Method for manufacturing a liquid inclusion and method for detecting an abnormality in a pipe

Abstract

To provide a manufacturing method of a liquid inclusion which can stably and intermittently discharge liquid from a nozzle arranged in piping by detecting an abnormality in the piping into which the liquid is intermittently supplied, and an in-piping abnormality detection method.SOLUTION: In a manufacturing method of a liquid inclination of the present invention for intermittently adding liquid 10 to an additive 11 by using a liquid adding device 1, when a cycle for intermittently supplying the liquid 10 to a nozzle 4 from a pump 6 is divided into a discharge zone and a non-discharge zone, the manufacturing method comprises: a discharge-time flow rate integration step for calculating an integration flow rate of the liquid 10 flowing in piping 3 in the discharge zone on the basis of a detection value of a flow rate sensor 2; a non-discharge time flow rate integration step for calculating the integration flow rate of the liquid 10 flowing in the piping 3 in the non-discharge zone on the basis of the detection value of the flow rate sensor 2; and a determination step for determining the adaptability of a discharge quantity of the liquid from the nozzle 4 on the basis of the integration flow rates of the discharge-time flow rate integration step and the non-discharge time flow rate integration step.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a liquid-containing product and a method for detecting an abnormality in a pipe.

Background Art

[0002] Devices and methods for manufacturing products using water supply or the liquid by intermittently supplying the liquid are known. For example, in Patent Document 1, the flow rate is detected based on a pulse signal from a flow meter provided in a water supply pipe, and when the time during which no pulse signal is output in the water supply is longer than a predetermined time, it is determined that an abnormality has occurred. A water supply device is described. The water supply device stops the water supply during the counting of the elapsed time, stops the counting when the water supply is restarted after the water supply is stopped, and extends the predetermined time by the delay time when the water supply is restarted.

[0003] Further, the present applicant has previously provided a liquid addition unit for adding a liquid to an additive, and a plunger type pump for feeding the liquid to the liquid addition unit in a fixed amount, and a pressure sensor capable of continuously detecting the pressure in the pipe is arranged in the pipe on the discharge side of the plunger type pump, and while monitoring the pressure value obtained from the pressure sensor, an intermittent addition method of the liquid is disclosed (Patent Document 2).

[0004] Further, Patent Document 3 describes a fluid supply device including a pump that intermittently discharges a fluid and a drive control device that controls the drive of the pump by a drive signal generated based on the measured flow rate of the supply path of the fluid. When outputting the drive signal, a predetermined command of an I2C bus is transmitted to a flow rate sensor, and upon receiving the command, the flow rate sensor measures the flow rate of the fluid in the supply path for a predetermined time and stores the measured flow rate in a memory.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

[0006] A liquid addition device that intermittently adds a liquid to an additive usually includes a pipe that forms a flow path of the liquid, a nozzle that adds the liquid to the additive, and a pump that intermittently supplies the liquid to the nozzle through the pipe. In such a device, it is effective in terms of stable supply of the liquid to monitor the adequacy of the liquid flow rate in the pipe during the discharge time when the pump discharges the liquid. However, when an abnormality such as air bubbles accumulating in the pipe occurs, it is difficult to grasp the abnormality at the discharge time, and the discharge amount of the liquid intermittently discharged from the nozzle to the additive may become unstable. Patent Documents 1 to 3 do not disclose a technique for detecting an abnormality in a pipe in which a liquid is intermittently supplied.

[0007] Therefore, an object of the present invention is to provide a method for producing a liquid-containing product and a method for detecting an abnormality in a pipe that can stably and intermittently discharge a liquid from a nozzle provided in the pipe by detecting an abnormality in the pipe in which the liquid is intermittently supplied. [Means for Solving the Problems]

[0008] The present invention relates to a method for producing a liquid-containing product in which a liquid is intermittently added to an additive using a liquid addition device. It is preferable that the liquid addition device includes a pump that intermittently supplies the liquid, a nozzle that discharges the liquid to the additive, a pipe that connects between the pump and the nozzle, and a flow rate sensor that detects the flow rate in the pipe. When the cycle of intermittently supplying the liquid from the pump to the nozzle is divided into a discharge section and a non-discharge section, The manufacturing method includes a discharge-time flow integration step of calculating the integrated flow rate of the liquid flowing in the pipe during the discharge period based on the detected value of the flow sensor, a non-discharge-time flow integration step of calculating the integrated flow rate of the liquid flowing in the pipe during the non-discharge period based on the detected value of the flow sensor, and preferably includes a determination step of determining the suitability of the discharge amount of the liquid from the nozzle based on the integrated flow rates of the discharge-time flow integration step and the non-discharge-time flow integration step, respectively.

[0009] The present invention also relates to a method for detecting an abnormality in a pipe that connects between a pump and a nozzle and through which liquid is intermittently supplied to the nozzle. Preferably, a flow sensor for detecting the flow rate in the pipe is provided in the pipe. When the period of intermittently supplying the liquid from the pump to the nozzle is divided into a discharge period and a non-discharge period, the method for detecting an abnormality in the pipe includes a flow integration step of calculating the integrated flow rate in the pipe during the non-discharge period based on the detected value of the flow sensor, and preferably includes a determination step of determining whether the integrated flow rate is within a predetermined range.

Advantages of the Invention

[0010] According to the method for manufacturing a liquid-containing product and the method for detecting an abnormality in a pipe of the present invention, by detecting an abnormality in a pipe in which liquid is intermittently supplied, the liquid can be stably and intermittently discharged from a nozzle provided in the pipe.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Embodiments for Carrying Out the Invention

[0012] Hereinafter, the method for producing a liquid-containing product of the present invention will be described with reference to the drawings based on its preferred embodiments. Figure 1 shows an embodiment of a liquid addition device according to the present invention. The liquid addition device 1 shown in Figure 1 (hereinafter simply referred to as "device 1") is a device that intermittently adds liquid 10 to the object to be added 11 to produce a liquid-containing product 12 containing the liquid 10.

