Roll press apparatus and method for manufacturing processed products

Abstract

This technology reduces the amount of workpieces that have uneven thickness in the width direction. [Solution] The roll press apparatus includes a sensor unit that measures the shapes of the first roll and the second roll and detects the deflection of the first roll and the second roll, and a control unit that operates at least one of the first bend unit and the second bend unit so as to impart reverse deflection to the first roll and the second roll in response to the deflection detected by the sensor unit.

Description

Technical Field

[0001] The present disclosure relates to a roll press device and a method for manufacturing a processed product.

Background Art

[0002] Patent Document 1 discloses a roll press device. This device includes a sensor for detecting the thickness of a workpiece downstream of a pair of rolls. The thickness of the workpiece is detected at three or more points in the width direction of the workpiece. Based on the thickness measurement values at three or more points and the thickness target value, the deflection of the roll and the distance between the rolls are adjusted so that the thickness in the width direction of the workpiece becomes uniform and reaches the target value.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the device described in Patent Document 1, since the first roll and the second roll are adjusted based on the thickness of the workpiece after the roll press process, there is a risk that at least the workpiece with a non-uniform thickness in the width direction will flow to the sensor arrangement position. The present disclosure provides a technique capable of reducing the generation amount (length) of workpieces with a non-uniform thickness in the width direction.

Means for Solving the Problems

[0005] A roll press apparatus according to one aspect of the present disclosure includes a first roll having a first rotation axis and a second roll having a second rotation axis, which grip a workpiece to be conveyed; a first bearing and a second bearing provided at both ends of the first rotation axis, respectively; a third bearing and a fourth bearing, provided at both ends of the second rotation axis, which are opposite to the first bearing and opposite to the second bearing; a first bend bearing and a second bend bearing, provided at both ends of the first rotation axis, which are located outside the first bearing and outside the second bearing; a third bend bearing and a fourth bend bearing, provided at both ends of the second rotation axis, which are located outside the third bearing and opposite to the first bend bearing and opposite to the fourth bend bearing; and at least one of the first bearing and the third bearing is provided in a direction that brings the first roll and the second roll closer together. The system comprises: a first pressurizing unit that applies a load; a second pressurizing unit that applies a load to at least one of the second bearing and the fourth bearing in a direction that brings the first roll and the second roll closer together; a first bending unit that applies a load to the first bending bearing and the third bending bearing in a direction that brings the first roll and the second roll closer together or further apart; a second bending unit that applies a load to the second bending bearing and the fourth bending bearing in a direction that brings the first roll and the second roll closer together or further apart; a sensor unit that measures the shapes of the first roll and the second roll and detects the deflection of the first roll and the second roll; and a control unit that operates at least one of the first bending unit and the second bending unit so that a reverse deflection is applied to the first roll and the second roll in response to the deflection detected by the sensor unit.

[0006] A method for manufacturing a workpiece relating to other aspects of the present disclosure includes: a first roll having a first rotation axis and a second roll having a second rotation axis, which clamp a workpiece being transported; a first bearing and a second bearing provided at both ends of the first rotation axis, respectively; a third bearing and a fourth bearing, which are provided at both ends of the second rotation axis and are opposite to the first bearing and opposite to the second bearing; a first bend bearing and a second bend bearing, which are provided at both ends of the first rotation axis and are located outside the first bearing and outside the second bearing; a third bend bearing and a fourth bend bearing, which are provided at both ends of the second rotation axis and are located outside the third bearing and opposite to the first bend bearing and opposite to the fourth bend bearing; a first pressurizing unit that applies a load to at least one of the first bearing and the third bearing in a direction that brings the first roll and the second roll closer together; and at least one of the second bearing and the fourth bearing. The other is a method for manufacturing a workpiece using a roll press apparatus comprising: a second press unit that applies a load in a direction that brings the first roll and the second roll closer together; a first bend unit that applies a load to the first bend bearing and the third bend bearing in a direction that brings the first roll and the second roll closer together or further apart; a second bend unit that applies a load to the second bend bearing and the fourth bend bearing in a direction that brings the first roll and the second roll closer together or further apart; and a sensor unit that measures the shapes of the first roll and the second roll and detects the deflection of the first roll and the second roll, the method comprising: determining whether or not deflection has been detected by the sensor unit; and operating at least one of the first bend unit and the second bend unit so as to impart reverse deflection to the first roll and the second roll in response to the detection of deflection by the sensor unit. [Effects of the Invention]

[0007] According to this disclosure, the amount of workpieces with uneven thickness in the width direction can be reduced. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a front view showing an example of a roll press apparatus according to one embodiment. [Figure 2] Figure 2 is a right side view showing an example of the roll press apparatus shown in Figure 1. [Figure 3] Figure 3 is a top view showing an example of the roll press apparatus shown in Figure 1. [Figure 4] Figure 4 is a perspective view showing an example of the roll press apparatus shown in Figure 1. [Figure 5] Figure 5 is a schematic diagram illustrating the placement of the sensors. [Figure 6] Figure 6 is a schematic diagram illustrating the deflection control of a roll press machine. [Figure 7] Figure 7 is a schematic diagram illustrating the thickness control of a roll press machine. [Figure 8] Figures 8(A) to (C) are schematic diagrams illustrating the procedure for measuring the deflection of a roll press machine. [Figure 9] Figure 9 is a flowchart showing the operation for controlling the deflection of the roll. [Figure 10] Figure 10 is a flowchart showing the operation for controlling the thickness of the workpiece. [Modes for carrying out the invention]

[0009] Embodiments of the present disclosure will be described in detail below with reference to the drawings. In the description of the drawings, identical elements are denoted by the same reference numerals, and redundant descriptions are omitted. The dimensional ratios in the drawings do not necessarily correspond to those described. The terms "top," "bottom," "left," and "right" are based on the illustrated state and are for convenience only.

