Anomaly detection device

Abstract

In a material transport system that moves materials at a constant speed and controls the material's tension to maintain a constant level, the system identifies the cause of any abnormalities in the material's tension. [Solution] The abnormality detection unit 12-3 for M3 of the abnormality detection unit 12 sets a threshold value LV1 for setting the torque within the normal range from the tension (tension setting values ​​ts2, ts3 and current tension values ​​tp2, tp3) of the inlet and outlet sections s2, s3 of the roll 4-2. sel and current threshold LV2 sel The abnormality detection unit 12-3 for M3 calculates the setting threshold LV1. sel and current threshold LV2 sel Furthermore, if it is determined that the actual torque L3 is abnormal based on the actual torque L3, an abnormality signal is generated and output based on the control state of motor 7-3, etc., indicating the location that caused the abnormality.

Description

[Technical Field]

[0001] The present invention relates to an abnormality detection device for detecting abnormalities in a material transport system that manages the tension of moving materials. [Background technology]

[0002] Conventionally, a material transport system is known that unwinds a base material made of sheet-like material, performs processes such as printing, annealing, coating, and washing on the unwinded material during transport, and then winds up the processed material.

[0003] In this material handling system, control is performed to ensure that the material travels at a constant speed between an unwinding roll that unwinds sheet-like material from the base material and a winding roll that winds up the processed material.

[0004] However, the materials being transported, such as cardboard, paper, and film, can expand or contract due to temperature, humidity, and other factors. Furthermore, if multiple different printing processes are performed during the material transport process, differences in printing conditions can also cause the materials to expand or contract. When materials expand or contract, the accuracy of the printing position decreases, resulting in a decline in the quality of the processed material.

[0005] To solve this problem, the tension of the material is kept constant by, for example, controlling the tension of the material detected by a tension detector, or by installing a dancer on the material transport line and controlling the roll position of the dancer by the pressure of a cylinder.

[0006] Thus, in a material handling system, control is performed to ensure that the material travels at a constant speed from the unwinding roll to the winding roll, while also maintaining a constant tension in the material.

[0007] The material transport system is equipped with a motor, pulse generator (PG), tension detector, etc., which perform the aforementioned control, and in order to achieve stable control, technology is required to detect any abnormalities that occur (see, for example, Patent Documents 1 and 2).

[0008] The technology described in Patent Document 1 acquires the current tension value and the corresponding tension set value calculated from actual torque, and determines whether or not an abnormality has occurred based on the characteristics of the time change in the relationship between these two values, and the characteristics of the time change in the relationship between these two values ​​during normal operation and during abnormal operation, which are stored in advance.

[0009] Furthermore, the technology described in Patent Document 2 calculates the measured braking force from the measured tension of the material, calculates a reference value for the braking force from a preset reference value for tension, and determines whether or not an abnormality has occurred by comparing the measured braking force with the reference value. [Prior art documents] [Patent Documents]

[0010] [Patent Document 1] International Publication No. 2018 / 029830 [Patent Document 2] Japanese Patent Application Publication No. 11-11758 [Overview of the Initiative] [Problems that the invention aims to solve]

[0011] In the aforementioned material transport system, it is possible to determine whether or not an abnormality has occurred in the tension of the material by using the technologies described in Patent Documents 1 and 2. However, the technologies described in Patent Documents 1 and 2 cannot identify the cause of the abnormality.

[0012] In other words, the operator of the material handling system can recognize that an anomaly has occurred regarding the tension of the material, but cannot identify the machine or other equipment that caused that anomaly.

[0013] Causes of abnormalities related to material tension include abnormal loads connected to the motor, failure of the tension sensor, motor failure, dancer roll failure, and motor slippage. Since operators cannot specifically recognize these issues, they must identify the cause of the abnormality through their own investigations, which can be time-consuming.

[0014] Therefore, operators desired to receive more specific notifications of anomalies, not only to recognize whether an anomaly had occurred, but also to narrow down the cause of the anomaly.

[0015] Therefore, the present invention has been made to solve the above-mentioned problems, and its objective is to provide an abnormality detection device that can identify the cause of an abnormality when the tension of the material is abnormal in a material transport system that moves the material at a constant speed and controls the material to maintain a constant tension. [Means for solving the problem]

[0018] In order to solve the aforementioned problem, Claim 1 The abnormality detection device is an abnormality detection device for a material transport system in which an unwinding roll unwinds and moves a sheet-like material, each of a plurality of rolls inserts and passes the material, and a winding roll winds up the material after it has passed through the plurality of rolls, and detects abnormalities in the system, and a setting threshold LV1 that indicates the normal range of torque of the motor that rotates the rolls based on a preset tension setting value ts of the material. sel A setting threshold generation unit to determine the current tension value tp of the material, which is input from a tension detector installed in the material transport system, and based on the current tension value tp, generates a current threshold value LV2 that indicates the normal range of the torque. sel A current threshold generation unit calculates the current value i flowing through the motor, and the actual torque L is calculated based on that current value i, and the setting threshold LV1 is determined by the setting threshold generation unit. sel and the current threshold value LV2 obtained by the current threshold value generation unit. selBased on the above, it is characterized by including an abnormality determination unit that determines the abnormality.

[0019] Also, the abnormality detection device according to claim 2 In the abnormality detection device according to claim 1 When the actual torque L does not satisfy the range indicated by the set threshold value LV1 sel it is determined that a motor load abnormality indicating an abnormality of the load connected to the motor has occurred. This is the feature.

[0020] Also, the abnormality detection device according to claim 3 The abnormality detection device In the abnormality detection device according to claim 2, When the actual torque L does not satisfy the range indicated by the set threshold value LV1 sel it is determined whether a PG abnormality indicating an abnormality of a PG (pulse generator) that detects the rotational position connected to the motor has occurred. This is the feature. <​​​​​​​​​​​​​​​​​​​​​The method is characterized by determining whether or not slip has occurred between the roll connected to the motor and the material, or between the motor and the roll connected to the motor, if the range indicated is met.

