Device and method for manufacturing glass roll

Abstract

To improve productivity when manufacturing a glass roll.SOLUTION: A glass roll manufacturing device 2 for taking up a glass ribbon 1 and obtaining a glass roll 25 comprises: a take-up unit 12 provided with a winding core support 16 that supports a winding core 10 for taking up, in a rolled shape, the glass ribbon 1 stacked on a protective sheet 5 in a take-up area 3 disposed at the downstream end of a conveyance path of the glass ribbon 1 and a sheet roll support 17 that supports a sheet roll 11 having the protective sheet 5 wound in a rolled shape, which are integrally movable; and a transfer mechanism 38 for transferring the take-up unit 12 by units between the take-up area 3 and a retreat area 39 away from the take-up area 3.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present disclosure relates to an apparatus and a method for manufacturing a glass roll.

Background Art

[0002] A glass roll is manufactured based on an ultra-thin glass ribbon (for example, having a thickness of 200 μm or less). Patent Document 1 discloses an example of a form for manufacturing a glass roll from a glass ribbon.

[0003] In this form, first, an ultra-thin glass ribbon is formed using the down-draw method. Next, the conveyance direction of the formed glass ribbon is changed from the longitudinal direction to the lateral direction. Then, unnecessary portions are cut off and removed from the glass ribbon being conveyed in the lateral direction. Finally, in a winding area arranged at the downstream end of the conveyance path of the glass ribbon, the glass ribbon is wound around a winding core in a state of being overlapped with a protective sheet to form a glass roll. The protective sheet is supplied from a sheet roll in which the protective sheet before being overlapped with the glass ribbon is wound in a roll shape.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] When manufacturing a glass roll by winding a glass ribbon in the above-described form, there is a problem that the productivity of the glass roll decreases due to poor maintainability of the manufacturing equipment arranged in the winding area.

[0006] As an example of manufacturing equipment, a power device that is connected to the shaft of the core and applies torque to rotate the core can be mentioned. Near the power device, a member for supporting the core (hereinafter referred to as the core support member), a member for supporting the sheet roll (hereinafter referred to as the sheet roll support member), etc. are arranged. The core support member is a member for placing the core before and after the start and completion of winding of the glass ribbon. The sheet roll support member is a member for placing the sheet roll before and after the start and completion of winding of the glass ribbon.

[0007] When performing maintenance work on the power device, it is necessary to evacuate all of the core, the core support member, the sheet roll, and the sheet roll support member from the winding area (near the power device) so as not to interfere with the work. However, no means have been taken to evacuate all of these together, and the time required for evacuation has become long, resulting in poor maintainability of the power device. This has led to a decrease in the productivity of the glass roll.

[0008] In view of the above circumstances, the technical problem to be solved is to increase the productivity in manufacturing the glass roll.

Means for Solving the Problem

[0009] The manufacturing apparatus for a glass roll for solving the above problems is a manufacturing apparatus for a glass roll for winding a glass ribbon to obtain a glass roll, and in a winding area arranged at the downstream end of the conveyance path of the glass ribbon, a core support section for supporting a core for winding the glass ribbon in a roll state in a state of being overlapped with a protective sheet, and a sheet roll support section for supporting a sheet roll around which the protective sheet is wound in a roll state, and includes a winding unit that is integrally movable, and further includes a transfer mechanism for transferring the winding unit in unit units between the winding area and a retracted area away from the winding area.

[0010] The manufacturing apparatus for this glass roll includes a take-up unit that integrally and movably supports a core and a sheet roll support portion that supports a sheet roll. The take-up unit can be transferred in unit form between a take-up area and a retracted area away from the take-up area by a transfer mechanism that transfers the unit. This can improve the maintainability of manufacturing equipment (for example, the power device described above) arranged in the take-up area. Specifically, when performing maintenance work on the manufacturing equipment, in order not to interfere with the work, when retracting all of the core, the core support portion, the sheet roll, and the sheet roll support portion from the take-up area (near the manufacturing equipment), it is possible to retract them together in unit form. Therefore, the time required for retraction can be shortened, and the maintainability of the manufacturing equipment can be improved. As a result, the productivity of the glass roll can be increased.

[0011] In the above configuration, it is preferable to provide a plurality of take-up units.

