18] FIG. 4 is a schematic cross-sectional view showing the overall configuration of a resin film manufacturing apparatus according to a second embodiment. [Figure 19] 10 is a flowchart showing the overall configuration of a control method for a resin film production apparatus according to a second embodiment at the start of resin film production. [Figure 20] 20 is a schematic cross-sectional view showing the resin film manufacturing apparatus in a control mode MD6 in FIG. 19. [Figure 21] 20 is a schematic cross-sectional view showing the resin film manufacturing apparatus in a control mode MD7 in FIG. 19. [Figure 22] 20 is a schematic cross-sectional view showing the resin film manufacturing apparatus in a control mode MD3 in FIG. 19. [Figure 23] 20 is a schematic cross-sectional view showing the resin film manufacturing apparatus in a control mode MD4 in FIG. 19. [Figure 24] 20 is a flowchart showing details of a control mode MD6 in FIG. 19. [Diagram 25] 25 is a schematic cross-sectional view showing the casting machine 30 and the longitudinal stretching machine 60 in step S61 in FIG. 24. [Figure 26]20 is a flowchart showing details of a control mode MD7 in FIG. 19. [Figure 27] 27 is a schematic cross-sectional view showing the longitudinal stretching machine 60 and the transverse stretching machine 70 in step S71 in FIG. 26. [Figure 28] 14 is a schematic cross-sectional view showing a transverse stretching machine 70 and a winding machine 40 in step S31 of FIG. 13 according to the second embodiment. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, specific embodiments will be described in detail with reference to the drawings. However, the present invention is not limited to the following embodiments. In addition, the following description and drawings are appropriately simplified for clarity of explanation.

[0010] (First embodiment) <Overall configuration of resin film manufacturing equipment> First, the overall configuration of a resin film manufacturing apparatus according to a first embodiment will be described with reference to Figures 1 and 2. Figure 1 is a schematic perspective view showing the overall configuration of a resin film manufacturing apparatus according to a first embodiment. Figure 2 is a schematic cross-sectional view showing the overall configuration of a resin film manufacturing apparatus according to a first embodiment.

[0011] Naturally, the right-handed xyz Cartesian coordinate system shown in Figure 1 and other drawings is for the convenience of explaining the positional relationship of the components. Usually, the positive direction of the z axis is vertically upward, and the xy plane is a horizontal plane, which is common among the drawings. In this specification, the resin film includes a resin sheet.

[0012] As shown in Figures 1 and 2, the resin film production apparatus according to the first embodiment includes an extruder 10, a T-die 20, a casting machine 30, a winding machine 40, and a controller 50. The resin film production apparatus according to the first embodiment is an extrusion molding type resin film production apparatus that extrudes a film-like molten resin 82a from a gap between the lips of the T-die 20 connected to the extruder 10. Note that the controller 50 is omitted in Figure 1.

[0013] The extruder 10 illustrated in Figures 1 and 2 is a screw-type extruder. As shown in Figure 2, the extruder 10 includes a cylinder 11 extending in the x-axis direction and a screw 12 extending in the x-axis direction housed inside the cylinder 11.

[0014] A screw motor SM is connected to the root of the screw 12. The screw motor SM is a drive source that drives the screw 12, and is controlled by a controller 50. It should be noted that there may be a single or multiple screws 12. For example, an extruder 10 having one screw 12 is called a single screw extruder, and an extruder 10 having two screws 12 is called a twin screw extruder.

[0015] A hopper 13 is provided above the end of the cylinder 11 on the negative x-axis direction side for feeding in a resin raw material 81, which is the raw material of the resin film 83. The resin raw material 81 is, for example, resin pellets or resin powder. Furthermore, a raw material feeder 14 is provided above the hopper 13 for feeding the resin raw material 81 into the cylinder 11. The raw material feeder 14 is of a screw type and includes a feeder hopper FH, a feeder screw FS, and a feeder motor FM. The driving system of the raw material feeder 14 is not limited in any way, and may be a belt system or a combination system of a screw system and a belt system.

[0016] Resin raw material 81 is fed into the feeder hopper FH and stored therein. When the feeder screw FS is rotated by the feeder motor FM, the resin raw material 81 in the feeder hopper FH is supplied to the inside of the cylinder 11 via the hopper 13. For example, the controller 50 feedback-controls the rotation of the feeder motor FM while monitoring the change in mass of the resin raw material 81 in the feeder hopper FH. With this configuration, the amount of resin raw material 81 supplied from the raw material feeder 14 to the extruder 10 can be controlled. A plurality of raw material feeders 14 may be provided.

[0017] The resin raw material 81 supplied from the hopper 13 to the inside of the cylinder 11 is transported from the base to the tip of the rotating screw 12, i.e., in the positive direction of the x-axis. Although not shown, a heater for heating the inside of the cylinder 11 is provided over substantially the entire area in the longitudinal direction on the outer circumferential surface of the cylinder 11, and the resin raw material 81 introduced into the cylinder 11 is heated in this manner, and is sheared and melted by the rotating screw 12 inside the cylinder 11, changing into molten resin 82.

[0018] As shown in FIG. 1, the T-die 20 is connected to the lower side of the tip (end in the positive x-axis direction) of the extruder 10. More specifically, as shown in FIG. 2, the T-die 20 is extended from the tip (end in the positive x-axis direction) of the extruder 10 in the positive x-axis direction and is connected to the lower end of an L-shaped pipe that extends further downward (negative z-axis direction). A film-like molten resin 82a is extruded downward (negative z-axis direction) from a gap in a lip located at the lower end of the T-die 20. Here, the lip spacing of the T-die 20 can be adjusted. As will be described in detail later, the lip spacing of the T-die 20 can be adjusted at multiple points along the longitudinal direction (y-axis direction) of the lip so that the thickness of the resin film 83 produced in the width direction (y-axis direction) is uniform.

[0019] 2, a gear pump GP is provided in a horizontal portion of the pipe connecting the extruder 10 and the T-die 20. The gear pump GP sucks in the molten resin extruded from the extruder 10 and discharges it into the T-die 20. The gear pump GP is composed of, for example, a pair of gears that mesh with each other. One of the gears of the gear pump GP is driven by a motor (not shown). The pump that sucks in the molten resin extruded from the extruder 10 and discharges it to the T-die 20 is not limited to a gear pump, and may be another type of pump. Also, a plurality of extruders 10 and gear pumps GP that supply the molten resin 82 to the T-die 20 may be provided.

[0020] As shown in Fig. 1, a pressure sensor PS is provided on the suction side of a gear pump GP in a pipe connecting an extruder 10 and a T-die 20. The pressure sensor PS measures the pressure of the molten resin on the suction side of the gear pump GP. The measured pressure measured by the pressure sensor PS is input to a controller 50.

[0021] As shown in FIGS. 1 and 2, the casting machine 30 includes a casting roll CS and a cooling roll CL. The cast roll CS cools the film-like molten resin 82a extruded from the T-die 20, and delivers the resin film 83 resulting from solidification of the film-like molten resin 82a to a cooling roll CL.

[0022] 1 and 2, the cooling roll CL transports the resin film 83 while cooling it. The casting roll CS and the cooling roll CL are each a driving roll driven by a driving source (not shown). The driving source is, for example, a variable speed motor such as a servo motor.

[0023] The casting roll CS and the cooling roll CL may each be provided with a cooling mechanism for cooling the resin film 83. The casting roll CS and the cooling roll CL may each be provided with a heating mechanism for heating the resin film 83. The casting machine 30 may include a plurality of casting rolls CS and a plurality of cooling rolls CL.