[0023] Furthermore, claims 6 The abnormality detection device is, according to the claim 5 In the abnormality detection device described above, the control deviation EP is calculated so that the current tension value tp matches the tension set value ts, and the tension of the material is controlled based on the control deviation EP, and the abnormality determination unit determines that the actual torque L matches the setting threshold LV1 sel The range indicated is not met, and the actual torque L is the current threshold LV2 sel The method is characterized in that, if the range indicated is met, and further if the control deviation EP is greater than a preset parameter B2, it is determined that the slip has occurred, and if the control deviation EP is less than or equal to the parameter B2 and a dancer for maintaining constant tension in the material is installed, it is determined that a dancer abnormality indicating a dancer malfunction has occurred.

[0024] Furthermore, claims 7 The abnormality detection device is, according to the claim 1 In the abnormality detection device described above, one of the plurality of rolls is designated as the target roll, the space between the target roll and the roll located next to the target roll and provided on the unwinding roll side is designated as the inlet section, and the space between the target roll and the roll located next to the target roll and provided on the winding roll side is designated as the outlet section, and the setting threshold generation unit generates the difference between the tension setting value ts in the inlet section and the tension setting value ts in the outlet section as the tension setting value difference TS dif The tension T at a predetermined rated torque is calculated as follows: mtr and the difference in tension set value TS dif Based on the above, the difference in tension set value TS dif The torque required to generate the desired output is set to the required torque LS. calThe threshold LV1 (=LS) is calculated using a coefficient based on the pre-set parameter C. cal The multiplication by (1±C) is calculated, the bandwidth is calculated from the upper and lower values ​​of the threshold LV1, and a fixed threshold LV2 (=LS) is determined using the pre-set parameter B1. cal Calculate ±B1), calculate the bandwidth from the upper and lower values ​​of the threshold LV2, and set the wider of the bandwidth of threshold LV1 and the bandwidth of threshold LV2 to the setting threshold LV1 sel The current threshold generation unit calculates the difference between the current tension value tp in the inlet section and the current tension value tp in the outlet section as the current tension value difference TP. dif The tension T at the predetermined rated torque is calculated as follows: mtr and the difference in current tension values ​​TP dif Based on the above, the difference in current tension values ​​TP dif The torque required to generate the current required torque LP cal The threshold LV3 (=LP) is calculated using the parameter C and the coefficient. cal The multiplication by (1±C) is calculated, the bandwidth is calculated from the upper and lower values ​​of the threshold LV3, and the fixed threshold LV4 (=LP) is calculated using the parameter B1. cal Calculate ±B1), calculate the bandwidth from the upper and lower values ​​of the threshold LV4, and set the wider of the bandwidth of threshold LV3 and the bandwidth of threshold LV4 to the current threshold LV2. sel It is characterized by being sought as such.

[0025] Furthermore, claims 8 The abnormality detection device is, according to the claim 1In the abnormality detection device described above, one of the plurality of rolls is designated as the target roll, the space between the target roll and the roll located next to the target roll and provided on the unwinding roll side is designated as the inlet section, the space between the target roll and the roll located next to the target roll and provided on the winding roll side is designated as the outlet section, the roll located next to the target roll and provided on the unwinding roll side is designated as the inlet roll, the roll located next to the target roll and provided on the winding roll side is designated as the outlet roll, the torque calculated based on the current value i flowing through the motor that rotates the target roll is designated as the target actual torque La, the torque calculated based on the current value i flowing through the motor that rotates the inlet roll is designated as the inlet actual torque Lb, and the torque calculated based on the current value i flowing through the motor that rotates the outlet roll is designated as the outlet actual torque Lc, and the abnormality determination unit determines that the target actual torque La corresponds to the setting threshold LV1 of the motor that rotates the target roll sel The range indicated is not met, and the target actual torque La corresponds to the current threshold LV2 of the motor that rotates the target roll. sel If it is determined that the range indicated is not met, the setting threshold LV1 corresponding to the motor that rotates the inlet roll will be determined. sel If the range indicated is not met, and it has been determined that a motor load abnormality has occurred in the motor that rotates the inlet roll, it is determined that a tension detector abnormality has occurred, indicating an abnormality in the tension detector installed in the inlet section, and the actual outlet torque Lc corresponds to the setting threshold LV1 of the motor that rotates the outlet roll. sel The method is characterized in that, when it has been determined that a motor load abnormality has occurred in the motor that rotates the outlet roll because the range indicated by is not met, it is determined that a tension detector abnormality has occurred, indicating an abnormality in the tension detector installed in the outlet section.

[0026] Furthermore, claims 9 The abnormality detection device is, according to the claim 1In the abnormality detection device described above, one of the plurality of rolls is designated as the target roll, the space between the target roll and the roll located next to the target roll and provided on the unwinding roll side is designated as the inlet section, the space between the target roll and the roll located next to the target roll and provided on the winding roll side is designated as the outlet section, the torque calculated based on the current value i flowing to the motor that rotates the target roll is designated as the target actual torque La, and for each of the inlet section and the outlet section, a control deviation EP is calculated so that the current tension value tp matches the tension set value ts, and the tension of the material is controlled based on the control deviation EP, and the abnormality determination unit determines that the target actual torque La matches the setting threshold LV1 sel The range indicated is not met, and the target actual torque La is the current threshold LV2 sel The method is characterized in that, if the range indicated is met, and further, if the control deviation EP of the inlet section is greater than a preset parameter B2, or if the control deviation EP of the outlet section is greater than the parameter B2, it is determined that a slip has occurred between the target roll connected to the motor and the material, or between the motor and the target roll connected to the motor. [Effects of the Invention]