[0012] By doing so, it becomes possible to further improve the productivity of the glass roll. This is due to the following reasons. When a glass roll with a glass ribbon of the desired length wound thereon is completed, in order to start manufacturing a new glass roll, for example, the following preparatory operations (1) to (3) need to be carried out. (1) Remove the core on which the glass ribbon has been wound from the winding unit and attach an empty core for starting the winding of a new glass ribbon to the winding unit. (2) Remove the sheet roll that has been used for winding the glass ribbon from the winding unit and attach an unused sheet roll for use in winding a new glass ribbon to the winding unit. (3) After fixing the end of the protective sheet on the unused sheet roll to the empty core, wind the protective sheet while applying tension around the empty core (for example, for several turns). A corresponding amount of time is required to complete all of the above preparatory operations (1) to (3). Therefore, if there is only a single winding unit, during the long period until all the preparatory operations are completed, the production of the glass roll has to be interrupted. In this case, the productivity of the glass roll is likely to decrease. On the other hand, if there are multiple winding units, while one of the multiple winding units is being used for manufacturing the glass roll in the winding area, for the other winding units, the above preparatory operations can be carried out in the evacuation area. As a result, when a glass roll is completed by one winding unit, it becomes possible to have the other winding units in a state where the preparatory operations are completed. For this reason, after evacuating one winding unit from the winding area, simply advancing another winding unit into the winding area enables the start of manufacturing a new glass roll. Consequently, it becomes possible to further improve the productivity of the glass roll. Needless to say, of course, the time required to advance another winding unit into the winding area after evacuating one winding unit from the winding area is significantly shorter compared to the time required to complete all of the above preparatory operations (1) to (3).

[0013] In the above configuration, it is preferable that a plurality of storage areas corresponding to the plurality of winding units are provided, and the transfer mechanism has a plurality of transfer paths respectively connecting the winding area and the plurality of storage areas.

[0014] In this way, since a plurality of storage areas are provided and the transfer mechanism has a plurality of transfer paths, the winding units transferred from the winding area to the storage area and the winding units transferred from the storage area to the winding area can pass through different transfer paths. As a result, it becomes possible to smoothly replace the winding units arranged in the winding area.

[0015] In the above configuration, each of the plurality of transfer paths has a shared section through which any of the plurality of winding units can pass, and a dedicated section that is connected to the shared section and through which only one of the plurality of winding units can pass. A winding area is provided at one end of the shared section, a connection point with the dedicated section is provided at the other end of the shared section, a connection point is provided at one end of the dedicated section, and it is preferable that a storage area is provided at the other end of the dedicated section.

[0016] In this way, since each of the plurality of transfer paths has a shared section through which any of the plurality of winding units can pass, it is possible to minimize the space required for providing the plurality of transfer paths. Furthermore, each transfer path has a shared section while also having a dedicated section through which only one winding unit can pass, so it is possible to avoid the smooth replacement of the winding units arranged in the winding area being hindered. Specifically, since each transfer path has a dedicated section, when the winding unit transferred from the winding area to the storage area finishes passing through the shared section and enters the dedicated section, it becomes possible to allow other winding units to enter the shared section from the dedicated section and head towards the winding area. As a result, it is possible to avoid the smooth replacement of the winding units arranged in the winding area being hindered. As described above, according to this configuration, it is possible to achieve both space saving and smooth replacement of the winding units.

[0017] In the above configuration, the transfer mechanism includes a first track extending along the shared section, a second track extending along the dedicated section, a carriage traveling on one of the first and second tracks, and a third track provided on the carriage. When the carriage reaches the connection point by traveling on one track, the third track and the other of the first and second tracks are configured to be continuous. It is preferable that the winding unit further includes a traveling body for traveling on the third track and the other track.

[0018] In this configuration, when the carriage travels on one of the first track extending along the shared section and the second track extending along the dedicated section, the third track provided on the carriage accordingly moves along the one track. When the carriage traveling on one track reaches the connection point between the shared section and the dedicated section, the third track on the carriage becomes continuous with the other of the first and second tracks. From the above, with the winding unit placed on the third track provided on the carriage, if the carriage travels on one track, it is possible to transfer the winding unit along the one track. Further, when the carriage reaches the connection point, since the third track and the other track are continuous, the winding unit having a traveling body can be transferred from the third track to the other track. And it becomes possible to transfer the winding unit along the other track. As such, the fact that the winding unit can be transferred along each of the one track and the other track means that the winding unit can be transferred along each of the first track and the second track, and by extension, along each of the shared section and the dedicated section. And according to this configuration, by simply transferring the winding unit between the continuous third track and the other track, a rapid handover of the winding unit from the shared section to the dedicated section, or from the dedicated section to the shared section can be realized. Moreover, by using the track for the transfer of the winding unit, the positioning of the winding unit can be facilitated. As a result, it is more advantageous for smoothly replacing the winding unit arranged in the winding area.

[0019] In the above configuration, it is preferable that the shared section extends in the same direction as the conveyance path of the glass ribbon.

[0020] In this way, simultaneously with the start of the transfer of the winding unit from the winding area to the evacuation area, the winding unit starts to move further downstream from the winding area arranged at the downstream end of the conveyance path of the glass ribbon. For this reason, it becomes possible to quickly secure a space between the winding unit and the downstream end of the conveyance path of the glass ribbon. This space can be used, for example, by an operator to inspect the state of the glass ribbon continuously conveyed to the downstream end of the conveyance path.

[0021] In the above configuration, the winding unit may further have a guide portion for guiding the feeding of the protective sheet along the supply path from the sheet roll to the core.

