Manufacturing method and manufacturing system for unvulcanized rubber sheet member

Abstract

To provide a manufacturing method and a manufacturing system capable of efficiently manufacturing an unvulcanized rubber sheet member while further accurately detecting occurrence of quality deterioration.SOLUTION: There is provided a manufacturing method for an unvulcanized rubber sheet member, in which: during conveyance of a rubber sheet member S in which an unvulcanized rubber R is rolled by a rolling device 2 by a conveying device 6a, temperature distribution data of a predetermined range A in a longitudinal direction over an entire width of a surface of the rubber sheet member S is sequentially measured by a thermography device 7 at a predetermined position on a conveyance line 6 to input the same to an arithmetic unit 8; and when the input temperature distribution data deviates from the temperature distribution data in the predetermined range A at the predetermined position on the conveyance line 6 of a rubber sheet member Sa classified as a non-defective product stored in advance as allowable range data, the arithmetic unit 8 determines that a quality of the rubber sheet member S has deteriorated, and issues a warning from a warning device 10.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a manufacturing method and manufacturing system for unvulcanized rubber sheet members, and more specifically, to a manufacturing method and manufacturing system that can efficiently manufacture unvulcanized rubber sheet members while more accurately detecting the occurrence of quality deterioration. [Background technology]

[0002] Unvulcanized rubber sheet members are used when manufacturing various rubber products such as tires and conveyor belts. These rubber sheet members are manufactured by rolling heated unvulcanized rubber by passing it between rolls (see, for example, Patent Document 1). Rubber sheet members are not only manufactured by rolling only unvulcanized rubber, but also in some cases, a rubber sheet member in which a reinforcing wire is covered with unvulcanized rubber is manufactured by passing a reinforcing wire between rolls together with the unvulcanized rubber.

[0003] If the manufacturing conditions of the rubber sheet member are not appropriate, quality abnormalities such as a rough surface of the rubber sheet member, rubber defects, scattered burnt rubber particles, and exposed reinforcing wires on the surface will occur. In the past, in order to ensure a predetermined quality of the manufactured rubber sheet member, it has been proposed to monitor the bank amount of unvulcanized rubber that remains above between the rolls (see the claims of Patent Document 1, etc.). The bank amount is estimated based on the temperature of the rubber sheet member measured immediately after passing between the rolls.

[0004] However, even if the bank amount is monitored, the actual surface condition of the manufactured rubber sheet member cannot be grasped, and therefore quality abnormalities cannot be detected sufficiently. Also, in order to visually check the surface of the manufactured rubber sheet member, the conveying speed on the conveying line must be slowed down, which reduces the productivity of the rubber sheet member. Therefore, there is room for improvement in efficiently manufacturing unvulcanized rubber sheet members while detecting the occurrence of quality deterioration with higher accuracy. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 3-161315 Summary of the Invention [Problem to be solved by the invention]

[0006] An object of the present invention is to provide a manufacturing method and a manufacturing system that can efficiently manufacture unvulcanized rubber sheet members while detecting the occurrence of quality deterioration with higher accuracy. [Means for solving the problem]

[0007] In order to achieve the above-mentioned object, the manufacturing method of an unvulcanized rubber sheet member of the present invention is characterized in that, in the manufacturing method of an unvulcanized rubber sheet member, a constituent material containing unvulcanized rubber is rolled and then transported on a conveying line, temperature distribution data in a predetermined range in the longitudinal direction across the entire width of the surface of the rubber sheet member being transported at a predetermined position on the conveying line is sequentially measured by a thermography device and sequentially input into a computing device, and the computing device pre-stores the temperature distribution data of the predetermined range at the predetermined position of the rubber sheet member classified as a good product as acceptable range data, and the computing device compares the input temperature distribution data with the acceptable range data, and if the input temperature distribution data falls outside the acceptable range data, it determines that a deterioration in quality has occurred in the corresponding range of the rubber sheet member where the temperature distribution data outside the acceptable range data was measured.