[0027] As described above, according to the present invention, in a material transport system that moves a material at a constant speed and controls the material's tension to maintain a constant level, it is possible to identify the cause of an abnormality in the material's tension. [Brief explanation of the drawing]

[0028] [Figure 1] This is a schematic diagram illustrating an example of the overall configuration of a material handling system. [Figure 2] This is a block diagram showing an example configuration of a material handling device. [Figure 3]This is a block diagram showing an example configuration of a reference speed control unit, a follow-up speed control unit, and a tension control unit. [Figure 4] This is a block diagram showing an example of the configuration of the anomaly detection unit. [Figure 5] Block diagram showing an example configuration of the anomaly detection unit for M3. [Figure 6] This flowchart shows an example of processing by the anomaly detection unit for M3. [Figure 7] This flowchart shows an example of the process for generating the setting threshold LV1sel (step S602). [Figure 8] This flowchart shows an example of the current threshold LV2sel generation process (step S603). [Figure 9] This is a flowchart showing an example of the tension detector and other abnormality detection process (step S608). [Figure 10] This flowchart shows an example of the abnormality detection process (step S609), such as the occurrence of slippage. [Modes for carrying out the invention]

[0029] The embodiments for carrying out the present invention will be described in detail below with reference to the drawings. The present invention is a material transport system that controls the speed and tension of a moving material to keep them constant, and is characterized in that the validity of the actual torque is determined by comparing the measured actual torque with the torque calculated from a preset tension setting value and / or the torque calculated from the measured current tension value, and if the actual torque is abnormal, the location that caused the abnormality is determined based on the motor control state, etc.

[0030] As a result, if the tension of the material is abnormal, an abnormality in the actual torque is detected, and an abnormality signal corresponding to the location where the abnormality occurred is output, allowing the operator to identify the cause of the abnormality.

[0031] [Material transport system 1] First, we will explain the general outline of the material transport system, including the material transport device. Figure 1 is a schematic diagram illustrating an example of the overall configuration of the material transport system.

[0032] This material transport system 1 includes an unwinding roll 2, a winding roll 3, rolls 4-1, 4-2, 4-3, processing devices 5-1, 5-2, tension detectors 6-1, ..., 6-4, and further includes motors 7-1, ..., 7-5, PG (pulse generators) 8-1, ..., 8-5, CT (current detectors) 9-1, ..., 9-5, and a material transport device 10. Hereinafter, motor 7-2 will be described as the reference motor, and motors 7-1, 7-3, 7-4, 7-5 other than the reference motor will be described as follow motors. Note that Figure 1 shows only the components related to the present invention, and components unrelated to the invention have been omitted.

[0033] In the material transport system 1, the unwinding roll 2 unwinds and moves a sheet of material, rolls 4-1, 4-2, and 4-3 each insert and pass the material, processing devices 5-1 and 5-2 perform processes such as printing, annealing, coating, and washing on the material, and the winding roll 3 winds up the material that has passed through and been processed as processed material. In this transport line, the material transport device 10 controls the speed and tension of the moving material to remain constant.

[0034] In the conveying line between the unwinding roll 2 and the winding roll 3, the section between the unwinding roll 2 and roll 4-1 is designated as section s1, the section between roll 4-1 and roll 4-2 is designated as section s2, the section between roll 4-2 and roll 4-3 is designated as section s3, and the section between roll 4-3 and winding roll 3 is designated as section s4.

[0035] The unwinding roll 2 consists of a base material on which a sheet of material is wound, and the material is unwound as motor 7-1 rotates. Rolls 4-1, 4-2, and 4-3 are devices that insert and pass the running material through a pair of upper and lower rolls, and operate in accordance with the rotation of the corresponding motors 7-2, 7-3, and 7-4. The winding roll 3 is a device that winds up the material that has passed through rolls 4-1, 4-2, and 4-3 and been processed by processing devices 5-1 and 5-2, and the processed material is wound up as motor 7-5 rotates.

[0036] Tension detector 6-1 detects the tension of the material traveling between the unwinding roll 2 and roll 4-1 and outputs the current tension value tp1 to the material conveying device 10. Tension detector 6-2 detects the tension of the material traveling between roll 4-1 and roll 4-2 and outputs the current tension value tp2 to the material conveying device 10. Tension detector 6-3 detects the tension of the material traveling between roll 4-2 and roll 4-3 and outputs the current tension value tp3 to the material conveying device 10. Tension detector 6-4 detects the tension of the material traveling between roll 4-3 and winding roll 3 and outputs the current tension value tp4 to the material conveying device 10.

[0037] Motor 7-1 (M1) is connected to unwinding roll 2 and PG8-1, motor 7-2 (M2) is connected to roll 4-1 and PG8-2, motor 7-3 (M3) is connected to roll 4-2 and PG8-3, motor 7-4 (M4) is connected to roll 4-3 and PG8-4, and motor 7-5 (M5) is connected to take-up roll 3 and PG8-5.

[0038] Motor 7-1 receives motor command MC1 from the material conveying device 10 and rotates the unwinding roll 2. Motors 7-2, 7-3, and 7-4 receive corresponding motor commands MC2, MC3, and MC4 from the material conveying device 10 and rotate rolls 4-1, 4-2, and 4-3. Motor 7-5 receives motor command MC5 from the material conveying device 10 and rotates the winding roll 3.

[0039] Motor 7-2 is a reference motor that maintains a constant speed for the moving material and performs reference travel control (reference speed control). Motors 7-1, 7-3, 7-4, and 7-5 are follower motors that follow motor 7-2 and perform follower travel control (follower speed control), as well as tension control to maintain a constant tension for the material moving through their respective sections s1, ..., s4. In the example in Figure 1, motor 7-1 controls the tension in section s1, motor 7-3 controls the tension in section s2, motor 7-4 controls the tension in section s3, and motor 7-5 controls the tension in section s4.