[0022] As a general rule, the feeding of the protective sheet from the sheet roll to the core is often guided by a guide portion (for example, a plurality of rollers or the like). In this case, among the preparatory operations for starting the manufacture of the new glass roll described above, in the operation of (3), after winding the protective sheet drawn out from the sheet roll around the guide portion, the end portion of the protective sheet is fixed to the empty core. As described above, when the guide portion exists, the operation of winding the protective sheet around the guide portion is newly included in the preparatory operations. Therefore, if each of the plurality of winding units has a guide portion, while one of the plurality of winding units is being used for the manufacture of the glass roll, it becomes possible to perform preparatory operations including the operation of winding the protective sheet around the guide portion in other winding units.

[0023] In the above configuration, the guide portion may have a pre-winding guide arranged adjacent to the upstream side of the core on the supply path, and the pre-winding guide may guide the feeding of the protective sheet so that the glass ribbon reaching the winding area and the protective sheet moving along the pre-winding guide are in the same posture.

[0024] In the above configuration, the pre-winding guide may guide the feeding of the protective sheet with the protective sheet in a horizontal posture.

[0025] In the above configuration, the sheet roll support portion may be disposed below the core support portion in the take-up unit, and the protective sheet may be configured to be superimposed on the outer peripheral surface side of the glass ribbon wound around the core.

[0026] Using the above-described glass roll manufacturing apparatus, it is possible to execute a method for manufacturing a glass roll. The manufacturing method includes a winding step of manufacturing a glass roll by winding a glass ribbon around a core in a state where the glass ribbon is superimposed on a protective sheet.

[0027] According to this manufacturing method, it is possible to similarly obtain the above-described actions and effects of the glass roll manufacturing apparatus.

[0028] The above manufacturing method preferably includes a replacement step of replacing the take-up unit disposed in the take-up area by transferring the take-up unit that supports the core around which the glass ribbon has been wound to the retracted area and transferring the take-up unit that supports the core before winding of the glass ribbon from the retracted area to the take-up area after completion of the winding step.

[0029] According to this manufacturing method, it is possible to similarly obtain the above-described actions and effects of the glass roll manufacturing apparatus.

Effects of the Invention

[0030] According to the glass roll manufacturing apparatus and manufacturing method in the present disclosure, it is possible to enhance the productivity when manufacturing a glass roll.

Brief Description of the Drawings

[0031]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Embodiments for Carrying Out the Invention

[0032] Hereinafter, embodiments of a manufacturing apparatus and a manufacturing method for a glass roll will be described with reference to the accompanying drawings. Note that the X direction, Y direction, and Z direction shown in each drawing referred to in the description of the embodiments are directions orthogonal to each other.

[0033] First, the glass ribbon handled by the manufacturing apparatus and manufacturing method for a glass roll will be described.

[0034] <Glass Ribbon> The glass ribbon 1 shown in FIGS. 1 and 2 is a long glass continuously formed by a known forming method such as the down-draw method typified by the overflow down-draw method, the slot down-draw method, or the float method.

[0035] The ear portions (the portions with a greater thickness than other portions) formed at both ends in the width direction of the glass ribbon 1 during forming have already been separated and removed from the glass ribbon 1. The thickness of the glass ribbon 1 is set to a thickness that can impart flexibility to the glass ribbon 1, for example, 200 μm or less, 100 μm or less, or 50 μm or less.

[0036] The glass ribbon 1 is typically an alkali-free glass that substantially does not contain an alkali metal oxide component. Alternatively, the glass ribbon 1 may be an alkali aluminosilicate glass containing an alkali metal oxide component.

[0037] Next, the manufacturing apparatus for the glass roll will be described.

[0038] <Manufacturing Apparatus for Glass Roll> As shown in FIGS. 1 and 2, the manufacturing apparatus 2 for the glass roll (hereinafter simply referred to as the manufacturing apparatus 2) includes a transport mechanism 4 for transporting the glass ribbon 1 toward a winding area 3 disposed at the downstream end of the transport path of the glass ribbon 1, and a winding mechanism 6 for winding the glass ribbon 1 that has reached the winding area 3 in a roll shape in a state of being overlapped with a protective sheet 5.

[0039] The transport mechanism 4 is configured to transport the glass ribbon 1 in a flat-lying posture (horizontal posture in the illustrated example). The present transport mechanism 4 includes a belt conveyor 7 for sending the glass ribbon 1 downstream. In the present embodiment, a belt-shaped resin sheet 9 is supplied from a supply device (not shown) to the transport surface 8 of the belt conveyor 7, and the glass ribbon 1 is transported while being placed on the resin sheet 9. The resin sheet 9 has a larger width dimension (dimension along the X direction) than the glass ribbon 1. The resin sheet 9 that has reached the downstream end of the belt conveyor 7 is guided downward from the transport surface 8 of the belt conveyor 7 and separated from the glass ribbon 1. Note that the transport mechanism 4 may be configured to omit the resin sheet 9 and directly support and transport the glass ribbon 1 with the belt conveyor 7.

