Defect log estimation method, defect log discharge method, and defect log estimation device and defect log discharge device

Abstract

To enhance reliability of logs to be produced.SOLUTION: A defective log estimation device 1 that estimates defectives of logs 5 in a production line 4 for continuously forming roll logs 5 by cutting a belt-like material every time the material is wound to a prescribed length, includes a detection part 6 and an estimation part 7. The detection part 6 inspects appearance of each log 5 and detects a log 5 with abnormality at a winding end 5a of the material, as a failure log 51. Besides the failure log 51 detected by the detection part 6, the estimation part 7 regards a subsequent log 52 formed next to the failure log 51 as a defective.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a method for estimating defective logs in a production line that continuously forms roll-shaped logs, a method for discharging the estimated defective logs, and an apparatus for carrying out the method and apparatus. [Background technology]

[0002] Logs from which rolled products such as toilet paper and kitchen paper are cut are formed by cutting a strip of material unwound from a large-diameter roll every time a predetermined length is wound. In a production line that continuously forms logs by rewinding material in this way, the tail of the material in any log that has been formed becomes the starting end of the material in the following log that is formed next (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Special Publication No. 2012-503582 Summary of the Invention [Problem to be solved by the invention]

[0004] However, if there is some abnormality in the end or beginning of a material in the above-mentioned production line, the log having the end or beginning of the material will be a defective product. If it is not possible to accurately detect defective logs, the reliability of the manufactured logs will decrease, and the reliability of the products cut out from the logs will also decrease.

[0005] The present invention was invented in consideration of the above problems, and one of the objects of the invention is to improve the reliability of the manufactured logs. However, the present invention is not limited to this object. Another object of the present invention is to achieve the effects and advantages derived from the configurations shown in the "Description of the Preferred Embodiments" described later, which cannot be obtained by the conventional technology. [Means for solving the problem]

[0006] The present method for estimating a defective log is a method for estimating whether a log is defective in a production line in which a strip-shaped material is cut every time it is wound to a predetermined length, and roll-shaped logs are continuously formed to be cut into a plurality of products, and the method includes a detection process for inspecting the appearance of each log and detecting a log having an abnormality at the end of the winding of the material as a failed log, and an estimation process for regarding not only the failed log detected in the detection process but also the subsequent log formed after the failed log as defective. The defect log discharge method of the present invention includes the defect log estimation method, and a discharge step of discharging both the failure log and the subsequent log that are deemed to be defective in the estimation step from the manufacturing line.

[0007] The present defective log estimation device is a defective log estimation device that estimates whether a log is defective in a production line in which a strip-shaped material is cut every time it is wound to a predetermined length, and roll-shaped logs are continuously formed to be cut into a plurality of products, and is equipped with a detection unit that inspects the appearance of each of the logs and detects as failed logs any logs that have an abnormality at the end of the winding of the material, and an estimation unit that considers not only the failed logs detected by the detection unit but also any subsequent logs formed after the failed logs to be defective. The defect log discharge device of the present invention includes the defect log estimation device, and a discharge part that discharges both the failure log and the subsequent log that are deemed to be defective by the estimation part from the manufacturing line. Effect of the Invention

[0008] According to the present invention, the reliability of the manufactured logs can be improved. [Brief description of the drawings]

[0009] [Figure 1] FIG. 2 is a schematic perspective view of a production line. [Diagram 2] 1A and 1B are schematic perspective views of a continuously formed log, (a) showing the material before cutting and (b) showing the material after cutting; [Diagram 3] FIG. 2 is a schematic diagram showing a failure log estimating device and a failure log discharging device together with a failure log and a subsequent log. [Figure 4] 1 is a perspective view illustrating the end of a failed log and the beginning of a succeeding log; FIG. [Diagram 5] FIG. 2 is a schematic diagram showing a failure log estimating device and a failure log discharging device together with two failure logs and a subsequent log. [Figure 6] 11 is a flowchart illustrating a defect log estimation method and a defect log discharge method. [Figure 7] FIG. 13 is a schematic diagram showing a defect log estimating device according to a modified example, together with a failure log. [Figure 8] FIG. 13 is a schematic diagram showing a defect log estimating device according to a modified example together with other failure logs. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The following describes the embodiments for carrying out the present invention. The embodiments described below are merely examples, and are not intended to exclude various modifications or application of techniques not specifically described herein. The configurations of the following embodiments can be modified in various ways without departing from the spirit of the invention. In addition, they can be selected or combined as necessary.