[0024] In the resin film manufacturing apparatus according to this embodiment, the resin film 83 discharged from the casting machine 30 is wound up by the winding machine 40. The winding machine 40 is a drive roll driven by a drive source (not shown). The winding machine 40 may include a plurality of drive rolls driven by a drive source. Also, a plurality of winding machines 40 may be provided.

[0025] The film thickness sensor FTS is, for example, a non-contact type thickness sensor, and measures the thickness distribution in the width direction of the resin film 83 being transported from the casting machine 30. In the example of FIG. 2, the film thickness sensor FTS is disposed so as to sandwich the resin film 83, which is transported horizontally, from above and below between the cooling roll CL and the winding machine 40. Since the film thickness sensor FTS is a non-contact type, it can be scanned in the width direction (y-axis direction) of the resin film 83. Therefore, the thickness distribution in the width direction of the resin film 83 can be measured by the compact film thickness sensor FTS. Furthermore, since the resin film 83 is transported horizontally, the thickness distribution can be measured with high accuracy even if the film thickness sensor FTS is scanned.

[0026] <Configuration and Operation of Controller 50> The controller 50 controls the extruder 10, the T-die 20, the casting machine 30, and the winding machine 40. That is, the controller 50 controls the entire resin film manufacturing apparatus according to this embodiment, and controls the production of the resin film 83. The controller 50 is not limited to any particular device, but is called, for example, a PLC (Programmable Logic Controller). The controller 50 may be, for example, a PC (Personal Computer).

[0027] Although not shown, the controller 50 includes a calculation unit such as a CPU (Central Processing Unit) and memories such as a RAM (Random Access Memory) and a ROM (Read Only Memory) in which various programs and various data are stored. In other words, the controller 50 has a function as a computer, and controls the extruder 10, the T-die 20, the casting machine 30, and the winding machine 40 based on the various programs and the like.

[0028] 2 can be configured, as hardware, by the above-mentioned CPU, memory, and other circuits. Also, as software, the controller 50 can be realized by a program stored in the memory. That is, the controller 50 can be realized in various forms by hardware, software, or a combination of both.

[0029] Regarding the control of the extruder 10, the controller 50 controls so as to maintain the pressure of the molten resin 82 on the suction side of the gear pump GP measured by the pressure sensor PS at a target pressure. Specifically, the controller 50 feedback-controls the supply amount of the resin raw material 81 from the raw material feeder 14 and the rotation speeds of the screw 12 and the gear pump GP based on the pressure of the molten resin 82 measured by the pressure sensor PS.

[0030] 2, the controller 50 feedback controls the feeder motor FM, the screw motor SM, and the gear pump GP based on the pressure of the molten resin 82 measured by the pressure sensor PS. By maintaining the pressure of the molten resin 82 on the suction side of the gear pump GP at a target pressure, the amount of the molten resin 82 flowing into the T-die 20 can be kept constant.

[0031] Here, when starting production of the resin film 83, the controller 50 feedback controls the rotation speed of the gear pump GP so as to maintain the pressure of the molten resin 82 on the suction side of the gear pump GP at a target pressure.

[0032] Increasing the rotation speed of the gear pump GP increases the amount of molten resin 82 sucked by the gear pump GP, and the pressure of the molten resin 82 on the suction side of the gear pump GP decreases. Conversely, decreasing the rotation speed of the gear pump GP decreases the amount of molten resin 82 sucked by the gear pump GP, and the pressure of the molten resin 82 on the suction side of the gear pump GP increases.

[0033] Therefore, when the controller 50 feedback controls the rotation speed of the gear pump GP, if the pressure measured by the pressure sensor PS is lower than the target pressure, the controller 50 reduces the rotation speed of the gear pump GP. Conversely, if the measured pressure is higher than the target pressure, the controller 50 increases the rotation speed of the gear pump GP.

[0034] On the other hand, during production of the resin film 83, the controller 50 feedback-controls the supply amount of the resin raw material 81 from the raw material feeder 14 and the rotation speed of the screw 12 so as to maintain the pressure of the molten resin 82 on the suction side of the gear pump GP at a target pressure. In other words, during production, the rotation speed of the gear pump GP is fixed.

[0035] Increasing the rotation speed of the screw 12 increases the amount of molten resin 82 extruded toward the gear pump GP, and the pressure of the molten resin 82 on the suction side of the gear pump GP increases. Conversely, decreasing the rotation speed of the screw 12 decreases the amount of molten resin 82 extruded toward the gear pump GP, and the pressure of the molten resin 82 on the suction side of the gear pump GP decreases.

[0036] Therefore, when the controller 50 feedback controls the rotation speed of the screw 12, if the pressure measured by the pressure sensor PS is lower than the target pressure, the rotation speed of the screw 12 is increased. In this case, the supply amount of the resin raw material 81 from the raw material feeder 14 is also increased at the same time. Conversely, if the measured pressure is higher than the target pressure, the rotation speed of the screw 12 is decreased. In this case, the supply amount of the resin raw material 81 from the raw material feeder 14 is also decreased at the same time.

[0037] 2, regarding the control of the T-die 20, the controller 50 feedback-controls the lip interval of the T-die 20 based on the thickness distribution of the resin film 83 acquired from the film thickness sensor FTS. More specifically, the controller 50 controls the lip interval of the T-die 20 so that the thickness of the resin film 83 becomes uniform in the width direction.

[0038] 2, regarding the control of the casting machine 30 and the winding machine 40, the controller 50 controls the rotation speeds of the casting roll CS, the cooling roll CL, and a driving source (e.g., a motor not shown) that drives the winding machine 40. For example, the controller 50 controls the rotation speed of the driving source that drives the winding machine 40 so as to maintain the tension of the resin film 83 in the winding machine 40 constant.

[0039] Furthermore, when starting the production of resin film 83, controller 50 starts driving winding machine 40 at a predetermined timing after detecting the passage of resin film 83 by film passage sensor S1 shown in Fig. 2. That is, winding of resin film 83 by winding machine 40 starts.

[0040] Here, film passing sensor S1 is a winding film passing sensor that is provided on the entrance side of winding machine 40 and detects the passage of resin film 83 conveyed at the start of production. On the other hand, in this embodiment, film passing sensor S1 is also provided on the exit side of casting machine 30 and can be said to detect that resin film 83 has passed through casting machine 30 at the start of production. There are no particular limitations on film passing sensor S1 as long as it can detect the passage of resin film 83, and it is, for example, a photoelectric sensor or a temperature sensor.

[0041] In FIG. 2, the film thickness sensor FTS is provided closer to the winder 40 than the film thickness sensor S1, but the film thickness sensor S1 may be provided closer to the winder 40 than the film thickness sensor FTS. Also, a film passage sensor may be provided at the exit side of the casting machine 30 and at the entrance side of the winding machine 40, respectively. Furthermore, generally, passing the resin film 83 through each device such as the casting machine 30 at the start of production is called "paper passing."

[0042] As described above, the resin film manufacturing apparatus according to the present embodiment includes a film passing sensor S1 provided on the inlet side of the winder 40 for detecting the passage of the resin film 83 that has been conveyed. Then, when the production of the resin film 83 is started, after the film passing sensor S1 detects that the resin film 83 has passed, the driving of the winder 40 is started. Therefore, in the resin film manufacturing apparatus according to the present embodiment, the winding of the resin film by the winder can be automatically started at the start of the production of the resin film.