[0040] The winding mechanism 6 includes a winding unit 12 in which a plurality of components including a core 10 and a sheet roll 11 form a unit, a power device 13 that applies torque for rotating the core 10, a bearing member 14 for supporting the rotating core 10 in cooperation with the power device 13, and a pair of bearing members 15, 15 for supporting the rotating sheet roll 11.

[0041] The winding unit 12 includes, as its components, a core 10 that serves as a core for winding the glass ribbon 1, a core support portion 16 capable of supporting the core 10, a sheet roll 11 around which the protective sheet 5 before being superposed on the glass ribbon 1 is wound in a roll shape, a sheet roll support portion 17 capable of supporting the sheet roll 11, and a guide portion 18 for guiding the feeding of the protective sheet 5 along the supply path from the sheet roll 11 to the core 10.

[0042] Each component 10, 11, 16, 17, 18 of the winding unit 12 is mounted on a common base 19, and the winding unit 12 can transfer all of the components 10, 11, 16, 17, 18 together.

[0043] The core 10 has a core body 20 and a shaft 21. The core body 20 is formed in a cylindrical or tubular shape, and the glass ribbon 1 can be wound around it. Note that the protective sheet 5 is wound around the circumferential surface of the core body 20 in advance before the start of winding of the glass ribbon 1 (see FIG. 6). The shaft 21 is assembled with the core body 20, and the core body 20 can be rotated along with the rotation of the shaft 21. One end of the shaft 21 is attached to the power device 13, and the other end of the shaft 21 is attached to the bearing member 14.

[0044] The core support portion 16 is an element that functions when the winding unit 12 is transferred. The core support portion 16 is provided at two locations, respectively on one end side and the other end side of the shaft 21 of the core 10. Each core support portion 16 has a support groove 22 at its top.

[0045] The support groove 22 is formed such that the opening width (width along the Y direction) gradually widens as it moves upward. When the winding unit 12 is being transferred, this support groove 22 can support the core 10 from below by bringing both side walls of the groove into contact with and supporting the shaft 21 of the core 10 (see FIGS. 5 and 6). When the glass ribbon 1 is being wound, the shaft 21 supported by the power device 13 and the bearing member 14 is configured to rotate in a state of being non-contact with the support groove 22.

[0046] The sheet roll 11 can continuously unwind the protective sheet 5 that is overlapped with the glass ribbon 1 and supply it to the core 10.

[0047] The sheet roll 11 includes a shaft 23, a core 24, and a belt-shaped protective sheet 5 wound around the core 24. The shaft 23 is assembled with the core 24. Both ends of this shaft 23 are respectively attached to the bearing members 15, 15. The core 24 is formed in a cylindrical or tubular shape. The protective sheet 5 is a sheet for protecting the glass ribbon 1 from scratches and the like, and as an example, a resin sheet (such as a PET sheet) is adopted. The protective sheet 5 has a larger width dimension than the glass ribbon 1. As a result, at both ends in the width direction of the protective sheet 5 in the glass roll 25 being manufactured, they protrude from the glass ribbon 1 respectively.

[0048] The sheet roll 11 and the sheet roll support portion 17 are arranged below the core 10 and the core support portion 16 in the winding unit 12. The protective sheet 5 unwound from the sheet roll 11 is configured to be overlapped on the outer peripheral surface side of the glass ribbon 1 wound around the core 10.

[0049] Note that the protective sheet 5 can also be configured to be overlapped on the inner peripheral surface side of the glass ribbon 1 wound around the core 10. In this case, it is preferable to arrange the sheet roll 11 and the sheet roll support portion 17 above the core 10 and the core support portion 16 in the winding unit 12.

[0050] The sheet roll support portion 17 is an element that functions when the winding unit 12 is being transferred. The sheet roll support portion 17 is provided at two locations, and is respectively provided at one end side and the other end side of the shaft 23. Each sheet roll support portion 17 has a support groove 26 at its top.

[0051] The support groove 26 is formed such that the opening width (width along the Y direction) gradually widens as it moves upward. This support groove 26 can support the sheet roll 11 from below by bringing both side walls of the groove into contact with the shaft 23 of the sheet roll 11 when the winding unit 12 is being transferred (see FIGS. 5 and 6). Of the two side walls of the support groove 26, the side wall on the side from which the protective sheet 5 is pulled out from the sheet roll 11 is higher than the other side wall. Note that when the glass ribbon 1 is being wound, the shaft 23 supported by the pair of bearing members 15, 15 is configured to rotate in a state of being non-contact with the support groove 26.

[0052] The guide portion 18 has a pre-winding guide 27 disposed adjacent to the upstream side of the core 10 (the glass roll 25 being manufactured) on the supply path of the above-described protective sheet 5. In the present embodiment, the pre-winding guide 27 is composed of a plurality (three in the illustrated example) of rollers 28 arranged along the Y direction. However, this is not limiting, and as a modification of the present embodiment, instead of the plurality of rollers 28, for example, a belt conveyor can also be used to constitute the pre-winding guide 27.