[0011] [1. Equipment] [1-1. Overall composition] As shown in Fig. 1, a defect log estimation device 1 and a defect log discharge device 2 according to this embodiment are applied to a production line 4 that manufactures a roll-shaped product 3. Here, the product 3 is exemplified as toilet paper (toilet roll) in which strip-shaped sanitary paper is wound into a roll. However, the product 3 is not particularly limited as long as it is a strip-shaped material wound into a roll, and may be, for example, kitchen paper, or a material other than paper.

[0012] The production line 4 is provided with a log forming part 10 which forms a roll-shaped log 5 which is longer in the axial direction than the product 3, an adjusting part 20 which temporarily stores the logs 5 formed in the log forming part 10 and adjusts the timing of sending out the logs 5, and a cutting part 30 which cuts the logs 5 sent out from the adjusting part 20 into a plurality of products 3. The production line 4 is further provided with a packaging part 40 which packages the products 3 cut out by the cutting part 30 in predetermined numbers, and a boxing part 50 which boxes the packages 9 of the products 3 packaged by the packaging part 40.

[0013] Hereinafter, upstream and downstream are defined based on the order of each process performed in the production line 4. In the production line 4, a log forming part 10, an adjusting part 20, a cutting part 30, a packaging part 40, and a boxing part 50 are arranged in this order from upstream to downstream.

[0014] The log forming part 10 unwinds the base paper 11 (material) from a base paper roll 12 around which the base paper 11 is wound in a strip shape that is wider than the product 3, and forms a log 5 by rewinding the base paper 11 with a winder 13. The log 5 is in the form of a roll whose axial length is equal to that of the base paper roll 12 and whose diameter is equal to that of the product 3. In the winder 13, embossing or printing may be applied to the base paper 11. Furthermore, the base paper roll 12 may be a primary base paper (jumbo roll) on which a single layer (one ply) of base paper 11 made of one sheet of paper material is wound, or a secondary base paper on which multi-layer (two or more plies) base paper 11 made of multiple sheets of paper material is wound.

[0015] The winder 13 cuts the base paper 11 every time it is wound around a cylindrical core 5c (long core tube) by a predetermined length, thereby continuously forming the log 5. As shown in Figs. 2(a) and (b), the base paper 11 is wound from the inner periphery (core 5c side) of the log 5 to the outer periphery (i.e., from the inside to the outside in the radial direction). Then, when a predetermined length of the base paper 11 is wound around the outer periphery of the core 5c, the base paper 11 is cut (divided) along a straight line L intersecting the longitudinal direction of the base paper 11 to form the log 5. Here, an example is shown in which the base paper 11 is cut along a straight line L extending in its width direction (direction perpendicular to the longitudinal direction). Note that Figs. 2(a) and (b) show an example of the base paper 11 cut above the core 5c, but the position of the base paper 11 when it is cut is not particularly limited.

[0016] As described above, of the base paper 11 that continuously forms logs 5, the portion downstream of the straight line L becomes the winding end 5a (tail) of one log 5, and the portion upstream of the straight line L (the portion separated from the winding end 5a) becomes the winding start end 5b of the next log 5. In each log 5, the winding end 5a of the base paper 11 is exposed on the outer peripheral surface, whereas the winding start end 5b of the base paper 11 is covered by the base paper 11 wrapped around the outside and is not visible.

[0017] As shown in Fig. 1, each log 5 has its end 5a glued (tail sealed) to the outer circumferential surface in a gluing part 14, which is the final process of the log forming part 10, and is then sent to a downstream adjusting part 20. In detail, in the gluing part 14, the transport of the log 5 is temporarily stopped, and the end 5a is opened (separated) from the outer circumferential surface by air, for example, while rotating the log 5. At this point, a sensor (not shown) that detects the end 5a of the log 5 (hereinafter also referred to as a "tail detection sensor") reacts (turns on) and detects that the end 5a has opened.