[0043] <Configuration of the T-die 20> Here, with reference to FIGS. 3 and 4, the configuration of the T-die 20 will be described in more detail. FIG. 3 is a cross-sectional view of the T-die 20. Further, FIG. 4 is a partial perspective view of the lower side (lip side) of the T-die 20.

[0044] As shown in FIGS. 3 and 4, the T-die 20 is composed of a pair of die blocks 21 and 22 that are abutted against each other. Each of the pair of abutted die blocks 21 and 22 is provided with a tapered portion that slopes downward from the outer surface toward the inner surface (abutting surface). That is, thin lips 21a and 22a are provided at the lower ends of the abutting surfaces of the die blocks 21 and 22.

[0045] An inlet 20a, a manifold 20b, and a slit 20c are formed on the abutting surfaces of the pair of die blocks 21 and 22. The inlet 20a extends downward (in the negative z-axis direction) from the upper surface of the T-die 20. The manifold 20b extends in the positive y-axis direction and the negative y-axis direction from the lower end of the inlet 20a. In this way, in the T-die 20, the inlet 20a and the manifold 20b are formed in a T-shape.

[0046] Furthermore, a slit 20c extending from the bottom surface of the manifold 20b to the lower surface of the T-die 20 extends in the y-axis direction. The molten resin 82 is extruded downward from the inlet 20a and the manifold 20b through the slit 20c (that is, the gap between the lips 21a and 22a).

[0047] Here, lip 21a is a fixed lip that does not move, whereas lip 22a is a movable lip connected to adjustment bolt 23. Lip 22a has a notched groove 22b formed obliquely upward from the outer surface toward the mating surface. Lip 22a is pushed and pulled by adjustment bolt 23, and can move with the bottom of notched groove 22b as a fulcrum. In this way, only lip 22a is a movable lip, and therefore the lip spacing can be easily adjusted with a simple configuration.

[0048] 3 and 4, the adjustment bolt 23 extends obliquely upward along the tapered portion of the die block 22. The adjustment bolt 23 is supported by holders 25a and 25b fixed to the die block 22. More specifically, the adjustment bolt 23 is screwed into a threaded hole formed in the holder 25a. On the other hand, the adjustment bolt 23 is inserted into a through hole formed in the holder 25b, but is not screwed into the holder 25b. The holders 25a and 25b do not have to be separate from the die block 22 but may be formed integrally with the die block 22. The adjustment bolt 23 may be screwed into the holder 25b.

[0049] Here, as shown in Fig. 4, a plurality of adjustment bolts 23 are arranged along the longitudinal direction (y-axis direction) of the lips 21a, 22a. The longitudinal direction of the lips 21a, 22a corresponds to the width direction of the resin film. In the example of Fig. 4, three adjustment bolts 23 are provided, but usually more adjustment bolts 23 are provided.

[0050] A motor 24 is provided for each adjustment bolt 23 to adjust the tightening amount of the adjustment bolt 23. In the example shown in Figs. 3 and 4, the motor 24 is connected to the upper end of each adjustment bolt 23 via a connecting member 27. By tightening the adjustment bolt 23 with the motor 24, the lip 22a can be pushed by the lower end surface of the adjustment bolt 23. Furthermore, the lower end of the adjustment bolt 23 is connected to the lip 22a by a connecting member 26 with a U-shaped cross section fixed to the lip 22a. Therefore, by loosening the adjustment bolt 23 with the motor 24, the lip 22a can also be pulled via the connecting member 26.

[0051] The distance between the lips 21a, 22a can be adjusted by the amount of tightening of the adjustment bolt 23. Specifically, when the amount of tightening of the adjustment bolt 23 is increased, the adjustment bolt 23 presses the lip 22a, narrowing the distance between the lips 21a, 22a. Conversely, when the amount of tightening of the adjustment bolt 23 is decreased, the distance between the lips 21a, 22a becomes wider. The amount of tightening of each adjustment bolt 23, i.e., the amount of rotation of each motor 24, is also controlled by the controller 50.

[0052] There is also a known method of heating each adjustment bolt 23 with a heater provided in each adjustment bolt 23 and fine-tuning the lip gap depending on the amount of thermal expansion. Specifically, when the heating temperature of the adjustment bolt 23 is increased, the amount of thermal expansion increases, so that the adjustment bolt 23 presses the lip 22a and the lip gap becomes narrower. Conversely, when the heating temperature of the adjustment bolt 23 is decreased, the amount of thermal expansion decreases and the lip gap becomes wider. In such a method, the heating of each heater is also controlled by the controller 50.

[0053] <Overall configuration of the control method for the resin film manufacturing device> Next, the overall configuration of the control method for the resin film production apparatus according to the first embodiment at the start of resin film production will be described with reference to Fig. 2 and Fig. 5 to Fig. 9. Fig. 5 is a flowchart showing the overall configuration of the control method for the resin film production apparatus according to the first embodiment at the start of resin film production.

[0054] Fig. 6 to Fig. 9 are schematic cross-sectional views showing the resin film manufacturing apparatus in the control modes MD1 to MD4, respectively, in Fig. 5. Fig. 2 shows the resin film manufacturing apparatus in the control mode MD5 in Fig. 5. The resin film manufacturing apparatus shown in Fig. 5 is controlled by a controller 50, which is a computer. Each of the control modes MD1 to MD5 shown in Fig. 5 will be described in detail later.

[0055] First, as shown in FIGS. 5 and 6, the extruder 10 starts to be driven, and a film-shaped molten resin 82a is extruded from the T-die 20 at a predetermined pressure (control mode MD1). Next, as shown in Figs. 5 and 7, the casting machine 30 starts to be driven, and the resin film 83 is carried out from the cooling roll CL while a film-like molten resin 82a is supplied to the casting roll CS (control mode MD2).

[0056] 5 and 8, the winder 40 starts to be driven, and the resin film 83 is passed through and wound by the winder 40 (control mode MD3). Specifically, after the film passing sensor S1 shown in FIG. 8 detects that the resin film 83 has passed through, the controller 50 starts to drive the winder 40 at a predetermined timing.

[0057] 5 and 9, the film thickness of the resin film 83 is adjusted (control mode MD4). Specifically, the controller 50 feedback-controls the lip interval of the T die 20 based on the thickness distribution of the resin film 83 acquired from the film thickness sensor FTS shown in FIG.

[0058] 2 and 5, after the control mode MD4 for adjusting the thickness of the resin film 83 ends, the controller 50 switches to a control mode MD5 for manufacturing a product. That is, the production of the resin film 83 as a product is started.

[0059] <Details of control mode MD1> Next, the control mode MD1 in Fig. 5 will be described in detail with reference to Fig. 6 and Fig. 10. Fig. 10 is a flowchart showing the details of the control mode MD1 in Fig. 5. The control shown in Fig. 10 is executed by the controller 50, which is a computer. Here, "start of control mode MD1" in Fig. 10 corresponds to "start of production" in Fig. 5. For example, the control mode MD1 is started by an operation on the controller 50 by an operator, and the subsequent control is executed by the controller 50.

[0060] First, as shown in FIG. 10, the gear pump GP shown in FIG. 6 is started and operated at the minimum rotation speed (step S11). Next, as shown in FIG. 10, the screw 12 shown in FIG. 6, that is, the screw motor SM, is started and accelerated to a target rotation speed (step S12).

[0061] Next, as shown in FIG. 10, the raw material feeder 14, ie, the feeder motor FM shown in FIG. 6 is started to increase the supply amount of the raw material resin 81 to the cylinder 11 up to a target supply amount (step S13).