[0010] [Configuration of a roll press machine] Figure 1 is a front view showing an example of a roll press apparatus according to one embodiment. Figure 2 is a right side view showing an example of the roll press apparatus of Figure 1. Figure 3 is a top view showing an example of the roll press apparatus of Figure 1. Figure 4 is a perspective view showing an example of the roll press apparatus of Figure 1. In the figures, the X and Y directions are horizontal, and the Z direction is vertical. Hereafter, the Z direction will also be referred to as the up and down direction.

[0011] The roll press device 1 shown in FIGS. 1 to 4 is a device that sandwiches and rolls and compresses the workpiece being conveyed. The workpiece is plate-shaped and made of metal, resin, cloth, etc. As an example, the workpiece is a material for the electrodes of secondary batteries, a material for the electrodes of fuel cells, a flexible printed board, a substrate with built-in components, a ceramic green sheet, a functional multilayer film, etc.

[0012] <​​​​​​​​​​​​​​​ The first pressing cylinder 41 and the second pressing cylinder 42 are devices that apply a load in the direction in which the upper roll 2 and the lower roll 3 approach each other to the third main bearing 31 and the fourth main bearing 32. The first pressing cylinder 41 and the second pressing cylinder 42 are, for example, electric cylinders or hydraulic cylinders. By the operation of the first pressing cylinder 41 and the second pressing cylinder 42, the gap interval between the upper roll 2 and the lower roll 3 is adjusted, and the thickness of the work W and the inclination of the thickness in the width direction of the work W are adjusted.

[0017] At both ends of the upper rotating shaft 20, a first bend bearing 23 and a second bend bearing 24 are further provided respectively. The first bend bearing 23 and the second bend bearing 24 rotatably support the upper rotating shaft 20. The first bend bearing 23 is located outside (end side) of the first main bearing 21. The second bend bearing 24 is located outside (end side) of the second main bearing 22.

[0018] At both ends of the lower rotating shaft 30, a third bend bearing 33 and a fourth bend bearing 34 are further provided respectively. The third bend bearing 33 and the fourth bend bearing 34 rotatably support the lower rotating shaft 30. The third bend bearing 33 is located outside (end side) of the third main bearing 31. The third bend bearing 33 is vertically opposed to the first bend bearing 23. The fourth bend bearing 34 is located outside (end side) of the fourth main bearing 32. The fourth bend bearing 34 is vertically opposed to the second bend bearing 24.

[0019] Between the first bend bearing 23 and the third bend bearing 33, a first bend cylinder 51 (an example of a first bend unit) is provided to apply a load to the first bend bearing 23 and the third bend bearing 33 in a direction that brings the upper roll 2 and the lower roll 3 closer together or further apart. The first bend cylinder 51 is, for example, an electric cylinder or a hydraulic cylinder. The first bend cylinder 51 is connected to the first bend bearing 23 and the third bend bearing 33 and is configured to brace or pull them together. Alternatively, instead of the first bend cylinder 51, a cylinder (an example of a first bend unit) that lifts or pushes down the first bend bearing 23 from above and a cylinder (an example of a first bend unit) that pushes down or pushes up the third bend bearing 33 from below may be provided. Or, in addition to the first bend cylinder 51, a plurality of the above-mentioned cylinders may be provided.

[0020] Between the second bend bearing 24 and the fourth bend bearing 34, a second bend cylinder 52 (an example of a second bend unit) is provided to apply a load to the second bend bearing 24 and the fourth bend bearing 34 in a direction that brings the upper roll 2 and the lower roll 3 closer together or further apart. The second bend cylinder 52 is, for example, an electric cylinder or a hydraulic cylinder. The second bend cylinder 52 is connected to the second bend bearing 24 and the fourth bend bearing 34 and is configured to brace or pull them together. Alternatively, instead of the second bend cylinder 52, a cylinder (an example of a second bend unit) that lifts or pushes down the second bend bearing 24 from above and a cylinder (an example of a second bend unit) that pushes down or pushes up the fourth bend bearing 34 from below may be provided. Or, in addition to the second bend cylinder 52, a plurality of the above-mentioned cylinders may be provided.

[0021] The deflection of the upper roll 2 and the lower roll 3 can be adjusted by the operation of the first bend cylinder 51 and the second bend cylinder 52. Deflection is a physical quantity measured with respect to a straight line, and is evaluated by the amount of deviation of the center of the roll relative to the straight line connecting the rotation centers of both end faces of the roll. For example, if the center of the roll deflects so that it protrudes 2 μm upwards compared to both ends, the deflection is evaluated as +2 μm.

[0022] As an example, suppose the upper roll 2 has a shape that deflects so that its center protrudes upward more than both ends, and the lower roll 3 has a shape that deflects so that its center protrudes downward more than both ends. In this case, when the first bend cylinder 51 applies a load so that the space between the first bend bearing 23 and the third bend bearing 33 widens (separates them), a force is applied that causes the upper roll 2 to move downward with the first main bearing 21 as the pivot point. Similarly, when the second bend cylinder 52 applies a load so that the space between the second bend bearing 24 and the fourth bend bearing 34 widens (separates them), a force is applied that causes the upper roll 2 to move downward with the second main bearing 22 as the pivot point. This imparts a reverse deflection to the upper roll 2, which cancels out the deflection of the upper roll 2, thus reducing the deflection of the upper roll 2. Similarly, in the case of the lower roll 3, a force is applied that causes the lower roll 3 to move upward with the third main bearing 31 and the fourth main bearing 32 as pivot points, and the deflection of the lower roll 3 is reduced.

