Winding device and winding system

Abstract

To provide a winding device that eliminates the need to bend the foil material when obtaining a wound body. [Solution] The winding device has a cylindrical or cylindrical shaft portion that rotates around a predetermined central axis and has an outer surface around which the supplied foil material is wound, and a first magnet provided on or inside the outer surface of the shaft portion that exerts a magnetic force on the foil material and causes the foil material to stick to the outer surface.

Description

Technical Field

[0001] The present invention relates to a winding device and a winding system.

Background Art

[0002] The tip of a foil material such as a corrugated plate or a flat plate is bent and the shaft portion is rotated while being hooked in a groove or the like on the outer peripheral surface of a cylindrical or columnar shaft portion, and the foil material is wound to obtain a wound body.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In a wound body using, for example, a corrugated plate as a foil material, the tops of the corrugated plates may or may not overlap each other. Therefore, the outer diameters of the wound bodies tend to be non-uniform. Further, it has been found that the outer periphery of the bent portion of the foil material constituting the wound body obtained by bending, for example, the tip of the foil material and hooking it on the outer periphery of the shaft portion is likely to bulge.

[0005] An object of the present invention is to provide a winding device that does not require bending of a foil material when obtaining a wound body, and a winding system having the winding device.

Means for Solving the Problems

[0006] A winding device according to an aspect of the present invention includes a columnar or cylindrical shaft portion that rotates around a predetermined central axis and has an outer peripheral surface around which a supplied foil material is wound, and a first magnet provided on the outer peripheral surface of the shaft portion or inside thereof, which applies a magnetic force to the foil material and attaches the foil material to the outer peripheral surface.

Effects of the Invention

[0007] According to the present invention, it is possible to provide a winding device that does not require bending of foil material when obtaining a wound body, and a winding system having the winding device. [Brief explanation of the drawing]

[0008] [Figure 1] A schematic diagram showing a winding system according to one embodiment. [Figure 2] A schematic block diagram of the winding system shown in Figure 1. [Figure 3] Figures 1 and 2 show the operation flow when winding the supplied foil material using the winding system. [Figure 4] A schematic diagram showing the winding system when the tip of the foil material is at the origin position. [Figure 5] (A) is a schematic diagram showing the positional relationship between the winding device, movable base, and winding retainer when the leading edge of the foil material is at the origin position, and (B) is a schematic diagram viewed from the direction indicated by arrow 5B in (A). [Figure 6] A schematic diagram of the winding system showing the tip of the foil material advanced from the origin position to the base member of the movable base. [Figure 7] (A) is a schematic diagram showing the positional relationship between the winding device, the movable base, and the winding retainer when the tip of the foil material is advanced from the origin position to the base member of the movable base, and (B) is a schematic diagram viewed from the direction indicated by arrow 7B in (A). [Figure 8] (A) is a schematic diagram showing the positional relationship between the winding device, movable base, and winding retainer when the shaft is rotated from the position shown in Figure 7(A) to attach the tip of the foil material to the first magnet, and (B) is a schematic diagram viewed from the direction indicated by arrow 8B in (A). [Figure 9] (A) is a schematic diagram showing the positional relationship between the winding device, the movable base, and the winding retainer when the rod-shaped member of the winding retainer is extended downward from the position shown in Figure 8(A), and (B) is a schematic diagram viewed from the direction indicated by arrow 9B in (A). [Figure 10](A) is a schematic diagram showing the positional relationship of the winding device, movable base, and winding retainer after the shaft is rotated from the position shown in Figure 9(A) to attach the foil material to the first magnet and then to the second magnet, and (B) is a schematic diagram viewed from the direction indicated by arrow 10B in (A). [Figure 11] (A) is a schematic diagram showing the positional relationship between the winding device, the movable base, and the winding retainer when the base member of the movable base is retracted relative to the outer surface of the shaft from the position shown in Figure 10(A), and (B) is a schematic diagram viewed from the direction indicated by arrow 11B in (A). [Figure 12] (A) is a schematic diagram showing the positional relationship between the winding device, the movable base, and the winding retainer when the shaft is rotated from the position shown in Figure 11(A) to wind the foil material onto the outer surface of the shaft, and (B) is a schematic diagram viewed from the direction indicated by arrow 12B in (A). [Figure 13] A schematic diagram showing the winding system immediately after the rotation of the corrugated sheet feed gear and shaft has stopped, after the foil material has been fed a predetermined number of waves. [Figure 14] This schematic diagram shows the winding system after the corrugated sheet has reached the state shown in Figure 13, the shaft is rotated to suppress the deflection of the foil material, and the foil material has been cut with a cutter. [Figure 15] (A) is a schematic diagram showing the relative positions of the winding device, movable base, and winding presser immediately after the foil material has been cut with a cutter, and (B) is a schematic diagram viewed from the direction indicated by arrow 15B in (A). [Figure 16] (A) is a schematic diagram showing the positional relationship between the winding device, movable base, and winding presser when the shaft has been rotated from the position shown in Figure 15(A) and the foil material has been wound onto the outer surface of the shaft, and (B) is a schematic diagram viewed from the direction indicated by arrow 16B in (A). [Figure 17] (A) is a schematic diagram showing the positional relationship between the winding device, the movable base, and the winding retainer when the roller is retracted upward from the position shown in Figure 16(A), and (B) is a schematic diagram viewed from the direction indicated by arrow 17B in (A). [Figure 18](A) is a schematic diagram showing the positional relationship among the winding device, the movable base, and the winding retainer in a state where the discharge plate is moved along the central axis of the shaft portion from the position shown in Fig. 17(A), and (B) is a schematic diagram viewed from the direction indicated by arrow 18B in (A). [Figure 19] (A) is a schematic diagram showing the positional relationship among the winding device, the movable base, and the winding retainer when the tip of the foil material is at the origin position, and (B) is a schematic diagram viewed from the direction indicated by arrow 19B in (A).

Embodiments for Carrying out the Invention

[0009] Hereinafter, embodiments for carrying out this invention will be described with reference to the drawings.

[0010] An embodiment of the winding system 10 will be described with reference to FIGS. 1 to 18. Here, mainly, an example of winding a corrugated plate (a plate with a substantially sinusoidal bend having a predetermined pitch and a predetermined amplitude) as the foil material 5 will be described, but it may also be used for winding a flat plate formed of the foil material 5. Note that the foil material 5 used in the winding system 10 according to this embodiment may be appropriately formed with through holes (vent passages), or may not be formed with through holes. When through holes are formed, the magnetic force by the magnets 34 and 36 described later is more likely to reach the outer peripheral side of the winding body 1.

[0011] In this embodiment, as the foil material 5, a metal material that adheres to a magnet is used. As the foil material 5, for example, ferritic stainless steel, martensitic stainless steel, or the like is used. As an example, the thickness of the foil material 5 is allowed to be about several tens of μm to several mm or less.

[0012] FIG. 1 shows a schematic diagram of the winding system 10. Here, an XYZ orthogonal coordinate system is taken in FIG. 1. The +X-axis direction is the direction in which the foil material 5 to be wound is conveyed along the conveying surface 52 of the conveying unit 16. The +Y-axis direction is along the depth direction orthogonal to the paper surface of FIG. 1. The +Z-axis direction is the direction toward the upper side of FIG. 1. Note that the origin O of the XYZ orthogonal coordinate system is taken at the position where the foil material 5 is cut by the cutter 20.

[0013] FIG. 2 shows a schematic block diagram of the winding system 10 shown in FIG. 1.

[0014] As shown in FIG. 1, the winding system 10 includes a winding device 12, a movable base 14, a conveying unit 16, a first sensor 18, a cutter 20, a second sensor 22, a winding retainer 24, a control unit 26 (see FIG. 2), and a storage box 28.

[0015] The winding device 12 includes a housing 30, a shaft portion (winding roller) 32, a first magnet 34, a second magnet 36, and a discharge plate (pusher) 38.

[0016] The housing 30 forms the frame of the winding device 12. The shaft portion 32, the first magnet 34, and the second magnet 36 are provided in the housing 30.