[0053] The pre-winding guide 27 is configured to guide the feeding of the protective sheet 5 so that the glass ribbon 1 that has reached the winding area 3 and the protective sheet 5 moving along the pre-winding guide 27 are in the same posture. In the present embodiment, on the pre-winding guide 27, the protective sheet 5 and the glass ribbon 1 overlapping on the protective sheet 5 are set to a horizontal posture. Of course, this is not the only case. As a modification of the present embodiment, the protective sheet 5 and the glass ribbon 1 may be set to an inclined posture inclined with respect to the horizontal plane. In this case, as an example, among the plurality of rollers 28 described above, the plurality of rollers 28 may be arranged so that the rollers 28 closer to the winding core 10 are located higher.

[0054] The power device 13 includes a drive source such as a motor (not shown), and is capable of rotating the shaft 21 of the winding core 10 while holding one end of the shaft 21. The present power device 13 and the bearing member 14 can cooperate to adjust the position of the rotating winding core 10 (shaft 21) in the vertical direction. Due to this function, in the present embodiment, the posture of the glass ribbon 1 immediately before winding is maintained in a horizontal posture.

[0055] To describe the above adjustment function in detail, as the glass ribbon 1 is wound around the winding core 10, the diameter of the glass roll 25 being manufactured gradually increases. Therefore, in order to maintain the posture of the glass ribbon 1 immediately before winding in a horizontal posture, it is necessary to gradually move the winding core 10 upward in accordance with the increase in the diameter of the glass roll 25. The above adjustment function is used for this upward movement of the winding core 10.

[0056] On the lower surface of the base 19, a block 31 is attached as a traveling body for causing the winding unit 12 to travel on the first rail 29 and the third rail 30 described later. As the first rail 29 and the third rail 30, for example, a linear guide can be adopted. On the other hand, as the block 31, for example, a block for a linear guide can be adopted. On the upper surface of the base 19, pins 32 are provided for fixing the position of the winding unit 12 on the first rail 29. Two pins 32 are provided, and the two pins 32 are arranged at intervals in the X direction.

[0057] As shown in FIGS. 2 and 3, the pin 32 can cooperate with the locking mechanism 33 to fix the position of the winding unit 12. The locking mechanism 33 includes a shaft 35 arranged on a base 34 on which the first rail 29 is laid, and an arm 36 that pivots around the shaft 35. A recess 37 for hooking on the pin 32 is formed in the arm 36. When the recess 37 catches on the pin 32 as the arm 36 pivots, the position of the winding unit 12 on the first rail 29 is fixed. Of course, when the glass ribbon 1 is wound, the position of the winding unit 12 is fixed. On the other hand, when the recess 37 comes off the pin 32 as the arm 36 pivots, the above-mentioned fixing is released, and the winding unit 12 can travel on the first rail 29. To cause the arm 36 to pivot, for example, a cylinder mechanism connected to the arm 36 can be used.

[0058] As shown in FIG. 4, the manufacturing apparatus 2 further includes a transfer mechanism 38 for transferring the winding unit 12. In FIG. 4, the illustration of the winding unit 12 is omitted to facilitate understanding of the structure of the transfer mechanism 38. The transfer mechanism 38 is a mechanism for transferring the winding unit 12 in unit form between the winding area 3 and a retraction area 39 away from the winding area 3.

[0059] In the manufacturing apparatus 2, two retraction areas 39 are provided for one winding area 3. The transfer mechanism 38 has two transfer paths 40 that connect the winding area 3 and the two retraction areas 39, respectively. The number of retraction areas 39 and the number of transfer paths 40 correspond to the number of winding units 12 provided in the manufacturing apparatus 2. That is, the manufacturing apparatus 2 is equipped with two of the above-described winding units 12 (see FIGS. 8 to 10).

[0060] Here, in the following description, one of the two retraction areas 39 may be referred to as the first retraction area 41 and the other as the second retraction area 42 for distinction. Also, one of the two transfer paths 40 may be referred to as the first transfer path 43 and the other as the second transfer path 44 for distinction. Further, one of the two winding units 12 may be referred to as the first winding unit 45 and the other as the second winding unit 46 for distinction (see FIGS. 8 to 10).

[0061] The first retraction area 41 is a dedicated area for retracting only one (the first winding unit 45) of the two winding units 12. And the first transfer path 43 that connects this first retraction area 41 and the winding area 3 is the path through which the first winding unit 45 passes during transfer. In contrast, the second retraction area 42 is a dedicated area for retracting only the other (the second winding unit 46) of the two winding units 12. And the second transfer path 44 that connects this second retraction area 42 and the winding area 3 is the path through which the second winding unit 46 passes during transfer.

