Monitoring System

Abstract

To provide a monitoring system that can be retrofitted to a rotary cutter device. [Solution] A monitoring system for monitoring the operating status of a rotary cutter device A, which is equipped with a cutter roll 1, an anvil roll 2, rotation support parts 31, 32, a pressure mechanism 4, and a frame 5, and includes at least one sensor 6-9 that detects a state quantity representing the operating status of the rotary cutter device A, a sensor attachment for retrofitting the sensors 6-9 to a non-rotating part of the rotary cutter device A, and a logger unit 100 that has the function of receiving the detection values ​​of the sensors 6-9 and the function of transmitting the detection values ​​to the outside.

Description

[Technical Field]

[0001] The present invention relates to a monitoring system that monitors and digitizes the operating status of a rotary cutter device that continuously cuts thin strip-shaped materials such as nonwoven fabrics and films into a predetermined shape. [Background technology]

[0002] In manufacturing lines for various products, there is an increasing demand every year to understand the operating status of equipment and to improve the accuracy of process management and equipment maintenance. In production lines for disposable diapers, sanitary napkins, and the like, a rotary cutter device is generally used to cut thin strip-shaped materials into a predetermined shape. The rotary cutter device includes a cutter roll having a cutting blade with a cutting shape and an anvil roll having a holder for the cutting blade. The cutter roll and the anvil roll are arranged parallel to each other, and these two rolls rotate in opposite directions while being close to or in contact with each other, so that the material passing between the cutter roll and the anvil roll can be continuously pushed through and cut.

[0003] As described above, a rotary cutter device is a device that continuously cuts material by rotating two rolls, but problems such as poor cutting can occur during continuous operation. In order to prevent problems such as poor cutting in a rotary cutter device, it is effective to monitor the operating status of the device. For example, Patent Document 1 discloses a rotary cutter device (rotary cutter device) equipped with an embedded monitoring unit. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 6863972 Summary of the Invention [Problem to be solved by the invention]

[0005] In Patent Document 1, the monitoring unit is embedded in at least one of the two drums (rolls). The partially embedded monitoring unit can obtain accurate measurements related to the cutting operation, such as the number of workpieces produced and the temperature of the cutting blade, while the machining is being performed. However, such a monitoring unit must be prepared from the initial design stage of the rotary cutter device and cannot be applied to existing rotary cutter devices. Furthermore, adjustment or repair of the embedded monitoring unit requires removing the rotating part of the rotary cutter device, which requires stopping the entire production line. Therefore, a monitoring unit embedded in a rotary cutter device has had problems such as the need for maintenance of the monitoring unit itself and a need to reconsider the design of the manufacturing line.

[0006] In view of the above circumstances, the problem that the present invention aims to solve is to provide a monitoring system that can be retrofitted to a rotary cutter device, so that the operating status of even existing rotary cutter devices can be grasped. [Means for solving the problem]

[0007] According to one aspect of the present invention, there is provided the following monitoring system. A monitoring system for monitoring the operating state of a rotary cutter device, the monitoring system comprising: a cutter roll having a barrel portion with a circumferential surface and a cutting blade with a cutting shape located on the circumferential surface; an anvil roll arranged parallel to the cutter roll and having a barrel portion with a circumferential surface that receives the cutting blade; rotation support portions arranged on both ends of the cutter roll and the anvil roll; a pressure mechanism that applies pressure to the rotation support portion of at least one of the two rolls, the cutter roll and the anvil roll, in a direction that sandwiches the two rolls; and a frame that holds the rotation support portion and the pressure mechanism, at least one sensor for detecting a state quantity representing an operating state of the rotary cutter device; a sensor attachment for attaching the sensor to a non-rotating portion of the rotary cutter device; a logger unit having a function of receiving a detection value of the sensor and a function of transmitting the detection value to an external device; With death, The sensor includes a displacement sensor that detects the displacement of the two rolls in the up-down direction, and the sensor attachment includes an attachment member for later attaching the displacement sensor to the rotation support portion or the frame. ,monitoring system. [Effects of the Invention]

[0008] The monitoring system according to the present invention includes a sensor attachment for retrofitting a sensor that detects a state variable representing the operating state of the rotary cutter device to a non-rotating part of the rotary cutter device, so it can be retrofitted to the rotary cutter device. Therefore, it can be applied to existing rotary cutter devices, and by acquiring a large amount of data, it is possible to improve the prediction and accuracy of maintenance inspections. [Brief explanation of the drawings]