[0023] As an example, suppose the upper roll 2 has a shape that deflects so that its center protrudes downwards more than both ends, and the lower roll 3 has a shape that deflects so that its center protrudes upwards more than both ends. In this case, when the first bend cylinder 51 applies a load so that the space between the first bend bearing 23 and the third bend bearing 33 is reduced (brings them closer together), a force is applied that causes the upper roll 2 to move upward with the first main bearing 21 as the pivot point. Similarly, when the second bend cylinder 52 applies a load so that the space between the second bend bearing 24 and the fourth bend bearing 34 is reduced (brings them closer together), a force is applied that causes the upper roll 2 to move upward with the second main bearing 22 as the pivot point. This imparts a reverse deflection to the upper roll 2, which cancels out the deflection of the upper roll 2, thus reducing the deflection of the upper roll 2. Similarly, in the case of the lower roll 3, a force is applied that causes the lower roll 3 to move downward with the third main bearing 31 and the fourth main bearing 32 as pivot points, and the deflection of the lower roll 3 is reduced.

[0024] The roll press device 1 includes a sensor unit 60 that measures the shapes of the upper roll 2 and the lower roll 3 and detects the deflection of the upper roll 2 and the lower roll 3. The sensor unit 60 includes three first distance sensors 61, 62, and 63 arranged on a straight line L1 along the upper rotation axis 20. The sensor unit 60 may include four or more first distance sensors. The first distance sensors 61, 62, and 63 measure the distance to the upper roll 2. Each first distance sensor is not particularly limited in its measurement principle as long as it can measure distance; it may be a non-contact sensor using a laser or the like, or a contact sensor like a linear gauge. Since the distances to three points on the upper roll 2 are detected by the first distance sensors, the deflection shape of the upper roll 2 can be measured.

[0025] The sensor unit 60 includes three second distance sensors 64, 65, and 66 arranged in a straight line along the lower rotation axis 30. The sensor unit 60 may also include four or more second distance sensors. The second distance sensors 64, 65, and 66 measure the distance to the lower roll 3. Each second distance sensor is not particularly limited in its measurement principle as long as it can measure distance; it may be a non-contact sensor using a laser or the like, or a contact sensor like a linear gauge. Since the distances to three points on the lower roll 3 are detected by the second distance sensors, the deflection shape of the lower roll 3 can be measured.

[0026] Figure 5 is a schematic diagram illustrating the placement of the sensors. As shown in Figure 5, the first distance sensor and the second distance sensor are placed as a pair. For example, the first distance sensor 61 and the second distance sensor 64 form a pair, the first distance sensor 62 and the second distance sensor 65 form a pair, and the first distance sensor 63 and the second distance sensor 66 form a pair. The first distance sensor 61 and the second distance sensor 64 are placed on a straight line L2 passing through the first center point 2A of the cross-section of the upper roll 2 and the second center point 3A of the cross-section of the lower roll 3. The other pairs are placed in a similar manner. This arrangement improves the accuracy of deflection detection.

[0027] The placement of the first distance sensor 61 and the second distance sensor 64 is not limited to being perfectly aligned on the straight line L2, but is also permitted to be slightly off the straight line L2. As shown in Figure 5, when the workpiece W is roll-pressed, the speed V2 of the workpiece W after roll-pressing is generally faster than the entry speed V1 of the workpiece W before roll-pressing. At a predetermined point within the contact arc, the roll peripheral speed V R The entry speed V1 of the workpiece W coincides with this point. This point is called the neutral point P1. The first distance sensor 61 may be located on a straight line L3 passing through the neutral point P1 and the first center point 2A (see first distance sensor 61A). By positioning the first distance sensor 61 within the range R1 defined by the straight lines L2 and L3, the accuracy of deflection detection can be improved. The same applies to other first distance sensors. The second distance sensor 64 may be located on a straight line L4 passing through the neutral point P1 and the second center point 3A (see second distance sensor 64A). By positioning the second distance sensor 64 within the range R2 defined by the straight lines L2 and L4, the accuracy of deflection detection can be improved. The same applies to other second distance sensors.

[0028] Returning to Figures 1 to 4, the roll press apparatus 1 may further include a thickness sensor unit 70 downstream of the upper roll 2 and the lower roll 3. The thickness sensor unit 70 detects the thickness of the workpiece W. The thickness sensor unit 70 may include, for example, a pair of distance sensors 71 and 72 arranged vertically, and detect the thickness of the workpiece W at two locations in the width direction. The thickness sensor unit 70 may also include either the pair of distance sensors 71 and 72 arranged vertically, and detect the thickness of the workpiece W at one location. The distance sensor is not particularly limited in its measurement principle as long as it can measure distance, and may be a non-contact sensor using a laser or the like, or a contact sensor like a linear gauge.