[0017] The shaft portion 32 is rotatably supported about the axis of a predetermined central axis C with respect to the housing 30. The shaft portion 32 is rotatable about the axis of the predetermined central axis C and is formed in a columnar (cylindrical body) or cylindrical (cylindrical body) shape having an outer peripheral surface around which the supplied foil material 5 is wound. The predetermined central axis C is provided parallel to the Y-axis. The length of the shaft portion 32 in the Y-axis direction may be greater than or less than the width of the conveying surface 52 in the Y-axis direction.

[0018] The winding system 10 shown in FIG. 2 has a first drive source (actuator) 32a provided on the shaft portion 32. The first drive source 32a is, for example, a motor or the like that rotates the shaft portion 32 about the axis of the predetermined central axis C. The first drive source 32a is controlled, for example, in terms of torque or rotational speed by the control unit 26.

[0019] The first magnet 34 shown in Figure 1 is provided on the outer circumferential surface of the shaft portion 32 or on its inner side. The first magnet 34 is shown as a rectangle when viewed from the Y-axis direction, but various shapes are permitted. The first magnet 34 exerts a magnetic force on the foil material 5, causing the foil material 5 to stick to the outer circumferential surface of the shaft portion 32. Preferably, the magnetic force of the first magnet 34 is formed to act in such a way that, when the foil material 5 is a corrugated sheet, the outermost foil material 5 of the wound body 1 is pulled toward the outer circumferential surface of the shaft portion 32.

[0020] The second magnet 36 is provided on the outer surface of the shaft portion 32 or inside it, spaced apart from the first magnet 34 in the circumferential direction of the outer surface of the shaft portion 32. The second magnet 36 is illustrated as a rectangle when viewed from the Y-axis direction, but various shapes are permitted. The distance between the first magnet 34 and the second magnet 36 is preferably greater than 0° and within 90° with respect to a predetermined central axis C. The second magnet 36 exerts a magnetic force on the foil material 5, causing the foil material 5 to stick to the outer surface. When the foil material 5 is a corrugated sheet, the magnetic force of the second magnet 36 is preferably formed to pull the outermost foil material 5 of the wound body 1 toward the outer surface of the shaft portion 32.

[0021] The first magnet 34 and the second magnet 36 are preferably permanent magnets, but electromagnets may also be used. If electromagnets are used, the control unit 26 may control the on / off state of the magnetic force of the first magnet 34 and the second magnet 36.

[0022] Furthermore, the magnetic forces of the first magnet 34 and the second magnet 36 are determined by the material of the foil material 5 constituting the winding body 1, the pitch and amplitude of the corrugated waves, the assumed outer diameter of the winding body 1, and the ease with which the winding body 1 can be discharged from the shaft portion 32.

[0023] The first magnet 34 and the second magnet 36 are positioned so as to be centered in the width direction of the foil material 5 being transported. In this embodiment, it is assumed that the foil material 5 passes through the center in the width direction of the transport surface 52 of the transport section 16. It is also assumed that the foil material 5 passes through the center in the width direction of the shaft section 32. In this case, the first magnet 34 and the second magnet 36 are positioned at the center or approximately center in the width direction (Y-axis direction) of the foil material 5 wound around the outer circumferential surface of the shaft section 32.

[0024] If the foil material 5 being transported is positioned biased towards one end in the width direction of the transport surface 52 of the transport section 16, the first magnet 34 and the second magnet 36 are positioned not at the center or approximately center of the shaft section 32, but shifted towards one end. Even in this case, the first magnet 34 and the second magnet 36 are positioned so as to be centered in the width direction of the foil material 5 being transported.

[0025] Thus, the first magnet 34 and the second magnet 36 are provided on the outer surface of the shaft portion 32 or on its inner side so that there is no bias in the magnetic force applied to the foil material 5 when the foil material 5 is wound, or the bias is minimized. For this reason, the first magnet 34 and the second magnet 36 are arranged on the shaft portion 32 so as to exert magnetic force on the center of the foil material 5 in the width direction, or they may be arranged at equal intervals along the width direction of the foil material 5 so as to exert magnetic force without bias in the width direction of the foil material 5.

[0026] The first magnet 34 and the second magnet 36 may each be used individually or in combination of multiple magnets. The first magnet 34 and the second magnet 36 may each be stacked, for example, along the radial direction of the shaft portion 32. When multiple first magnets 34 and second magnets 36 are arranged in the Y-axis direction, it is preferable that the gap between the magnets is located in the center of the foil material 5. For this reason, it is preferable that the first magnet 34 is provided so as to exert a magnetic force symmetrically in the width direction with respect to the center of the foil material 5 in the width direction along the axial direction of the shaft portion 32. Similarly, it is preferable that the second magnet 36 is provided so as to exert a magnetic force symmetrically in the width direction with respect to the center of the foil material 5 in the width direction along the axial direction of the shaft portion 32.

[0027] The discharge plate 38 has an annular portion 39 which serves as a through hole through which the outer circumferential surface of the shaft portion 32 is inserted. When the winding body 1 is being created, the discharge plate 38 is positioned at one end of the outer circumferential surface of the shaft portion 32 in the Y-axis direction, and the winding body 1 can be moved along the outer circumferential surface of the shaft portion 32 to the other end. The annular portion 39 of the discharge plate 38 moves so as not to come into contact with the first magnet 34 and the second magnet 36.

[0028] In order to discharge the wound corrugated sheet 5 attached to the magnets 34 and 36, it is necessary to minimize the clearance between the annular portion 39 of the discharge plate 38 and the outer surface of the shaft portion 32 so as not to damage the corrugated sheet 5 during discharge. For example, suppose the minimum height of the corrugated sheet 5 is 1.25 mm. In this case, it is preferable that the hole diameter of the annular portion 39 of the discharge plate 38 be 61.2 mm, given that the outer diameter of the shaft portion 32 is 60 mm. In this case, the discharge plate 38 can be in contact with the corrugated sheet 5 for approximately half of its height.

[0029] Furthermore, because the clearance between the annular portion 39 of the discharge plate 38 and the outer surface of the shaft portion 32 is small, it is necessary to design the system so that the discharge plate 38 does not come off the shaft portion 32 when the discharge plate 38 is in the forward position (see Figure 18(B)).

[0030] Furthermore, with respect to the discharge plate 38, parts of the first retainer 72 and the second retainer 74 are positioned to interfere if the discharge plate 38 is moved relative to the shaft portion 32. However, parts of the first retainer 72 and the second retainer 74 move relative to the discharge plate 38 so as not to interfere with each other. This is controlled, for example, by the control unit 26.

[0031] The winding system 10 shown in Figure 2 has a second drive source (actuator) 38a provided on the discharge plate 38. The second drive source 38a is a linear actuator (electric cylinder) using a motor and ball screw, etc., or an air cylinder, which moves the discharge plate 38 in the Y-axis direction parallel to a predetermined central axis C. The second drive source 38a is controlled by the control unit 26.

[0032] Therefore, each time a wound body 1 is created, the discharge plate 38 moves from one end of the shaft portion 32 in the Y-axis direction to the other end, pushing the wound body 1 towards the other end of the shaft portion 32.

[0033] In this embodiment, the operation of the discharge plate 38 is described using an example where the second drive source 38a is used, but the discharge plate 38 may also be moved manually along the Y-axis.

[0034] The movable base 14 can move horizontally along the tangential direction of the outer surface of the shaft portion 32, allowing it to approach and move away from the outer surface of the shaft portion 32. When the movable base 14 approaches the outer surface of the shaft portion 32, it guides the foil material 5 to the outer surface of the shaft portion 32.

[0035] The movable base 14 includes a base member (plate-shaped member) 42 that moves horizontally and has a plane for guiding the foil material 5, a third drive source (actuator) 44 that allows the base member 42 to move closer to and further away from the outer circumferential surface of the shaft portion 32, and a connecting member 46.