[0062] Each of the two transfer paths 40 has a shared section 47 through which both of the two winding units 12 pass and a dedicated section 48 through which only one of the two winding units 12 passes. The shared section 47 and the dedicated section 48 are connected at a connection point 49. One end of the shared section 47 has the winding area 3, and the other end has the connection point 49. One end of the dedicated section 48 has the connection point 49, and the other end has the retraction area 39.

[0063] In this embodiment, the dedicated section 48 included in the first transfer path 43 and the dedicated section 48 included in the second transfer path 44 have the same length. As a result, both the first transfer path 43 and the second transfer path 44 have the same length. On the other hand, in comparison between the shared section 47 and the dedicated section 48, the shared section 47 is shorter than the dedicated section 48.

[0064] In this embodiment, the shared section 47 extends in the same direction as the conveyance path of the glass ribbon 1. On the other hand, the dedicated section 48 extends in the same direction as the width direction of the glass ribbon 1. That is, the shared section 47 and the dedicated section 48 extend in directions orthogonal to each other.

[0065] The transfer mechanism 38 includes a first rail 29 as a first track extending along the shared section 47, a second rail 52 as a second track extending along the dedicated section 48, two carriages 53 traveling on the second rail 52, and a third rail 30 as a third track laid on the upper surface of each carriage 53. Two of each of the rails 29, 52, 30 are laid.

[0066] When comparing the first rail 29 and the third rail 30 with the second rail 52, the distance between the two rails in the former is longer than the distance between the two rails in the latter. Here, as the second rail 52, a linear guide can be adopted in the same manner as the first rail 29 and the third rail 30, for example.

[0067] It is possible to place the winding unit 12 on each of the two carriages 53. Specifically, by placing the block 31 attached to the base 19 of the winding unit 12 on the third rail 30 on the carriage 53, it is possible to place the winding unit 12 on the carriage 53. One of the two carriages 53 is a dedicated carriage for placing the first winding unit 45. The other of the two carriages 53 is a dedicated carriage for placing the second winding unit 46.

[0068] On the lower surface of the carriage 53, a block 54 for running the carriage 53 on the second rail 52 is attached (see FIGS. 5 and 6). As the block 54, similar to the block 31, for example, a block for a linear guide can be adopted.

[0069] To run the carriage 53 on the second rail 52, for example, a feed mechanism (not shown) is used. The feed mechanism may be a known mechanism. For example, a feed mechanism including a drive wheel, a driven wheel arranged at an interval in the X direction from the drive wheel, and a belt wound around both wheels may be used. In this case, if the belt and the carriage 53 are connected, as the belt rotates, the carriage 53 runs on the second rail 52. In addition, a ball screw mechanism, a chain drive mechanism, etc. may be used as the feed mechanism, or the operator may push the carriage 53 to make it run without using a feed mechanism. When using a feed mechanism, two carriages 53 may be run by a common feed mechanism or by different feed mechanisms.

[0070] In this embodiment, different feed mechanisms are used for the running of the two carriages 53. The operations of the two carriages 53 are controlled so that the two carriages 53 run on the second rail 52 in the manner exemplified below. Within the range where the second rail 52 is laid, there are three locations: a first retraction area 41, a connection point 49, and a second retraction area 42, which are spaced apart in the X direction. The operations of the two carriages 53 are controlled so that the two carriages 53 are present at two adjacent locations among these three locations. In other words, the operations of the two carriages 53 are controlled so that both of the two carriages 53 do not exist in the retraction area 39.

[0071] When the carriage 53 travels on the second rail 52 and reaches the connection point 49, the third rail 30 on the carriage 53 and the first rail 29 on the base 34 are in a continuous state. At this time, the winding unit 12 can transfer from the first rail 29 to the third rail 30, or from the third rail 30 to the first rail 29. To move the winding unit 12 on both rails 29 and 30 for transfer, a feed mechanism (not shown) is used. The feed mechanism may be a known mechanism (e.g., a chain drive mechanism, etc.).

[0072] Summarizing the manner in which the winding unit 12 is transferred between the winding area 3 and the retraction area 39 from the configuration described above, it is as follows. When being transferred on the dedicated section 48 (between the retraction area 39 and the connection point 49) of the transfer path 40, it is transferred while being placed on the carriage 53 that travels on the second rail 52 by obtaining power from the feed mechanism. When being transferred on the shared section 47 (between the winding area 3 and the connection point 49) of the transfer path 40, the winding unit 12 that obtains power from the feed mechanism is transferred by traveling on the first rail 29 and the third rail 30.

[0073] Hereinafter, a method for manufacturing a glass roll using the above manufacturing apparatus 2 will be described.

[0074] <Method for Manufacturing a Glass Roll> This manufacturing method includes a winding step P1 and a replacement step P2.