[0040] PG8-1,...,8-5 outputs pulse signals p1,...,p5 indicating the rotational position of the corresponding motors 7-1,...,7-5 to the material transport device 10, and CT9-1,...,9-5 detects the current flowing through the corresponding motors 7-1,...,7-5 and outputs current values ​​i1,...,i5 to the material transport device 10.

[0041] The material conveying device 10 controls the movement so that the material's travel speed (speed FB (feedback)) between the unwinding roll 2 and the winding roll 3 matches a preset travel speed setting value VS.

[0042] Furthermore, the material conveying device 10 controls the tension so that the current tension value tp of the material (tp1, ..., tp4 are collectively referred to as tp) matches a preset tension setting value ts (ts1, ..., ts4 are collectively referred to as ts).

[0043] Furthermore, the material transport device 10 performs the aforementioned travel control and tension control, and also detects abnormalities occurring in the material transport system 1.

[0044] [Material conveying device 10] Next, the material conveying device 10 shown in Figure 1 will be described in detail. Figure 2 is a block diagram showing an example configuration of the material conveying device 10. This material conveying device 10 includes a control unit 11 and an abnormality detection unit (abnormality detection device) 12 according to an embodiment of the present invention. The control unit 11 includes a reference speed control unit 21, a follow speed control unit 22, a tension control unit 23, and an actual torque calculation unit 24.

[0045] The reference speed control unit 21 of the control unit 11 receives a pulse signal p2, for example, from motor 7-2, which is the reference motor, and calculates the speed FB, which is the material's travel speed, from the pulse signal p2. The reference speed control unit 21 then generates a motor command MC2 so that the travel speed matches the travel speed set value VS, and outputs this to motor 7-2. This performs reference speed control.

[0046] The tracking speed control unit 22 receives pulse signals p1, p3, P4, and p5 from, for example, motors 7-1, 7-3, 7-4, and 7-5 as tracking motors, and calculates the material speed FB from the pulse signals p1, p3, P4, and p5. The tracking speed control unit 22 then adds the control deviations EP1, ..., EP4 generated by the tension control unit 23 (described later) to the travel speed set value VS, and uses the sum of these as the tracking speed. It then generates motor commands MC1, MC3, MC4, and MC5 so that the speed FB matches the tracking speed, and outputs these to the corresponding motors 7-1, 7-3, 7-4, and 7-5. This enables tracking speed control and tension control.

[0047] The tension control unit 23 receives current tension values ​​tp1,..., tp4 as input and generates control deviations EP1,..., EP4 so that the current tension values ​​tp1,..., tp4 match the corresponding preset tension setting values ​​ts1,..., ts4. The tension control unit 23 then outputs the control deviations EP1,..., EP4 to the tracking speed control unit 22, thereby performing tension control together with the tracking speed control unit 22. The tension control unit 23 also outputs the control deviations EP1,..., EP4 to the anomaly detection unit 12.

[0048] The actual torque calculation unit 24 receives current values ​​i1, ..., i5 as input, calculates the corresponding actual torques (current torque values ​​applied to the shafts of motors 7-1, ..., 7-5) L1, ..., L5 based on the current values ​​i1, ..., i5, and outputs the actual torques L1, ..., L5 to the abnormality detection unit 12. For example, the actual torque L3 is calculated based on the current value i3 input from CT9-3.

[0049] Figure 3 is a block diagram showing an example configuration of the reference speed control unit 21, the follow speed control unit 22, and the tension control unit 23.

[0050] The reference speed control unit 21 is a component that controls the motor 7-2 (M2) and includes a converter 41, a subtractor 42, and a controller 43. The converter 41 receives a pulse signal p2 from PG8-2 and counts the pulse signal p2 to convert the pulse signal p2 into a speed FB that indicates the rotational speed of the motor 7-2. The converter 41 then outputs the speed FB to the subtractor 42.

[0051] The subtractor 42 receives a reference speed of a pre-set running speed setting value VS, as well as a speed FB from the converter 41, subtracts the speed FB from the reference speed, and outputs the resulting speed deviation to the controller 43.

[0052] The controller 43 receives the speed deviation from the subtractor 42 and generates the motor command MC2 so that the speed deviation becomes zero. Then, the controller 43 outputs the motor command MC2 to the motor 7-2.

[0053] As a result, through feedback control, the rotational speed of motor 7-2 will match the reference speed of the travel speed setting value VS. In other words, the material will travel at the travel speed of the preset travel speed setting value VS.

[0054] The tracking speed control unit 22 includes a tracking speed control unit 22' for M3, as well as tracking speed control units for M1, M4, and M5 (not shown). Figure 3 shows only the configuration of the tracking speed control unit 22' for M3.

[0055] Note that the configurations of the tracking speed control units for M1, M4, and M5, which are not shown, are the same as those of the tracking speed control unit 22' for M3, and are therefore omitted.

[0056] The M3 tracking speed control unit 22' is a component that controls the motor 7-3 (M3) and includes a converter 44, an adder 45, a subtractor 46, and a controller 47. The converter 44 receives a pulse signal p3 from PG8-3 and counts the pulse signal p3 to convert the pulse signal p3 into a speed FB that indicates the rotational speed of the motor 7-3. The converter 44 then outputs the speed FB to the subtractor 46.

[0057] The adder 45 receives a reference speed of a preset running speed setting value VS, and also receives a control deviation EP2 from the tension control unit 23' for M3(s2), which will be described later. The adder 45 adds the control deviation EP2 to the reference speed, and outputs the tracking speed to the subtractor 46 as the result of the addition. Here, the control deviation EP2 is generated in conjunction with the tension control of section s2, and the tension control of section s2 is performed by motor 7-3.

