Method for controlling operation of roll line in commercial laundry line

Abstract

To avoid wasteful energy consumption in a roll line operated at high speed by lowering a processing speed in a roll or a folder when feed delay occurs.SOLUTION: An operation mode is switched between an ordinary operation mode (high-speed processing mode) and an energy saving operation mode (low-speed processing mode) by comparing the number of stocked articles in a buffer provided between a feeding station at the beginning of a roll line and a roll, the number of stocked articles determined by detecting an operating state of feeding equipment disposed in parallel with the feeding station, and the number of stocked articles for switching (threshold) that is previously set in a controller.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] This invention relates to a method for operating a line (hereinafter referred to as a "roll line") from the supply of items to be washed (hereinafter referred to as "items") to rolls (ironers) such as chest rolls and calender rolls installed in the latter half of a commercial laundry line to the folder. [Background technology]

[0002] As shown in Figure 1, the items to be washed after being processed in the continuous washing machine, spin-drying machine, and dryer, or washer-spin-drying machine, installed on a commercial laundry line, are manually fed one by one into feeding station 5 at the beginning of the roll line, and pass through buffer 1, feeder 2, roll 3, and folder 4 to become finished products that are delivered to customers.

[0003] In recent years, in order to increase the throughput of laundry lines, rolls, feeders and folders capable of processing at speeds exceeding 50 m / min have come to be used.

[0004] To fully utilize this high processing speed, there is an example in which a buffer 1 is placed in front of the feeder 2 to temporarily store products, as shown in Figure 1, and efficiently send products to the feeder. The buffer 1 can also be integrated with the feeder 2, and serves to absorb any deviation between the input speed of the input station 5 and the processing speed of the roll 3. In other words, installing the buffer 1 makes it possible to stock products in front of the feeder 2 located downstream, so that even if there is a temporary slowdown in the input speed at the input station 5, products can be supplied to the feeder 2 and the roll 3 one after another at a specified interval. This makes it possible to operate the roll line at essentially the maximum processing speed.

[0005] For example, Patent Document 1 proposes a cloth conveying device in which a plurality of supply positions and discharge positions are arranged in parallel on a conveying line (functioning as a buffer) on which a plurality of traveling bodies equipped with holding chucks for holding cloths travel in a circular manner. Each supply position is equipped with an inserting machine that hands over cloths to traveling bodies waiting on the conveying line, and since the traveling bodies and the inserting machines can process in parallel, the waiting time of the traveling bodies and the inserting machines is shortened, thereby increasing processing efficiency. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-59661 Summary of the Invention [Problem to be solved by the invention]

[0007] The purpose of installing a buffer on a roll line is to increase productivity through high-speed processing, and so the processing speed is often set at 50 m / min or more so that processing can be carried out at the maximum speed possible for the rolls.In addition, to be able to handle high-speed roll processing, four or more loading stations (with four loading workers) may be set up in parallel.

[0008] However, even if Roll 3 and Folder 4 are operating at high speed, if there is an operator who is not familiar with the work or if one operator is absent, the supply of goods to Roll 3 may not be able to keep up. This means that the rolls and folders are operating unnecessarily, resulting in unnecessary consumption of energy (electricity and steam).

[0009] For example, in the case of a calender roll, the number of cylinders is increased to enable high-speed processing, and the products are transported at high speed so that they can be ironed at the cylinder temperature and contact time required for the products. In this case, if the products cannot be fed in time, unnecessary heat is dissipated from the cylinders, steam is wasted, and electricity is wasted by operating the machine at a speed faster than necessary.

[0010] The object of this invention is to prevent unnecessary energy consumption by detecting a supply delay in a roll line operated at high speed and reducing the processing speed of the rolls 3 and folders 4 to perform energy-saving operation. [Means for solving the problem]

[0011] This invention solves the above problem by controlling the operating speed of the roll line in accordance with the status of the transfer of items from the buffer 1 to the feeder 2, which is determined by detecting the number of items stocked in the buffer 1 located between the input station 5 at the head of the roll line and the roll 3, the operating status of the input equipment arranged in parallel to the input station 5, etc.

[0012] The number of items stocked in the buffer 1 can be detected by using a proximity sensor to detect the number of transport chucks 11 gripping items, the difference between the number of transport chucks moving toward the feeder and the number of transport chucks moving in the return direction, etc. Also, if the controller of the buffer 1 is counting the number of items stocked, that data can be received.

[0013] By comparing the acquired stock number with the switching stock number (threshold value) previously set in the controller 8 and switching between normal operation mode (high-speed processing mode) and energy-saving operation mode (low-speed processing mode), it is possible to avoid wasting steam and electricity when the supply volume cannot keep up with the set processing speed of the roll line.