[0036] The base member 42 is made of a material that exhibits a magnetic shielding effect. It is preferable that the base member 42 be made of a soft magnetic material or a non-magnetic material. An example of a material for the base member 42 is stainless steel.

[0037] The third drive source 44 is controlled by the control unit 26. For example, an air cylinder is used as the third drive source 44. It is preferable to use a double-acting type air cylinder 44. It is preferable that the cylinder portion 44a of the air cylinder 44 is fixed to, for example, the housing 50 of the conveying unit 16, which will be described later, and that the rod portion 44b is extendable and retractable in a predetermined direction relative to the cylinder portion 44a. The rod portion 44b is connected to the base member 42 and the connecting member 46. As a result, when the rod portion 44b of the air cylinder 44 extends and retracts, the base member 42 fixed to the rod portion 44b can move between predetermined positions relative to the outer circumferential surface of the shaft portion 32. In addition, the base member 42 moves relative to the discharge plate 38 so as not to interfere with each other. This is controlled, for example, by the control unit 26.

[0038] When the base member 42 moves from the position indicated by the solid line in Figure 1 (see Figure 5) to the position furthest towards the +X axis (indicated by the dashed line in Figure 1), the end (downstream end) 42a of the base member 42 is positioned above the first magnet 34 shown in Figures 5 and 6 (in the +Z axis direction). The base member 42 is made of a material such that the magnetic force of the first magnet 34 does not affect the foil material 5 that is guided to the outer circumferential surface of the shaft portion 32 through the base member 42.

[0039] Furthermore, the clearance (in the Z-axis direction) between the upper surface of the base member 42 of the movable base 14 and the outer circumferential surface of the shaft portion 32 should be as small as possible. Depending on the strength of the movable base 14, a clearance of about 1 mm is preferable.

[0040] The conveying unit 16 conveys the foil material 5 in a predetermined direction. More specifically, the conveying unit 16 feeds the foil material 5 to the outer circumferential surface of the shaft portion 32 of the winding device 12. The conveying unit 16 comprises a housing 50, a conveying surface 52, and a corrugated sheet feed gear 54 that feeds the foil material 5 from the upstream side to the downstream side along the conveying surface 52.

[0041] The housing 50 is provided with a transport surface 52 and a corrugated sheet feed gear 54.

[0042] The conveying surface 52 can be a simple flat surface, and various types such as rollers and belts can be used. Preferably, the conveying surface 52 is formed as a horizontal surface that conveys the foil material 5 in the horizontal direction. The length of the conveying surface 52 in the depth direction (Y-axis direction) is formed to be greater than the width of the foil material 5 in the width direction. The smaller the clearance between the conveying surface 52 and the guide surface (upper surface) of the base member 42 of the movable base 14, the better. In this embodiment, the conveying surface 52 is positioned, for example, about 8 mm to 10 mm higher than the guide surface (upper surface) of the base member 42 of the movable base 14.

[0043] Furthermore, the downstream end 52a of the conveying surface 52 is positioned downstream (towards the X-axis) of the upstream end 42b of the base member 42 of the movable base 14, regardless of the position of the base member 42 within its movable range. Therefore, the downstream end 52a of the conveying surface 52 is positioned along the X-axis between the downstream end 42a and the upstream end 42b of the base member 42.

[0044] The corrugated sheet feed gear 54 does not move relative to the conveying surface 52, but rotates in place around a rotation axis parallel to a predetermined central axis C of the shaft portion 32. There is a gap between the conveying surface 52 and the lower end of the corrugated sheet feed gear 54 into which the corrugated sheet, as foil material 5, fits. The gap depends on the pitch, amplitude, etc., of the corrugated sheet, as foil material 5. The corrugated sheet feed gear 54 is used in the same way as a spur gear (pinion gear), and the corrugated sheet 5 is preferably used in the same way as a rack. Therefore, the relationship between the corrugated sheet, as foil material 5, and the corrugated sheet feed gear 54 is used in the same way as a rack and pinion relationship. As a result, the corrugated sheet feed gear 54, by rotating in a predetermined direction in place, contacts the surface of the corrugated sheet, as foil material 5, and can move the corrugated sheet, as foil material 5, along the conveying surface 52 from the upstream side to the downstream side.

[0045] The length of each corrugated sheet feed gear 54 in the depth direction (Y-axis direction) may be longer or shorter than the width of the foil material 5, or they may be formed to be approximately the same length. The corrugated sheet feed gear 54 may be formed so that multiple gears, spaced appropriately apart with a width smaller than the width of the foil material 5 in the depth direction, move in conjunction with each other. In this embodiment, the length of the corrugated sheet feed gear 54 in the depth direction is assumed to be longer than the width of the foil material 5.

[0046] The winding system 10 shown in Figure 2 is provided in the housing 50 and has a fourth drive source (actuator) 56 that rotates the corrugated sheet feed gear 54. The rotational speed of the third drive source 56 is controlled by the control unit 26, for example. A motor or the like can be used for the third drive source 56. The third drive source 56 is used as a crest counter to count the number of crests of the corrugated sheet 5 corresponding to the rotational speed of the corrugated sheet feed gear 54. When winding a corrugated sheet as foil material 5, the corrugated sheet 5 can be wound with a predetermined number of crests.

[0047] Furthermore, the feeding speed of the corrugated sheet 5 by the corrugated sheet feed gear 54 is greater than the winding speed of the corrugated sheet 5 at the shaft 32. In other words, the control unit 26 controls the drive sources 32a and 56, respectively, so that the feeding speed that sends the foil material 5 to the outer surface of the shaft 32 is greater than the winding speed of the foil material 5 at the shaft 32. This prevents the pitch between the peaks of the corrugated sheets 5 from stretching.

[0048] A first sensor 18 is provided on the transport surface 52 of the transport unit 16. The first sensor 18 is provided upstream of the cutter 20 of the transport unit 16. The first sensor 18 is a touch sensor having a contact surface that detects contact with the foil material 5. The contact surface of the touch sensor 18 may be flush with the transport surface 52, but it is preferable that it protrudes slightly in the +Z axis direction, for example by about 0.5 mm. The touch sensor 18 is controlled by the control unit 26 to detect contact and separation of the foil material 5 from the transport surface 52 of the transport unit 16. The touch sensor 18 should be positioned to detect contact with the foil material 5 at the center of the foil material 5 in the width direction. In this embodiment, since the foil material 5 is a corrugated sheet, multiple (two in this case) touch sensors 18 are arranged spaced apart in the X axis direction. It is preferable that such a distance is set so that one of the lower tops of the corrugated sheet 5 is in contact with both touch sensors 18.

[0049] In addition, as the first sensor 18, a photoelectric sensor fixed to the transport surface 52 or its vicinity within the housing 50 may be used. In this case, the photoelectric sensor 18 can, for example, emit laser light in the Y-axis direction and detect whether the top of the corrugated sheet (foil material) 5, which is transported in the X-axis direction, is in contact with or separated from the transport surface 52.

[0050] The first sensor 18 may also detect the proximity and separation of the foil material 5 from the transport unit 16. In other words, the first sensor 18 does not necessarily have to detect contact between the foil material 5 and the transport surface 52 on the transport unit 16, but may also detect whether the foil material 5 has moved closer to the transport surface 52 on the transport unit 16 than a predetermined distance, or whether it has moved further away from the transport surface 52 on the transport unit 16 than a predetermined distance.

[0051] The cutter 20 is located on the downstream side of the transport unit 16, along the flow direction of the foil material 5 relative to the touch sensor 18. In this embodiment, the cutter 20 is located above the transport surface 52 of the transport unit 16 (on the transport unit 16). Therefore, the cutter 20 is located on the transport unit 16. The length of the cutter 20 in the depth direction (Y-axis direction) is greater than the width of the foil material 5 in the width direction, and greater than the length of the transport surface 52 in the depth direction (Y-axis direction). The cutter 20 is used, for example, as a movable circular blade. The cutter 20 is used, for example, together with a receiving part (fixed blade) 20a fixed to the housing 50. The receiving part 20a extends along the transport surface 50 in the Y-axis direction. Normally, the circular blade 20 does not interfere with the movement of the foil material 5 in the X-axis direction and is waiting on the front or back side of the foil material 5 in the Y-axis direction. When the circular blade 20 moves in the Y-axis direction, the foil 5 between it and the receiving part (fixed blade) 20a is cut.