[0009] [Figure 1] 1A and 1B show an example of the configuration of a rotary cutter device to which a monitoring system according to the present invention is applied, in which (a) is a front view and (b) is a left side view. [Figure 2] An example of a monitoring system according to the present invention is shown in a state where it is applied to the rotary cutter device shown in Figure 1, where (a) is a front view, (b) is a left side view, and (c) is a right side view. [Figure 3] FIG. 10 is a perspective view showing an example of an attachment member for a temperature sensor. [Figure 4] FIG. 10 is a perspective view showing an example of an attachment member for a rotation sensor. [Figure 5] FIG. 10 is a perspective view showing an example of an attachment member for a displacement sensor. [Figure 6] FIG. 10 is a perspective view showing an example of an attachment member for a pressure sensor. [Figure 7] FIG. 1 is a perspective view showing an example of a camera attachment. [Figure 8] FIG. 10 is a perspective view showing an example of an attachment for the logger unit. DETAILED DESCRIPTION OF THE INVENTION

[0010] An example of the configuration of a rotary cutter device to which the monitoring system according to the present invention is applied is shown in Figure 1. The rotary cutter device A shown in the figure includes a cutter roll 1, an anvil roll 2, rotation support units 31 and 32, a pressure mechanism 4, and a frame 5. The cutter roll 1 is a roll having a body 11 with a circumferential surface 111 and cutting blades 12 with a desired cutting shape that are located on this circumferential surface 111. The cutter roll 1 also has a pair of guide rings 13 that sandwich the cutting blades 12. The height of each guide ring 13 is approximately the same as the distance from the circumferential surface 111 to the cutting edge of the cutting blade 12. The anvil roll 2 is a roll having a body 21 with a circumferential surface 211. By arranging the anvil roll 2 parallel to the cutter roll 1, the circumferential surface 211 of the anvil roll 2 can receive the cutting blade 12 of the cutter roll 1. These two rolls, the cutter roll 1 and the anvil roll 2, are rotated by rotating at least one of the rolls using a rotation drive mechanism, but the rotation drive mechanism is omitted in Fig. 1. The same applies to Fig. 2, which will be described later. In FIG. 1, reference numerals 1a and 2a indicate the end of the cutter roll 1 and the end of the anvil roll 2, respectively. The rotation support parts 31 are provided to rotatably hold both ends of the cutter roll 1, and the rotation support parts 32 are provided to rotatably hold both ends of the anvil roll 2. In the rotary cutter device A, the rotation support parts 31 and 32 are made of bearing boxes. The pressure mechanism 4 applies pressure to the two rolls, the cutter roll 1 and the anvil roll 2, in a sandwiching direction. In the rotary cutter device A, the pressure mechanism 4 has a pair of air cylinders 41 and a compressed air supply unit 42 that supplies compressed air to the air cylinders 41. The compressed air is supplied to the compressed air supply unit 42 from an external compressed air source (not shown in the drawing) via a compressed air supply port 421. The frame 5 holds the rotation support parts 31 and 32 and the pressure mechanism 4. In this embodiment, the device frame 5 is made up of a top plate 51, a bottom plate 52, and pillars 53.

[0011] Fig. 2 shows an example of a monitoring system according to the present invention applied to the rotary cutter device A shown in Fig. 1. The monitoring system shown in the figure (hereinafter referred to as "this monitoring system") has a temperature sensor 6, a rotation sensor 7, a displacement sensor 8, and a pressure sensor 9 as sensors for detecting state quantities representing the operating state of the rotary cutter device A, as well as a camera 10 for photographing the operating state of the rotary cutter device A. Furthermore, as will be described in detail later, this monitoring system has a sensor attachment including attachment members for retrofitting the sensors 6 to 9 to non-rotating parts of the rotary cutter device A, and also has a logger unit 100 that has the function of receiving the detected values ​​of the sensors 6 to 9.

[0012] FIG. 3 shows an example of an attachment member for the temperature sensor 6. The attachment member 61 shown in the figure is used to attach the temperature sensor 6 to the rotation support member 31 or 32, which is a non-rotating part of the rotary cutter device A. The temperature sensor 6 is attached to the rotation support member 31 or 32 by screwing or magnetically fastening it to the rotation support member 31 or 32. In this monitoring system, the temperature sensors 6 are attached to the rotation support members 31 and 32 at four locations (top, bottom, left, and right) as shown in FIG. 1, and detect the temperature of each rotation support member 31 and 32. This configuration differs from the configuration in Patent Document 1, which detects the temperature of the roll itself, which is the rotating part. Because the rotation support member is the main heat source in a rotary cutter device, it is preferable to detect the temperature of the rotation support member to monitor the heat generation state of the rotary cutter device.