[0008] The manufacturing system for unvulcanized rubber sheet members of the present invention is equipped with a rolling device for rolling constituent materials including unvulcanized rubber, and a conveying device arranged on a conveying line downstream of the rolling device, and is characterized in that the manufacturing system for unvulcanized rubber sheet members has a thermography device for sequentially measuring temperature distribution data in a predetermined range in the longitudinal direction across the entire width of the surface of the rubber sheet member being conveyed by the conveying device at a predetermined position on the conveying line, and a calculation device to which the temperature distribution data measured by the thermography device is sequentially input, wherein the temperature distribution data in the predetermined range at the predetermined position of the rubber sheet member classified as a good product is pre-stored as acceptable range data, and the sequentially input temperature distribution data is compared with the acceptable range data by the calculation device, and if the input temperature distribution data deviates from the acceptable range data, it is determined that a quality abnormality exists in the corresponding range of the rubber sheet member where the temperature distribution data outside the acceptable range data was measured. Effect of the Invention

[0009] According to the present invention, the temperature distribution data in a predetermined range in the longitudinal direction across the entire width of the surface of the rubber sheet member at the predetermined position on the conveying line is compared with the allowable range data to determine whether or not quality degradation has occurred in the rubber sheet member. This is advantageous for determining whether or not quality degradation has occurred with greater accuracy by covering the entire surface of the rubber sheet member. In addition, since the temperature distribution data is measured in a non-contact manner using a thermography device for the rubber sheet member being conveyed on the conveying line, the productivity of the rubber sheet member is not impaired. This is advantageous for efficiently manufacturing the rubber sheet member. [Brief description of the drawings]

[0010] [Figure 1] 1 is an explanatory diagram illustrating an embodiment of a manufacturing system for an unvulcanized rubber sheet member in a side view. FIG. [Diagram 2] FIG. 2 is an explanatory diagram illustrating the manufacturing system of FIG. 1 in a plan view. [Diagram 3]FIG. 4 is an explanatory diagram illustrating a schematic example of temperature distribution data of a rubber sheet member measured by a thermography device. [Figure 4] 2 is an explanatory diagram illustrating a rubber sheet member S in which reinforcing wires are embedded, as viewed from above; FIG. [Diagram 5] 5 is an explanatory diagram illustrating a schematic example of temperature distribution data of the rubber sheet member of FIG. 4 measured by a thermography device. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method and a system for producing an unvulcanized rubber sheet member according to the present invention will be described with reference to the embodiments shown in the drawings.

[0012] 1 and 2, an embodiment of a manufacturing system 1 for an unvulcanized rubber sheet member of the present invention (hereinafter referred to as the manufacturing system 1) rolls a constituent material including unvulcanized rubber R to manufacture a rubber sheet member S. In this embodiment, the constituent material of the rubber sheet member S is unvulcanized rubber R alone.

[0013] The manufacturing system 1 includes a rolling mill 2, a conveying device 6a arranged on a conveying line 6 downstream of the rolling mill 2, a thermography device 7, and a computing device 8. In this embodiment, the manufacturing system 1 further includes a display 9 and a warning device 10.

[0014] The rolling device 2 has rolls 3 that are rotated by a rotation drive unit 3a such as a motor, a rubber feed unit 4, and a control unit 5. The opposing rolls 3 rotate in opposite directions. One of the opposing rolls 3 is equipped with a gap adjustment unit 3b. A fluid cylinder or the like is used for the gap adjustment unit 3b. The gap between the opposing rolls 3 can be adjusted by moving a rod of the gap adjustment unit 3b back and forth.

[0015] The rubber feed section 4 feeds unvulcanized rubber R, which is a constituent material of the rubber sheet member S, between the opposing rolls 3. The rubber feed section 4 may be a belt conveyor device or the like.

[0016] The rotation speed of the rotary drive unit 3a (roll 3) and the movement of the gap adjustment unit 3b (gap between opposing rolls 3) are controlled by the control unit 5. The rotation speed and the gap are set to appropriate values ​​based on the specifications of the rubber sheet member S to be manufactured. Note that various types of known rolling devices can be used as the rolling device 2.

[0017] The conveying line 6 conveys the rubber sheet material S to the next process or a storage location immediately after it has been rolled by the opposing rolls 3. In the conveying line 6, the rubber sheet material S is placed on a conveying device 6a and conveyed. As the conveying device 6a, various known belt conveyor devices and the like can be used. In the conveying line 6, the side adjacent to the rolling device 2 is the upstream side.

[0018] The thermography device 7 includes a camera 7a and a data processing unit 7b connected to the camera 7a. The thermography device 7 uses the camera 7a to capture an image of a predetermined range A in the longitudinal direction across the entire width of the surface of the rubber sheet member S being transported (moved) by the transport device 6a at a predetermined position P on the transport line 6. The image data captured by the camera 7a is input to the data processing unit 7b and processed to obtain temperature distribution data Ds (image data) of the predetermined range A.