[0018] This tail detection sensor detects that the end 5a, which opens from the outer peripheral surface of the log 5, has reached a predetermined position as it is wound up as the log 5 rotates. When the tail detection sensor turns off, the end 5a is detected as having reached the predetermined position, and the rotation of the log 5 is stopped. As a result, the log 5 is set with the end 5a open at the predetermined position. Then, glue is applied to the end 5a or to a part of the outer peripheral surface to which it is to be attached, and the end 5a is attached to the outer peripheral surface, completing the process in the gluing part 14.

[0019] The adjusting part 20 stores a plurality of logs 5 in an accumulator 21, and sequentially sends the logs 5 to the downstream cutting part 30. Here, an example of the adjusting part 20 that sends the logs 5 two at a time toward the cutting part 30 will be shown.

[0020] The cutting part 30 cuts the logs 5 sent from the adjusting part 20 in the axial direction at predetermined intervals with a log saw 31. In this way, each log 5 is cut into a plurality of products 3. The packaging part 40 inserts, for example, four products 3 (two products x two layers) as one set into a packaging bag 19 and seals the opening 22 of the packaging bag 19 to form a package 9. The box packing section 50 packs a plurality of (for example, four) packages 9 as one set into a cardboard box 23. Then, the packages 9 packed in the cardboard box 23 are shipped.

[0021] [1-2.Main part configuration] <Defect log estimation device> The defective log estimation device 1 estimates a defective log 5 in the above-mentioned production line 4. The defective log 5 here is a log 5 having an abnormality at the winding end 5a or the winding start end 5b of the log 5. The defect log estimating device 1 of the present embodiment is provided in the log forming part 10 in the above-mentioned production line 4. However, the defect log estimating device 1 may be provided upstream of the cutting part 30, for example, in the adjusting part 20 or between the log forming part 10 and the adjusting part 20.

[0022] 3, the defective log estimation device 1 includes a detection unit 6 that inspects the appearance of each log 5, and an estimation unit 7 that estimates whether the log 5 is defective based on information transmitted from the detection unit 6. Here, the detection unit 6 and the estimation unit 7 that are provided as functions of an electronic control unit 15 are illustrated. The electronic control unit 15 is connected to a camera 16 that captures an image of the appearance of each log 5, including the winding end 5a exposed on the outer circumferential surface. Data of the image captured by the camera 16 is transmitted (input) to the electronic control unit 15.

[0023] The detection unit 6 inspects the appearance of each log 5, for example, by analyzing data transmitted from the camera 16 to the electronic control device 15. Then, based on the inspection result, the detection unit 6 detects the log 5 having an abnormality at the winding end 5a as a failure log 51, and transmits information on the detected failure log 51 to the estimation unit 7.

[0024] The detection unit 6 of this embodiment detects a log 5 whose winding end 5a is not linear as a failed log 51. However, the detection content by the detection unit 6 is not limited to this. The detection unit 6 only needs to detect a failed log 51 based on the presence or absence of an abnormality in the winding end 5a, which can be determined from the appearance of each log 5, and may detect, for example, a log 5 whose winding end 5a is dirty as a failed log 51.

[0025] As described above, the winding end 5a exposed on the outer periphery of the log 5 is visible from the outside, so the detection unit 6 can detect a failed log 51 having an abnormality in the winding end 5a by inspecting the appearance of the log 5. On the other hand, the winding start end 5b of the log 5 is not visible from the outside, so even if the appearance of the log 5 is inspected, it is not possible to detect a log 5 having an abnormality in the winding start end 5b.

[0026] Therefore, the estimation unit 7 considers not only the failure log 51 detected by the detection unit 6 (log 5 having an abnormality at the winding end 5a) but also the subsequent log 52 formed after this failure log 51 as defective. That is, based on the information transmitted from the detection unit 6, the estimation unit 7 considers both the failure log 51 having an abnormality at the winding end 5a and the subsequent log 52 following this failure log 51 (the subsequent log 52 in addition to the failure log 51) as defective.

[0027] The winding end 5a of the failed log 51 and the winding start end 5b of the succeeding log 52 are adjacent to each other on the base paper 11 before it is cut along the straight line L. For this reason, if there is an abnormality in the winding end 5a of the failed log 51, it can be assumed that there is also some abnormality in the winding start end 5b of the succeeding log 52.