[0052] Furthermore, the cutter 20 may be formed as a so-called guillotine cutter, having a blade that extends continuously in the Y-axis direction and is wider than the width of the foil material 5, and capable of cutting the foil material 5 with a blade that moves in the Z-axis direction. Alternatively, a laser cutter may be used for the cutter 20. If a laser cutter is used for the cutter 20, the receiving portion 20a may be unnecessary.

[0053] The cut ends (front and rear ends) of the foil material 5 are formed, for example, straight in the width direction.

[0054] The winding system 10 shown in Figure 2 is provided in the housing 50 and has a fifth drive source (actuator) 62 that moves the cutter 20. The fifth drive source 62 may be an air cylinder that moves the cutter 20 along the Y-axis, or a linear actuator (electric cylinder) using a motor and a ball screw, etc. The fifth drive source 62 is controlled by the control unit 26. Depending on the cutting method of the cutter 20, the fifth drive source 62 may move the cutter 20 in the Z-axis direction.

[0055] As shown in Figure 1, in this embodiment, the position where the cutter 20 cuts the foil material 5 is defined as the origin position O of the winding system 10. After the sensor 18 detects that the foil material 5 is closer than a predetermined distance or in contact with the transport surface 52 on the transport unit 16, the cutter 20 is controlled by the control unit 26 to cut the foil material 5 at the origin position O.

[0056] Furthermore, it is preferable that the position of the transport surface 52 downstream of the origin position O (+X-axis direction) is, for example, about 0.5 mm lower than the position upstream of the origin O (-X-axis direction).

[0057] Downstream of the transport unit 16, a second sensor 22 is provided above and downstream of the cutter 20, in the direction of flow of the foil material 5, to detect the rear end (cut end) 5c of the foil material 5. The second sensor 22 can detect, for example, the presence of the foil material 5 between the downstream end 52a of the transport surface 52 of the transport unit 16 and the outer circumferential surface of the shaft 32. The second sensor 22 is preferably provided above the base member 42 of the movable base 14. The second sensor 22 is controlled by the control unit 26 to detect the rear end of the foil material 5 on the transport surface 52 of the transport unit 16 that has been cut by the cutter 20. The second sensor 22 is provided, for example, on the housing 30.

[0058] The second sensor 22 may preferably be an optical sensor, and may detect not only the rear end 5c of the foil material 5 (see Figure 16(A)) but also the front end 5a of the foil material 5 (see Figure 7(A)). For example, the second sensor 22 can detect the presence or absence of the foil material 5 directly below the second sensor 22 (in the -Z axis direction). Alternatively, the second sensor 22 may detect the presence or absence of the foil material 5 at or near the downstream end 52a of the transport surface 52. In this embodiment, the second sensor 22 detects when the rear end 5c of the foil material 5 passes directly below the second sensor 22.

[0059] The winding retainer 24 is provided, for example, on the housing 30. The winding retainer 24 faces the outer circumferential surface of the shaft portion 32 and is movable in directions toward and toward a predetermined central axis C of the shaft portion 32. In this embodiment, the winding retainer 24 is provided above the shaft portion 32. When the winding retainer 24 is moved toward the predetermined central axis C of the shaft portion 32, it presses the foil material 5 of the winding body 1 toward the outer circumferential surface of the shaft portion 32.

[0060] In this embodiment, the winding retainer 24 has a first retainer 72 and a second retainer 74. The first retainer 72 is preferably provided directly above a predetermined central axis C of the shaft portion 32. The second retainer 74 is provided on the movable base 14 side upstream (-X axis direction) along the direction of movement of the foil material 5 compared to the first retainer 72.

[0061] The first presser foot 72 has a sixth drive source (actuator) 82 and a roller 84.

[0062] The sixth drive source 82 is, for example, an air cylinder. The air cylinder 82 has a cylinder portion 82a and a rod-shaped member 82b that is movable in directions toward and toward a predetermined central axis C of the shaft portion 32 below the cylinder portion 82a. The cylinder portion 82a is preferably fixed to the winding device 12. The rod-shaped member 82b is preferably movable along the Z-axis direction.

[0063] Furthermore, it is preferable to use an air cylinder 82 with a low downward thrust force from the roller 84. For this reason, the rod-shaped member 82b is designed to move upward so as to move into the cylinder 82a, away from the winding body 1, when the winding body 1 comes into contact with the roller 84 supported by the rod-shaped member 82b.

[0064] Furthermore, it is preferable to use an air cylinder 82 that can withstand the moment load that may be received from the winding body 1, etc. For this reason, the rod-shaped member 82b is used such that even if the winding body 1 comes into contact with the roller 84 supported by the rod-shaped member 82b, the protruding portion of the rod-shaped member 82b at the lower end of the cylinder portion 82a is used as a pivot point to prevent swinging in the X-axis direction and swinging in the Y-axis direction.

[0065] The roller 84 is mounted on the rod-shaped member 82b and faces the outer circumferential surface of the shaft portion 32. It is more preferable that the roller 84 is supported at the lower end of the rod-shaped member 82b. The roller 84 has a rotation axis which is preferably parallel to a predetermined central axis C of the shaft portion 32. Therefore, as the foil material 5 is wound onto the winding body 1, the roller 84 in contact with the winding body 1 rotates. At this time, the roller 84 rotates in the opposite direction to the rotation direction of the outer circumferential surface of the shaft portion 32 around the predetermined central axis C.

[0066] Furthermore, the rod-shaped member 82b follows the contact between the foil material 5 and the roller 84, causing the roller 84 to move closer to and further away from the outer circumferential surface of the shaft portion 32. As a result, the winding body 1 is wound without applying a large gravitational force from the outer circumferential surface of the winding body 1 in the direction of the central axis of the winding body 1 (a predetermined central axis C of the shaft portion 32).

[0067] The second presser 74 includes a seventh drive source (actuator) 92 and a presser member 94.

[0068] The seventh drive source 92 is, for example, an air cylinder. The air cylinder 92 has a cylinder portion 92a and a rod-shaped member 92b that is movable in directions toward and away from the outer circumferential surface of the shaft portion 32, which is lower to the cylinder portion 92a. The cylinder portion 92a is preferably fixed to the winding device 12. The rod-shaped member 92b is preferably movable along the Z-axis direction.

[0069] Furthermore, it is preferable to use an air cylinder 92 that can withstand the moment load that may be received from the winding body 1, etc. For this reason, the rod-shaped member 92b is used such that even if the winding body 1 comes into contact with the retaining member 94 supported by the rod-shaped member 92b, the protruding portion of the rod-shaped member 92b at the lower end of the cylinder portion 92a is used as a pivot point to prevent swinging in the X-axis direction and swinging in the Y-axis direction.

[0070] The rod-shaped member 92b of the air cylinder 92 may be one that has a downward thrust similar to that of the rod-shaped member 82b of the air cylinder 82, or it may be one that has a higher downward thrust than the rod-shaped member 82b of the air cylinder 82.

[0071] The pressing member 94 is provided at the lower end of the rod-shaped member 92b. The pressing member 94 guides the foil material 5 between itself and the base member 42 of the movable base 14 when the base member 42 of the movable base 14 is spaced apart from the outer circumferential surface of the shaft portion 32. In this embodiment, it is preferable that the pressing member 94 extends in the Y-axis direction to a length equal to or greater than the width of the foil material 5, or to a length equal to the total length along the Y-axis direction of the shaft portion 32. On the other hand, it is preferable that the length of the pressing member 94 in the Y-axis direction is longer than the width of the transport surface 52 in the Y-axis direction. A projection (not shown) extending in the -X-axis direction may be formed near the center of the pressing member 94 in the width direction. By providing a projection, the rear end 5c of the foil material is prevented from floating after cutting, and the sensor 22 can reliably detect the rear end 5c of the foil material.