[0058] The subtractor 46 receives the tracking speed from the adder 45 and the speed FB from the converter 44, subtracts the speed FB from the tracking speed, and outputs the resulting speed deviation to the controller 47.

[0059] The controller 47 receives the speed deviation from the subtractor 46 and generates a motor command MC3 so that the speed deviation becomes zero. Then, the controller 47 outputs the motor command MC3 to the motor 7-3.

[0060] As a result, through feedback control, the rotational speed of motor 7-3 will match the tracking speed obtained by adding the control deviation EP2 to the reference speed of the travel speed setting value VS. In other words, the material will travel at the travel speed of the preset travel speed setting value VS, and the current tension value tp2 of the material in section s2 will match the tension setting value ts2.

[0061] The tension control unit 23 includes a tension control unit 23' for M3(s2), as well as tension control units for M1(s1), M4(s3), and M5(s4), which are not shown. Figure 3 shows only the configuration of the tension control unit 23' for M3(s2).

[0062] Note that the configurations of the tension control units for M1(s1), M4(s3), and M5(s4), which are not shown, are the same as those of the tension control unit 23' for M3(s2), and are therefore omitted.

[0063] The tension control unit 23' for M3(s2) is a component that generates the control deviation EP2 of section s2 when the tracking speed control unit 22' for M3 controls the motor 7-3, and includes a subtractor 48 and a controller 49.

[0064] The subtractor 48 receives a pre-set tension setting value ts2 for section s2 and the current tension value tp2 from the tension detector 6-2 installed in section s2, subtracts the current tension value tp2 from the tension setting value ts2, and outputs the resulting tension deviation to the controller 49.

[0065] The controller 49 receives the tension deviation from the subtractor 48 and generates a control deviation EP2 so that the tension deviation becomes 0. The controller 49 then outputs the control deviation EP2 to the M3 tracking speed control unit 22' and the abnormality detection unit 12.

[0066] As a result, the control deviation EP2 is reflected in the tracking speed, and a motor command MC3 that reflects the control deviation EP2 is generated. Then, the tension of the material in section s2 (current tension value tp2) comes to match the tension set value ts2.

[0067] Returning to Figure 2, the abnormality detection unit 12 receives preset tension setting values ​​ts1,..., ts4, current tension values ​​tp1,..., tp4, and pulse signals p1,..., p5, as well as control deviations EP1,..., EP4 from the tension control unit 23 of the control unit 11, and further receives actual torques L1,..., L5 from the actual torque calculation unit 24.

[0068] The abnormality detection unit 12 detects various abnormalities for each of the motors 7-1, ..., 7-5 based on the preset tension set values ​​ts1, ..., ts4, current tension values ​​tp1, ..., tp4, actual torques L1, ..., L5, pulse signals p1, ..., p5, and control deviations EP1, ..., EP4, etc., for the corresponding inlet and outlet sections s1, ..., s4, and generates and outputs various abnormality signals.

[0069] Figure 4 is a block diagram showing an example configuration of the abnormality detection unit 12 according to an embodiment of the present invention. This abnormality detection unit 12 includes an abnormality detection unit 12-1 for M1, an abnormality detection unit 12-2 for M2, an abnormality detection unit 12-3 for M3, an abnormality detection unit 12-4 for M4, and an abnormality detection unit 12-5 for M5.

[0070] The M1 abnormality detection unit 12-1 determines whether the actual torque L1 of the motor 7-1 is abnormal, and if it determines that it is abnormal, it determines the location that caused the abnormality and generates an abnormality signal that reflects that location.

[0071] Specifically, the M1 abnormality detection unit 12-1 detects the torque threshold (setting threshold LV1) within the normal range from the tension (tension setting value ts1 and current tension value tp1) of the outlet section s1 of the unwinding roll 2 connected to the motor 7-1. sel and current threshold LV2 sel The M1 abnormality detection unit 12-1 then calculates the threshold value and the actual torque L1, and if it determines that the actual torque L1 is abnormal, it generates and outputs an abnormality signal indicating the location that caused the abnormality, based on the control state of the motor 7-1, etc.

[0072] The M2 abnormality detection unit 12-2 determines whether the actual torque L2 of the motor 7-2 is abnormal, and if it determines that it is abnormal, it determines the location that caused the abnormality and generates an abnormality signal that reflects that location.

[0073] Specifically, the M2 abnormality detection unit 12-2 calculates a threshold torque within the normal range from the tensions (tension set values ​​ts1, ts2 and current tension values ​​tp1, tp2) of the inlet and outlet sections s1, s2 of the roll 4-1 connected to the motor 7-2. Then, based on the threshold and the actual torque L2, if the M2 abnormality detection unit 12-2 determines that the actual torque L2 is abnormal, it generates and outputs an abnormality signal indicating the location that caused the abnormality, based on the control state of the motor 7-2, etc.

[0074] The M3 abnormality detection unit 12-3 determines whether the actual torque L3 of the motor 7-3 is abnormal, and if it determines that it is abnormal, it determines the location that caused the abnormality and generates an abnormality signal that reflects that location.

[0075] Specifically, the M3 abnormality detection unit 12-3 calculates a threshold torque within the normal range from the tensions (tension set values ​​ts2, ts3 and current tension values ​​tp2, tp3) of the inlet and outlet sections s2, s3 of the roll 4-2 connected to the motor 7-3. Then, based on the threshold and the actual torque L3, if the M3 abnormality detection unit 12-3 determines that the actual torque L3 is abnormal, it generates and outputs an abnormality signal indicating the location that caused the abnormality, based on the control state of the motor 7-3, etc.

[0076] The M4 abnormality detection unit 12-4 determines whether the actual torque L4 of the motor 7-4 is abnormal, and if it determines that it is abnormal, it determines the location that caused the abnormality and generates an abnormality signal that reflects that location.