[0014] The controller 8 for the roll 3 installed on the roll line is equipped with one or more operation mode setting devices 22, 23 for setting operation programs or various operation parameters for a normal operation mode in which the roll is operated at high speed and an energy-saving operation mode, and a switching means 24 for switching between the operation modes.

[0015] The controller 8 for the roll 3 or the controller controlling the feeder 2 or the entire line is equipped with a setter 25 that sets the threshold for the detection signal of a sensor (not shown) that detects the accumulation state of items to be washed in the buffer 1. When it is desirable to switch the operating speed gradually, a waiting time setting means 27 is provided that sets the waiting time when switching the operating mode. The operating mode of the roll 3 is switched when the number of items to be washed stocked in the buffer 1 reaches the threshold or after the time set in the waiting time setting means 27 has elapsed. The operation of the roll line without the waiting time setting means 27 is the same as when the waiting time setting means 27 is set to 0.

[0016] As a trigger for switching the operating state of the roll 3, a proximity sensor or photoelectric sensor that detects the stock status of the items to be washed can be installed in the buffer 1, and the detection signal from the sensor, or the operating status of equipment such as the conveying chuck 11 in the items to be washed input station 5 of the buffer 1 or feeder 2, can be used as the trigger.This makes it easy to realize the structure of the device or controller that embodies this invention, and it can also be easily applied to existing roll lines. [Effects of the Invention]

[0017] This invention allows the operating speed of the roll line (feeder 2, roll 3, folder 4) to be reduced according to the product supply speed, avoiding unnecessary high-speed operation. This reduces wasteful heat dissipation from roll 3 and reduces the power consumption of the entire line due to continued high-speed operation, resulting in significant energy savings. Energy can also be saved by lowering the steam pressure supplied to the roll cylinder when the operating speed is reduced. Furthermore, damage and deterioration of parts due to high-speed operation can be reduced, extending the life of the machine.

[0018] Conventionally, as a means for saving energy in a washing line, technologies have been proposed that aim to save energy for the feeder alone, or for the roll alone, whereas this invention combines feeder 2 and roll 3 to save energy for the entire line, which has the effect of making it possible to save energy for the entire roll line with relatively simple control. [Brief explanation of the drawings]

[0019] [Figure 1] Schematic side view showing an example of a roll line [Figure 2] Flowchart showing the control procedure of the first embodiment [Figure 3] Operation diagram showing the operation of the roll of the first embodiment [Figure 4] Flowchart showing the control procedure of the second embodiment [Figure 5] An operation diagram showing the operation of the roll of the second embodiment DETAILED DESCRIPTION OF THE INVENTION

[0020] Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings. FIG. 1 is a diagram schematically illustrating a roll line in a washing line for linen products such as sheets and towels. Items (hereinafter referred to as "sheets") that are washed in a continuous washing machine and sent to the roll line in lots after passing through a spin dryer and a dryer are manually gripped at both upper corners of the sheet by conveying chucks 11 at input station 5 of buffer 1. Having gripped the sheet, conveying chuck 11 rises and moves within buffer 1 toward feeder 2, stopping at the end of multiple waiting conveying chucks to wait. Note that some machines are configured to transfer items from a lifting chuck provided at the input station to a conveying chuck that circulates within the buffer.

[0021] When a receiving permission signal is received from the feeder 2, the leading transport chuck 11 hands the sheet w to the feeder 2 and returns to the insertion station 5 side, where it waits at the end of the transport chucks waiting to be inserted. By providing a sensor to detect the transport chucks 11 and counting the number of transport chucks moving to the feeder side and the number of transport chucks returning to the insertion station side, it is possible to detect the number of sheets waiting in the buffer (stock number).

[0022] Other methods for detecting the number of stocks include directly detecting the number of waiting transport chucks and sheets using a photoelectric sensor or proximity sensor, or calculating the number by comparing the operating status of the transport chucks at the loading station with the operating speed of the feeders and rolls.

[0023] The feeder 2 spreads the upper side of the sheet w it receives, spreads the lower side of the hanging sheet outward by applying negative pressure, and sends it to the roll 3 on the conveyor 6.

[0024] At the roll 3, the sheet w is conveyed by a conveyor belt 12 while being pressed against a heated chest or a plurality of cylinders 13, where it is ironed, and then sent to a folder 4 by a conveyor 7, where it is folded into a predetermined shape to become a finished product.

[0025] An operation program 21 for controlling the operation of the machine is registered in the controller 8 of the roll 3, and the operation program 21 is provided with a normal operation mode setter 22 and an energy-saving operation mode setter 23 for setting various parameters such as the conveying speed and cylinder steam pressure in each operation mode. The set value of the energy-saving operation mode setter 23 can also be set as a ratio to the set value in the normal operation mode.