[0029] [Details of deflection control] Figure 6 is a schematic diagram illustrating the deflection control of a roll press machine. The roll press machine 1 includes a control unit 80. The control unit 80 is, for example, a PLC (Programmable Logic Controller). A PLC is a device that has a processor, memory, display, input / output unit, etc. The control unit 80 may be configured as a computer system including, for example, a CPU (Central Processing Unit), memory such as RAM (Random Access Memory) and ROM (Read Only Memory), input / output devices such as a touch panel, mouse, keyboard, and display, and communication devices such as a network card. Alternatively, the control unit 80 may be incorporated as a circuit. The control unit 80 may be realized by multiple control units (i.e., they may be physically separated).

[0030] The control unit 80 is connected to the sensor unit 60 and receives the measurement values ​​from the sensor. The control unit 80 calculates the amount of deflection based on the measurement values ​​from three locations. For example, the direction in which the detection point is close to the sensor is treated as positive. First, the control unit 80 calculates the average value by averaging the two measurement values ​​closest to both ends of the upper roll 2. Then, the control unit 80 subtracts the average value from the measurement value in the center of the upper roll 2 to obtain the amount of deflection. The control unit 80 calculates the amount of deflection for the lower roll 3 in the same way. Then, the control unit 80 calculates the average value of the deflection amount of the upper roll 2 and the deflection amount of the lower roll 3.

[0031] In response to the detection of deflection by the sensor unit 60, the control unit 80 operates at least one of the first bend cylinder 51 and the second bend cylinder 52 so as to impart reverse deflection to the upper roll 2 and the lower roll 3. Reverse deflection is a deflection that bends in the opposite direction to the deflection detected by the sensor unit 60. The control unit 80 determines an amount of movement to counteract the amount of deflection. The amount of movement may be a fixed value. The control unit 80 outputs a signal indicating the determined amount of movement to the first bend cylinder 51 and the second bend cylinder 52. As a result, the amount of deflection of the upper roll 2 and the lower roll 3 changes and is detected again by the sensor unit 60. By repeating the above operation, the control unit 80 can reduce the deflection of the upper roll 2 and the lower roll 3.

[0032] [Details of thickness control] Figure 7 is a schematic diagram illustrating the thickness control of a roll press machine. The control unit 80 is connected to the thickness sensor unit 70 and receives the measurement values ​​from the sensor. The control unit 80 operates at least one of the first pressurizing cylinder 41 and the second pressurizing cylinder 42 so that the detection result of the thickness sensor unit 70 becomes a predetermined target value. If the thickness sensor unit 70 has two thickness sensors 71 and 72 corresponding to the first pressurizing cylinder 41 and the second pressurizing cylinder 42, the control unit 80 controls the first pressurizing cylinder 41 and the second pressurizing cylinder 42 independently. This allows adjustment of the thickness in the width direction and the thickness gradient of the workpiece W. If the thickness sensor unit 70 has only one thickness sensor, the control unit 80 controls the first pressurizing cylinder 41 and the second pressurizing cylinder 42 synchronously. This allows adjustment of the thickness of the workpiece W.

[0033] The control unit 80 determines whether the difference from the target value is within an acceptable range. If the difference from the target value is not within an acceptable range, the control unit 80 determines the amount of movement for the first pressurizing cylinder 41 and the second pressurizing cylinder 42. The amount of movement may be a fixed value. The control unit 80 outputs a signal indicating the determined amount of movement to the first pressurizing cylinder 41 and the second pressurizing cylinder 42. As a result, the distance between the upper roll 2 and the lower roll 3 changes and is detected again by the thickness sensor unit 70. By repeating the above operation, the control unit 80 can perform feedback control of the thickness.

[0034] [Procedure for measuring deflection] Figures 8(A) to 8(C) are schematic diagrams illustrating the procedure for measuring the deflection of a roll press machine. As shown in Figure 8(A), first, the distance sensors are reset. The control unit 80 sets the measurement distance between the first distance sensors 61, 62, 63 and the second distance sensors 64, 65, 66 to 0 without transporting the workpiece W and without applying load to the first pressurizing cylinder 41, the second pressurizing cylinder 42, the first bending cylinder 51, and the second bending cylinder 52.

[0035] Next, the control unit 80 operates each cylinder so that a predetermined reverse deflection is applied to the upper roll 2 and the lower roll 3 as the workpiece W passes through. As a specific example, the control unit 80 operates the first bending cylinder 51 and the second bending cylinder 52 without transporting the workpiece W and with no load applied to the first pressing cylinder 41 and the second pressing cylinder 42. The predetermined reverse deflection is the amount of deflection that is applied in advance so as to eliminate the deflection that occurs when the workpiece W is roll-pressed without deflection correction. The predetermined reverse deflection is either acquired in advance or set based on experience or the results of other equipment. Figure 8(B) illustrates the shape of the rolls when a load is applied to the first pressing cylinder 41 and the second pressing cylinder 42 and the reaction force of the first bending cylinder 51 and the second bending cylinder 52 is received, in order to explain the reverse deflection. In the actual procedure where no load is applied to the first pressing cylinder 41 and the second pressing cylinder 42, no reverse deflection occurs in the rolls at this stage.

[0036] Next, as shown in Figure 8(C), the control unit 80 transports the workpiece W and puts the first pressurizing cylinder 41, the second pressurizing cylinder 42, the first bending cylinder 51, and the second bending cylinder 52 into a state where a load can be applied. In this way, by putting the control unit 80 into a bend cylinder state that can impart reverse deflection before transporting the workpiece W, it is possible to suppress the occurrence of large deflections at the start of the roll press process.