[0019] In this way, the thermography device 7 sequentially measures the temperature distribution data Ds in the predetermined range A. The number of cameras 7a (thermography device 7) is not limited to one, and multiple cameras, such as two, may be used. The temperature distribution data Ds measured by the thermography device 7 is sequentially input to the calculation device 8.

[0020] A computer is used for the calculation device 8. In the calculation device 8, temperature distribution data Da in a predetermined range A at a predetermined position P of a rubber sheet member Sa classified as a non-defective product that meets the quality standard and has no abnormalities is stored in advance as allowable range data Da (image data). For example, temperature distribution data Ds in a predetermined range A at a predetermined position P measured by a thermography device 7 for a non-defective rubber sheet member S is stored in the calculation device 8 as allowable range data Da. In other words, the allowable range data Da is index data that means that no abnormality occurs if the temperature is within the predetermined range A. Since the allowable range data Da may vary greatly depending on the rubber specifications (rubber types), it is desirable to grasp and use the allowable range data Da for each rubber specification (rubber type).

[0021] On the other hand, the temperature distribution data Ds in the predetermined range A at the predetermined position P measured by the thermography device 7 for the rubber sheet member S where an abnormality has occurred is recognized as unqualified data. The allowable range data Da is set so as to ensure that this unqualified data is not included.

[0022] As the allowable range data Da, the entire area in the specified range A may be set to the same temperature range, but partially different temperature ranges may be set. For example, the entire area of ​​the specified range A may be divided into several areas in the width direction, and a temperature range may be set for each divided area. In a wide rubber sheet member S, the ends in the width direction are more likely to be cooled during transportation than the center in the width direction, so the allowable range data Da may be set so that the temperature range at the ends in the width direction is slightly lower than that at the center in the width direction. Alternatively, when reinforcing wires F are embedded in the rubber sheet member S, the surface temperature of the rubber sheet member S may differ depending on the position where the reinforcing wires F are embedded, so partially different temperature ranges may be set in the specified range A as the allowable range data Da.

[0023] The display 9 displays data input to the arithmetic device 8, data that has been processed by the arithmetic device 8, etc. The display 9 can also function as a warning device 10, which will be described later.

[0024] The warning device 10 operates based on a determination made by the computing device 8. Examples of the warning device 10 include a warning light, an alarm, and various devices that display a warning.

[0025] Next, an example of a procedure for producing the unvulcanized rubber sheet member S according to the present invention will be described.

[0026] As shown in Fig. 1 and Fig. 2, unvulcanized rubber R is fed into a rolling mill 2 using a rubber feed section 4. In the rolling mill 2, the unvulcanized rubber R passes between a pair of rotating rolls 3 to produce a rolled rubber sheet member S. The produced rubber sheet member S is then continuously and uninterruptedly transported downstream on a conveying line 6 by a conveying device 6a.

[0027] A camera 7a of a thermography device 7 is installed at a predetermined position P of the conveying line 6. The thermography device 7 sequentially measures temperature distribution data Ds of a predetermined range A in the longitudinal direction across the entire width of the surface of the rubber sheet member S being conveyed at the predetermined position P, and sequentially inputs the measured data to a calculation device 8.

[0028] The calculation device 8 compares the input temperature distribution data Ds with the stored allowable range data Da. Then, it judges whether the input temperature distribution data Ds is outside the allowable range data Da. If the input temperature distribution data Ds contains at least one of a temperature higher or lower than the temperature range set as the allowable range data Da, the calculation device 8 judges that the input temperature distribution data Ds is outside the allowable range data Da. If it is judged in this way, the calculation device 8 judges that a quality deterioration has occurred in the corresponding range of the rubber sheet member S where the temperature distribution data Ds outside the allowable range data Da was measured.

[0029] For example, if the surface of the rubber sheet member S is excessively heated for some reason, causing the surface to become rough, or if burnt rubber particles are scattered, the input temperature distribution data Ds will contain a temperature higher than the temperature range set as the allowable range data Da. If the rubber of the rubber sheet member S is partially missing (has a hole), the input temperature distribution data Ds will contain a temperature lower than the temperature range set as the allowable range data Da.