[0062] Then, when the pressure of the molten resin 82 reaches the target pressure, the pressure is controlled to be maintained at the target pressure (step S14). Specifically, the controller 50 feedback-controls the rotation speed of the gear pump GP so as to maintain the pressure of the molten resin 82 on the suction side of the gear pump GP, which is measured by the pressure sensor PS shown in FIG. 6, at a predetermined target pressure. This completes the control mode MD1. Of course, between each step of the process, a predetermined time may be determined by a timer or the like. The same applies below. Note that steps S12 to S14 may be repeatedly performed by increasing stepwise the target rotation speed of the screw in step S12, the target supply amount of the raw material in step S13, and the target pressure in step S14.

[0063] <Details of control mode MD2> Next, details of the control mode MD2 in Fig. 5 will be described with reference to Fig. 11 and Fig. 12. Fig. 11 is a flowchart showing details of the control mode MD2 in Fig. 5. Fig. 12 is a schematic cross-sectional view showing the casting machine 30 in step S21 in Fig. 11. The control shown in FIG. 11 is also executed by the controller 50, which is a computer.

[0064] First, as shown in FIG. 11, the casting machine 30 is started, a film-like molten resin 82a is supplied to the casting roll CS, and the conveyance of the resin film 83 from the cooling roll CL is started (step S21).

[0065] Here, an example of step S21 will be described with reference to Fig. 12. In the example shown in Fig. 12, the casting machine 30 includes a dummy film feeder FF, a dummy film cutter FC, nip rolls NR1 and NR2, and a temperature sensor TS, in addition to the cast roll CS and cooling roll CL shown in Fig. 2.

[0066] 12, before starting the casting machine 30, a dummy film DF1 for casting is passed through a cast roll CS and a cooling roll CL. Specifically, the dummy film DF1 supplied from a dummy film feeder FF is passed through the cast roll CS and the cooling roll CL, and the leading end of the dummy film DF1 is sandwiched between the cooling roll CL and the nip roll NR2. This operation is performed manually, for example, but may also be performed by a robot or the like.

[0067] When the temperature sensor TS detects the film-like molten resin 82a, the casting machine 30, i.e., the cast roll CS and the cooling roll CL, starts to rotate at a low speed. At this time, the nip roll NR1 presses the film-like molten resin 82a against the dummy film DF1 on the cast roll CS to stick it on. The dummy film DF1 is fed from the dummy film feeder FF in accordance with the rotation of the cast roll CS and the cooling roll CL.

[0068] Alternatively, the driving of the casting roll CS and the cooling roll CL may be started at a predetermined timing after the start of the control mode MD2 (in other words, after the completion of the control mode MD1) without detecting the film-like molten resin 82a by the temperature sensor TS. In other words, the temperature sensor TS may not be used.

[0069] Thereafter, when the film passing sensor S1 shown in Fig. 12 detects the resin film 83 carried out from the cooling roll CL, the dummy film DF1 is cut by the dummy film cutter FC. Here, for example, the width of the dummy film DF1 and the width of the resin film 83 are different, and multiple film passing sensors S1 are arranged in the depth direction of Fig. 12. Therefore, the film passing sensor S1 can detect the resin film 83 and distinguish it from the dummy film DF1. 11, the supply amount of the molten resin 82 is increased to a target value (step S22). With the above, the control mode MD2 is completed.

[0070] <Details of control mode MD3> Next, details of the control mode MD3 in Fig. 5 will be described with reference to Fig. 13 and Fig. 14. Fig. 13 is a flowchart showing details of the control mode MD3 in Fig. 5. Fig. 14 is a schematic cross-sectional view showing the casting machine 30 and the winding machine 40 in step S31 in Fig. 13. The control shown in FIG. 13 is also executed by the controller 50, which is a computer.

[0071] First, as shown in Fig. 13, the winder 40 is started and starts winding the resin film 83 under constant speed control (step S31). Specifically, the resin film 83 is detected by the film passing sensor S1, and the winder 40 is started at a predetermined timing after step S22 in Fig. 11.

[0072] Now, an example of step S31 will be described with reference to Fig. 14. In the example shown in Fig. 14, a winding film connection device FW1 that connects films together is provided between the film passing sensor S1 and the winding machine 40. The film connection device FW1 welds, for example, resin films together.

[0073] Before starting the winding machine 40 in step S31, the leading end of the winding dummy film DF2 is fixed to the winding machine 40. On the other hand, the trailing end of the dummy film DF2 is placed in the film splicing device FW1. This operation is, for example, a manual operation, but may also be performed by a robot or the like.

[0074] Then, after the film passing sensor S1 detects the resin film 83 carried out from the casting machine 30, the film connecting device FW1 connects the resin film 83 and the dummy film DF2 at a predetermined timing, and then starts the winding machine 40. Through this series of operations, the resin film 83 can be automatically passed through the winding machine 40, and winding of the resin film 83 can be automatically started.

[0075] Next, as shown in FIG. 13, after the tension due to the resin film 83 is detected in the winder 40, the control of the winder 40 is switched from constant rotation control to constant tension control (step S32). 13, the line operation conditions are changed to the set values ​​of the control mode MD3 (step S33). For example, the line speed is increased to the set value of the control mode MD3. This completes the control mode MD3.

[0076] <Details of control mode MD4> Next, the control mode MD4 in Fig. 5 will be described in detail with reference to Fig. 15. Fig. 15 is a flowchart showing the details of the control mode MD4 in Fig. 5. The control shown in FIG. 15 is also executed by the controller 50, which is a computer.

[0077] First, as shown in Fig. 15, the line operation conditions are changed to the set values ​​for film thickness adjustment (step S41). For example, the line speed is increased to the set value for film thickness adjustment. Next, as shown in Fig. 15, a film thickness adjustment is performed (step S42). Specifically, the controller 50 feedback-controls the lip interval of the T-die 20 based on the thickness distribution of the resin film 83 acquired from the film thickness sensor FTS shown in Fig. 9.

[0078] 15, if the thickness of the resin film 83 is not within the predetermined range (NO in step S43), the film thickness adjustment in step S42 is continued. On the other hand, if the thickness of the resin film 83 is within the predetermined range (YES in step S43), the control mode MD4, i.e., the film thickness adjustment, is completed. The line speed may be increased stepwise up to a set value for adjusting the film thickness, and steps S41 to S43 may be repeated.

[0079] <Details of control mode MD5> Next, the control mode MD5 in Fig. 5 will be described in detail with reference to Fig. 16. Fig. 16 is a flowchart showing the details of the control mode MD5 in Fig. 5. The control shown in FIG. 16 is also executed by the controller 50, which is a computer.

[0080] First, as shown in Fig. 16, the line operation conditions are changed to the set values ​​for product production (step S51). For example, the line speed is increased to the set value for product production. Next, as shown in Fig. 16, the control method of the extruder 10 is switched from the control method at the start of production to the control method for product production (step S52). With the above, the control mode MD5 is completed.

[0081] As described above, in the control method of the extruder 10 at the start of production, the rotation speed of the gear pump GP is feedback-controlled so as to maintain the pressure of the molten resin 82 on the suction side of the gear pump GP at a target pressure. On the other hand, in the control method of the extruder 10 during product production, the supply amount of the resin raw material 81 from the raw material feeder 14 and the rotation speed of the screw 12 are feedback-controlled so as to maintain the pressure of the molten resin 82 on the suction side of the gear pump GP at a target pressure. At that time, the rotation speed of the gear pump GP is fixed. In FIG. 16, the completion of the control mode MD5 means the continuation of product manufacturing.