[0037] [Operation of the roll press machine] Figure 9 is a flowchart illustrating the operation for controlling the deflection of the roll. The flowchart shown in Figure 9 (manufacturing method MT1) is started when the control unit 80 has acquired the allowable range of roll deflection and an operation instruction has been given by the worker. The allowable range of roll deflection is stored in advance, for example, in a memory device. The control unit 80 acquires the allowable range of roll deflection by reading it from the memory device.

[0038] As shown in Figure 9, the sensor unit 60 detects the amount of deflection of the upper roll 2 and the lower roll 3 in step S10. The control unit 80 obtains the amount of deflection from the sensor unit 60. Subsequently, in step S12, the control unit 80 determines whether the amount of deflection detected in step S10 is within a previously obtained allowable range.

[0039] If the amount of deflection detected in step S10 is determined to be within a previously acquired allowable range (step S12: YES), the control unit 80 generates a command in step S14 to maintain the cylinder positions of the first bend cylinder 51 and the second bend cylinder 52. If the amount of deflection detected in step S10 is determined to be outside a previously acquired allowable range (step S12: NO), the control unit 80 generates a command in step S16 to extend or retract the first bend cylinder 51 and the second bend cylinder 52.

[0040] In step S18, the control unit 80 outputs the command generated in step S14 or step S16 to the first bend cylinder 51 and the second bend cylinder 52. The first bend cylinder 51 and the second bend cylinder 52 operate based on the command. This completes the flowchart shown in Figure 9. The manufacturing method MT1 repeatedly executes the flowchart shown in Figure 9 from the beginning until the termination condition is met. The termination condition is met when the scheduled processing of the workpiece W is completed, or when a termination instruction is received from the worker.

[0041] Figure 10 is a flowchart showing the operation for controlling the thickness of the workpiece. The flowchart shown in Figure 10 (manufacturing method MT2) is started when the control unit 80 acquires the target value and tolerance range of the workpiece W and an operation instruction is given by the worker.

[0042] As shown in Figure 10, the thickness sensor unit 70 detects the thickness of the workpiece W in step S20. The control unit 80 obtains the thickness of the workpiece W from the thickness sensor unit 70. Subsequently, in step S22, the control unit 80 determines whether the thickness of the workpiece W detected in step S20 is within a previously obtained tolerance range.

[0043] If it is determined in step S20 that the thickness of the workpiece W is within a previously acquired tolerance range (step S22: YES), the control unit 80 generates a command in step S24 to maintain the cylinder positions of the first pressurizing cylinder 41 and the second pressurizing cylinder 42. If it is determined in step S20 that the thickness of the workpiece W is outside a previously acquired tolerance range (step S22: NO), the control unit 80 generates a command in step S26 to extend or retract the first pressurizing cylinder 41 and the second pressurizing cylinder 42.

[0044] In step S28, the control unit 80 outputs the command generated in step S24 or step S26 to the first pressurizing cylinder 41 and the second pressurizing cylinder 42. The first pressurizing cylinder 41 and the second pressurizing cylinder 42 operate based on the command. This completes the flowchart shown in Figure 10. The manufacturing method MT2 repeatedly executes the flowchart shown in Figure 10 from the beginning until the termination condition is met. The termination condition is met when the scheduled processing of the workpiece W is completed, or when a termination instruction is received from the worker.

[0045] The flowcharts shown in Figures 9 and 10 can be operated independently or executed simultaneously. Furthermore, if thickness sensors corresponding to the first pressurizing cylinder 41 and the second pressurizing cylinder 42 are provided, the flowchart shown in Figure 10 may be executed for the first pressurizing cylinder 41 and the second pressurizing cylinder 42, respectively.

[0046] [Summary of Embodiments] In the roll press device 1, the shapes of the upper roll 2 and the lower roll 3 are measured to detect the deflection of the upper roll 2 and the lower roll 3. In response to the detection of deflection, at least one of the first bend cylinder 51 and the second bend cylinder 52 operates to impart reverse deflection to the upper roll 2 and the lower roll 3. As a result, the deflection of the upper roll 2 and the lower roll 3 is eliminated, and the upper and lower edges of the cross-section in the width direction of the workpiece W become straight lines without curvature. Therefore, the roll press device 1 can obtain a workpiece W with reduced bulging or indentation in the center in the width direction. Thus, compared to the case where the deflection of the upper roll 2 and the lower roll 3 is adjusted based on the thickness of the workpiece W after roll pressing, the roll press device 1 can reduce the amount of workpieces with uneven thickness in the width direction.

[0047] Depending on the material of the workpiece W and the conditions of the roll press processing, simply adjusting the deflection of the upper roll 2 and lower roll 3 may result in the upper and lower edges of the cross-section of the workpiece W being straight lines, but one end of the workpiece W being thicker than the other. Therefore, the roll press device 1 detects the thickness of the workpiece W pressed using the upper roll 2 and lower roll 3 after the deflection has been eliminated, and adjusts the distance between the upper roll 2 and lower roll 3 through feedback control. Since the upper and lower edges of the cross-section of the workpiece W are straight lines without curvature, there is no need to consider the bulge or indentation in the center of the workpiece W in the width direction. Therefore, there is no need to detect the thickness at three points in the width direction and determine their relative sizes. In other words, the roll press device 1 can directly compare the detected thickness of the workpiece W after roll press processing with the target value and feed back to adjust the distance (spacing) between the upper roll 2 and lower roll 3, allowing for faster feedback. Therefore, the roll press device 1 can reduce the amount (length) of defective parts. In addition, since only one or two measurement points are required for thickness, equipment costs are also reduced.

[0048] [Differentiation] Although various exemplary embodiments have been described above, the examples are not limited to those described above, and various omissions, substitutions, and modifications may be made.