[0030] The surface temperature of the rubber sheet member S decreases as it is transported downstream on the transport line 6. If the surface temperature becomes too low, it becomes difficult to detect the occurrence of quality deterioration, so the predetermined position P on the transport line 6 where the temperature distribution data Ds is measured by the thermography device 7 is preferably near the rolling device 2. For example, if the position where the rubber sheet member S passes between the pair of rolls 3 is set as a reference point, it is advisable to set the predetermined position P within a range from this reference point where the length of the rubber sheet member S is, for example, 0.5 m to 3 m.

[0031] Fig. 3 shows an example of temperature distribution data Ds of the rubber sheet member S measured by the thermography device 7. In the temperature distribution data Ds shown in Fig. 3, areas with temperatures higher than the temperature range set as the allowable range data Da are shown diagrammatically in a vertical and horizontal checkered pattern, and areas with temperatures lower than this temperature range are shown diagrammatically in a diagonal checkered pattern.

[0032] When the display 9 is provided, the temperature distribution data Ds inputted to the calculation device 8 is displayed in a different color for each preset temperature division. This makes it easy to grasp the temperature state of the surface of the rubber sheet member S simply by looking at the display 9. The colors displayed on the display 9 are set in a gradation format so that high and low temperatures can be easily grasped. In actual temperature distribution data Ds, there are some temperature differences (temperature distribution) in areas other than the vertical and horizontal grid patterns and the diagonal grid patterns, so these areas other than the grid patterns are often displayed with a distribution of multiple colors rather than simply white as in FIG. 3.

[0033] In this embodiment, when the calculation device 8 determines that quality degradation has occurred, a warning is issued by the warning device 10 to notify the occurrence of quality degradation. If a configuration is made such that a warning display is displayed on the display 9 to notify the occurrence of quality degradation, the display 9 functions as the warning device 10. By providing the warning device 10, the deterioration of the quality of the rubber sheet member S can be grasped without delay, and therefore prompt countermeasures can be taken.

[0034] Furthermore, position identification data that identifies the position of the range determined by the calculation device 8 as having a quality degradation in the rubber sheet member S is output to the outside. The measured temperature distribution data Ds is associated with the measurement time and the conveying speed of the conveying device 6a, and stored in the calculation device 8, so that the position identification data can be calculated by calculation processing. This position identification data is displayed on the display 9 and output to the outside. This position identification data can also be printed by a printer or the like and output to the outside. Using the position identification data makes it easier to perform processing such as removing the range determined to have a quality degradation from the sheet member S.

[0035] As shown in Fig. 4, the rubber sheet member S may have a specification in which reinforcing wires F are embedded in the unvulcanized rubber R. Steel cords or organic fiber cords are used as the reinforcing wires F. In this rubber sheet member S, a large number of steel cords extending in the longitudinal direction are embedded side by side in the width direction as the reinforcing wires F. This rubber sheet member S is manufactured by passing the unvulcanized rubber R together with the reinforcing wires F between rolls 3.

[0036] As shown in FIG. 4, quality abnormalities may occur, such as the reinforcing wire F being cut and exposed on the surface of the rubber sheet member S. FIG. 5 shows an example of temperature distribution data Ds of such a rubber sheet member S. In the temperature distribution data Ds shown in FIG. 5, the area with a temperature lower than the temperature range set as the allowable range data Da is shown in a diagonal lattice pattern. The part of the reinforcing wire F exposed on the surface of the rubber sheet member S is cooled and becomes lower in temperature than the surrounding rubber, so that the exposed part of the reinforcing wire F is clearly displayed as the temperature distribution data Ds, as shown in FIG. 5. In the actual temperature distribution data Ds, there is a slight temperature difference (temperature distribution) even in the area other than the diagonal lattice pattern, so that the area other than the lattice pattern is often displayed with multiple colors distributed therein, rather than simply being a single white color as shown in FIG. 5.

[0037] As described above, according to the present invention, the calculation device 8 compares the temperature distribution data Ds with the allowable range data Da to determine whether or not quality degradation has occurred in the rubber sheet member S. The temperature distribution data Ds is acquired by sequentially measuring a predetermined range A in the longitudinal direction across the entire width of the surface of the rubber sheet member S being transported at a predetermined position P on the transport line 6, which is advantageous for covering the entire surface of the rubber sheet member S and determining with higher accuracy whether or not quality degradation has occurred.