[0075] The winding step P1 is a step of manufacturing the glass roll 25. In the winding step P1, as already described in the description of the manufacturing apparatus 2, the glass ribbon 1 is wound around the core 10 in the manner shown in FIGS. 1 and 2. Thereby, a glass roll 25 (see FIG. 7) around which a glass ribbon 1 of a desired length is wound is manufactured. Thus, the winding step P1 is completed.

[0076] When the winding process P1 is completed, the replacement process P2 is then started. The replacement process P2 is a process of replacing the winding unit 12 disposed in the winding area 3. Specifically, the winding unit 12 with the glass roll 25 thereon is retracted from the winding area 3, and instead, the winding unit 12 with an empty core 10 thereon (the winding unit 12 for which the preparation for starting the production of a new glass roll 25 has been completed) is advanced into the winding area 3.

[0077] Here, the winding unit 12 with the glass roll 25 thereon is the winding unit 12 shown in FIG. 5. On the same winding unit 12, a core 10 around which the glass ribbon 1 has been wound and a sheet roll 11 after being used for winding the glass ribbon 1 are placed. On the other hand, the winding unit 12 with an empty core 10 thereon is the winding unit 12 shown in FIG. 6. On the same winding unit 12, an empty core 10 for newly starting the winding of the glass ribbon 1 and an unused sheet roll 11 for newly winding the glass ribbon 1 are placed. At the end of the protective sheet 5 in the unused sheet roll 11, several turns of the protective sheet 5 are wound around the empty core 10 after being fixed thereto.

[0078] Note that in the state of FIG. 6, it is preferable that tension is applied to the protective sheet 5 in the path from the sheet roll 11 to the empty core 10. By setting such a state, it is possible to stably wind the glass ribbon 1. The tension can be controlled, for example, by providing a dancer roller (not shown) in the guide portion 18 or by providing a torque controller for controlling the rotational torque of the shaft 23, which is the rotation axis of the sheet roll 11, in the bearing member 15.

[0079] The replacement of the winding unit 12 is performed in the flow as shown in FIGS. 8 to 10. Note that since FIGS. 8 to 10 are diagrams schematically showing the replacement flow, illustration of some components of the manufacturing apparatus 2 described above is omitted.

[0080] First, as shown in FIG. 8, for the winding unit 12 (here, the first winding unit 45) on which the glass roll 25 is placed, the transfer from the winding area 3 toward the connection point 49 is started. At this time, at the connection point 49, the dedicated carriage 53 of the first winding unit 45 is in a standby state. The winding unit 12 (here, the second winding unit 46) on which the empty core 10 is placed is in a standby state in the second retracted area 42.

[0081] Thereafter, the first winding unit 45 travels on the first rail 29 and the third rail 30, and as shown in FIG. 9, the first winding unit 45 arrives at the connection point 49. The first winding unit 45 that has arrived at the connection point 49 is placed on the carriage 53 (see FIG. 5).

[0082] At this time, in the second winding unit 46 in the second retracted area 42, the preparations for starting the production of a new glass roll 25 have already been completed. This is because while the first winding unit 45 is being used for the production of the glass roll 25 in the winding area 3, all of the above-mentioned preparatory operations (1) to (3) (see paragraph

[0012] ) for the second winding unit 46 are completed.

[0083] For the first winding unit 45 that has arrived at the connection point 49, the transfer from the connection point 49 toward the first retracted area 41 is subsequently started. At the same time, for the second winding unit 46, the transfer from the second retracted area 42 toward the connection point 49 is started. At this time, the second winding unit 46 is in a state of being placed on the carriage 53.

[0084] Thereafter, the carriage 53 on which the first winding unit 45 is placed and the carriage 53 on which the second winding unit 46 is placed both travel on the second rail 52, and as shown in FIG. 10, the first winding unit 45 arrives at the first retracted area 41. Further, the second winding unit 46 arrives at the connection point 49.

[0085] For the first take-up unit 45 that has arrived at the first retraction area 41, the preparatory operations (1) to (3) described above are started. In this preparatory operation, from the shapes of the support grooves 22 and 26 described above, it becomes possible to quickly place the core 10 and the sheet roll 11 on the core support portion 16 and the sheet roll support portion 17, respectively.

[0086] For the second take-up unit 46 that has arrived at the connection point 49, the transfer from the connection point 49 toward the take-up area 3 is subsequently started (see also FIG. 6). Thereafter, the second take-up unit 46 travels on the third rail 30 and the first rail 29 and arrives at the take-up area 3. As a result, the take-up unit 12 arranged in the take-up area 3 is replaced, and the replacement process P2 is completed.

[0087] By repeatedly executing the manufacturing method shown above, the take-up unit 12 is reciprocally transferred between the take-up area 3 and the retraction area 39.

[0088] When performing maintenance on the power device 13 and the like arranged in the take-up area 3, the transfer of the take-up unit 12 between the take-up area 3 and the retraction area 29 is stopped, and maintenance is performed after ensuring that the take-up unit 12 does not exist in the take-up area 3.

[0089] Here, the following modification examples can also be applied to the above embodiment.