[0049] For example, in this embodiment, the first pressurizing cylinder 41 and the second pressurizing cylinder 42 may be configured as a single pressurizing unit. Alternatively, the first pressurizing cylinder 41 and the second pressurizing cylinder 42 may operate synchronously and in the same manner.

[0050] The first main bearing 21 and the second main bearing 22 do not necessarily have to be fixedly supported by the main frame 6. In other words, the first main bearing 21 and the second main bearing 22 may be configured to be pressurized by a pressurizing cylinder.

[0051] The roll press device 1 may be operated to impart a desired amount of deflection. For example, the roll press device 1 can also be used to adjust the thickness of the workpiece W after roll pressing, making it thicker in the center in the width direction or thinner in the center.

[0052] The roll press device 1 may acquire the coating pattern before the roll press process if the workpiece W is intermittently coated. For example, one pattern detection sensor can be installed upstream of the upper roll 2 and the lower roll 3. The pattern detection sensor is, as an example, a thickness sensor. The roll press device 1 may then calculate the start and end timings for pressing the coated portion based on the coating pattern. The roll press device 1 may also adjust the first press cylinder 41 and the second press cylinder 42 so that excessive load is not applied at the start and end timings for pressing the coated portion. This can increase the yield rate.

[0053] The roll press device 1 may be equipped with pattern detection sensors corresponding to the first pressure cylinder 41 and the second pressure cylinder 42. In this case, the start and end timings for pressing the coated portion can be adjusted for each of the first pressure cylinder 41 and the second pressure cylinder 42 to prevent excessive load from being applied. Furthermore, even if there is variation (undulation) in the coating thickness in the feeding direction, appropriate roll pressing can be performed, thereby suppressing variations in the thickness of the workpiece W after roll pressing.

[0054] The roll press device 1 may be equipped with three or more pattern detection sensors upstream of the upper roll 2 and the lower roll 3. In this case, the control unit 80 can determine the thickness trend (uniformity, inclination, etc.) at the edges and center in the width direction of the coating based on the detection results of the pattern detection sensors. Based on the determined thickness trend of the coating, the control unit 80 may correct the amount of movement of the first bend cylinder 51 and the second bend cylinder 52. The control unit 80 also calculates the increase or decrease in the distance (gap) between the upper roll 2 and the lower roll 3 that changes as a result of this correction. The control unit 80 may then adjust the first pressurizing cylinder 41 and the second pressurizing cylinder 42 based on the calculated distance. Alternatively, the control unit 80 may apply the correction only to the upper rotation axis 20 of the fixed roll (in this case, the upper roll 2). In other words, when applying the correction, the control unit 80 may configure it to lift only the first bend bearing 23 and the second bend bearing 24 upward. This simplifies the control calculations for the first pressurizing cylinder 41 and the second pressurizing cylinder 42.

[0055] The roll press device 1 may operate the first bend cylinder 51 and the second bend cylinder 52 using position control with position as the control value, or it may operate using load control with load as the control value.

[0056] [Summary of the embodiments of this disclosure] This disclosure includes the following aspects:

[0057] (Clause 1) The roll press apparatus comprises a first roll having a first rotation axis and a second roll having a second rotation axis, which clamp the workpiece to be conveyed; a first bearing and a second bearing provided at both ends of the first rotation axis, respectively; a third bearing and a fourth bearing, provided at both ends of the second rotation axis, which are opposite to the first bearing and opposite to the second bearing; a first bend bearing and a second bend bearing, provided at both ends of the first rotation axis, which are located outside the first bearing and outside the second bearing; a third bend bearing and a fourth bend bearing, provided at both ends of the second rotation axis, which are located outside the third bearing and opposite to the first bend bearing and opposite to the fourth bearing; and a load applied to at least one of the first bearing and the third bearing in the direction in which the first roll and the second roll are close together. The system includes: a first pressurizing unit that applies a load; a second pressurizing unit that applies a load to at least one of the second bearing and the fourth bearing in a direction that brings the first roll and the second roll closer together; a first bending unit that applies a load to the first bending bearing and the third bending bearing in a direction that brings the first roll and the second roll closer together or further apart; a second bending unit that applies a load to the second bending bearing and the fourth bending bearing in a direction that brings the first roll and the second roll closer together or further apart; a sensor unit that measures the shapes of the first roll and the second roll and detects the deflection of the first roll and the second roll; and a control unit that operates at least one of the first bending unit and the second bending unit so that a reverse deflection is applied to the first roll and the second roll in response to the deflection detected by the sensor unit.

[0058] In this roll press apparatus, the shapes of the first and second rolls are measured, and the deflection of the first and second rolls is detected. In response to the detected deflection, at least one of the first and second bend units operates to impart reverse deflection to the first and second rolls. Reverse deflection is a deflection that bends in the opposite direction to the deflection detected by the sensor unit. As a result, the deflection of the first and second rolls is eliminated, and the upper and lower edges of the cross-section in the width direction of the workpiece become straight lines without curvature. Therefore, the roll press apparatus can produce workpieces with reduced bulging or indentation in the center in the width direction. Thus, compared to adjusting the deflection of the first and second rolls based on the thickness of the workpiece after roll pressing, the roll press apparatus can reduce the amount of workpieces with uneven thickness in the width direction.