[0013] An example of an attachment member for the rotation sensor 7 is shown in Figure 4. The attachment member 71 shown in the figure is used to attach the rotation sensor 7 to the rotation support part 31, which is a non-rotating part of the rotary cutter device A, and the rotation sensor 7 is attached to the rotation support part 31 by fastening it to the rotation support part 31 with a screw or a magnet. In this monitoring system, the rotation sensor 7 is made up of a proximity sensor, and detects the number of rotations of the cutter roll 1 by detecting the face plate 1b attached to the end part 1a of the cutter roll 1. In this monitoring system, the rotation sensor 7 is attached to the rotation support part 31 to detect the rotation speed of the cutter roll 1, but the rotation sensor 7 may also be attached to the rotation support part 32 to detect the rotation speed of the anvil roll 2. The rotation sensor 7 is fixed to a non-rotating part and may be installed in a position where it can detect the rotation speed, and it may be attached to the frame 5 as well as to the rotation support parts 31 and 32. Furthermore, the rotation sensor 7 may be attached to both the rotation support portion 31 and the rotation support portion 32 to detect the rotation speeds of the cutter roll 1 and the anvil roll 2, respectively.

[0014] 5 shows an example of an attachment member for the displacement sensor 8. The attachment member 81 shown in the figure is used to attach the displacement sensor 8 to the rotation support part 31, which is a non-rotating part of the rotary cutter device A, and the displacement sensor 8 is attached to the rotation support part 31 by fastening it to the rotation support part 31 with a screw or a magnet. In this monitoring system, the displacement sensor 8 detects the vertical displacement of the two rolls, the cutter roll 1 and the anvil roll 2, by measuring the distance between it and a displacement measuring tool 32a attached to the rotation support part 32. In this monitoring system, the displacement sensor 8 is attached to the rotation support part 31 to detect the vertical displacement of the two rolls, but the displacement sensor 8 may also be attached to the frame 5 (pillar 53) to detect the vertical displacement of the two rolls.

[0015] 6 shows an example of an attachment member for the pressure sensor 9. The attachment member 91 shown in the figure is used to attach the pressure sensor 9 to the compressed air supply unit 42 of the pressurizing mechanism 4, and is attached to the compressed air supply unit 42 by screws or magnets so that the pressure sensor 9 is in communication with the compressed air supply unit 42. In this monitoring system, the pressure sensor 9 measures the air pressure in the compressed air supply unit 42 to detect the pressurizing force applied by the pneumatic pressurizing mechanism 4. In this monitoring system, the pressure mechanism 4 is of the pneumatic type, but it can also be of the hydraulic type. In this case, the pressure sensor detects the pressure applied by the hydraulic pressure mechanism by measuring the hydraulic pressure of the hydraulic pressure mechanism.

[0016] FIG. 7 shows the installation state of the camera 10. In this monitoring system, the camera 10 is attached to the frame 5 (top plate 51) of the rotary cutter device A using a camera attachment 101. However, the camera 10 does not necessarily have to be attached to the rotary cutter device A itself, and may be attached to a location other than the rotary cutter device A. In short, the camera 10 should be installed in a location that can capture the operating status of the rotary cutter device A. The operating status to be captured should preferably capture the introduction section where the material passes through the cutting section of the rotary cutter device, or the discharge section after passing through. This makes it easier to grasp not only the data but also the overall situation when an abnormality occurs. Multiple cameras 10 may be installed.

[0017] 8 shows the installation state of the logger unit 100. In this monitoring system, the logger unit 100 is attached to the frame 5 (pillar 53) of the rotary cutter device A using an attachment 1001. However, the logger unit 100 does not necessarily have to be attached to the rotary cutter device A itself, and may be attached to a location other than the rotary cutter device A.

[0018] In this monitoring system, the logger unit 100 has, as its main functions, a function to receive the detection values ​​of the above-mentioned sensors 6 to 9 (hereinafter referred to as the "receiving function"), and a function to transmit the received detection values ​​to the outside (hereinafter referred to as the "transmitting function"). In the receiving function, the logger unit 100 receives the detected values ​​of the sensors 6 to 9 via wired or wireless connections (wired connections in this monitoring system). In the transmission function, the logger unit 100 can transmit each received detection value to the outside in real time (hereinafter referred to as "real-time transmission"). It can also transmit the detection value received from each of the sensors 6 to 9 when an abnormal detection value is detected (hereinafter referred to as "abnormal transmission"). Furthermore, it can perform both real-time transmission and abnormal transmission. Real-time transmission can transmit continuously acquired data, but it can also transmit periodically at any time interval. Here, to perform abnormal transmission, the logger unit 100 needs to determine whether the detection value received from each of the sensors 6 to 9 is abnormal. Therefore, when performing abnormal transmission, thresholds that serve as criteria for determining whether each detection value from each of the sensors 6 to 9 is abnormal are input into the logger unit 100 in advance. That is, the logger unit 100 compares the detection value received from each of the sensors 6 to 9 with the corresponding threshold to determine whether the detection value is abnormal. In addition to transmitting the detection value to the outside, the logger unit 100 can also record the detection value on a recording medium external to the logger unit 100.