[0072] When the retaining member 94 is lowered, it is desirable that its lower surface height be slightly higher than the amplitude height of the corrugated sheet 5. When the retaining member 94 is lowered, its lower surface height is approximately 2 mm higher than the upper surface of the conveying surface 52.

[0073] The control unit 26 is composed of, for example, a computer and includes a processor (processing circuit) and a storage medium. The processor may include a CPU (Central Processing Unit), an ASIC (Application Specific Integrated Circuit), a microcontroller, an FPGA (Field Programmable Gate Array), or a DSP (Digital Signal Processor). The storage medium may include a main memory such as memory, as well as an auxiliary storage device. Examples of storage media include HDDs (Hard Disk Drives), SSDs (Solid State Drives), magnetic disks, optical disks (CD-ROMs, CD-Rs, DVDs, etc.), magneto-optical disks (MOs, etc.), and non-volatile memory such as semiconductor memory that allows writing and reading at any time.

[0074] In the control unit 26, there may be only one processor and one storage medium, or there may be multiple processors and storage mediums. In the control unit 26, the processor performs processing by executing programs stored in the storage medium, etc. Furthermore, the programs executed by the processor of the control unit 26 may be stored on a computer (server) connected to the control unit 26 via a network such as the Internet, or on a server in a cloud environment. In this case, the processor downloads the programs via the network.

[0075] The control unit 26 controls each of the drive sources 32a, 38a, 44, 56, 62, 82, and 92 using a processor or the like, and the storage medium functions as a data storage unit.

[0076] Furthermore, at least a portion of the processing performed by the control unit 26 may be executed by a cloud server configured in the cloud environment. The infrastructure of the cloud environment consists of virtual processors such as virtual CPUs and cloud memory. In one example, the control of each drive source 32a, 38a, 44, 56, 62, 82, 92 is performed by a virtual processor, and the cloud memory functions as a data storage unit.

[0077] The storage box 28 is located on the front side along the axial direction of the central axis C of the shaft portion 32. The storage box 28 is used to house the wound body 1 wound by the winding device 12 and then to transport it.

[0078] Below, an example of a series of operations of the winding system 10 according to this embodiment will be described using Figures 3 to 18.

[0079] Figure 3 shows a flow chart of a series of operations of the winding system 10 according to this embodiment.

[0080] Figures 4 to 18 schematically show a series of operations of the winding system 10 according to this embodiment.

[0081] Figures 5, 7-12, and 15-18 are schematic diagrams showing the positional relationship between the winding device 12, the base member 42 of the movable base 14, and the rollers 84 and pressing member 94 of the winding presser 24, viewed from the direction shown in the figures. Appropriate components such as the conveying section 16 and the sixth drive source 82 and seventh drive source 92 of the winding presser 24 are omitted from the illustration.

[0082] Figure 5(A) is a schematic diagram viewed from the direction indicated by arrow 5A in Figure 5(B). Similarly, Figures 7(A), 8(A), 9(A), 10(A), 11(A), 12(A), 15(A), 16(A), 17(A), and 18(A) are schematic diagrams viewed from the direction indicated by arrow A in (B) of each figure.

[0083] [Origin position (Step S1)] As shown in Figure 4, the tip of the foil material (corrugated sheet) 5 is assumed to be at the origin O (the cutting position by the cutter 20). At this time, the rod portion 44b is retracted relative to the cylinder portion 44a, and as shown in Figures 5(A) and 5(B), the downstream end 42a of the base member 42 of the movable base 14 is retracted and separated from the outer circumferential surface of the shaft portion 32. The first magnet 34 is positioned above the central axis C of the shaft portion 32 and upstream (-X axis direction) along the X axis direction with respect to a predetermined central axis C of the shaft portion 32. This position is defined as the initial position of the first magnet 34. The second magnet 36 is positioned, for example, below the central axis C of the shaft portion 32 and upstream (-X axis direction) along the X axis direction with respect to a predetermined central axis C of the shaft portion 32. The second magnet 36 may be positioned above the central axis C of the shaft portion 32, for example, or at the same height.

[0084] [Corrugated sheet forward (Step S2)] When the control unit 26 receives a command to start operation and detects that the foil material 5 is in contact with the first sensor 18 (see Figure 4), it drives the third drive source 44 of the movable base 14 to extend the rod portion 44b relative to the cylinder portion 44a. As shown in Figures 6, 7(A), and 7(B), the downstream end 42a of the base member 42 of the movable base 14 is advanced toward the outer circumferential surface of the shaft portion 32, and the control unit 26 drives the third drive source 56 to rotate the corrugated sheet feed gear 54 in a predetermined direction to guide the foil material 5 from the upstream side to the downstream side, so that the tip 5a of the foil material 5 is placed on the outer circumferential surface of the shaft portion 32 through the transport surface 52 and the base member 42.

[0085] When the base member 42 of the movable base 14 and the foil material 5 by the corrugated sheet feed gear 54 are moved simultaneously, the base member 42 of the movable base 14 approaches the outer surface of the shaft portion 32 before the foil material 5 reaches the outer surface of the shaft portion 32.

[0086] Since the base member 44 of the movable base 14 is located about 8 to 10 mm lower than the transport surface 52, the foil material 5 is easily transferred from the transport surface 52 to the base member 44 of the movable base 14. Also, since the outer circumferential surface of the shaft portion 32 is located about 1 mm lower than the base member 44 of the movable base 14, the foil material 5 is easily transferred from the base member 44 of the movable base 14 to the outer circumferential surface of the shaft portion 32.

[0087] When the downstream end 42a of the base member 42 moves furthest towards the +X axis, the end (downstream end) 42a of the base member 42 is positioned above the first magnet 34 (+Z axis) as shown in Figures 5 and 6. When the base member 42 is viewed from above, the first magnet 34 is hidden and not visible. Furthermore, as described above, the base member 42 is made of a material that exhibits a magnetic shielding effect, so the magnetic force of the first magnet 34 does not easily reach the upper side of the base member 42 due to the base member 42. For this reason, the tip 5a of the foil material 5 passes over the base member 42 of the movable base 14 in a state where it is less affected by the magnetic force of the first magnet 34 and reaches the outer circumferential surface of the shaft portion 32.

[0088] [Corrugated sheet winding operation (Step S3)] The control unit 26 controls the first drive source 32a to rotate the shaft portion 32 around a predetermined central axis C from the position shown in Figure 7 to the position shown in Figure 8, thereby moving the first magnet 34 downstream of the downstream end 42a of the base member 42 in the +X axis direction. To this end, the shaft portion 32 is rotated to a position where the base member 42 is not positioned between the first magnet 34 and the foil material (corrugated sheet) 5 (step S31). The rotation angle at this time is, for example, within 45° of the initial position of the first magnet 34 (see Figure 7).

[0089] At this time, the magnetic force from the first magnet 34 attracts the tip 5b of the foil material 5, causing the tip 5b of the foil material 5 to stick to the outer surface of the first magnet 34 and the shaft portion 32.

[0090] With the tip 5b of the foil material 5 attached to the outer circumferential surface of the shaft portion 32, as shown in Figure 9, the sixth drive source 82 of the first presser 72 of the winding presser 24 is driven to extend the rod-shaped member 82b downward, and the seventh drive source 92 of the second presser 74 is driven to extend the rod-shaped member 92b downward (step S32).

[0091] At this time, the gap between the lower end of the roller 84 of the first presser 72 of the winding presser 24 and the outer circumferential surface of the shaft portion 32 is set to be smaller than the amplitude height of the corrugated sheet 5. In this embodiment, it is set to be about 1 mm. The roller 84 is connected to the sixth drive source (actuator) 82 and presses the foil material 5 with an appropriate low thrust. Therefore, even if the foil material (corrugated sheet) 5 comes into contact with the roller 84 supported at the lower end of the rod-shaped member 82b, the top of the foil material (corrugated sheet) 5 is prevented from being crushed.