[0077] Specifically, the M4 abnormality detection unit 12-4 calculates a threshold torque within the normal range from the tensions (tension set values ​​ts3, ts4 and current tension values ​​tp3, tp4) of the inlet and outlet sections s3, s4 of the roll 4-3 connected to the motor 7-4. Then, based on the threshold and the actual torque L4, if the M4 abnormality detection unit 12-4 determines that the actual torque L4 is abnormal, it generates and outputs an abnormality signal indicating the location that caused the abnormality, based on the control state of the motor 7-4, etc.

[0078] The M5 abnormality detection unit 12-5 determines whether the actual torque L5 of the motor 7-5 is abnormal, and if it determines that it is abnormal, it determines the location that caused the abnormality and generates an abnormality signal that reflects that location.

[0079] Specifically, the M5 abnormality detection unit 12-5 calculates a threshold torque within the normal range from the tension of the inlet section s4 (tension set value ts4 and current tension value tp4) for the winding roll 3 connected to the motor 7-5. Then, based on the threshold value and the actual torque L5, if the M5 abnormality detection unit 12-5 determines that the actual torque L5 is abnormal, it generates and outputs an abnormality signal indicating the location that caused the abnormality, based on the control state of the motor 7-5, etc.

[0080] As a result, each of the M1 abnormality detection units 12-1 and others outputs an abnormality signal indicating the location where the corresponding actual torque L1, ..., L5 abnormality occurred, allowing the operator to identify the cause of the abnormality.

[0081] [Anomaly detection unit for M3 12-3] Next, the abnormality detection unit 12 shown in Figure 4 will be explained using the M3 abnormality detection unit 12-3 as an example. Figure 5 is a block diagram showing an example configuration of the M3 abnormality detection unit 12-3, and Figure 6 is a flowchart showing an example of processing by the M3 abnormality detection unit 12-3.

[0082] The M3 abnormality detection unit 12-3 includes a rated torque tension calculation unit 51, a setting threshold generation unit 52, a current threshold generation unit 53, and abnormality determination units 54 and 55. As described above, the M3 abnormality detection unit 12-3 determines whether the actual torque L3 of the motor 7-3 is abnormal, and if it determines that it is abnormal, it determines the location that caused the abnormality and generates and outputs an abnormality signal that reflects this. Motor 7-3 is the target motor.

[0083] The rated torque tension calculation unit 51 receives preset motor information and magnetic flux ratio FL for the motor 7-3 (target motor), and calculates the tension T at the rated torque on the mechanical shaft of the roll 4-2 (target roll) connected to the motor 7-3 based on the motor information and magnetic flux ratio FL. mtr [N] is calculated (step S601). Then, the tension calculation unit 51 at rated torque calculates the tension T at rated torque. mtr The values ​​are output to the setting threshold generation unit 52 and the current threshold generation unit 53.

[0084] Motor information includes the capacity P [kW] of motor 7-3 and the base rotational speed N. base [min -1 ], reduction ratio i and roll diameter D of roll 4-2 [mm φ The magnetic flux ratio FL is a preset value when motor 7-3 is a constant torque motor, and a value corresponding to the rotational speed [rps] of motor 7-3 is used when motor 7-3 is a constant output motor.

[0085] Tension T at rated torque mtr [N] is the tension that can be generated by motor 7-3, and is calculated by the following formula. [Mathematics 1] T mtr ={(P×1000×60) / (2×π×N base )} × i × {2 / (D / 1000)} × FL ...(1)

[0086] The setting threshold generation unit 52 calculates the tension T at rated torque from the rated torque tension calculation unit 51. mtr Along with the input, the pre-set tension setting value ts2 for section s2, the pre-set tension setting value ts3 for section s3, and the pre-set parameters B1 and C are also input.

[0087] Here, section s2 is the inlet section between the target roll 4-2 and the roll 4-1 (inlet roll) located next to roll 4-2 and provided on the unwinding roll 2 side. Section s3 is the outlet section between the target roll 4-2 and the roll 4-3 (outlet roll) located next to roll 4-2 and provided on the winding roll 3 side.

[0088] The setting threshold generation unit 52 uses parameters B1 and C to generate a setting threshold LV1 based on tension setting values ​​ts2 and ts3. sel The generation process is performed, and the setting threshold LV1 sel The setting threshold generation unit 52 generates the setting threshold LV1 (step S602) and proceeds to step S604. sel The following is output to the abnormality detection unit 54. Setting threshold LV1 sel Details of the generation process will be described later.

[0089] This setting threshold LV1 sel This indicates the normal range of torque obtained from tension set values ​​ts2 and ts3 in motor 7-3 that rotates roll 4-2.

[0090] The current threshold generation unit 53 calculates the tension T at rated torque from the rated torque tension calculation unit 51. mtr Along with inputting the current tension value tp2 for section s2 from tension detector 6-2, and the current tension value tp3 for section s3 from tension detector 6-3, the current threshold generation unit 53 receives the pre-set parameters B1 and C.

[0091] The current threshold generation unit 53 uses parameters B1 and C to generate the current threshold LV2 based on the current tension values ​​tp2 and tp3. sel The generation process is performed, and the current threshold LV2 sel The current threshold generation unit 53 generates the current threshold LV2 (step S603) and proceeds to step S607. sel The current threshold value LV2 is output to the abnormality detection unit 55.sel Details of the generation process will be described later.

[0092] This current threshold LV2 sel This indicates the normal range of torque obtained from the current tension values ​​tp2 and tp3 in the motor 7-3 that rotates roll 4-2.