[0026] The controller 8 further includes a mode switching means 24, a threshold value setting device 25 for setting a threshold value for the number of sheets stocked in the buffer (hereinafter referred to as the "switching stock number"), a start-up waiting time setting device 26 for setting a start-up waiting time, a switching waiting time setting device 27 for setting a waiting time for mode switching, and a receiving means 28 for receiving the stock number detected on the buffer 1 side. The controller 8 switches the operation mode when the time set in the switching waiting time setting device 27 has elapsed after the received stock number has reached the set switching stock number.

[0027] In addition, if multiple mode setters 22 and 23 are provided corresponding to the number of workers, such as a normal operation mode and an energy-saving operation mode when the number of workers at the input station 5, which is normally four, decreases to three, it is possible to save energy when there are no workers.

[0028] In addition, in a line where the operating speed of the roll line is controlled by a controller on the feeder side, mode setters 22, 23, mode switching means 24, threshold setter 25, switching waiting time setter 27 and stock number receiving means 28 are provided in the controller on the feeder 2 side. [Example]

[0029] Figure 2 is a flowchart showing the operation when the stock number is the same when switching from normal operation mode to energy-saving operation mode and when switching from energy-saving operation mode to normal operation mode, and Figure 3 is an operation diagram when the procedure of Figure 2 is executed with the operating program parameters set as follows. Normal operating speed: 45m / min Switch stock: 15 Switching wait time: 300 seconds Energy-saving operating speed: 35m / min Normal operating steam pressure 0.8MPa Energy-saving operation steam pressure 0.65MPa

[0030] Loop A, which repeats step s5 from YES in step s3 in Fig. 2, is a loop when the device is operating in the normal operation mode, and corresponds to the operation in section A in Fig. 3. Loop C, which repeats step s8 from NO in step s3 in Fig. 2 via NO in step s6, corresponds to the operation in section C in Fig. 3 when the device is operating in the energy saving operation mode.

[0031] Loop B, which repeats NO in step s3 to NO in step s6 and NO in step s7 in Fig. 2, is the operation during switchover waiting time when transitioning from the normal operation mode to the energy-saving operation mode, and corresponds to the operation in section B in Fig. 3. Loop D, which repeats YES in step s3 to NO in step s4 in Fig. 2, is the operation during switchover waiting time when transitioning from the energy-saving operation mode to the normal operation mode, and corresponds to the operation in section D in Fig. 3.

[0032] In FIG. 2, when the roll line is started after preparatory operations of each machine such as heating the cylinders, the roll controller 8 sets the steam pressure to the normal operating steam pressure and the operating speed to the normal operating speed (step s1) and starts operation. After the waiting time set if necessary has elapsed (step s2), the detected stock number is compared in step s3 with the set switching stock number.

[0033] If operation is started with a certain amount of stock accumulated, the answer in step s3 will be YES, and loop A will be repeated until the stock amount falls below the switching stock amount, maintaining normal operation mode. If the input of items cannot keep up with the processing speed in normal operation mode, the stock amount will decrease as shown in line a of section A in Figure 3.

[0034] When the stock quantity falls below the switching stock quantity in normal operation mode in loop A, step s3 becomes NO, and a switching wait state is entered, returning to step s3 from NO in steps s6 and s7. If NO in step s3 is maintained even after the switching wait time has elapsed, the operation mode is switched to energy-saving operation mode in step s8, and the energy-saving operation mode in loop C is entered. In energy-saving operation mode, the stock quantity gradually increases, as shown by line c in section C of Figure 3. When the stock quantity exceeds the switching stock quantity, step s3 becomes YES, and after the switching wait time has elapsed in loop D, the operation returns to normal operation mode in step s5.

[0035] In this way, operation continues by alternating between normal operation mode and energy-saving operation mode (section E in Figure 3), and when a stop signal is received, roll 3 stops when the stock count reaches 0 (YES in steps s6 and s9 in Figure 2).

[0036] In Figure 3, the steam pressure p and operating speed v are switched instantaneously, and the stock quantity is shown to switch instantly between decreasing and increasing states, but in reality it takes time to switch the steam pressure and operating speed, so the V-shaped or inverted V-shaped portions of the diagram showing the change in stock quantity actually become U-shaped or J-shaped or inverted U-shaped or inverted J-shaped changes. [Example]

[0037] Figure 4 is a flowchart showing the operation when the stock number when switching from normal operation mode to energy-saving operation mode (switching stock number A) is different from the stock number when switching from energy-saving operation mode to normal operation mode (switching stock number B), and Figure 5 is an operation diagram when the procedure of Figure 4 is executed with the operating program parameters set as follows. Normal operating speed: 45m / min Switch stock number A 10 pieces Switch stock number B: 20 Switching wait time: 300 seconds Energy-saving operating speed: 35m / min Normal operating steam pressure 0.8MPa Energy-saving operation steam pressure 0.65MPa