[0019] In this monitoring system, the logger unit 100 further has a function of activating the recording function of the camera 10 when an abnormal detection value is detected in the detection values ​​received from each of the sensors 6 to 9. For example, it is possible to record images (video) for a predetermined time (e.g., several tens of seconds) before and after the point in time when an abnormal detection value is detected in the detection values ​​received from each of the sensors 6 to 9. The recording includes not only images but also audio data, making it possible to grasp the situation when an abnormality occurs in more detail. In this monitoring system, the logger unit 100 also has the function of receiving image (video) data from the camera 10 and transmitting it to the outside. [Example]

[0020] The monitoring system of the present invention was applied to an existing rotary cutter device to check its operating status, as shown in Figure 2. Temperature sensors 1 to 4 were attached to the rotation support parts at both ends of the cutter roll and anvil roll shown in Figure 2(a). Table 1 shows some of the data that was acquired. Here, regular real-time transmission and transmission in the event of an abnormality were carried out, and data before and after normal and abnormal times was transmitted. The data acquired included the date and time of acquisition, cumulative number of rotations, number of rotations, amount of cutter roll positional displacement, amount of pressure applied, and temperatures at both ends of the cutter roll and anvil roll. As shown in Table 1, this monitoring system was able to extract data from the areas before and after the abnormality, allowing for a clear understanding of the details of the abnormality. The displacement values ​​confirmed that the roll was floating. Furthermore, the recorded data confirmed the occurrence of an abnormal noise and that the material being cut had become twisted as it passed through the cutting section. The recorded images and sound information allowed for a clear understanding of how the abnormality occurred. The data obtained from this monitoring system made it possible to identify any abnormalities, and by linking it to the recording function of the installed cameras, the situation could be confirmed in more detail, which enabled smooth maintenance and inspection of the existing rotary cutter equipment.

[0021] [Table 1] [Explanation of symbols]

[0022] A Rotary cutter device 1 cutter roll 1a End of cutter roll 1b Face plate 11 Torso 111 Circumferential surface 12 cutting blade 13 Guide ring 2 Anvil Roll 2a End of anvil roll 21 Torso 211 Circumferential surface 31, 32 Rotation support part (bearing box) 32a Displacement measuring tool 4. Pressure mechanism 41 Air Cylinder 42 Compressed air supply unit 421 Compressed air supply port 5 frames 51 Top plate 52 Bottom plate 53 pillars 6 Temperature Sensor 61 Attachment parts (sensor attachment) 7 Rotation Sensor 71 Attachment parts (sensor attachment) 8 Displacement Sensor 81 Attachment parts (sensor attachment) 9. Pressure Sensor 91 Attachment parts (sensor attachment) 10 Camera 101 Camera Attachment 100 logger units 1001 Attachment

Claims

1. A monitoring system for monitoring the operating state of a rotary cutter device, the monitoring system comprising: a cutter roll having a barrel portion with a circumferential surface and a cutting blade with a cutting shape located on the circumferential surface; an anvil roll arranged parallel to the cutter roll and having a barrel portion with a circumferential surface that receives the cutting blade; rotation support portions arranged on both ends of the cutter roll and the anvil roll; a pressure mechanism that applies pressure to the rotation support portion of at least one of the two rolls, the cutter roll and the anvil roll, in a direction that sandwiches the two rolls; and a frame that holds the rotation support portion and the pressure mechanism, at least one sensor for detecting a state quantity representing an operating state of the rotary cutter device; a sensor attachment for attaching the sensor to a non-rotating portion of the rotary cutter device; a logger unit having a function of receiving a detection value of the sensor and a function of transmitting the detection value to an external device; and The sensor includes a displacement sensor that detects vertical displacement of the two rolls, and the sensor attachment includes an attachment member for retrofitting the displacement sensor to the rotation support portion or the frame.

2. the sensors further include a temperature sensor, a rotation sensor that detects the number of rotations of at least one of the two rolls, and a pressure sensor that detects the pressure applied by the pressure mechanism; 2. The monitoring system of claim 1, wherein the sensor attachment further includes an attachment member for retrofitting the temperature sensor to the rotation support, an attachment member for retrofitting the rotation sensor to the rotation support or the frame, and an attachment member for retrofitting the pressure sensor to the pressurizing mechanism.

3. The monitoring system according to claim 1 , wherein the logger unit transmits an abnormal detection value to an external device when an abnormal detection value is detected among the detection values ​​received from the sensor.

4. Further, a camera is provided to photograph the operating state of the rotary cutter device, 4. The monitoring system according to claim 1, wherein the logger unit further comprises a function of activating a recording function of the camera when an abnormal detection value is detected in the detection value received from the sensor.

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