[0013] The device 1 of this embodiment includes a pump 6 that intermittently supplies (intermittent supply) the liquid 10, a nozzle 4 that discharges the liquid 10 to the object to be added 11, a pipe 3 that connects between the pump 6 and the nozzle 4, and a flow rate sensor 2 that detects the flow rate in the pipe 3 (see Figure 1). Further, the device 1 of this embodiment includes a control means 5 that controls the entire device 1. Figure 1 shows only the main part of the device 1 and does not show all the configurations of the device 1.

[0014] The pipe 3 of this embodiment forms a flow path between the pump 6 and the nozzle 4, and the liquid 10 is intermittently supplied from the pump 6 to the nozzle 4 through the pipe 3. In the device 1 of this embodiment, a flow rate sensor 2 that detects the flow rate of the liquid 10 flowing in the pipe 3 is provided. As the flow rate sensor 2, various types such as differential pressure type, electromagnetic type, area type, ultrasonic type, turbine type, thermal type, Coriolis type, volumetric type, and vortex type can be used. From the viewpoints of maintainability, corrosion resistance, and abrasion resistance, it is preferable to use a non-contact type flow rate sensor such as ultrasonic type or electromagnetic type. The flow rate value (detection value) of the liquid 10 flowing in the pipe 3 measured by the flow sensor 2 is transmitted to the control means 5 described later.

[0015] In the apparatus 1 of the present embodiment, a pump 6 and a storage tank (not shown) of the liquid 10 are connected by a pipe 3a, and the liquid 10 is supplied from the storage tank to the pump 6 through the pipe 3a (FIG. 1). As shown in FIG. 2, the pump 6 of the present embodiment is a rotary plunger type pump including a plunger 62 and a cylinder 61 into which the plunger 62 is inserted. The pump 6 is configured to suck and discharge the liquid 10 from the suction port and the discharge port provided on the circumferential surface of the cylinder 61 according to the rotation angle of the plunger 62. By continuously rotating the plunger 62, the pump 6 periodically sucks and discharges the liquid 10. Thereby, in the apparatus 1, the liquid 10 is intermittently supplied from the pump 6 to the nozzle 4 through the pipe 3.

[0016] More specifically, the pump 6 of the present embodiment includes a columnar plunger 62 having a notch 62a with a non-circular cross section on one side of the tip, and a cylinder 61 having a suction port 6a and a discharge port 6b on a part of the circumferential surface, and the plunger 62 is inserted into the cylinder 61 (see FIG. 2). Further, the pump 6 includes a drive joint 63 connected to the rear end of the plunger 62 such that the rotation axes C1 and C2 have an angle θ, and a drive source 64 such as a servo motor that rotationally drives the drive joint 63 (see FIG. 1). In the plunger 62 of the present embodiment, a pin 62b projects from the outer peripheral surface of the rear end portion thereof, and the rear end portion of the plunger 62 and the drive joint 63 are connected by the pin 62b and a special bearing (ball joint) 63b provided on a part of the circumferential direction of the cylindrical portion of the drive joint 63. As the drive source 64, various motors can be used. From the viewpoint of further improving the control accuracy, it is preferable to use a servo motor as the drive source 64, and it is more preferable to use an AC servo motor. The drive source 64 of this embodiment is provided with an encoder and a driver (not shown). The encoder is used to monitor the rotation angle of the motor. The driver performs feedback control on the rotation speed and rotation angle of the motor based on the operation command of the control means 5 described later.

[0017] The plunger type pump 6 rotates the drive coupling 63 in one direction by the servo motor 64 connected to the shaft portion 63a. As shown in FIGS. 2(a) to 2(d), the plunger 62 moves forward and backward while rotating within the cylinder 61, thereby sucking the liquid 10 from the suction port 6a and discharging the sucked liquid 10 from the discharge port 6b. FIG. 2(a) shows a state in which the liquid is being sucked while the plunger 62 is retracted, FIG. 2(b) shows a state in which the suction is completed, FIG. 2(c) shows a state in which the liquid is being discharged while the plunger 62 is advanced, and FIG. 2(d) shows a state in which the discharge is completed. FIGS. 2(e) to 2(h) are cross-sectional views corresponding to FIGS. 2(a) to 2(d), respectively, and show a cross-section passing through the suction port 6a and the discharge port 6b and perpendicular to the rotation axis of the plunger.

[0018] The plunger type pump 6 shown in FIG. 2 can change the stroke length of the plunger 62 by changing the angle θ between the rotation axis C1 of the plunger 62 and the rotation axis C2 of the drive coupling 63, thereby increasing or decreasing the discharge amount per stroke. More specifically, when the angle θ is 0°, the discharge amount is zero, but when the angle θ is greater than 0°, the discharge amount per stroke increases according to the magnitude of the angle. The rear end portion of the plunger 62 and the drive coupling 63 are connected by a pin 62b protruding from the outer peripheral surface of the rear end portion of the plunger 62 and a special bearing (ball coupling) 63b provided in a part of the circumferential direction of the cylindrical portion of the drive coupling 63. The plunger 62 is rotated and advanced and retracted by rotating the drive coupling 63 connected via the special bearing (ball coupling) 63b by a drive source 64 such as a servo motor. Such pumps are well-known, and commercially available ones or the like can be used. For example, a metering pump provided as "Hi-Sera Pump (registered trademark) V series" by Iwaki Co., Ltd. can be used, and for example, the Hi-Sera Pump V-15 type or the like can be preferably used.