[0093] The abnormality detection unit 54 moves from step S602 and generates the setting threshold LV1 from the setting threshold generation unit 52. sel Along with inputting the actual torque, the actual torque L3 (target actual torque) of the motor 7-3 is input from the actual torque calculation unit 24 of the control unit 11. Then, the abnormality determination unit 54 determines if the actual torque L3 is set to threshold LV1 sel Determine whether or not it is within the bandwidth (step S604). Setting threshold LV1 sel The bandwidth is set to threshold LV1 sel This is the absolute value of the difference between the upper and lower values. Setting threshold LV1 sel Details regarding the bandwidth will be discussed later.

[0094] In step S604, the abnormality determination unit 54 determines that the actual torque L3 is set to threshold LV1 sel If it is determined that the actual torque L3 is within the bandwidth (step S604:Y), then the actual torque L3 is set to the threshold LV1 sel The range indicated is met, and it is determined to be normal. The abnormality detection unit 54 then receives a new actual torque L3 and updates it, and repeats the determination in step S604.

[0095] On the other hand, in step S604, the abnormality determination unit 54 determines that the actual torque L3 is set to threshold LV1 sel If it is determined that the actual torque L3 is not within the bandwidth (step S604:N), the actual torque L3 is set to the threshold LV1 sel The range indicated by the error is not met, and it is determined that there is an abnormality, so an abnormality is output to the abnormality determination unit 55. The abnormality determination unit 54 then determines that an abnormality has occurred in the load connected to motor 7-3 and outputs a motor load abnormality signal for motor 7-3 indicating this (step S605).

[0096] The abnormality detection unit 54 receives a pulse signal p3 from PG8-3 and, based on the pulse signal p3, determines whether or not an abnormality has occurred in PG8-3 connected to the target motor, motor 7-3 (performing PG abnormality determination) (step S606), and proceeds to step S607. If the abnormality detection unit 54 determines that an abnormality has occurred in PG8-3, it outputs a PG abnormality signal for PG8-3.

[0097] Specifically, the abnormality determination unit 54 includes a counter for performing PG abnormality determination in step S606, a time measurement unit, and a PG abnormality determination unit. The counter receives A-phase pulse signals and B-phase pulse signals from, for example, a rotary encoder which is PG8-3, and calculates a 4x multiplied count value CT by counting the A-phase pulse signals and B-phase pulse signals. The time measurement unit monitors the change in the 4x multiplied count value CT and records the time during which the count value CT is maintained at the same value as time data (time t1,..., t n ) is measured as follows.

[0098] The PG abnormality detection unit determines the time t1,...,t n The degree to which it fluctuates is the coefficient of variation t cv The coefficient of variation t is calculated as follows: cv If the coefficient of variation t is greater than a preset threshold, it is determined that the duty cycle of the A-phase pulse signal and the B-phase pulse signal has changed, and an abnormality has occurred in PG8-3. cv This is a predetermined number of time intervals t1,...,t n The mean value of t ave and standard deviation t dev Calculate the standard deviation t dev The mean value t ave It can be obtained by dividing by .

[0099] The abnormality determination unit 55 transitions from step S603 or step S606 to generate the current threshold value LV2 from the current threshold value generation unit 53. selThe control unit 11 inputs the actual torque L3 of motor 7-3 from the actual torque calculation unit 24. The abnormality determination unit 55 also inputs the control deviations EP2 and EP3 of sections s2 and s3 from the tension control unit 23 of control unit 11, as well as a preset parameter B2.

[0100] If the abnormality detection unit 54 inputs an abnormality, the abnormality detection unit 55 will determine that the actual torque L3 is at the current threshold LV2. sel Determine whether or not it is within the bandwidth (step S607). Current threshold LV2 sel The bandwidth is currently used threshold LV2 sel This is the absolute value of the difference between the upper and lower values ​​in [the specified range]. Current threshold LV2 sel Details regarding the bandwidth will be discussed later.

[0101] In step S607, the abnormality determination unit 55 determines that the actual torque L3 is at the current threshold LV2 sel If it is determined that the actual torque L3 is not within the bandwidth (step S607:N), the actual torque L3 is set to the threshold LV1 sel The range indicated is not met, and the current threshold LV2 sel If the range indicated is not met, it is determined to be abnormal. The abnormality determination unit 55 then performs abnormality determination processing for the tension detector, etc., and outputs various abnormality signals according to the determination result (step S608). Details of the abnormality determination processing for the tension detector, etc. will be described later.

[0102] On the other hand, in step S607, the abnormality determination unit 55 determines that the actual torque L3 is at the current threshold LV2 sel If it is determined that the actual torque L3 is within the bandwidth (step S607:Y), then the actual torque L3 is set to the threshold LV1 sel The range indicated is not met, and the current threshold LV2 sel If the conditions within the specified range are met, it is determined that there is an abnormality. The abnormality determination unit 55 then performs abnormality determination processing, such as slip occurrence, and outputs various abnormality signals according to the determination result (step S609). Details of the abnormality determination processing, such as slip occurrence, will be described later.

[0103] <Set threshold value LV1 sel Generation process (step S602)> Next, the set threshold value LV1 shown in step S602 of FIG. 6 sel An example of the generation process will be described. FIG. 7 shows the set threshold value LV1 sel It is a flowchart showing an example of the generation process (step S602).

[0104] The set threshold value generation unit 52 subtracts the tension set value ts3 of the preset section s2 from the tension set value ts2 of the preset section s2 to obtain the tension set value difference TS dif to obtain (step S701).

[0105] Tension set value difference TS dif [N] is calculated by the following formula. [Equation 2] TS dif =ts2 - ts3 ···(2)

[0106] The set threshold value generation unit 52 uses the tension set value difference TS calculated in step S701 dif divides it by the tension T at rated torque input from the rated torque tension calculation unit 51 mtr and multiplies the division result by 100 to obtain the required torque for setting (motor load ratio for setting) LS cal to obtain (step S702).