[0028] For example, as shown in FIG. 4, if the base paper 11 is not properly cut along the straight line L, an abnormality occurs in which the winding end 5a of the log 5 (failed log 51) downstream of the straight line L and the winding start 5b of the log 5 (subsequent log 52) upstream of the straight line L are not both linear. More specifically, if a portion 5d of the winding end 5a of the failed log 51 is longer than the other portions, the corresponding portion 5e of the winding start 5b of the subsequent log 52 will be insufficient. In this way, if the winding end 5a of the failed log 51 is not linear, it can be estimated that the winding start 5b of the subsequent log 52, which is the part cut off from the winding end 5a of the failed log 51, is also not linear.

[0029] Similarly, if dirt is present in the region of the base paper 11 that overlaps with the straight line L, an abnormality occurs in which dirt is present at both the end 5a of the log 5 (failed log 51) downstream of the straight line L and the start 5b of the log 5 (following log 52) upstream of the straight line L. In this case as well, if the end 5a of the failed log 51 is dirty, it can be estimated that the start 5b of the following log 52 and the start 5b of the following log 52 that has been separated from the end 5a of the failed log 51 are also dirty. Based on such an estimation, the estimation unit 7 regards the subsequent log 52 as defective in addition to the failure log 51 even if there is no abnormality such as a poor cut or dirt at the winding end 5a of the subsequent log 52.

[0030] 5, if there is an abnormality in the winding end 5a of the subsequent log 52 formed next to the failure log 51, the detection unit 6 also detects this subsequent log 52 as a failure log 51. That is, in this case, since both of the two consecutive logs 5 are detected as failure logs 51, the log 5 formed later (the middle log 5 of the three logs 5 shown in FIG. 5) of the two consecutive failure logs 51 corresponds to both the failure log 51 and the subsequent log 52. In this case, the estimation unit 7 estimates that the two consecutive failure logs 51 and the subsequent log 52 formed next to these failure logs 51 are defective.

[0031] <Bad log ejection device> 3 and 5, the defect log discharge device 2 includes the above-mentioned defect log estimation device 1, and a discharge part 8 that discharges both the failure log 51 and the subsequent log 52 that are deemed to be defective by the estimation unit 7 from the production line 4. Here, the discharge part 8 is exemplified in such a way that the failure log 51 and the subsequent log 52 are pushed out from the production line 4 by a push-out member 18. The operation of the push-out member 18 is controlled by, for example, an electronic control device 15 based on the estimation result by the estimation unit 7.

[0032] The specific mechanism of the discharge part 8 is not particularly limited as long as it can discharge each log 5 from the production line 4. As the discharge part 8, for example, a mechanism for making the transport path of the failed log 51 and the subsequent log 52 in the production line 4 different from the transport path of the other normal logs 5, or a mechanism for blowing off or pulling out the failed log 51 and the subsequent log 52 from the production line 4 by air injection or suction may be applied. The discharge part 8 in this embodiment is disposed upstream of the gluing part 14. Therefore, in the production line 4, both the failure log 51 and the subsequent log 52 are discharged from the discharge part 8 to the outside of the production line 4 before they reach the gluing part 14.

[0033] [2. Method] 6, processes corresponding to the above-mentioned parts are carried out on the production line 4. Specifically, on the production line 4, a log forming process S10, an adjusting process S20, a cutting process S30, a packaging process S40, and a boxing process S50 are carried out in this order. In each of the above steps, processing is performed by a device in which the "step" in the name is replaced with a "part." For example, in the log forming step S10, processing is performed by the log forming part 10, and in the adjustment step S20, processing is performed by the adjustment part 20. The log forming step S10 includes a gluing step S14 that corresponds to the above-mentioned gluing part 14. In the gluing step S14, the winding end 5a of the log 5 is glued by the gluing part 14.