[0019] The apparatus 1 of the present embodiment includes an adjustment mechanism for the discharge amount of the plunger pump 6 (not shown). The adjustment mechanism has a mechanism for rotating either the rotation axis C1 of the plunger 62 or the rotation axis C2 of the drive coupling 63 in the plunger pump 6 shown in FIG. 2 so that the angle θ increases or decreases with respect to the other. As such a mechanism, an actuator that rotates a support portion (not shown) fixing the cylinder 61 with respect to a fixing base (not shown) rotatably supporting the drive coupling 63 can be used. By such an actuator, the angle θ between the rotation axis C1 of the plunger 62 and the rotation axis C2 of the drive coupling 63 can be increased or decreased, and the stroke length of the plunger 62 and the discharge amount per stroke can be increased or decreased. As the actuator, various well-known ones such as those using a ball screw, those using a linear motor, those using hydraulic pressure or pneumatic pressure, etc. can be used without particular limitation. Those using a ball screw are preferable from the viewpoint of controlling the discharge amount with high precision. Instead of rotating the support portion fixing the cylinder 61 with respect to the fixing base supporting the drive coupling, the actuator may be one that rotates the support portion supporting the drive coupling 63 with respect to the fixing base fixing the cylinder 61.

[0020] As the pump 6, any pump configured to enable intermittent supply other than a rotary plunger pump can be used. For example, a continuous discharge type pump used in combination with an intermittently driven drive source 64, a valve opening and closing type pump used in combination with a continuously driven drive source 64 and provided with a valve at the discharge port, etc. can be used. Examples of the continuous discharge type pump include Mono Pump (registered trademark) and the like.

[0021] In the present embodiment, as shown in FIG. 3, the pump 6 periodically repeats the discharge of the liquid 10 from the discharge port 6b and the suction of the liquid 10 from the suction port 6a by the continuous rotation of the plunger 62. Thereby, the liquid 10 is intermittently supplied from the pump 6 to the nozzle 4. That is, the operating pump 6 periodically repeats the discharge of the liquid 10 and the non-discharge of not discharging the liquid 10. In the timing chart shown in FIG. 3, due to such intermittent supply, the section P where the instantaneous flow rate of the liquid 10 flowing in the pipe 3 between the pump 6 and the nozzle 4 exceeds 0 (hereinafter, also referred to as "liquid passage section P") and the section where the instantaneous flow rate becomes 0 appear alternately. The instantaneous flow rate of the liquid 10 flowing in the pipe 3 is detected by the flow rate sensor 2.

[0022] The cycle of the intermittent supply from the pump 6 to the nozzle 4 through the pipe 3 (hereinafter, also simply referred to as "the cycle of the intermittent supply of the pump 6") is divided into a discharge section in which the liquid 10 is supplied from the pump 6 to the nozzle 4 and a non-discharge section in which the liquid 10 is not supplied from the pump 6 to the nozzle 4. The discharge section is set to include the liquid passage section P in the timing chart of the cycle of the intermittent supply of the pump 6. Such a timing chart is created in advance based on the measured values when the liquid 10 is supplied from the pump 6 to the nozzle 4 through the normal pipe 3. The "normal pipe 3" is a pipe in which no abnormality such as a bubble accumulation occurs. The non-discharge section is set in advance so as not to include the liquid passage section P in the timing chart. Each of the discharge section and the non-discharge section is a target section for calculating the integrated flow rate described later by integrating the instantaneous flow rate of the liquid 10 flowing in the pipe 3.

[0023] From the perspective of controlling the flow rate of the liquid 10 to the nozzle 4 with higher precision, it is preferable to divide the intermittent supply cycle of the pump 6 into a discharge section and a non-discharge section based on the set value related to the control of the pump 6. In such a case, the start and end of the discharge section, and the start and end of the non-discharge section are indicated by the said set value. In this way, by setting the discharge section and the non-discharge section according to the timing of the behavior (discharge / non-discharge) of the pump 6 instead of the flow rate of the liquid 10 flowing in the pipe 3, it is possible to grasp the abnormality in the pipe 3 described later with higher precision. Also, even if the rotational speed of the servo motor 64 is changed, it is difficult to cause a measurement error in the integrated flow rate. As the set value related to the control of the pump 6, a parameter indicating the discharge and non-discharge of the pump 6 can be adopted.

[0024] Examples of the parameter indicating the discharge and non-discharge of the pump 6 include the rotation angle of the plunger 62. For example, when the rotation angle of the plunger 62 is used as the said parameter, the discharge and non-discharge of the pump 6 can be indicated by a predetermined angle range within one rotation (0 to 360°, see Fig. 3) in the axial direction of the plunger 62. The rotation angle of such a plunger 62 can be grasped by an angle sensor or the like that interlocks with the rotation of the plunger.

[0025] In addition to the detection angle of the angle sensor that interlocks with the rotation of the plunger, as the said parameter, the rotation angle of the drive source 64 (servo motor 64) or the like can be used. For example, when the plunger 62 is rotated once in the axial direction by one rotation of the servo motor 64, since one rotation of the servo motor 64 corresponds to one cycle of the intermittent supply of the pump 6, the discharge and non-discharge of the pump 6 can be indicated by a predetermined angle range within one rotation of the servo motor 64.

[0026] Also, when the plunger 62 is rotated once in the axial direction by multiple rotations of the servo motor 64 using a speed reducer or the like, the multiple rotations of the servo motor 64 correspond to one cycle of the intermittent supply of the pump 6. In that case, by converting the angular range of multiple rotations of the servo motor 64 into the angular range of one rotation of the plunger 62 (0 to 360°), the discharge and non-discharge of the pump 6 can be indicated by a predetermined angular range within one rotation of the servo motor 64. For example, when the plunger 62 is rotated once in the axial direction by five rotations (0 to 1800°) of the servo motor 64, the entire angular range (0 to 1800°) of the five rotations of the servo motor 64 is converted into the angular range of one rotation (0 to 360°). Thereby, the discharge and non-discharge of the pump 6 can be indicated by a predetermined angular range within one rotation of the servo motor 64. The rotation angle of the servo motor 64 can be grasped by using the encoder described above.