[0082] (Embodiment 2) <Overall configuration of resin film manufacturing equipment> Next, the overall configuration of a resin film manufacturing apparatus according to a second embodiment will be described with reference to Fig. 17 and Fig. 18. Fig. 17 is a schematic perspective view showing the overall configuration of a resin film manufacturing apparatus according to a second embodiment. Fig. 18 is a schematic cross-sectional view showing the overall configuration of a resin film manufacturing apparatus according to a first embodiment.

[0083] 17 and 18, the resin film manufacturing apparatus according to this embodiment further includes a longitudinal stretching machine 60 and a transverse stretching machine 70 between the casting machine 30 and the winding machine 40 shown in Fig. 1 and Fig. 2. In detail, the longitudinal stretching machine 60 is provided downstream of the casting machine 30, and the transverse stretching machine 70 is provided downstream of the longitudinal stretching machine 60.

[0084] As shown in Fig. 17 and Fig. 18, the longitudinal stretching machine 60 stretches the resin film 83 discharged from the casting machine 30 in the longitudinal direction while transporting the same. The longitudinal stretching machine 60 illustrated in Fig. 17 and Fig. 18 includes five rolls R1 to R5. Each of the rolls R1 to R5 is a driving roll driven by a driving source (not shown). The driving source is, for example, a variable speed motor such as a servo motor.

[0085] The longitudinal stretching machine 60 only needs to include a plurality of drive rolls for transporting the resin film 83, and the number and arrangement of the drive rolls included in the longitudinal stretching machine 60 are appropriately determined. Each of the rolls R1 to R5 may be provided with at least one of a cooling mechanism for cooling the resin film 83 and a heating mechanism for heating the resin film 83. Furthermore, the longitudinal stretching machine 60 may include one or more nip rolls for pressing the resin film 83 against any of the rolls R1 to R5. The nip rolls are not drive rolls.

[0086] 17, the transverse stretching machine 70 stretches the resin film 83 discharged from the longitudinal stretching machine 60 in its width direction (y-axis direction). More specifically, the transverse stretching machine 70 includes a pair of rails RL1 and RL2. A large number of clips (not shown) are slidably arranged in parallel over the entire rails RL1 and RL2.

[0087] In Fig. 17, the arrows on the rails RL1 and RL2 indicate the movement direction of the clip. As shown in Fig. 17, the rails RL1 and RL2 have a loop structure with an outward path along which the clip moves in the conveying direction of the resin film 83 (positive direction of the x-axis) and a return path along which the clip moves in the opposite direction (negative direction of the x-axis). That is, in the transverse stretching machine 70, the clip goes around along the rails RL1 and RL2 having the loop structure. As shown in FIG. 17, the rails RL1 and RL2 have a configuration symmetrical with respect to a plane parallel to the xz plane.

[0088] 17, in rails RL1 and RL2, the outgoing path proceeding in the conveyance direction (positive direction of the x-axis) and the returning path proceeding in the opposite direction (negative direction of the x-axis) are arranged substantially parallel to each other. The returning path of rail RL1 is arranged on the outer side in the width direction of resin film 83 (negative direction of the y-axis). The returning path of rail RL2 is also arranged on the outer side in the width direction of resin film 83 (positive direction of the y-axis).

[0089] As shown in Fig. 17, the outward paths of rails RL1 and RL2 have a pair of parallel portions parallel to the x-axis at both ends in the longitudinal direction (x-axis direction), and an inclined portion inclined in the y-axis direction between the parallel portions. The inclined portion of rail RL1 is inclined in the negative direction of the y-axis, and the inclined portion of rail RL2 is inclined in the positive direction of the y-axis. That is, in the inclined portions of the outward paths of rails RL1 and RL2, the distance between rails RL1 and RL2 in the y-axis direction becomes wider as the rails progress in the positive direction of the x-axis.

[0090] 17, in the portions where the clips come into contact with the resin film 83, the clips move in the positive x-axis direction along the rails RL1, RL2 while gripping both ends of the resin film 83 in the width direction (y-axis direction). Therefore, as shown in FIG 17, in the oblique portions of the outward passes of the rails RL1, RL2, the resin film 83 is stretched in the width direction (y-axis direction) while being transported in the positive x-axis direction.

[0091] 17, in the portions of the rails RL1, RL2 that are not in contact with the resin film 83, the clips move along the rails RL1, RL2 without gripping the resin film 83. More specifically, the clips grip the resin film 83 at the entrance of the transverse stretching machine 70, i.e., the rear ends (ends on the negative x-axis direction side) of the rails RL1, RL2, and move in the positive x-axis direction along the rails RL1, RL2 while gripping the resin film 83. Then, the clips release the resin film 83 at the exit of the transverse stretching machine 70, i.e., the front ends (ends on the positive x-axis direction side) of RL1, RL2. 1 also has a drive source that drives clips for transporting the resin film 83. The drive source is, for example, a variable speed motor such as a servo motor.

[0092] <Configuration and Operation of Controller 50> In this embodiment, when the production of the resin film 83 starts, the controller 50 detects that the resin film 83 has passed by the film passing sensor S2 shown in FIG. 18, and then starts driving the longitudinal stretching machine 60 at a predetermined timing.

[0093] Here, the film passing sensor S2 is a film passing sensor for longitudinal stretching that is provided on the entrance side of the longitudinal stretching machine 60 and detects the passage of the resin film 83 conveyed at the start of production. On the other hand, the film passing sensor S2 is provided on the exit side of the casting machine 30 instead of the film passing sensor S1 in Fig. 2 and can also be said to detect the passage of the resin film 83 through the casting machine 30 at the start of production. A film passage sensor may be provided at the outlet side of the casting machine 30 and at the inlet side of the longitudinal stretching machine 60, respectively.

[0094] In this way, the resin film manufacturing apparatus according to this embodiment is provided with a film passing sensor S2 that is provided on the entrance side of the longitudinal stretching machine 60 and detects the passage of the transported resin film 83. Then, when the production of the resin film 83 starts, the film passing sensor S2 detects that the resin film 83 has passed, and then the longitudinal stretching machine 60 starts to be driven. Therefore, in the resin film manufacturing apparatus according to this embodiment, the longitudinal stretching machine can automatically start stretching the resin film in the longitudinal direction when the production of the resin film starts.

[0095] In addition, in this embodiment, when production of the resin film 83 starts, the controller 50 detects that the resin film 83 has passed by the film passing sensor S3 shown in FIG. 18, and then starts gripping the resin film 83 by the transverse stretching machine 70 at a predetermined timing.

[0096] Here, the film passing sensor S3 is a film passing sensor for transverse stretching that is provided on the entrance side of the transverse stretching machine 70 and detects the passage of the resin film 83 conveyed at the start of production. On the other hand, the film passing sensor S3 is provided on the exit side of the longitudinal stretching machine 60 and can be said to detect the passage of the resin film 83 through the longitudinal stretching machine 60 at the start of production. A film passage sensor may be provided at the exit side of the longitudinal stretching machine 60 and at the entrance side of the transverse stretching machine 70, respectively.