[0092] Furthermore, the pressing member 94 of the second pressing member 74 of the winding presser 24 is set so that the gap between it and the foil material (corrugated sheet) 5 is calculated to be approximately 0.1 mm to 1 mm. This prevents the top of the foil material (corrugated sheet) 5 from being crushed by the impact when the pressing member 94 descends. Also, because the gap is small, it prevents the corrugated sheet 5 from bending between the pressing member 94 and the roller 84.

[0093] Then, as shown in Figure 10, the control unit 26 controls the fourth drive source 56 to rotate the corrugated sheet feed gear 54 and feed the foil material (corrugated sheet) 5 downstream, and also controls the first drive source 32a to rotate the shaft portion 32 by about 90° relative to the position shown in Figure 9 (step S33). As a result, the foil material 5 also attaches to the second magnet 36 at a position behind the tip portion 5b of the foil material 5 to which the first magnet 34 is attached. Therefore, the second magnet 36 attaches to the foil material 5 following the first magnet 34.

[0094] Immediately after the foil material 5 is attached to the first magnet 34 and the second magnet 36 in this manner, as shown in Figure 11, the control unit 26 controls the third drive source 44 to retract the rod portion 44b relative to the cylinder portion 44a, moving the base member 42 in the -X axis direction upstream of the foil material 5, and moving it backward and away from the outer circumferential surface of the shaft portion 32 (step S34). For this purpose, the control unit 26 positions the base member 42 of the movable base 14 at a distance from the outer circumferential surface of the shaft portion 32. At this time, the control unit 26 controls the third drive source 44 of the movable base 14 to move the downstream end 42a of the base member 42 of the movable base 14 away from the outer circumferential surface of the shaft portion 32 by at least the thickness by which the foil material 5 overlaps. When the foil material 5 is corrugated, the downstream end 42a of the base member 42 of the movable base 14 away from the outer circumferential surface of the shaft portion 32 by at least twice the amplitude of the corrugated sheet 5. The pressing member 94 of the winding presser 24 guides the foil material between itself and the base member 42 of the movable base 14 at a position where the base member 42 of the movable base 14 is separated from the outer circumferential surface of the shaft portion 32.

[0095] [Rewinding (Step S4)] Subsequently, the control unit 26 controls the third drive source 56 of the corrugated sheet feed gear 54 to feed the foil material 5 toward the outer circumferential surface of the shaft portion 32, and controls the first drive source 32a of the shaft portion 32 to wind the foil material 5 onto the outer circumferential surface of the shaft portion 32.

[0096] As shown in Figure 12, the foil material (corrugated sheet) 5 is wound around the outer surface of the shaft portion 32, and the foil material 5 is overlapped radially outward around the outer surface of the shaft portion 32. Therefore, when the foil material (corrugated sheet) 5 is wound, the roller 84 comes into contact with the foil material 5. When the foil material (corrugated sheet) 5 comes into contact with the roller 84, the rod-shaped member 82b that supports the roller 84 moves upward.

[0097] In addition, when winding the corrugated sheet as foil material 5, the pitch between the peaks is the same, but the overlapping can be random. Therefore, in the wound body 1, for example, the convex parts of the corrugated sheet 5 may overlap, or the concave parts may face the convex parts.

[0098] Furthermore, as shown in Figures 11 and 12, when the foil material 5 is further layered on the outer surface of the shaft portion 32, the roller 84 rises further.

[0099] Then, the control unit 26 stops the rotation of the corrugated sheet feed gear 54 and the shaft 32 when the number of waves of the foil material (corrugated sheet) 5 fed by the corrugated sheet feed gear 54, as shown in Figure 13, reaches a predetermined number.

[0100] [Cutting operation (Step S5)] The feeding speed of the foil material (corrugated sheet) 5 by the corrugated sheet feed gear 54 is faster than the winding speed of the foil material 5 by the outer surface of the shaft 32. Therefore, when the rotation of the corrugated sheet feed gear 54 and the shaft 32 is stopped, the foil material 5 flexes in the area enclosed by the dashed line indicated by the symbol R in Figure 13, and the foil material 5 between the pressing member 94 and the corrugated sheet feed gear 54 lifts up relative to the transport surface 52. When the control unit 26 detects that the foil material 5 has moved away from the first sensor 18, it drives the first drive source 32a of the shaft member 32 and winds the foil material 5 onto the outer surface of the shaft member 32. Then, when the control unit 26 detects that the foil material 5 has approached or come into contact with the first sensor 18 on the transport surface 52, it stops driving the first drive source 32a of the shaft 32 and drives the fifth drive source 62 to move the cutter 20 in the Y-axis direction from the front or back side of the foil material 5 in the Y-axis direction, as shown in Figure 14, and cuts the foil material 5. If, for example, a guillotine blade is used as the cutter 20, the foil material 5 may be cut by lowering the blade of the cutter 20 toward the foil material 5. The control unit 26 also determines that the deflection of the foil material 5 has been eliminated when the first sensor 18 detects that the foil material 5 has approached or come into contact with the first sensor 18, which is closer than a predetermined distance.

[0101] When a circular movable blade is used as the cutter 20, the control unit 26 keeps the cutter 20 on the front or back side of the foil material 5 in the Y-axis direction. When a guillotine blade is used as the cutter 20, for example, the control unit 26 cuts the foil material 5 with the cutter 20 and then controls the fifth drive source 62 to immediately raise the cutter 20 relative to the transport surface 52. At this time, the winding device 12 shown in Figure 15 maintains the same arrangement as the winding device 12 shown in Figure 12.

[0102] [Rewinding (Step S6)] As shown in Figure 16, the control unit 26 drives the first drive source 32a to rotate the shaft 32. When the second sensor 22 detects the rear end 5c of the foil material 5, the control unit 26 stops the rotation of the shaft 32. At this time, the winding of the foil material 5 in the winding device 12 is completed, and the winding body 1 is manufactured. The rear end 5c of the foil material 5 may be, for example, on the base member 42.

[0103] [Winding retainer (roller 84) rises (step S7)] As shown in Figure 17, in this state, the control unit 26 controls the sixth drive source (actuator) 82 of the first presser 72, raising the roller 84 supported at the lower end of the rod-shaped member 82b. As a result, the roller 84 moves upward away from the winding body 1. Meanwhile, the presser member 94 is in contact with the vicinity of the rear end of the foil material 5. Therefore, the shape of the winding body 1 is maintained even when the roller 84 moves away.

[0104] [Discharge plate advance (step S8)] The control unit 26 controls the second drive source 38a of the discharge plate 38 to move the discharge plate 38 from the position shown in Figure 17 to the position shown in Figure 18.

[0105] The discharge plate 38 removes the wound body 1 that is attached to the outer surface of the shaft portion 32 by magnets 34 and 36. The control unit 26 moves the second drive source 38a of the discharge plate 38, moving from one end of the shaft portion 32 in the Y-axis direction to the other end each time a wound body 1 is created, pushing the wound body 1 towards the other end of the shaft portion 32.

[0106] When removed in this manner, if the magnets 34 and 36 are positioned only in the center of the width direction of the shaft portion 32, moving the winding body 1, i.e., the foil material 5, in a predetermined direction from the shaft portion 32 will eliminate the influence of the magnets 34 and 36 on the winding body 1. However, because the retaining member 94 extends to the end of the shaft portion 32, the winding body 1 can maintain its wound shape.

[0107] The wound body 1 is placed, for example, in a storage box 28 adjacent to the shaft portion 32 in the axial direction. The wound body 1, once housed in the storage box 28, is then transported.

[0108] Subsequently, the control unit 26 controls the second drive source 38a to return the discharge plate 38 to its original position, and also controls the seventh drive source (actuator) 92 of the second retainer 74 to raise the retainer member 94 that is supported at the lower end of the rod-shaped member 92b. At this time, the control unit 26 may also control the first drive source 32a of the shaft portion 32 to position the first magnet 34 and the second magnet 36, which are arranged on the shaft portion 32, to the positions shown in Figure 7. That is, the first magnet 34 may be placed in its initial position.