[0027] When the pump 6 is a continuous discharge type pump used in combination with a drive source 64 that is intermittently driven, an electric signal for giving an operation command of the operation or non-operation of the drive source 64 can be used as a parameter indicating the discharge and non-discharge of the pump 6. That is, based on the electric signal, the cycle of the intermittent supply of the pump 6 can be divided into a discharge section and a non-discharge section. When the pump 6 is a valve opening / closing type pump used in combination with a drive source 64 that is continuously driven and a valve is provided at the discharge port, an electric signal for giving an operation command of the valve opening / closing can be used as a parameter indicating the discharge and non-discharge of the pump 6. That is, based on the electric signal, the cycle of the intermittent supply of the pump 6 can be divided into a discharge section and a non-discharge section.

[0028] In this embodiment, the cycle of the intermittent supply of the pump 6 is divided into a discharge section and a non-discharge section using the angular range (0 to 360°) of the rotation angle of the servo motor 64. For example, the range of the rotation angle of the servo motor 64 from 210° to 90° is set as the discharge section, and the range of the rotation angle of the servo motor 64 from 90° to 210° is set as the non-discharge section. In this case, the angular range (210° to 90°) of the servo motor 64 representing the discharge section includes the liquid passage section P, and the angular range (90° to 210°) of the servo motor 64 representing the non-discharge section does not include the liquid passage section P.

[0029] From the viewpoint of more accurately grasping the discharge amount of the liquid 10 from the nozzle 4, it is preferable that the discharge section includes the liquid passage section P and is set in a range wider than the section P. For example, when the discharge section and the non-discharge section are represented by the rotation angle of the servo motor 64 or the rotation angle of the pump 6, on the premise that the discharge section includes the angular range corresponding to the liquid passage section P, with respect to the corresponding angular range, preferably more than +0° and less than or equal to +50°, more preferably +10° or more and +40° or less, and even more preferably +20° or more and +30° or less, it is set wider than the liquid passage section P. From the viewpoint of further suppressing noise and more accurately grasping the dripping of the liquid 10 from the nozzle 4, it is preferable that the non-discharge section does not include the liquid passage section P and is set in a range narrower than the section P. That is, preferably, the non-discharge section does not include the angular range corresponding to the liquid passage section P.

[0030] A part of the discharge section and the non-discharge section may be set to overlap. Also, a blank section where no special control or monitoring is performed may be set between the discharge section and the non-discharge section.

[0031] During the intermittent supply cycle of the pump 6, a discharge section and a non-discharge section are alternately repeated (see Fig. 3). In the present embodiment, within one cycle of the rotation of the plunger 62, the sections are switched in the order of the discharge section, the non-discharge section, and the discharge section. In the timing chart in Fig. 3, a liquid passage section P appears periodically. The peak area of the instantaneous flow rate in the liquid passage section P becomes the integrated flow rate described later. There is a time lag t between the start point of the discharge of the pump 6 and the start point of the liquid passage section P, which is due to the response time of the flow rate sensor 2. Therefore, the liquid passage section P ends with a delay from the end point of the discharge of the pump 6.

[0032] The nozzle 4 of the present embodiment is provided at the downstream end of the pipe 3 connected to the pump 6 and includes a discharge port for discharging the liquid 10. The nozzle 4 may discharge the liquid 10 to the additive 11 without contacting the additive 11, or may contact the additive 11 and discharge the liquid 10 to the additive 11. When the nozzle 4 discharges the liquid 10 in a state of contacting the additive 11, the nozzle 4 is provided with a lifting mechanism so as to be able to take a state of contacting and a state of non-contact with respect to the additive 11. Examples of such a lifting mechanism include those provided with an air cylinder or a cam mechanism, and those provided with a linear slider. With the intermittent supply of the liquid 10 by the pump 6, the nozzle 4 intermittently discharges (intermittent discharge) the liquid 10 to the additive 11.

[0033] The apparatus 1 of the present embodiment continuously conveys the additives 11 intermittently arranged along the conveyance path in the conveyance direction by a known conveyance means such as a belt conveyor, and adds the liquid 10 from the aforementioned nozzle 4 to each of the individual additives 11 one by one.

[0034] Figure 1 shows the configuration of the control means 5 of the present embodiment. The control means 5 of the present embodiment includes a flow rate integration unit 51, a determination unit 52, an abnormal time control unit 53, a pump control unit 54, and a nozzle control unit 55. The control means 5 is electrically connected to the pump 6, the drive source 64, the flow rate sensor 2, and the nozzle 4, and controls the operations thereof. Further, the control means 5 of the present embodiment is also electrically connected to an actuator (not shown) which is an adjustment mechanism for the discharge amount of the pump 6.

[0035] The control means 5 is configured to include a PLC (Programmable Logic Controller), and the control of each part in the control means 5 is executed by the PLC. Alternatively, the control means 5 may be configured to include a CPU, a ROM, a RAM, etc. In this case, for example, the CPU expands a program stored in the ROM or a disk into the RAM and executes it, whereby the control of each part of the control means 5 is realized. Further, the above control may be realized by an ASIC (Application Specific Integrated Circuit) or an FPGA (Field Programmable Gate Array), or may be realized by a combination of an ASIC and an FPGA.

[0036] Based on the detection value measured by the flow rate sensor 2, the flow rate integration unit 51 calculates the integrated flow rate of the liquid 10 flowing in the pipe 3 during the discharge section (hereinafter, also referred to as "discharge integrated flow rate"). The discharge integrated flow rate can be calculated by integrating the instantaneous flow rate of the liquid 10 flowing in the pipe 3 during the discharge section. Further, based on the detection value measured by the flow rate sensor 2, the flow rate integration unit 51 calculates the integrated flow rate of the liquid 10 flowing in the pipe 3 during the non-discharge section (hereinafter, also referred to as "non-discharge integrated flow rate"). The non-discharge integrated flow rate can be calculated by integrating the instantaneous flow rate of the liquid 10 flowing in the pipe 3 during the non-discharge section.