[0097] As described above, the resin film manufacturing apparatus according to this embodiment includes a film passing sensor S3 that is provided on the entrance side of the transverse stretching machine 70 and detects the passage of the transported resin film 83. Then, when the production of the resin film 83 starts, the film passing sensor S3 detects that the resin film 83 has passed, and then the transverse stretching machine 70 starts gripping the resin film 83. Therefore, in the resin film manufacturing apparatus according to this embodiment, the transverse stretching machine can automatically start stretching the resin film in the width direction when the production of the resin film starts.

[0098] Furthermore, in this embodiment, similarly to the first embodiment, when production of the resin film 83 starts, the controller 50 starts driving the winding machine 40 at a predetermined timing after the film passing sensor S1 shown in Fig. 18 detects that the resin film 83 has passed. That is, the winding machine 40 starts winding the resin film 83.

[0099] Here, even in this embodiment, the film passing sensor S1 is a winding film passing sensor that is provided on the entrance side of the winding machine 40 and detects the passage of the resin film 83 conveyed at the start of production. On the other hand, in this embodiment, the film passing sensor S1 is provided on the exit side of the transverse stretching machine 70, which can also be said to detect that the resin film 83 has passed through the transverse stretching machine 70 at the start of production. A film passage sensor may be provided at the exit side of the transverse stretching machine 70 and at the entrance side of the winding machine 40, respectively.

[0100] In this way, the resin film production apparatus according to this embodiment also includes a film passage sensor S1 that is provided on the entrance side of the winding machine 40 and detects the passage of the transported resin film 83. Then, when production of the resin film 83 starts, the film passage sensor S1 detects that the resin film 83 has passed, and then the winding machine 40 starts to operate. Therefore, in the resin film production apparatus according to this embodiment, the winding machine can automatically start winding up the resin film when production of the resin film starts.

[0101] As described above, the resin film production apparatus according to this embodiment includes film passing sensors S2, S3, and S1 that detect the passage of the transported resin film 83 at the inlet sides of the longitudinal stretching machine 60, the transverse stretching machine 70, and the winding machine 40, respectively. When production of the resin film 83 is started, the film passing sensors S2, S3, and S1 detect the passage of the resin film 83, and then driving of the longitudinal stretching machine 60, gripping of the resin film 83 by the transverse stretching machine 70, and driving of the winding machine 40 are started in this order.

[0102] Therefore, in the resin film manufacturing apparatus according to this embodiment, when the production of the resin film starts, the longitudinal stretching machine, transverse stretching machine, and winding machine can automatically start longitudinal stretching, transverse stretching, and winding of the resin film in sequence. The other configuration is similar to that of the resin film manufacturing apparatus according to the first embodiment shown in FIG. 2, and therefore description thereof will be omitted.

[0103] <Overall configuration of the control method for the resin film manufacturing device> Next, the overall configuration of the control method for the resin film production apparatus according to the second embodiment at the start of resin film production will be described with reference to Figures 18 to 23. Figure 19 is a flowchart showing the overall configuration of the control method for the resin film production apparatus according to the second embodiment at the start of resin film production.

[0104] As shown in FIG. 19, the control method for a resin film manufacturing apparatus according to this embodiment further includes control modes MD6 and MD7 between the control modes MD2 and MD3 shown in FIG.

[0105] Figures 20 and 21 are schematic cross-sectional views showing the resin film manufacturing apparatus in control modes MD6 and MD7, respectively, in Figure 19. Figures 22 and 23 are schematic cross-sectional views showing the resin film manufacturing apparatus in control modes MD3 and MD4, respectively, in Figure 19. Figure 18 shows the resin film manufacturing apparatus in control mode MD5 in Figure 19.

[0106] 19 is controlled by a controller 50, which is a computer. The control modes MD6 and MD7 added in this embodiment will be described in detail later. Moreover, the control modes MD1 and MD2 shown in FIG. 19 are common to the control modes MD1 and MD2 shown in FIG. 5, and therefore a detailed description thereof will be omitted.

[0107] 19 and 20, after control mode MD2, the driving of the longitudinal stretching machine 60 is started, and the resin film 83 is passed through the longitudinal stretching machine 60 to stretch the resin film 83 in the longitudinal direction (control mode MD6). Specifically, the controller 50 detects the resin film 83 conveyed out of the casting machine 30 by the film passing sensor S2 shown in FIG. 20, and then starts driving the longitudinal stretching machine 60 at a predetermined timing.

[0108] 19 and 21, the resin film 83 is passed through the transverse stretching machine 70 to stretch the resin film 83 in the width direction (control mode MD7). Specifically, the controller 50 detects the resin film 83 discharged from the longitudinal stretching machine 60 by the film passing sensor S3 shown in FIG. 21, and then starts holding the resin film 83 by the transverse stretching machine 70 at a predetermined timing.

[0109] 19 and 22, the winder 40 is started to be driven, and the resin film 83 is passed through and wound by the winder 40 (control mode MD3). Specifically, the controller 50 detects the resin film 83 conveyed out of the transverse stretching machine 70 by the film passing sensor S1 shown in FIG. 22, and then starts driving the winder 40 at a predetermined timing.

[0110] 19 and 23, the film thickness of the resin film 83 is adjusted (control mode MD4). Specifically, the controller 50 feedback controls the lip interval of the T-die 20 based on the thickness distribution of the resin film 83 acquired from the film thickness sensor FTS shown in FIG. 23. In this embodiment, the film thickness sensor FTS measures the widthwise thickness distribution of the resin film 83 during transport carried out from the transverse stretching machine 70. A film thickness sensor may be further provided at least one of the outlets of the casting machine 30 and the longitudinal stretching machine 60.

[0111] 18 and 19, after the control mode MD4 for adjusting the thickness of the resin film 83 ends, the controller 50 switches to a control mode MD5 for manufacturing a product. That is, the production of the resin film 83 as a product is started.

[0112] <Details of control mode MD6> Next, details of the control mode MD6 in Fig. 19 will be described with reference to Fig. 24 and Fig. 25. Fig. 24 is a flowchart showing details of the control mode MD6 in Fig. 19. Fig. 25 is a schematic cross-sectional view showing the casting machine 30 and the longitudinal stretching machine 60 in step S61 in Fig. 24. The control shown in FIG. 24 is also executed by the controller 50, which is a computer.

[0113] 24, the longitudinal stretching machine 60 is started, and the resin film 83 is passed through the longitudinal stretching machine 60 (step S61). Specifically, after the resin film 83 conveyed out from the casting machine 30 is detected by the film passing sensor S2, the longitudinal stretching machine 60 is started at a predetermined timing.

[0114] Here, an example of step S61 will be described with reference to Fig. 25. In the example shown in Fig. 25, a film connection device FW2 for longitudinal stretching that connects films together is provided between the film passing sensor S2 and the longitudinal stretching machine 60. The film connection device FW2 welds, for example, resin films together, in the same manner as the film connection device FW1.

[0115] Prior to starting the longitudinal stretching machine 60 in step S61, the leading end of the dummy film DF3 for longitudinal stretching is sandwiched between the roll R5 and the nip roll NR3 at the rear end of the longitudinal stretching machine 60. On the other hand, the rear end of the dummy film DF3 is placed in the film splicing device FW2. This operation is, for example, a manual operation, but may also be performed by a robot or the like.

[0116] Then, after the resin film 83 is detected by the film passing sensor S2, the resin film 83 and the dummy film DF3 are connected by the film connecting device FW2 at a predetermined timing, and then the longitudinal stretching machine 60 is started. By this series of operations, the resin film 83 can be automatically passed through the longitudinal stretching machine 60, and the longitudinal stretching of the resin film 83 can be automatically started.