[0059] (Clause 2) In the roll press apparatus described in Clause 1, if the deflection detected by the sensor unit is such that the center of the first roll is further away from the second roll than both ends, and the center of the second roll is further away from the first roll than both ends, the control unit may operate the first bend unit to apply a load to the first bend bearing and the third bend bearing in the direction that separates the first roll and the second roll, and operate the second bend unit to apply a load to the second bend bearing and the fourth bend bearing in the direction that separates the first roll and the second roll. For example, if the first roll and the second roll are arranged vertically, the first roll has a shape that deflects so that its center protrudes upward than both ends, and the second roll has a shape that deflects so that its center protrudes downward than both ends. In this case, since the opposing bend bearings are subjected to loads in the opposite directions that separate them, the first roll and the second roll are subjected to opposite deflections, and the roll press apparatus can eliminate the deflection of the first roll and the second roll.

[0060] (Clause 3) In the roll press apparatus described in Clause 1 or 2, if the deflection detected by the sensor unit is such that the center of the first roll is closer to the second roll than both ends, and the center of the second roll is closer to the first roll than both ends, the control unit may perform at least one of the following: operate the first bend unit to apply a load to the first bend bearing and the third bend bearing in the direction that brings the first roll and the second roll closer together; and operate the second bend unit to apply a load to the second bend bearing and the fourth bend bearing in the direction that brings the first roll and the second roll closer together. For example, if the first roll and the second roll are arranged vertically, the first roll has a shape that deflects so that its center protrudes downwards than both ends, and the second roll has a shape that deflects so that its center protrudes upwards than both ends. In this case, since the opposing bend bearings are subjected to loads in the direction that brings them closer together, the first roll and the second roll are subjected to opposite deflections, and the roll press apparatus can eliminate the deflections of the first roll and the second roll.

[0061] (Clause 4) In the roll press apparatus described in any one of Clauses 1 to 3, the sensor unit may include three or more first distance sensors arranged in a straight line along the first rotation axis and three or more second distance sensors arranged in a straight line along the second rotation axis. In this case, the roll press apparatus can detect the amount of deflection for each roll, and the amount of deflection can be detected with high accuracy because the three distance sensors are arranged in the same straight line. (Clause 5) In the roll press apparatus described in Clause 4, each first distance sensor and each second distance sensor may be arranged on a straight line passing through the center point of the cross-section of the first roll and the center point of the cross-section of the second roll. In this case, the roll press apparatus can detect the deflection of the first roll and the second roll with greater accuracy. (Clause 6) The roll press apparatus described in any one of Clauses 1 to 5 further comprises a thickness sensor unit provided downstream of the first and second rolls, which detects the thickness of the workpiece at one or two locations in the width direction of the workpiece, and the control unit may operate at least one of the first and second press units so that the detection result of the thickness sensor unit becomes a predetermined target value. Depending on the material of the workpiece, the conditions of the roll press processing, etc., simply adjusting the deflection of the upper and lower rolls may result in the upper and lower edges of the cross-section in the width direction of the workpiece being straight lines, but one end of the workpiece in the width direction being thicker than the other. For this reason, the roll press apparatus detects the thickness of the workpiece pressed using the upper roll 2 and lower roll 3 after the deflection has been eliminated, and adjusts the distance between the upper and lower rolls by feedback control. Since the upper and lower edges of the cross-section of the workpiece are straight lines without curvature, there is no need to consider the bulge or indentation in the center of the workpiece in the width direction. Therefore, there is no need to detect the thickness at three points in the width direction and determine their relative sizes. In other words, the roll press machine can directly compare the detected thickness of the workpiece after roll pressing with the target value and use that feedback to adjust the distance (spacing) between the first and second rolls, thus enabling faster feedback. Therefore, the roll press machine can reduce the amount (length) of defective parts. In addition, since thickness measurement is only required at one or two locations, equipment costs are also reduced.

[0062] (Clause 7) A method for manufacturing a workpiece relating to other aspects of the present disclosure includes: a first roll having a first rotation axis and a second roll having a second rotation axis, which clamp a workpiece being transported; a first bearing and a second bearing provided at both ends of the first rotation axis, respectively; a third bearing and a fourth bearing, provided at both ends of the second rotation axis, opposite to the first bearing and opposite to the second bearing; a first bend bearing and a second bend bearing, provided at both ends of the first rotation axis, which are located outside the first bearing and outside the second bearing; a third bend bearing and a fourth bend bearing, provided at both ends of the second rotation axis, which are located outside the third bearing and opposite to the first bend bearing and opposite to the fourth bend bearing; a first pressurizing unit that applies a load to at least one of the first bearing and the third bearing in a direction that brings the first roll and the second roll closer together; and a small portion of the second bearing and the fourth bearing. A method for manufacturing a workpiece using a roll press apparatus comprising, at least one of the following: a second pressing unit that applies a load in a direction that brings the first roll and the second roll closer together; a first bending unit that applies a load to the first bending bearing and the third bending bearing in a direction that brings the first roll and the second roll closer together or further apart; a second bending unit that applies a load to the second bending bearing and the fourth bending bearing in a direction that brings the first roll and the second roll closer together or further apart; and a sensor unit that measures the shapes of the first roll and the second roll and detects the deflection of the first roll and the second roll, the method comprising: determining whether or not deflection has been detected by the sensor unit; and operating at least one of the first bending unit and the second bending unit so as to impart reverse deflection to the first roll and the second roll in response to the detection of deflection by the sensor unit. This method produces the same effect as the apparatus described above. [Explanation of Symbols]

[0063] 1...Roll press device, 2...Upper roll (example of the first roll), 3...Lower roll (example of the second roll), 21...First main bearing (example of the first bearing), 22...Second main bearing (example of the second bearing), 23...First bend bearing, 24...Second bend bearing, 31...Third main bearing (example of the third bearing), 32...Fourth main bearing (example of the fourth bearing), 33...Third bend bearing, 34...Fourth bend bearing, 41...First pressurizing cylinder (example of the first pressurizing unit), 42...Second pressurizing cylinder (example of the second pressurizing unit), 51...First bend cylinder (example of the first bend unit), 52...Second bend cylinder (example of the second bend unit), 60...Sensor unit, 61, 62, 63...First distance sensor, 64, 65, 66...Second distance sensor, 70...Thickness sensor unit, 80...Control unit, W...Workpiece.