[0037] The flow rate integration unit 51 stores the calculated data of the discharged integrated flow rate and the non-discharged integrated flow rate in time series. These integrated flow rates are stored in time series and are associated with the time of the corresponding discharge section or non-discharge section during the operation time of the apparatus 1 and stored. Then, the flow rate integration unit 51 stores the data storing the integrated flow rate and the time (time stamp) of the discharge section or non-discharge section corresponding thereto in a storage unit (not shown) provided in the control means 5. The flow rate integration unit 51 performs control regarding each data of the discharged integrated flow rate and the non-discharged integrated flow rate, such as control of writing the data to the storage unit and reading the data from the storage unit.

[0038] The determination unit 52 determines the propriety of the discharge amount of the liquid 10 from the nozzle 4 based on the discharged integrated flow rate. The discharged integrated flow rate reflects the supply amount of the liquid 10 from the pump 6 to the nozzle 4 during the discharge section. Therefore, the discharged integrated flow rate can be used as an index for determining whether the discharge amount of the liquid 10 added to the additive 11 from the nozzle 4 is appropriate. Such a discharge amount of the liquid 10 can be set based on the product design value of the liquid content 12, that is, the content of the liquid 10 in the liquid content 12. The determination unit 52 monitors the discharge amount of the liquid 10 from the nozzle 4 by determining whether the discharged integrated flow rate is within the set range.

[0039] The determination unit 52 determines the propriety of the discharge amount of the liquid 10 from the nozzle 4 based on the non-discharged integrated flow rate. The non-discharged integrated flow rate reflects the supply amount of the liquid 10 from the pump 6 to the nozzle 4 during the non-discharge section. The non-discharge section is a section in which the liquid 10 is not supplied to the nozzle 4 during the intermittent supply cycle of the pump 6. Therefore, normally, the non-discharged integrated flow rate is calculated as 0 or a very small numerical value close to 0. For example, when the apparatus 1 is operating, as shown in Fig. 4(a), the instantaneous flow rate of the liquid 10 in the pipe 3 changes periodically. The peak of each instantaneous flow rate shown in Fig. 4(a) is observed in the discharge section (see Fig. 4(c)).

[0040] On the other hand, if the non-discharge integrated flow rate exceeds a predetermined value, it can be determined that the liquid 10 is being supplied to the nozzle 4 unintentionally. For example, in the abnormal graph (gray line) shown in Fig. 4(c), although it is a non-discharge section, a change in the instantaneous flow rate of the liquid 10 in the pipe 3 is observed in this non-discharge section. This is presumably because an abnormality such as a bubble accumulation has occurred in the pipe 3, and the flow rate of the liquid 10 flowing through the pipe 3 has become unstable. More specifically, when the flow rate of the liquid 10 passing through the pipe 3 decreases, a part of the pipe 3 becomes a negative pressure (water column separation). Due to the inertial force, the surrounding liquid 10 gathers at the location with the negative pressure, and a water hammer phenomenon occurs where the liquid 10 collides with each other. The water hammer phenomenon is likely to occur when the liquid 10 is intermittently supplied through the pipe 3. When such an abnormality occurs in the pipe 3, liquid dripping may occur from the nozzle 4. Such liquid dripping also appears as a change in the instantaneous flow rate in the non-discharge section. When liquid dripping occurs in the non-discharge section, there is a risk that the conveyance path of the additive 11 will be contaminated by the liquid 10, or that the discharge amount of the liquid 10 with respect to the additive 11 will be too small, resulting in defective products. That is, by monitoring whether the non-discharge integrated amount exceeds a predetermined value, an abnormality in the pipe 3 can be detected. When the abnormality in the pipe 3 continues, as shown in Fig. 4(b), in addition to the peak of the instantaneous flow rate in the discharge section, the peak of the instantaneous flow rate in the non-discharge section [the peak of the arrow shown in Fig. 4(b)] is also periodically observed. Thus, the non-discharge integrated flow rate can be used as an index for determining an abnormality in the pipe 3.

[0041] Based on each of the discharge integrated flow rate and the non-discharge integrated flow rate, the determination unit 52 determines the appropriateness of the discharge amount of the liquid 10 from the nozzle 4 for each discharge section or each non-discharge section during the operation of the apparatus 1. The determination unit 52 associates the determination result with the discharge section or non-discharge section that is the subject of the determination, and stores these data in a storage unit (not shown) provided in the control means 5.

[0042] The determination performed by the determination unit 52 of the present embodiment is based on a relational expression (hereinafter, also referred to as the "integrated flow rate - discharge amount relational expression") obtained in advance between the discharge amount of the liquid 10 discharged from the nozzle 4 and the integrated flow rate in the pipe 3. In this relational expression, the discharge amount (g) of the liquid 10 discharged from the nozzle 4 increases in proportion to the integrated flow rate (mL) of the liquid 10 flowing in the pipe 3, and the specific gravity of the liquid 10 becomes the proportionality coefficient of this relational expression. Hereinafter, the "integrated flow rate of the liquid 10 flowing in the pipe 3" will also be simply referred to as the "integrated flow rate", and the "discharge amount of the liquid 10 discharged from the nozzle 4" will also be simply referred to as the "nozzle discharge amount". The integrated flow rate - discharge amount relational expression is created by measuring the discharge amount of the nozzle 4 when the apparatus 1 is operated while changing the integrated flow rate.