[0117] 25, the resin film 83 discharged from the casting machine 30 is conveyed to the film splicing device FW2 by the conveyor CV1. The conveyor CV1 is driven by a conveyor motor CM1. The conveyor motor CM1 is controlled by the controller 50.

[0118] It should be noted that the conveyor CV1 shown in Fig. 25 is not essential. On the other hand, in Fig. 14, the resin film 83 carried out from the casting machine 30 may be transported to the film connecting device FW1 by a conveyor (not shown).

[0119] Next, as shown in Fig. 24, when the resin film 83 conveyed out of the longitudinal stretching machine 60 is detected by the film passing sensor S3 shown in Fig. 25, the line operation conditions are changed to the set values ​​of the control mode MD6 (step S62). For example, the line speed is increased to the set value of the control mode MD6. With the above, the control mode MD6 is completed.

[0120] <Details of control mode MD7> Next, details of the control mode MD7 in Fig. 19 will be described with reference to Fig. 26 and Fig. 27. Fig. 26 is a flowchart showing details of the control mode MD7 in Fig. 19. Fig. 27 is a schematic cross-sectional view showing the longitudinal stretching machine 60 and the transverse stretching machine 70 in step S71 in Fig. 26. The control shown in FIG. 26 is also executed by the controller 50, which is a computer.

[0121] 26, the resin film 83 is gripped at the entrance of the transverse stretching machine 70 (step S71). Specifically, after the film passing sensor S3 detects the resin film 83 conveyed out of the longitudinal stretching machine 60, the transverse stretching machine 70 starts gripping the resin film 83 at a predetermined timing. Before step S71, the transverse stretching machine 70 is started, and the clips are rotating along the rails RL1 and RL2.

[0122] Here, an example of step S71 will be described with reference to Fig. 27. In the example shown in Fig. 27, a film connection device FW3 for transverse stretching that connects films together is provided between the film passing sensor S3 and the transverse stretching machine 70. The film connection device FW3 welds, for example, resin films together, in the same manner as the film connection device FW1.

[0123] 27, before step S71, the leading end of the dummy film DF4 for transverse stretching is placed at the entrance of the transverse stretching machine 70. On the other hand, the trailing end of the dummy film DF4 is placed at the film splicing device FW3. This operation is, for example, a manual operation, but may also be performed by a robot or the like.

[0124] 27, the dummy film DF4 is placed on a conveyor CV2 extending from the film splicing device FW3 to the entrance of the transverse stretching machine 70. The conveyor CV2 can transport the dummy film DF4 while sucking it with a suction blower SB. The conveyor CV2 is driven by a conveyor motor CM2. The conveyor motor CM2 and the suction blower SB are controlled by a controller 50.

[0125] Then, after the resin film 83 is detected by the film passing sensor S3, the resin film 83 and the dummy film DF4 are connected by the film connecting device FW3 at a predetermined timing, and then the conveyor CV2 is started and the transverse stretching machine 70 starts to grip the resin film 83. By this series of operations, the resin film 83 can be automatically passed through the transverse stretching machine 70, and the transverse stretching of the resin film 83 can be automatically started.

[0126] More specifically, by the above series of operations, the dummy film DF4 connected to the resin film 83 is conveyed by the conveyor CV2, while the leading end of the dummy film DF4 is held by a clip at the entrance of the transverse stretching machine 70. Thereafter, when it is determined that the resin film 83 is held by the clip, for example, after a predetermined time has elapsed, the conveyor motor CM2 and the suction blower SB are stopped.

[0127] 27, the resin film 83 discharged from the casting machine 30 may be transported to the film connecting device FW3 by a conveyer (not shown). In addition, a sensor for confirming that the resin film 83 is gripped by the clip may be provided separately at the entrance of the transverse stretching machine 70.

[0128] Next, as shown in FIG. 26, while the resin film 83 is being passed through the transverse stretching machine 70, the line speed is increased to the set value of the control mode MD7 (step S72). Then, as shown in FIG. 26, after the resin film 83 conveyed out of the transverse stretching machine 70 is detected by the film passing sensor S1 shown in FIG. 27 (step S73), the control mode MD7 is completed.

[0129] <Details of control mode MD3> Next, the control mode MD3 in Fig. 19 will be described in detail with reference to Fig. 13 and Fig. 28. Fig. 13 is common to the first embodiment. Fig. 28 is a schematic cross-sectional view showing the transverse stretching machine 70 and the winding machine 40 at step S31 in Fig. 13 in the second embodiment.

[0130] First, as shown in Fig. 13, the winder 40 is started and starts winding the resin film 83 under constant rotation control (step S31). Specifically, after step S73 in Fig. 26 in which the film passing sensor S1 detects the resin film 83, the winder 40 is started at a predetermined timing.

[0131] Here, an example of step S31 in this embodiment will be described with reference to Fig. 28. In the example shown in Fig. 28, a winding film connection device FW1 that connects the films together is provided between the film passing sensor S1 and the winding machine 40.

[0132] Before starting the winding machine 40 in step S31, the leading end of the dummy film DF2 is fixed to the winding machine 40. On the other hand, the trailing end of the dummy film DF2 is placed in the film splicing device FW1. This operation is, for example, a manual operation, but may also be performed by a robot or the like.

[0133] Then, after the film passing sensor S1 detects the resin film 83 conveyed out of the transverse stretching machine 70, the film connecting device FW1 connects the resin film 83 and the dummy film DF2 at a predetermined timing, and then starts the winding machine 40. Through this series of operations, the resin film 83 can be automatically passed through the winding machine 40, and winding of the resin film 83 can be automatically started.

[0134] The subsequent steps S32 and S33 shown in FIG. 13 are the same in this embodiment as in the first embodiment, and therefore the description thereof will be omitted. The details of the control modes MD4 and MD5 are similar to those of the first embodiment shown in Figs. 15 and 16, and therefore a detailed description thereof will be omitted. The other configurations are similar to those of the first embodiment, so the description will be omitted. In this embodiment, only one of the longitudinal stretching machine 60 and the transverse stretching machine 70 may be provided. On the other hand, at least one of the longitudinal stretching machine 60 and the transverse stretching machine 70 may be provided in plurality.

[0135] In the above examples, the program includes instructions (or software code) that, when loaded into a computer, cause the computer to perform one or more functions described in the embodiments. The program may be stored on a non-transitory computer-readable medium or a tangible storage medium. By way of example and not limitation, the computer-readable medium or tangible storage medium includes random-access memory (RAM), read-only memory (ROM), flash memory, solid-state drive (SSD) or other memory technology, CD-ROM, digital versatile disc (DVD), Blu-ray® disk or other optical disk storage, magnetic cassette, magnetic tape, magnetic disk storage or other magnetic storage device. The program may be transmitted on a transitory computer-readable medium or communication medium. By way of example and not limitation, the transitory computer-readable medium or communication medium includes electrical, optical, acoustic, or other forms of propagated signals.