Claims

1. A first roll having a first rotation axis and a second roll having a second rotation axis, which grip the workpiece being transported, The first bearing and the second bearing are provided at both ends of the first rotating shaft, A third bearing is provided at each end of the second rotating shaft, facing the first bearing, and a fourth bearing is provided facing the second bearing. A first bend bearing is provided at each end of the first rotating shaft, and a second bend bearing is provided at the outside of the first bearing and at the outside of the second bearing, A third bend bearing is provided at each end of the second rotating shaft, located outside the third bearing and facing the first bend bearing, and a fourth bend bearing is located outside the fourth bearing and facing the second bend bearing. A first pressurizing unit that applies a load to at least one of the first bearing and the third bearing in a direction that brings the first roll and the second roll closer together, A second pressurizing unit is provided to at least one of the second bearing and the fourth bearing, which applies a load in the direction that brings the first roll and the second roll closer together. A first bending unit that applies a load to the first bending bearing and the third bending bearing in a direction that brings the first roll and the second roll closer together or further apart, A second bending unit applies a load to the second bending bearing and the fourth bending bearing in a direction that brings the first roll and the second roll closer together or further apart. A sensor unit that measures the shapes of the first roll and the second roll and detects the deflection of the first roll and the second roll, A control unit that operates at least one of the first bend unit and the second bend unit so as to impart reverse deflection to the first roll and the second roll in response to the detection of deflection by the sensor unit, A roll press device equipped with the following features.

2. If the deflection detected by the sensor unit is such that the center of the first roll is further away from the second roll than both ends, and the center of the second roll is further away from the first roll than both ends, The control unit, The first bending unit is operated such that a load is applied to the first bending bearing and the third bending bearing in a direction that causes the first roll and the second roll to move apart. The second bending unit is operated such that a load is applied to the second bending bearing and the fourth bending bearing in a direction that causes the first roll and the second roll to move apart. A roll press apparatus according to claim 1, which performs at least one of the following:

3. If the deflection detected by the sensor unit is such that the center of the first roll is closer to the second roll than both ends, and the center of the second roll is closer to the first roll than both ends, The control unit, The first bending unit is operated such that a load is applied to the first bending bearing and the third bending bearing in a direction that brings the first roll and the second roll closer together. The second bending unit is operated such that a load is applied to the second bending bearing and the fourth bending bearing in a direction that brings the first roll and the second roll closer together. A roll press apparatus according to claim 1 or 2, which performs at least one of the following:

4. The roll press apparatus according to claim 1 or 2, wherein the sensor unit includes three or more first distance sensors arranged in a straight line along the first rotation axis and three or more second distance sensors arranged in a straight line along the second rotation axis.

5. The roll press apparatus according to claim 4, wherein each first distance sensor and each second distance sensor are arranged on a straight line passing through the center point of the cross-section of the first roll and the center point of the cross-section of the second roll.

6. Further comprising a thickness sensor unit provided downstream of the first and second rolls, which detects the thickness of the workpiece at one or two locations in the width direction of the workpiece, The roll press apparatus according to claim 1 or 2, wherein the control unit operates at least one of the first pressurizing unit and the second pressurizing unit so that the detection result of the thickness sensor unit becomes a predetermined target value.

7. A first roll having a first rotation axis and a second roll having a second rotation axis, which grip the workpiece being transported, The first bearing and the second bearing are provided at both ends of the first rotating shaft, A third bearing is provided at each end of the second rotating shaft, facing the first bearing, and a fourth bearing is provided facing the second bearing. A first bend bearing is provided at each end of the first rotating shaft, and a second bend bearing is provided at the outside of the first bearing and at the outside of the second bearing, A third bend bearing is provided at each end of the second rotating shaft, located outside the third bearing and facing the first bend bearing, and a fourth bend bearing is located outside the fourth bearing and facing the second bend bearing. A first pressurizing unit that applies a load to at least one of the first bearing and the third bearing in a direction that brings the first roll and the second roll closer together, A second pressurizing unit is provided to at least one of the second bearing and the fourth bearing, which applies a load in the direction that brings the first roll and the second roll closer together. A first bending unit that applies a load to the first bending bearing and the third bending bearing in a direction that brings the first roll and the second roll closer together or further apart, A second bending unit applies a load to the second bending bearing and the fourth bending bearing in a direction that brings the first roll and the second roll closer together or further apart. A sensor unit that measures the shapes of the first roll and the second roll and detects the deflection of the first roll and the second roll, A method for manufacturing a processed product using a roll press device equipped with the following: The steps include determining whether or not deflection has been detected by the sensor unit, The steps include: operating at least one of the first bend unit and the second bend unit so that a reverse deflection is applied to the first roll and the second roll in response to the detection of deflection by the sensor unit; A method for manufacturing processed goods, including those mentioned above.

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