[0043] The determination unit 52 of the present embodiment determines the suitability of the nozzle discharge amount in either or both of the discharge section and the non - discharge section based on the integrated flow rate - discharge amount relational expression. From the viewpoint of more precisely controlling the content of the liquid 10 in the liquid inclusion 12, it is preferable that the determination unit 52 determines the suitability of the nozzle discharge amount at least in the discharge section based on the integrated flow rate - discharge amount relational expression. For example, when the nozzle discharge amount in the discharge section obtained by the integrated flow rate - discharge amount relational expression is outside the range of the product design value of the liquid inclusion 12, the determination unit 52 determines that the nozzle discharge amount in the discharge section is not appropriate. On the other hand, when the nozzle discharge amount in the discharge section obtained by the integrated flow rate - discharge amount relational expression is within the range of the product design value of the liquid inclusion 12, the determination unit 52 determines that the nozzle discharge amount in the discharge section is appropriate.

[0044] The abnormality control unit 53 issues an alarm signal, an operation command to exclude defective products from the production line, and a stop command to stop the operation of the apparatus 1 based on the determination result derived by the determination unit 52. More specifically, when the determination unit 52 determines that the discharge amount of the liquid 10 in the non-discharge section is not appropriate based on the non-discharge integrated flow rate, the abnormal-time control unit 53 issues an alarm signal notifying an abnormality in the pipe 3 based on the determination result. Thereby, for example, an alarm is issued via a speaker provided in the control means 5. Alternatively, alarm information is displayed on a display means such as a display provided in the control means 5 to issue an alarm. The alarm generated by the alarm signal may be visual information or auditory information.

[0045] Further, when the non-discharge integrated flow rate is excessive, the abnormal-time control unit 53 issues a stop command to stop the operation of the apparatus 1. If the non-discharge integrated flow rate indicating liquid dripping in the non-discharge section is excessive, defective products are generated. To prevent this, the abnormal-time control unit 53 determines whether the non-discharge integrated flow rate is excessive, and if it is excessive, stops the operation of the apparatus 1. Such determination is made based on a preset excessive value of the non-discharge integrated flow rate.

[0046] Also, when the determination unit 52 determines that the discharge amount of the liquid 10 in the discharge section is not appropriate based on the discharge integrated flow rate, the abnormal-time control unit 53 issues an operation command to exclude the liquid content 12 corresponding to the determination result from the production line. Such an operation command is transmitted to an exclusion mechanism (not shown) that excludes defective products. The exclusion mechanism is installed downstream in the conveyance direction of the liquid content 12 from the nozzle 4, and has a mechanism for excluding the liquid content 12 produced in the discharge section where it is determined that the discharge amount of the liquid 10 is not appropriate, as a defective product, outside the production line. Furthermore, the abnormal-time control unit 53 counts the number of times (hereinafter, also referred to as the "exclusion count") of excluding the defective product outside the production line. When such a number of times continuously reaches a predetermined number of times or more, a stop command to stop the operation of the apparatus 1 is issued.

[0047] The pump control unit 54 issues an operation command to adjust the discharge integrated flow rate based on the integrated flow rate - discharge flow rate relational expression. For example, when the determination unit 52 determines that the nozzle discharge flow rate in the discharge section is not appropriate, the pump control unit 54 issues an operation command to the pump 6, and adjusts the supply amount of the liquid 10 from the pump 6 to the nozzle 4 so that the nozzle discharge flow rate in the discharge section falls within the range of the product design value of the liquid inclusion 12. The pump 6 that receives such an operation command adjusts the discharge amount per stroke (the discharge amount of the liquid 10 in the pump 6) by changing the angle θ between the rotation axis C1 of the plunger 62 and the rotation axis C2 of the drive coupling 63, thereby changing the stroke length of the plunger 62. The pump control unit 54 repeats the adjustment of the discharge amount of the liquid 10 in the pump 6 until the determination unit 52 determines that the nozzle discharge flow rate is appropriate, that is, until the nozzle discharge flow rate in the discharge section falls within the range of the product design value of the liquid inclusion 12.

[0048] The nozzle control unit 55 controls the discharge of the liquid 10 by the nozzle 4 to add the liquid 10 to the additive 11. For example, the nozzle control unit 55 controls the opening and closing of the discharge port provided in the nozzle 4 to control the discharge of the liquid 10 discharged from the nozzle 21.

[0049] Next, a method for manufacturing a liquid inclusion using the apparatus 1 of the present embodiment (hereinafter simply referred to as the "manufacturing method") will be described with reference to the flowchart shown in FIG. 5. The manufacturing method of the present embodiment includes a discharge - time flow - rate integration step of calculating a discharge integrated flow rate based on the detection value of the flow - rate sensor 2, a non - discharge - time flow - rate integration step of calculating a non - discharge integrated flow rate based on the detection value of the flow - rate sensor 2, a discharge determination step of determining the appropriateness of the nozzle discharge flow rate in the discharge section based on the discharge integrated flow rate, and a non - discharge determination step of determining the appropriateness of the nozzle discharge flow rate in the non - discharge section based on the non - discharge integrated flow rate.

[0050] Furthermore, the manufacturing method of the present embodiment includes an alarm issuing step of issuing an alarm signal for notifying an abnormality in the pipe 3 based on the determination result of the non-discharge determination step, an exclusion step of excluding the defective products from the manufacturing line based on the determination result of the discharge determination step, and a flow rate adjustment step of adjusting the discharge integrated flow rate based on the determination result of the discharge determination step and the integrated flow rate-discharge amount relational expression.

[0051] Prior to the operation of the apparatus 1, the manufacturing apparatus of the present embodiment fills the pipe 3a from at least inside the pump 6 with the liquid 10 from a storage tank (not shown), and then executes the flow shown in FIG. 5.

[0052] First, in step S1, the control means 5 operates the pump 6 by the drive source 64. Step S1 is executed when the first additive 11 is arranged at a predetermined position in the manufacturing line and the photoelectric sensor detects the additive 11 and the control means 5 receives the signal. In the next step S2, the flow rate integration unit 51 determines whether the current state of the apparatus 1 is in the discharge section based on the rotation angle of the servo motor 64. If it is determined in step S2 that it is not in the discharge section, the process proceeds to step S6. If it is determined in step S2 that it is in the discharge section, the process proceeds to step S3.