[0136] The invention made by the present inventor has been specifically described above based on an embodiment, but it goes without saying that the present invention is not limited to the embodiment already described, and various modifications are possible without departing from the gist of the invention. [Explanation of symbols]

[0137] 10 Extruder 11 Cylinders 12 Screw 13 Hopper 14 Raw material feeder 20 T die 20a Introduction 20b manifold 20c slit 21, 22 Die Block 21a, 22a Lip 22b Notch groove 23 Adjustment bolt 24 Motor 25a, 25b holder 26 Connecting members 27 Connecting members 30 Casting Machine 40 Winder 50 Controller 60 Longitudinal stretching machine 70 Lateral stretching machine 81 Resin raw materials 82 Molten Resin 82a Film-like molten resin 83 Resin Film CL Cooling Roll CM1, CM2 Conveyor motor CS Cast Roll CV1, CV2 Conveyors DF1~DF4 Dummy Film FC Dummy Film Cutter FF Dummy Film Feeder FH Feeder hopper FM Feeder Motor FS Feeder Screw FTS Film Thickness Sensor FW1~FW3 Film Connection Device GP Gear Pump NR1~NR3 Nip roll PS Pressure Sensor R1~R5 Roll RL1, RL2 rails S1~S3 Film passing sensor SB Suction Blower SM Screw Motor TS Temperature Sensor

Claims

1. an extruder that melts and extrudes the input resin raw material; a die connected to the extruder for forming the molten resin into a film; A casting machine including a cast roll that cools the film-like molten resin extruded from the die and carries out a resin film solidified from the molten resin; a winding machine for winding up the produced resin film; a winding film passage sensor provided on an inlet side of the winding machine for detecting passage of the transported resin film; A controller for controlling the production of the resin film, When the production of the resin film is started, the controller After the winding film passage sensor detects that the resin film has passed, the winding machine is started to be driven. Resin film manufacturing equipment.

2. a winding film connection device provided between the winding film passage sensor and the winding machine for connecting the films, When the production of the resin film is started, the controller the resin film detected by the winding film passing sensor and a winding dummy film fixed in advance to the winding machine are connected by the winding film connecting device, and then the winding machine is started to be driven. The resin film manufacturing apparatus according to claim 1 .

3. The winding film connection device welds the winding dummy film and the resin film together. The resin film manufacturing apparatus according to claim 2 .

4. The controller: When the winding machine starts to be driven, the winding machine is controlled to have a constant speed. After detecting the tension in the winding machine, control of the winding machine is switched to constant tension control. The resin film manufacturing apparatus according to any one of claims 1 to 3.

5. a longitudinal stretching machine provided downstream of the casting machine and stretching the resin film in a longitudinal direction; A longitudinal stretching film passage sensor is provided on the inlet side of the longitudinal stretching machine and detects the passage of the transported resin film, When the production of the resin film is started, the controller After detecting that the resin film has passed by the longitudinal stretching film passage sensor, the operation of the longitudinal stretching machine is started. The resin film manufacturing apparatus according to any one of claims 1 to 3.

6. A longitudinal stretching film connection device is provided between the longitudinal stretching film passing sensor and the longitudinal stretching machine, and connects the films together, When the production of the resin film is started, the controller The resin film detected by the longitudinal stretching film passing sensor and a longitudinal stretching dummy film previously fixed to the longitudinal stretching machine are connected by the longitudinal stretching film connecting device, and then the longitudinal stretching machine is started to be driven. The resin film manufacturing apparatus according to claim 5 .

7. The longitudinal stretching film connection device welds the longitudinal stretching dummy film and the resin film together, The resin film manufacturing apparatus according to claim 6.

8. a transverse stretching machine provided downstream of the longitudinal stretching machine and stretching the resin film in a width direction; A transverse stretching film passage sensor is provided on the inlet side of the transverse stretching machine and detects the passage of the transported resin film, When the production of the resin film is started, the controller After the transverse stretching film passing sensor detects that the resin film has passed, the transverse stretching machine starts holding the resin film. The resin film manufacturing apparatus according to claim 5 .

9. A film connection device for transverse stretching is provided between the film passing sensor for transverse stretching and the transverse stretching machine, and connects the films to each other. When the production of the resin film is started, the controller The resin film detected by the film passing sensor for transverse stretching and a dummy film for transverse stretching extended to an entrance of the transverse stretching machine are connected by the film connecting device for transverse stretching, and then the transverse stretching machine starts to grip the resin film. The resin film manufacturing apparatus according to claim 8.

10. The film connection device for transverse stretching welds the dummy film for transverse stretching and the resin film together. The resin film manufacturing apparatus according to claim 9 .

11. an extruder that melts and extrudes the input resin raw material; a die connected to the extruder for forming the molten resin into a film; A casting machine including a cast roll that cools the film-like molten resin extruded from the die and carries out a resin film solidified from the molten resin; A control method for a resin film manufacturing apparatus including a winding machine that winds up the manufactured resin film, When the production of the resin film is started, the computer (a) executing a step of starting operation of the winding machine after detecting that the resin film has passed by a winding film passage sensor provided on an inlet side of the winding machine; A method for controlling a resin film manufacturing apparatus.

12. a winding film connection device provided between the winding film passage sensor and the winding machine for connecting the films, In step (a), the resin film detected by the winding film passing sensor and a winding dummy film fixed in advance to the winding machine are connected by the winding film connecting device, and then the winding machine is started to be driven. A method for controlling the resin film manufacturing apparatus according to claim 11.

13. In step (a), The winding film connection device welds the winding dummy film and the resin film together. A method for controlling the resin film production apparatus according to claim 12.

14. In step (a), When the winding machine starts to be driven, the winding machine is controlled to have a constant speed. After detecting the tension in the winding machine, control of the winding machine is switched to constant tension control. A method for controlling the resin film production apparatus according to any one of claims 11 to 13.

15. The resin film manufacturing apparatus comprises: The apparatus further includes a longitudinal stretching machine provided downstream of the casting machine and stretching the resin film in a longitudinal direction, When the production of the resin film is started, the computer Prior to step (a), (b) performing a step of starting the operation of the longitudinal stretching machine after detecting the passage of the resin film by a longitudinal stretching film passage sensor provided on the inlet side of the longitudinal stretching machine; A method for controlling the resin film production apparatus according to any one of claims 11 to 13.

16. The resin film manufacturing apparatus comprises: A longitudinal stretching film connection device is provided between the longitudinal stretching film passing sensor and the longitudinal stretching machine, and connects the films together, In step (b), The resin film detected by the longitudinal stretching film passing sensor and a longitudinal stretching dummy film previously fixed to the longitudinal stretching machine are connected by the longitudinal stretching film connecting device, and then the longitudinal stretching machine is started to be driven. A method for controlling the resin film production apparatus according to claim 15.

17. In step (b), The longitudinal stretching film connection device welds the longitudinal stretching dummy film and the resin film together, A method for controlling the resin film production apparatus according to claim 16.

18. The resin film manufacturing apparatus comprises: The apparatus further includes a transverse stretching machine provided downstream of the longitudinal stretching machine and stretching the resin film in a width direction, When the production of the resin film is started, the computer After step (b) and before step (a), (c) performing a step of starting to grip the resin film by the transverse stretching machine after detecting that the resin film has passed by a film passage sensor for transverse stretching provided on the inlet side of the transverse stretching machine; A method for controlling the resin film production apparatus according to claim 15.

19. The resin film manufacturing apparatus comprises: A film connection device for transverse stretching is provided between the film passing sensor for transverse stretching and the transverse stretching machine, and connects the films to each other. In step (c), The resin film detected by the film passing sensor for transverse stretching and a dummy film for transverse stretching extended to an entrance of the transverse stretching machine are connected by the film connecting device for transverse stretching, and then the transverse stretching machine starts to grip the resin film. A method for controlling the resin film production apparatus according to claim 18.

20. In step (c), The film connection device for transverse stretching welds the dummy film for transverse stretching and the resin film together. A method for controlling the resin film production apparatus according to claim 19.

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