[0090] In the above embodiment, the rails 29, 52, 30 (linear guides) are adopted as the first to third rails, and the blocks 31, 54 (blocks for linear guides) are adopted as the traveling bodies for traveling on the rails 29, 52, 30. However, this is not the only case. The first to third rails may be, for example, grooves formed on the floor surface of a glass manufacturing factory, and the traveling bodies may be wheels, caterpillars, balls, or the like.

[0091] In the above-described embodiment, on the dedicated section 48, the winding unit 12 is transported while being placed on the carriage 53, and on the shared section 47, the winding unit 12 itself travels for transportation. However, this is not the only way. On the shared section 47, the winding unit 12 may be transported while being placed on the carriage 53, and on the dedicated section 48, the winding unit 12 may be transported by itself traveling.

Explanation of Signs

[0092] 1 Glass ribbon 2 Glass roll manufacturing apparatus 3 Winding area 5 Protective sheet 10 Winding core 11 Sheet roll 12 Winding unit 16 Winding core support part 17 Sheet roll support part 18 Guide part 25 Glass roll 27 Guide immediately before winding 29 First rail 30 Third rail 31 Block 38 Transfer mechanism 39 Retraction area 40 Transfer path 41 First retraction area 42 Second retraction area 43 First transfer path 44 Second transfer path 45 First winding unit 46 Second winding unit 47 Shared section 48 Dedicated section 49 Connection point 52 Second rail 53 Carriage P1 Winding process P2 Replacement process

Claims

1. A manufacturing apparatus for a glass roll for winding a glass ribbon to obtain a glass roll, comprising: a core support portion that supports a core for winding the glass ribbon in a roll shape in a winding area disposed at a downstream end of a conveyance path of the glass ribbon, with the glass ribbon superposed on a protective sheet; a winding unit integrally and movably provided with a sheet roll support portion that supports a sheet roll around which the protective sheet is wound in a roll shape; A manufacturing apparatus for a glass roll, further comprising a transfer mechanism that transfers the winding unit in unit units between the winding area and a retraction area away from the winding area.

2. The manufacturing apparatus for a glass roll according to claim 1, characterized in that a plurality of the winding units are provided.

3. A plurality of the retraction areas corresponding to the plurality of winding units are provided, The manufacturing apparatus for a glass roll according to claim 2, characterized in that the transfer mechanism has a plurality of transfer paths connecting the winding area and the plurality of retraction areas respectively.

4. Each of the plurality of transfer paths has a shared section through which any of the plurality of winding units can pass, and a dedicated section connected to the shared section and through which only one of the plurality of winding units can pass, The winding area is provided at one end of the shared section, and a connection point with the dedicated section is provided at the other end of the shared section, The manufacturing apparatus for a glass roll according to claim 3, characterized in that the connection point is provided at one end of the dedicated section, and the retraction area is provided at the other end of the dedicated section.

5. The transfer mechanism has a first track extending along the shared section, a second track extending along the dedicated section, a carriage traveling on one of the first and second tracks, and a third track provided on the carriage, When the carriage travels on the one track and reaches the connection point, the third track and the other of the first and second tracks are configured to be continuous, The manufacturing apparatus for a glass roll according to claim 4, characterized in that the winding unit further has a traveling body for traveling on the third track and the other track.

6. The manufacturing apparatus for a glass roll according to claim 4 or 5, characterized in that the shared section extends in the same direction as the conveyance path of the glass ribbon.

7. The manufacturing apparatus for a glass roll according to any one of claims 2 to 5, further comprising a guide portion for guiding the feeding of the protective sheet along a supply path from the sheet roll to the core.

8. The guide portion has a pre-winding guide disposed adjacent to the upstream side of the core on the supply path, The manufacturing apparatus for a glass roll according to claim 7, wherein the pre-winding guide guides the feeding of the protective sheet so that the glass ribbon that has reached the winding area and the protective sheet that is moving along the pre-winding guide are in the same posture.

9. The manufacturing apparatus for a glass roll according to claim 8, wherein the pre-winding guide guides the feeding of the protective sheet with the protective sheet in a horizontal posture.

10. In the winding unit, the sheet roll support portion is disposed below the core support portion, The manufacturing apparatus for a glass roll according to claim 9, wherein the protective sheet is configured to be superposed on the outer peripheral surface side of the glass ribbon wound around the core.

11. A method for manufacturing a glass roll, comprising a winding step of manufacturing a glass roll by winding the glass ribbon around the core in a state where the glass ribbon is superposed on the protective sheet, using the manufacturing apparatus for a glass roll according to any one of claims 2 to 5.

12. The method for manufacturing a glass roll according to claim 11, further comprising a replacement step of replacing the winding unit disposed in the winding area by transferring the winding unit that supports the core around which the glass ribbon has been wound from the winding area to the retracted area and transferring the winding unit that supports the core before winding of the glass ribbon from the retracted area to the winding area.

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