[0053] In step S3, the integrated flow rate of the liquid 10 flowing in the pipe 3 is calculated. For such calculation, the instantaneous flow rate of the liquid 10 flowing in the pipe 3 is used. In the subsequent step S4, the flow rate integration unit 51 determines whether the discharge section has ended based on the rotation angle of the servo motor 64. If it is determined that the discharge section has not ended, the process returns to step S3, and steps S3 and S4 are repeated until the discharge section ends. Thereby, until the discharge section ends, the calculation of the integrated flow rate of the liquid 10 flowing in the pipe 3 is continued, and the discharge integrated flow rate is calculated. Steps S3 and S4 are executed 1000 to 100,000 times per second. In step S4, when it is determined that the discharge interval has ended based on the rotation angle of the servo motor 64, the flow rate integration unit 51 stores the integrated discharge flow rate of the discharge interval to be calculated in the storage unit of the control means 5, and proceeds to step S5. Thus, in steps S2 to S5, the flow rate integration unit 51 performs the discharge-time flow rate integration process.

[0054] In step S5, based on the integrated discharge flow rate, it is determined whether the nozzle discharge amount in the discharge interval is appropriate. That is, the determination unit 52 executes the discharge determination process. The determination unit 52 of the present embodiment obtains the nozzle discharge amount in the discharge interval to be calculated from the calculated integrated discharge flow rate by the integrated flow rate - discharge amount relational expression, and determines whether the nozzle discharge amount is appropriate. Specifically, it is determined whether the nozzle discharge amount in the discharge interval is within the range of the product design value of the liquid inclusion 12. In step S5, when it is determined that the nozzle discharge amount in the discharge interval is appropriate, the process proceeds to step S6, and when it is determined that the nozzle discharge amount is not appropriate, the process proceeds to step S10.

[0055] In step S10, the pump control unit 54 adjusts the integrated discharge flow rate based on the integrated flow rate - discharge amount relational expression. The pump control unit 54 of the present embodiment adjusts the stroke length of the plunger 62 so that the nozzle discharge amount in the discharge interval is within the range of the product design value of the liquid inclusion 12, and adjusts the discharge amount of the liquid 10 in the pump 6 (the discharge amount of the liquid 10 of the pump 6). That is, in step S10, the pump control unit 54 performs the flow rate adjustment process.

[0056] In the subsequent step S11, based on the determination result of step S5, the abnormal-time control unit 53 issues an operation command to exclude defective products from the production line. As a result, the defective products are excluded from the production line. Such defective products refer to the liquid inclusion 12 for which it is determined in step S5 that the nozzle discharge amount is not within the range of the product design value. That is, in step S11, the abnormal-time control unit 53 performs the exclusion process. After the execution of step S11, the process proceeds to step S12.

[0057] In step S12, the abnormal-time control unit 53 counts the number of defective product eliminations since the start of operation of the apparatus 1, and determines whether or not the number of eliminations is equal to or greater than a predetermined number. When it is determined that the number of eliminations is equal to or greater than the predetermined number, the abnormal-time control unit 53 issues a stop command to stop the operation of the apparatus 1. The stoppage of the operation of the apparatus 1 due to the continuous occurrence of defective products can be used as an opportunity to perform maintenance on the pipe 3. In step S12, when it is determined that the number of eliminations is not equal to or greater than the predetermined number, the process proceeds to step S6.

[0058] In step S6, similar to step S3, the integrated flow rate of the liquid 10 flowing through the pipe 3 is calculated. Such an integrated flow rate is the integrated flow rate during the non-discharge interval. In the subsequent step S7, the flow rate integration unit 51 determines whether or not the non-discharge interval has ended based on the rotation angle of the servo motor 64. When it is determined that the discharge interval has not ended, the process returns to step S6, and steps S6 and S7 are repeated until the non-discharge interval ends. Thereby, the calculation of the integrated flow rate of the liquid 10 flowing through the pipe 3 is continued until the non-discharge interval ends, and the non-discharge integrated flow rate is calculated. Steps S6 and S7 are executed 1000 to 100,000 times per second. In step S7, when it is determined based on the rotation angle of the servo motor 64 that the non-discharge interval has ended, the flow rate integration unit 51 stores the non-discharge integrated flow rate of the non-discharge interval to be calculated in the storage unit of the control means 5, and the process proceeds to step S8. In this way, the flow rate integration unit 51 executes steps S6 and S7 to perform the non-discharge-time flow rate integration process.

[0059] In step S8, based on the non-discharge integrated flow rate, it is determined whether the nozzle discharge amount in the non-discharge section is appropriate. That is, the determination unit 52 executes the non-discharge determination process. The determination unit 52 in the present embodiment obtains the nozzle discharge amount in the non-discharge section to be calculated from the calculated non-discharge integrated flow rate by the integrated flow rate-discharge amount relational expression, and determines whether the nozzle discharge amount is appropriate. Specifically, it is determined whether the nozzle discharge amount in the non-discharge section is less than or equal to a predetermined value. If this nozzle discharge amount exceeds the predetermined value, it can be determined that liquid dripping from the nozzle 4 occurs in the non-discharge section. In step S8, if it is determined that the nozzle discharge amount in the non-discharge section is appropriate, the process proceeds to step S9; if it is determined that the nozzle discharge amount is not appropriate, the process proceeds to step S13.

[0060] In step S13, the abnormal-time control unit 53 issues an alarm signal notifying an abnormality in the pipe 3. Thereby, an alarm is issued. After this step S13, the process proceeds to step S14. In step S14, the abnormal-time control unit 53 determines whether the non-discharge integrated flow rate calculated in step S8 is excessive. If it is determined that the non-discharge integrated flow rate is equal to or greater than a preset excessive value, the abnormal-time control unit 53 issues a stop command to stop the operation of the apparatus 1. The stop of the operation of the apparatus 1 by this can be used as an opportunity to perform maintenance on the pipe 3. In step S14, if it is determined that the non-discharge integrated flow rate is less than the excessive value, the process proceeds to step S9.