[0109] Then, the winding system 10 repeats the operations from step S1 to step S8, as explained using Figures 3 to 18, to obtain a series of operations to obtain a winding body 1, thereby obtaining multiple winding bodies 1.

[0110] According to this embodiment, the shaft portion 32 is used as a cylinder to attach the foil material (corrugated sheet) 5 to the outer surface of the shaft portion 32 by the first magnet 34. In this case, when obtaining the wound body 1 from the foil material 5, it is not necessary to bend the tip or other parts of the foil material 5. Furthermore, a wound body 1 without such bent parts does not require straightening of the bent parts during subsequent use, resulting in a winding body 1 that is easy to use. In addition, since it is not necessary to bend, for example, the tip of the foil material 5, it is not necessary to consider the bulge on the outer circumference of the bent part of the foil material 5 when it is formed as a wound body 1.

[0111] Therefore, by using the winding device 12 according to this embodiment, it is possible to obtain a wound body 1 by winding the foil material 5 onto the outer surface of the shaft portion 32 without creating a hook portion on the foil material 5 for the outer surface of the shaft portion 32. Thus, according to this embodiment, it is possible to provide a winding device 12 that does not require bending of the foil material 5 when obtaining the wound body 1.

[0112] By using a first magnet 34 provided on the outer circumferential surface of the shaft portion 32 and a second magnet 36 on the outer circumferential surface of the shaft portion 32 spaced circumferentially apart from the first magnet 34, the foil material 5 can be attached at multiple positions in the circumferential direction on the outer circumferential surface of the shaft portion 32, thereby suppressing the bulging of the winding body 1 and making the diameter of each winding body 1 uniform. Therefore, by using the winding device 12 according to this embodiment, the winding body 1 can be easily contained within an appropriate outer diameter.

[0113] When the winding body 1 is wound around the outer circumferential surface of the shaft portion 32, the first magnet 34 and the second magnet 36 are positioned so as to be in the center of the foil material 5 in the width direction. Therefore, when the winding body 1 is wound around the outer circumferential surface of the shaft portion 32, unevenness in the magnetic force applied to the foil material 5 can be prevented, and meandering of the foil material 5 during winding can be suppressed. In addition, since the direction in which the foil material 5 is conveyed is adjusted to be perpendicular to the central axis C of the shaft portion 32, meandering of the foil material 5 can be suppressed, and a good winding body 1 can be obtained.

[0114] Furthermore, by using the winding device 12 according to this embodiment, it is possible to prevent bulging of the outer circumference of the hooking point of the winding body 1, and to obtain a winding body 1 that can be easily contained within an appropriate outer diameter. In addition, such a winding body 1 can ensure good transportability.

[0115] Furthermore, by using a movable base 14 that can move closer to and further away from the outer circumferential surface of the shaft portion 32, the position in which the foil material 5 is attached to the first magnet 34 can be adjusted. In this embodiment, the arrangement of the base member 42 of the movable base 14 relative to the outer circumferential surface of the shaft portion 32, and the position of the first magnet 34 relative to the base member 42 of the movable base 14 (rotation angle of the shaft portion 32) when attempting to attach the foil material 5 to the outer circumferential surface of the shaft portion 32 can be adjusted. Therefore, when obtaining the wound body 1, the tip 5b of the foil material 5 (see Figures 7 to 10) can be attached to the first magnet 34.

[0116] Furthermore, the winding system 10 can switch between a position where the magnetic force of the first magnet 34 is applied to the foil material 5 and a position where it is not applied, depending on the position where the base member 42 of the movable base 14 is positioned. This prevents the foil material 5 from sticking to unintended positions on the outer surface of the shaft member 32.

[0117] Furthermore, by using the winding presser 24 to lightly press down on the foil material 5 while winding it on the outer surface of the shaft portion 32, the winding diameter of the winding body 1, i.e., the outer diameter of the winding body 1, can be easily kept within an appropriate range. In addition, by using the pressing member 94 of the second presser 74 of the winding presser 24, which is long in a direction parallel to the central axis C of the shaft portion 32, the outer diameter of the winding body 1 can be maintained, and the wound winding body 1 can be discharged without being easily unraveled by the elasticity of the winding body 1. Therefore, when using the winding body 1 in a subsequent process, it has a stable outer diameter, which improves handling when gripping the winding body 1 using, for example, a robot.

[0118] As the sixth drive source (actuator) 82 of the first presser 72 of the winding presser 24, a product with an appropriate low thrust and appropriate moment load resistance is adopted. Therefore, even if the foil material (corrugated sheet) 5 comes into contact with the roller 84 supported at the lower end of the rod-shaped member 82b, it is possible to prevent the tops of the corrugated sheets of the foil material 5 from being crushed. Therefore, it is possible to suppress the expansion of the pitch between the tops of the foil material (corrugated sheet) 5. In addition, the roller 84 supported at the lower end of the rod-shaped member 82b is set so as not to come into contact with the outer circumferential surface of the shaft portion 32, making it difficult to deform the foil material (corrugated sheet) 5 with forces such as when the rod-shaped member 82b is lowered.

[0119] When force is applied to the rod-shaped member 82b via the roller 84, the sixth drive source (air cylinder) 82 has moment resistance to maintain the rod-shaped member 82b in a straight position relative to the cylinder portion 82a. As a result, the runout of the roller 84 is suppressed. This prevents the foil material 5 from meandering.

[0120] As the seventh drive source (actuator) 92 of the second presser 74 of the winding presser 24, an appropriate moment-resistant load component is adopted. When force is applied to the rod-shaped member 92b via the presser member 94, the seventh drive source (air cylinder) 92 has moment-resistant properties that maintain the rod-shaped member 92b in a straight state relative to the cylinder portion 92a. Therefore, the vibration of the presser member 94 is suppressed. The presser member 94 is formed to press the entire widthwise direction of the foil material 5. Therefore, when the winding body 1, that is, the wound foil material 5, is discharged in the axial direction of the shaft portion 32, the foil material 5 can be continuously held down until it reaches the storage box 28 of the winding body 1. Thus, the winding body 1 can be stored in the storage box 28 of the winding body 1 while maintaining its outer diameter.

[0121] Furthermore, when the foil material 5 is a corrugated sheet, multiple winding bodies 1, each having the same or nearly the same predetermined number of wave crests, can be obtained by counting the number of wave crests based on the rotation of the corrugated sheet feed gear 54.

[0122] Before the foil material 5 is wound around the outer circumferential surface of the shaft 32, the control unit 26 of the winding system 10 controls the drive source 32a of the shaft 32 to position the first magnet 34 above the central axis C and on the side from which the foil material 5 is supplied. Before the foil material 5 is wound around the outer circumferential surface of the shaft 32, the control unit 26 of the winding system 10 controls the drive source 32a of the shaft 32 to rotate the shaft 32 so that the foil material 5, guided beyond the downstream end of the movable base 14, is moved to a position where it attaches to the first magnet 34. Furthermore, the control unit 26 of the winding system 10 controls the drive source 32a of the shaft 32 to rotate the shaft 32 so that the foil material 5, guided beyond the downstream end of the movable base 14, is moved to a position where it attaches to the second magnet 36. Finally, the control unit 26 controls the drive source 44 of the movable base 14 to move the movable base 14 away from the outer circumferential surface of the shaft 32.

[0123] In this embodiment, an example was described in which a winding device 12 using two magnets, a first magnet 34 and a second magnet 36. In this embodiment, the winding device 12 only requires the first magnet 34.

[0124] In this embodiment, an example was described in which a predetermined number of corrugated sheets of foil material 5 is transported downstream from the corrugated sheet feed gear 54 by counting the number of corrugations of the corrugated sheet material 5. For example, the transport surface 52 may be movable by a belt conveyor, roller conveyor, etc., driven by an appropriate drive source instead of the corrugated sheet feed gear 54 and drive source 56. In this case, the transport surface 52 is not limited to corrugated sheets, but transports flat foil material 5 in a predetermined direction at a predetermined speed. Therefore, with the winding device 12 according to this embodiment, foil material 5 can be obtained as a wound body 1 regardless of whether it is corrugated or flat. Also, with the winding system 10 according to this embodiment, foil material 5 can be obtained as a wound body 1 regardless of whether it is corrugated or flat. In this case, the control unit 26 can obtain the length of the foil material 5 to be obtained as one wound body 1 based on the transport speed of the transport surface 52.