[0038] The flowchart in Figure 4 is shown with a different flow from the flowchart in Figure 2 because there are now two conditions for determining the number of stocks, 10 and 20 (s3 becomes s31 and s32). However, loops A, B, C, and D correspond to sections A, B, C, and D in Figure 5, and are the same as those in Figures 2 and 3 in that section A is the normal operation section, section B is the section where operation switches from normal operation to energy-saving operation, section C is the energy-saving operation section, and section D is the section where operation switches from energy-saving operation to normal operation.

[0039] In the flowchart of FIG. 4, the processing performed in steps s1, s2, and s4 to s9 is the same as that in FIG. 4, the steam pressure and operating speed setting values ​​in the energy-saving operation mode in s8 are set as numerical values, whereas in FIG. 4, the steam pressure and operating speed setting values ​​are set as reduction rates of X% and Y% relative to the setting values ​​in the normal operation mode.

[0040] That is, in the second embodiment, the speed and steam pressure are reduced and the system switches to energy-saving operation mode five minutes after the detected number of stocks falls below 10, and then normal operation speed and steam pressure are restored five minutes after the number of stocks exceeds 20. This reduces the number of times the operation mode is switched and the number of times the operation speed and steam pressure are changed, as shown in Figure 5, making it possible to operate the roll line stably.

[0041] In the above embodiment, the operation mode is switched based on the number of switching stocks set in the controller, but it is also possible to control the operation mode based on the presence or absence of stock, so that if there is no stock, the energy-saving operation mode is used, and if there is at least one stock, the normal operation mode is used.

[0042] Furthermore, in the above embodiment, the number of items stocked in the buffer 1 is used as a trigger for switching the operation mode, but it is also possible to change the operation state based on the number of workers feeding items into the roll line. For example, if the specified number of people at the feeding station is four, if the number of people detected by a human presence sensor or the like is less than this, the operation status can be determined to be low, and if the specified number of people is present, the operation status can be determined to be normal, and the operation mode can be switched.

[0043] The input operation status can also be determined using the operation status of the input chuck of items into buffer 1. For example, if the number of times items are chucked within a certain period is less than the number expected for the current processing speed, the operation status is determined to be low, and if it is more than that, the operation status is determined to be normal.

[0044] In either case, when the operating status is low, the processing speed of the roll line is reduced and the steam pressure setting of the roll is also lowered to save energy.Then, when the operating status improves, the processing speed of the roll line and the steam pressure of the roll are returned to the set values.

[0045] Furthermore, in the above embodiment, the energy-saving operation mode is one mode, but it is also possible to change it stepwise into multiple energy-saving operation modes. That is, the method of decreasing (increasing) the processing speed and steam pressure may be decreased (increased) stepwise. Taking the stock number as an example, the stock number N and M (N>M) at which the energy-saving operation mode is switched may be set, and when N is lowered, the stock number may be decreased by one step, and when M is lowered, the stock number may be decreased by another step (totaling two steps). When increasing, the stock number may be increased stepwise in the same way, or the number of steps may be different when decreasing and increasing. In short, the operation mode may be switched in a way that is considered optimal for the characteristics of the roll line and the products being processed. [Explanation of symbols]

[0046] 1 buffer 2 feeders 3 rolls 5. Input Station 8 Controller 11 Transport chuck 22 Normal operation mode setting device 23 Energy-saving operation mode setting device 24 Mode switching means 25 Threshold setting device 27 Switching wait time setting device w Items to be washed

Claims

1. A method for controlling the operation of a roll line including a loading station for loading items to be washed, rolls such as chest rolls and calendar rolls, and a buffer for storing the loaded items between the loading station and the rolls, A method for controlling the operation of a roll line in a commercial laundry line, comprising: an operation mode setting device for setting various parameters for high-speed processing and low-speed processing; a controller including a means for switching between the operation modes; the rolls operated based on instructions from the controller; and a setting device for setting a threshold value for detection signals from sensors that detect the storage state of items to be washed in the buffer and the operating status of the loading station, wherein the operation mode is switched from high-speed processing mode to low-speed processing mode when the detection signal reaches the threshold value or after a set waiting time from when the detection signal reaches the threshold value.

2. 2. The operation control method according to claim 1, wherein the object of detection of the sensor is the stock status of the items to be washed in the buffer.

3. 2. The operation control method according to claim 1, wherein the object of detection by the sensor is the operating status of the insertion devices arranged in parallel in the insertion station.

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