[0034] The defect log estimation method according to the present embodiment is included in a defect log formation step S10, and is performed in the above-mentioned defect log estimation device 1. The defect log estimation method includes a detection step S11 performed in the above-mentioned detection unit 6, and an estimation step S12 performed in the above-mentioned estimation unit 7. In detail, the detection step S11 inspects the appearance of each log 5 as described above, and detects a log 5 having an abnormality in the winding end 5a of the base paper 11 as a failure log 51. The detection step S11 of this embodiment detects a log 5 having an abnormality in the winding end 5a as a failure log 51. In the estimation step S12, not only the failure log 51 detected in the detection step S11 but also the subsequent log 52 formed next to the failure log 51 is regarded as a defective product. The detection step S11 and the estimation step S12 of the present embodiment are performed before the gluing step S14.

[0035] The defect log discharge method includes the above-described defect log estimation method and a discharge step S13 performed in the discharge part 8. Specifically, the discharge step S13 discharges both the failure log 51 and the subsequent log 52 that are deemed to be defective in the estimation step S12 from the production line 4. The discharge step S13 in this embodiment is performed after the defect log estimation method is performed (after the detection step S11 and the estimation step S12) and before the gluing step S14.

[0036] [3. Actions and Effects] (1) As described above, in a production line 4 where multiple logs 5 are continuously formed, if there is an abnormality at the winding end 5a of any log 5, there is a high possibility that there is also an abnormality at the winding start end 5b of the next log 5 formed. For this reason, by regarding not only a failed log 51 having an abnormality at the winding end 5a but also the subsequent log 52 formed after the failed log 51 as a defective product, the accuracy of estimating defective products in the logs 5 can be improved. Therefore, according to the defect log estimation device 1 and the defect log estimation method, it is possible to accurately estimate defective products from the log 5 manufactured on the production line 4. As a result, the reliability of the manufactured log 5 can be improved.

[0037] (2) In the production line 4 where the base paper 11 is cut along a straight line L extending in its width direction (a direction intersecting with the longitudinal direction), if the winding end 5a of any log 5 is not straight, there is a high possibility that the winding start end 5b of the next log 5 formed will also not be straight. For this reason, by detecting a log 5 whose winding end 5a is not straight as a failed log 51 and regarding both this failed log 51 and the subsequent log 52 formed after it as defective products, it is possible to accurately estimate defective products that have had cutting defects.

[0038] (3) By discharging both the failure log 51 and the subsequent log 52 that are deemed to be defective from the production line 4, the failure log 51 having an abnormality at the winding end 5a and the subsequent log 52 that is likely to have an abnormality at the winding start end 5b can be removed from the production line 4. Therefore, according to the defective log discharge device 2 and the defective log discharge method, defective products can be accurately removed from the logs 5 produced on the production line 4. This makes it possible to more reliably improve the reliability of the logs 5 produced.

[0039] (4) If the failed log 51 and the subsequent log 52 are discharged from the production line 4 before the winding end 5a of the log 5 is glued, the gluing (tail sealing) process of the winding end 5a of the failed log 51 and the subsequent log 52 that are considered to be defective can be omitted. This reduces unnecessary consumption of glue and contributes to the efficiency of the tail sealing process.

[0040] [4. Modifications] The production line 4 may be provided with a notification part that notifies an operator by a buzzer or a lamp that the estimation unit 7 has deemed the failure log 51 and the subsequent log 52 to be defective products, instead of (or in addition to) the above-mentioned discharge part 8. When such a notification part is provided, a notification step corresponding to the notification part is executed instead of (or in addition to) the above-mentioned discharge step S13. Note that when a notification part is provided instead of the discharge part 8, the production line 4 may be automatically temporarily stopped in accordance with the processing (notification step) by the notification part, thereby prompting the operator to manually discharge the failure log 51 and the subsequent log 52 from the production line 4.

[0041] The detection method of the failure log 51 in the detection unit 6 and the detection process S11 is not particularly limited as long as it is based on an inspection of the appearance of the log 5. For example, the detection unit 6 may detect a log 5 having a tail seal defect at the winding end 5a as a failure log 51 by inspecting the appearance of the log 5 downstream of the gluing part 14. In this case, the failure log estimating device 1 and the failure log discharging device 2 are disposed downstream of the gluing part 14, and the failure log estimating method and the failure log discharging method (detection process S11, estimation process S12, and discharge process S13) are performed after the gluing process S14. In addition, the detection unit 6 and the detection process S11 may be incorporated in the gluing part 14 and the gluing process S14.