[0061] In step S9, it is determined whether the next additive 11 is arranged at a predetermined position in the production line. Such determination is executed in the same manner as in step S1, by the photoelectric sensor detecting the additive 11 and the control means 5 receiving the signal. If the next additive 11 is detected, the process returns to step S2, and the operations after step S2 are repeated. In step S9, if it is determined that there is no next additive 11, the operation of the apparatus 1 is stopped. That is, the production of the liquid-containing substance 12 by the apparatus 1 is stopped.

[0062] Next, the liquid inclusion 12 produced by the production method of the present invention will be described in detail. As the liquid inclusion 12, a product containing the liquid 10 can be adopted without particular limitation. For example, a sheet-shaped heating device including a heat generating layer can be used as the liquid inclusion 12. Such a heating device includes a composite sheet in which a fiber sheet made of a fiber material and a heat generating layer composed of an oxidizable metal powder or the like are laminated, and is produced by adding an electrolyte solution containing an electrolyte to the heat generating layer of the composite sheet. That is, in the present embodiment, the additive 11 is a composite sheet, and the liquid 10 added to the additive 11 is an electrolyte solution. The heating device generates heat by the heat generated by the oxidation reaction between oxygen in the air and the oxidizable metal powder. When manufacturing this heating device (product), various conventionally known materials can be used without particular limitation.

[0063] The liquid inclusion 12 preferably includes a holding member capable of holding the liquid 10. Examples of the holding member include a water-absorbing polymer and a member provided with water-absorbing fibers such as cellulose-based fibers. For example, a polymer sheet in which a layer made of a water-absorbing polymer is disposed and integrated between two moisture-permeable sheets can be used as the holding member. In this case, it is preferable that the additive 11 includes a holding member and is configured to be able to hold the liquid 10 added to the additive 11.

[0064] The viscosity of the liquid 10 used in the production of the liquid inclusion 12 is not particularly limited and can have a viscosity that can be discharged by a general pump.

[0065] Next, the method for detecting an abnormality in a pipe according to the present invention will be described based on its preferred embodiment. The method for detecting an abnormality in a pipe in the present embodiment includes at least a non-discharge time flow integration step and a non-discharge determination step in the production method of the liquid inclusion described above. With such a configuration, the nozzle discharge amount in the non-discharge section can be monitored. For example, when the nozzle discharge amount exceeds a predetermined value in the non-discharge section, it can be determined that liquid leakage from the nozzle 4 has occurred in the non-discharge section, and the presence or absence of an abnormality such as a water hammer phenomenon in the pipe 3 can be detected. The method for detecting an abnormality in a pipe according to the present embodiment can appropriately apply the descriptions in the non-discharge time flow integration step and the non-discharge determination step described above.

[0066] The present invention is not limited to the above-described embodiments and can be appropriately modified. For example, although the control means 5 in the above-described embodiment includes the pump control unit 54, it does not necessarily have to include this. That is, the method for manufacturing a liquid-containing substance of the present invention does not necessarily have to include a flow rate adjustment step. Also, although the control means 5 in the above-described embodiment includes the nozzle control unit 55, it does not necessarily have to include this.

Explanation of Reference Numerals

[0067] 1 Liquid addition device 2 Flow sensor 3 Pipe 4 Nozzle 5 Control means 6 Pump 10 Liquid 11 Additive 12 Liquid-containing substance 51 Flow integration unit 52 Determination unit 53 Abnormality control unit 54 Pump control unit 55 Nozzle control unit 61 Cylinder 62 Plunger 63 Drive joint 64 Drive source

Claims

1. A method for manufacturing a liquid-containing product in which a liquid is intermittently added to an object to which the liquid is added, using a liquid addition device, wherein the liquid addition device includes a pump that intermittently supplies the liquid, a nozzle that discharges the liquid to the object to which the liquid is added, a pipe that connects between the pump and the nozzle, and a flow rate sensor that detects the flow rate in the pipe, when the period of intermittently supplying the liquid from the pump to the nozzle is divided into a discharge section and a non-discharge section, a discharge-time flow rate integration step of calculating an integrated flow rate of the liquid flowing in the pipe in the discharge section based on a detection value of the flow rate sensor; a non-discharge-time flow rate integration step of calculating an integrated flow rate of the liquid flowing in the pipe in the non-discharge section based on a detection value of the flow rate sensor; and a determination step of determining the appropriateness of the discharge amount of the liquid from the nozzle based on the integrated flow rates in the discharge-time flow rate integration step and the non-discharge-time flow rate integration step, respectively. A method for manufacturing a liquid-containing product.

2. In the determination step, the determination is made for the integrated flow rate in either or both of the discharge section and the non-discharge section based on a relational expression between the discharge amount of the liquid discharged from the nozzle and the integrated flow rate of the liquid flowing in the pipe, which has been obtained in advance. The method for manufacturing a liquid-containing product according to Claim 1.

3. Based on the relational expression, the supply amount of the liquid from the pump in the discharge section is adjusted. The method for manufacturing a liquid-containing product according to Claim 2.

4. Based on a set value related to the control of the pump, the period is divided into the discharge section and the non-discharge section. The method for manufacturing a liquid-containing product according to any one of Claims 1 to 3.

5. In the determination step, when it is determined that the discharge amount of the liquid based on the integrated flow rate in the discharge-time flow rate integration step is not appropriate, the liquid-containing product corresponding to the determination is excluded from the production line. The method for manufacturing a liquid-containing product according to any one of Claims 1 to 4.

6. In the determination step, when it is determined that the discharge amount of the liquid based on the integrated flow rate in the non-discharge-time flow rate integration step is not appropriate, an alarm is issued as an abnormality in the pipe. The method for manufacturing a liquid-containing product according to any one of Claims 1 to 5.

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