[0125] Figure 19(A) is a schematic diagram showing the positional relationship between the winding device 12, the movable base 14, and the winding presser 24 when the tip 5a of the foil material 5 is at the origin position, and Figure 19(B) is a schematic diagram viewed from the direction indicated by arrow 19B in Figure 19(A). Note that Figure 19(A) is a schematic diagram viewed from the direction indicated by arrow 19A in Figure 19(B).

[0126] In the embodiments described above, the first magnet 34 and the second magnet 36 were described in an example where they exert a magnetic force at approximately the center of the foil material 5 in the width direction. As shown in Figure 19, the first magnet 34 may be arranged along the axial direction of the shaft portion 32 along a predetermined central axis C of the shaft portion 32, thereby exerting a magnetic force on the foil material 5. For this reason, it is preferable that the first magnet 34 is arranged along the axial direction of the shaft portion 32 so as to exert a magnetic force symmetrically in the width direction with respect to the center of the foil material 5 in the width direction. Similarly, the second magnet 36 may be arranged along the axial direction of the shaft portion 32 along a predetermined central axis C of the shaft portion 32, thereby exerting a magnetic force on the foil material 5. For this reason, it is preferable that the second magnet 36 is arranged along the axial direction of the shaft portion 32 so as to exert a magnetic force symmetrically in the width direction with respect to the center of the foil material 5 in the width direction.

[0127] It should be noted that the present invention is not limited to the embodiments described above, and can be modified in various ways during implementation without departing from its essence. Furthermore, each embodiment may be combined as appropriate, and in that case, the combined effects can be obtained. Moreover, the above embodiments include various inventions, and various inventions can be extracted by selecting combinations from the multiple constituent elements disclosed. For example, if the problem can be solved and effects obtained even if some constituent elements are deleted from all the constituent elements shown in the embodiment, then the configuration with these deleted constituent elements can be extracted as an invention. [Explanation of Symbols]

[0128] 1...Winding body, 5...Foil material (corrugated sheet), 10...Winding system, 12...Winding device, 14...Movable base, 16...Conveying section, 18...First sensor (touch sensor), 20...Cutter, 22...Second sensor, 24...Winding presser, 26...Control unit, 30...Housing, 32...Shaft section, 32a...First drive source, 34...First magnet, 36...Second magnet, 38...Discharge plate, 38a...Second drive source, 39...Ring section, 42...Base member (plate-shaped member), 44...Third drive Power source (air cylinder), 44a...cylinder section, 44b...rod section, 46...connecting member, 50...housing, 52...conveying surface, 54...corrugated sheet feed gear, 56...fourth drive source, 62...fifth drive source, 72...first presser, 74...second presser, 82...sixth drive source (air cylinder), 82a...cylinder section, 82b...rod-shaped member, 84...roller, 92...seventh drive source (air cylinder), 92a...cylinder section, 92b...rod-shaped member, 94...presser member.

Claims

1. A cylindrical or cylindrical shaft portion that rotates around a predetermined central axis and has an outer surface around which the supplied foil material is wound, A first magnet is provided on the outer circumferential surface or inside thereof of the shaft portion, exerts a magnetic force on the foil material, and causes the foil material to stick to the outer circumferential surface. A winding device having the following features.

2. The present invention has a second magnet which is provided on the outer surface of the shaft or on the inside thereof, spaced apart in the circumferential direction from the outer surface of the shaft with respect to the first magnet, and which exerts a magnetic force on the foil material and causes the foil material to stick to the outer surface. The distance between the first magnet and the second magnet is greater than 0° and within 90° with respect to the central axis. The winding device according to claim 1.

3. The first magnet is provided so as to exert the magnetic force symmetrically in the width direction with respect to the center of the foil material in the width direction along the axial direction of the shaft portion. The winding device according to claim 1 or claim 2.

4. The winding device according to claim 2, A movable base that moves horizontally along the tangential direction of the outer surface of the shaft portion, allowing it to approach and move away from the outer surface of the shaft portion, and which guides the foil material to the outer surface of the shaft portion when it is close to the outer surface of the shaft portion, A drive source for rotating the shaft portion, and a control unit for controlling the drive source of the movable base, Equipped with, The control unit, Before the foil material is wound around the outer circumferential surface of the shaft, the drive source of the shaft is controlled to position the first magnet on the upper side of the central axis and on the side from which the foil material is supplied. Before the foil material is wound around the outer circumferential surface of the shaft, the drive source of the movable base is controlled to bring the movable base closer to the outer circumferential surface of the shaft, and the first magnet is positioned between the central axis of the shaft and the movable base. The drive source of the shaft is controlled to rotate the shaft so that the foil material guided beyond the downstream end of the movable base is rotated to a position where it attaches to the first magnet, and further rotate the foil material to a position where it attaches to the second magnet. The drive source of the movable base is controlled to separate the movable base from the outer surface of the shaft portion. Winding system.

5. The shaft portion has a winding press that faces the outer circumferential surface of the shaft portion, is movable in a direction approaching and away from the central axis of the shaft portion, and presses the foil material toward the outer circumferential surface of the shaft portion when moved toward the central axis of the shaft portion, The control unit controls the drive source that moves the winding presser, The control unit rotates the shaft to a position where the foil material guided beyond the downstream end of the movable base attaches to the first magnet, and then controls the drive source of the winding presser to move the winding presser in a direction approaching the central axis of the shaft, thereby guiding the foil material to the outer circumferential surface of the shaft. The winding system according to claim 4.

6. The aforementioned winding retainer is, A rod-shaped member that is movable in directions approaching and away from the central axis of the shaft portion, A roller is provided on the rod-shaped member and faces the outer circumferential surface of the shaft portion, It has, The roller rotates in a direction opposite to the rotational direction of the outer circumferential surface around the axis of the central shaft of the shaft portion. The rod-shaped member follows the contact between the foil material and the roller, causing the roller to move closer to and further away from the outer circumferential surface of the shaft portion. The winding system according to claim 5.

7. When the control unit positions the movable base at a position separated from the outer circumferential surface of the shaft portion, it controls the drive source of the movable base to separate the downstream end of the movable base from the outer circumferential surface of the shaft portion by at least the thickness by which the foil material can be overlapped. The winding retainer includes a retaining member that guides the foil material between the movable base and the movable base at a position where the movable base is separated from the outer circumferential surface of the shaft portion. The winding system according to claim 5.

8. A winding device according to claim 1 or claim 2, A conveying unit that sends the foil material to the outer surface of the shaft portion of the winding device. A drive source for rotating the shaft portion, and a control unit for controlling the drive source of the transport portion for sending the foil material to the outer circumferential surface of the shaft portion, Equipped with, The control unit controls the drive source so that the feed speed for sending the foil material to the outer surface of the shaft is greater than the winding speed of the foil material in the shaft. Winding system.

9. A cutter is provided on the transport section, the position where the foil material is cut is set as the origin position of the winding system, and the cutter is controlled by the control unit to cut the foil material at the origin position, A sensor is provided upstream of the cutter in the transport section and is controlled by the control unit to detect the proximity, contact, and separation of the foil material from the transport section. Equipped with, The control unit, The drive source of the transport unit is driven to transport the foil material from the origin position through the downstream end of the transport unit toward the outer surface of the shaft unit. The drive source of the shaft is driven to rotate the shaft to a predetermined rotation angle, attaching it to the first magnet, winding the foil material onto the outer surface of the shaft, and then stopping the transport unit and the drive source of the shaft. When the sensor detects the proximity or contact of the foil material with the transport unit, the cutter is driven to cut the foil material at the origin position. The drive source of the shaft is driven to complete winding the foil material. The winding system according to claim 8.

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