[0042] In the detection unit 6 and the detection step S11, instead of (or in addition to) the camera 16, a plurality of sensors 17 may be used that are spaced apart in the width direction along which the straight line L extends, as illustrated in FIG. 7. Each sensor 17 detects the position (length) of the winding end 5a that is opened (separated) from the outer peripheral surface of the log 5 for processing in the gluing part 14 and the gluing step S14. In such a configuration, for example, based on the variation in the position of the winding end 5a detected by the plurality of sensors 17, it is possible to recognize whether the winding end 5a of each log 5 forms a straight line or not. The sensor 17 of this modification may also function as the tail detection sensor provided in the gluing part 14, or may be provided separately from the tail detection sensor.

[0043] 8, in a failed log 51 in which a portion 5d of the end 5a is significantly longer than the other portions (e.g., longer than the outer circumference of the log 5), this portion 5d wraps around the outer circumference of the log 5, preventing the entire end 5a from opening (coming off) from the outer circumference. In this case, since none of the sensors 17 detect the end 5a, it is possible to recognize that there is an abnormality in the end 5a. Note that the abnormality of the portion 5d of the end 5a wrapping around the outer circumference of the log 5 can be detected even when only one sensor 17 is provided as the tail detection sensor. In this way, in the detection unit 6 and the detection step S11, even when the above-mentioned sensor 17 is used, the failure log 51 can be detected by inspecting the appearance of each log 5. [Explanation of symbols]

[0044] 1. Defect log estimation device 2. Bad log ejection device 3 Products 4 Production Line 5 Logs 5a End of winding 5b Starting end of winding 5c Core 5d. Longer part 5e Missing Part 6. Detection unit 7 Estimation part 8. Discharge Part 10 Log formation part 11 Base paper (materials) 12 Raw material roll 13 Winder 14 Gluing part 15 Electronic control device 16 Cameras 17 Sensors 18 Extrusion member 20 Adjustment Part 21 Accumulator 30 Cutting Part 31 Log saw 40 Packaging Part 50 Packing Part 51 Failure Log 52 Subsequent logs L straight line

Claims

1. 1. A method for estimating defective logs in a production line in which a strip-shaped material is cut every time a predetermined length is wound to continuously form roll-shaped logs to be cut into a plurality of products, the method comprising the steps of: a detection step of inspecting the appearance of each of the logs and detecting the logs having an abnormality at the end of the material as a failed log; and an estimation step of regarding not only the failure log detected in the detection step but also a subsequent log formed next to the failure log as a defective product. The defect log estimation method according to the present invention.

2. In the manufacturing line, the material is cut along a straight line intersecting a longitudinal direction of the material to form the logs; The detection step detects the log whose winding end is not linear as the failed log.

2. The method for estimating a failure log according to claim 1.

3. The defect log estimation method according to claim 1 or 2, and a discharge step of discharging both the failure log and the subsequent log that are deemed to be defective in the estimation step from the manufacturing line. A method for discharging a defective log.

4. The discharge step is performed before a gluing step in which the winding end of the log is glued in the production line.

4. The method for discharging a defect log according to claim 3.

5. A defective log estimation device for estimating defective products in a production line in which a strip-shaped material is cut every time a predetermined length is wound to continuously form a roll-shaped log to be cut into a plurality of products, the device comprising: a detection unit that inspects the appearance of each of the logs and detects the logs having an abnormality at the end of the winding of the material as a failure log; An estimation unit that considers not only the failure log detected by the detection unit but also a subsequent log formed next to the failure log to be a defective product. A defect log estimation device comprising:

6. In the manufacturing line, the material is cut along a straight line intersecting a longitudinal direction of the material to form the logs; The detection unit detects the log whose winding end is not linear as the failed log.

6. The failure log estimation device according to claim 5.

7. The defect log estimation device according to claim 5 or 6, and a discharge part that discharges both the failure log and the subsequent log that are deemed to be defective by the estimation part from the manufacturing line. A defect log ejection device characterized by the above.

8. The discharge part is disposed upstream of a gluing part in which the winding end of the log is glued in the production line.

8. The defect log ejection device according to claim 7.

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