[0038] Moreover, the temperature distribution data Ds is acquired by non-contact measurement using the thermography device 7 for the rubber sheet member S being conveyed on the conveying line 6. Therefore, it is not necessary to extremely slow down the conveying speed of the rubber sheet member S in order to detect quality deterioration on the surface of the rubber sheet member S. This is therefore advantageous for efficient manufacturing without impairing the productivity of the rubber sheet member S.

[0039] The manufacturing conditions may be changed when the calculation device 8 determines that a quality deterioration has occurred in the sheet member S. That is, in order to prevent the calculation device 8 from continuously determining that a quality deterioration has occurred, a specific condition selected in advance among the conditions for manufacturing the rubber sheet member S is changed to improve the process conditions.

[0040] Examples of the specific condition include the temperature of the unvulcanized rubber R when it is fed into the rolling device 2 by the rubber feed section 4, the amount of the unvulcanized rubber R, the rotation speed of the rolls 3, roll crossing conditions, etc. It is preferable to select a condition that significantly affects the temperature of the rubber sheet member S immediately after production as the specific condition.

[0041] The specific conditions are changed based on the results of comparing the temperature distribution data Ds that is out of the allowable range data Da with the allowable range data Da. If the difference (temperature difference) between the two is larger, the degree of change in the specific conditions is made larger. This is advantageous for manufacturing good rubber sheet members S with higher productivity. [Explanation of symbols]

[0042] 1. Manufacturing System 2. Rolling equipment 3 Rolls 3a Rotation drive unit 3b Gap adjustment section 4 Rubber feed section 5. Control section 6. Conveyor Line 6a Transport device 7 Thermography equipment 7a Camera 7b Data processing section 8 Arithmetic unit 9. Display 10 Warning device F Reinforcement wire R Unvulcanized rubber S Rubber sheet material

Claims

1. In a method for producing an unvulcanized rubber sheet member, a constituent material including unvulcanized rubber is rolled and then conveyed on a conveying line, A method for manufacturing an unvulcanized rubber sheet member, characterized in that at a predetermined position on the conveying line, temperature distribution data in a predetermined range in the longitudinal direction across the entire width of the surface of the rubber sheet member being conveyed is sequentially measured by a thermography device and the temperature distribution data in the predetermined range at the predetermined position of the rubber sheet member classified as a good product is pre-stored in the computing device as acceptable range data, and the computing device compares the input temperature distribution data with the acceptable range data, and if the input temperature distribution data falls outside the acceptable range data, determines that a deterioration in quality has occurred in the corresponding range of the rubber sheet member where the temperature distribution data outside the acceptable range data was measured.

2. A manufacturing method for an unvulcanized rubber sheet member as described in claim 1, wherein when the computing device determines that quality degradation has occurred, it issues a warning to notify of the occurrence of quality degradation and outputs to the outside position identification data that identifies the position of the relevant range in the rubber sheet member.

3. A method for manufacturing an unvulcanized rubber sheet member as described in claim 2, wherein the input temperature distribution data is displayed on a display with different colors for each preset temperature range, and the position identification data is output to the outside by being displayed on the display.

4. A method for manufacturing an unvulcanized rubber sheet member as described in any one of claims 1 to 3, in which, when the computing device determines that a quality deterioration has occurred, pre-selected specific conditions among the conditions for manufacturing the rubber sheet member are changed based on a comparison result between the temperature distribution data that falls outside the allowable range data and the allowable range data, so as to avoid the computing device determining that a quality deterioration is continuing to occur.

5. A manufacturing system for an unvulcanized rubber sheet member, comprising: a rolling device for rolling a constituent material including unvulcanized rubber; and a conveying device disposed on a conveying line downstream of the rolling device, a thermography device which sequentially measures temperature distribution data in a predetermined range in the longitudinal direction across the entire width of the surface of the rubber sheet member being transported by the transport device at a predetermined position on the transport line, and a calculation device to which the temperature distribution data measured by the thermography device is sequentially input, The system for manufacturing unvulcanized rubber sheet members is configured such that the calculation device pre-stores temperature distribution data of the specified range at the specified position of the rubber sheet member classified as a non-defective product as acceptable range data, the calculation device compares the temperature distribution data that is sequentially input with the acceptable range data, and if the input temperature distribution data falls outside the acceptable range data, it is determined that a quality abnormality exists in the corresponding range of the rubber sheet member where the temperature distribution data that falls outside the acceptable range data was measured.

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