[0107] Required torque for setting LS cal [%] is the torque required to generate the tension set value difference TS dif between the inlet section s2 and the outlet section s3 of the roll 4-2 connected to the motor 7-3, and is calculated by the following formula. [Equation 3] LS cal =(TS dif / T mtr )×100 ···(3)

[0108] The setting threshold generation unit 52 generates the required setting torque LS calculated in step S702. cal Based on the preset parameter C, the threshold LV1 is calculated (step S703).

[0109] The threshold value LV1[%] is the required torque LS for setting. cal The value is the median, and the parameter C is the coefficient. It consists of an upper and lower value, and is calculated using the following formula. [Math 4] LV1=LS cal ×(1±C) ···(4)

[0110] This allows you to calculate the required torque LS for setting from the tension setting values ​​ts2 and ts3. cal For this, a threshold value LV1 is obtained, consisting of an upper value and a lower value with parameter C as the coefficient.

[0111] The setting threshold generation unit 52 sets the upper value (LS) of the threshold LV1. cal ×(1+C)) and the lower value (LS cal The absolute value of the difference between ×(1-C)) is calculated and this is taken as the bandwidth of the threshold LV1 (step S704).

[0112] The bandwidth [%] of threshold LV1 is calculated using the following formula: [Number 5] LV1 bandwidth = |{LS cal ×(1+C)}-{LS cal ×(1-C)}| ...(5)

[0113] The setting threshold generation unit 52 generates the required setting torque LS calculated in step S702. cal Based on the preset parameter B1, the threshold LV2 is calculated (step S705).

[0114] The threshold value LV2[%] is the required torque LS for setting. calThe value is the median, and the parameter B1 is a fixed value. The upper and lower values ​​are calculated using the following formula. [Number 6] LV2=LS cal ±B1 ···(6)

[0115] The setting threshold generation unit 52 sets the upper value (LS) of the threshold LV2. cal +B1) and the lower value (LS cal The absolute value of the difference between -B1) and is used as the bandwidth of the threshold LV2 (step S706).

[0116] The bandwidth [%] of threshold LV2 is calculated using the following formula: [Number 7] LV2 bandwidth = |(LS cal +B1)-(LS cal -B1)| ···(7)

[0117] The setting threshold generation unit 52 sets the wider of the bandwidth of threshold LV1 calculated in step S704 and the bandwidth of threshold LV2 calculated in step S706 to the setting threshold LV1 sel Select as (step S707).

[0118] For example, the difference in tension setting value TS dif If it is small, the required torque LS for setting cal The threshold LV1 also becomes smaller, and the bandwidth of the threshold LV1 using the coefficient parameter C becomes narrower. In this case, the threshold LV1 is set to threshold LV1 sel When used as such, the setting threshold LV1 sel Because the bandwidth is narrow, in step S604 shown in Figure 6, the actual torque L3 is set to the threshold LV1 sel It is not possible to properly determine whether or not the data is within the specified bandwidth.

[0119] In contrast, the difference in tension set value TS dif Because it is small, the required torque for setting LS calEven if it becomes smaller, the bandwidth of the threshold LV2 using the fixed parameter B1 will not narrow. In this case, the threshold LV2 is set to threshold LV1 sel By using it in this way, the determination process in step S604 shown in Figure 6 can be performed appropriately.

[0120] This will enable the setting threshold LV1 sel In the generation process (step S602), two thresholds LV1 and LV2 are calculated, and the one with the wider bandwidth is set as threshold LV1. sel By being selected as such, the determination process in step S604 shown in Figure 6 can be performed appropriately.

[0121] <Current threshold LV2 sel Generation process (step S603)> Next, the current threshold LV2 shown in step S603 of Figure 6 sel An example of the generation process will be explained. Figure 8 shows the current threshold LV2. sel This is a flowchart showing an example of the generation process (step S603).

[0122] The current threshold generation unit 53 subtracts the current tension value tp3 of section s3, input from tension detector 6-3, from the current tension value tp2 of section s2, input from tension detector 6-2, thereby generating the current tension value difference TP dif We find (step S801).

[0123] Tension current value difference TP dif [N] is calculated using the following formula. [Number 8] TP dif =tp2-tp3 ···(8)

[0124] The current threshold generation unit 53 generates the current tension value difference TP calculated in step S801. dif The tension T at rated torque is input from the rated torque tension calculation unit 51. mtr By dividing by and multiplying the result by 100, we obtain the currently required torque (current motor load factor) LPcal We find the answer (step S802).

[0125] Current required torque LP cal [%] is the difference in current tension TP between the inlet section s2 and the outlet section s3 of the roll 4-2 connected to the motor 7-3. dif This is the torque required to generate [the specified value], and it is calculated using the following formula. [Number 9] LP cal =( TP dif / T mtr ) × 100 ···(9)

[0126] The current threshold generation unit 53 generates the current required torque LP calculated in step S802. cal Based on the previously defined parameter C, the threshold LV3 is calculated (step S803).

[0127] The threshold LV3[%] is the currently required torque LP cal The value is the median, and the parameter C is the coefficient. It consists of an upper and lower value, and is calculated using the following formula. [Number 10] LV3=LP cal ×(1±C) ···(10)

[0128] This allows us to calculate the current required torque LP from the current tension values ​​tp2 and tp3. cal For this, a threshold value LV3 is obtained, consisting of an upper value and a lower value with parameter C as the coefficient.

[0129] The current threshold generation unit 53 generates the upper value (LP) of the threshold LV3. cal ×(1+C)) and the lower value (LP cal The absolute value of the difference between ×(1-C)) is calculated and this is taken as the bandwidth of the threshold LV3 (step S804).

[0130] The bandwidth [%] of threshold LV3 is calculated using the following formula. [Number 11] LV3 bandwidth = |{LP cal ×(1+C)}-{LP cal ×(1-C)}| ...(11)

[0131] The current threshold generation unit 53 generates the current required torque LP calculated in step S802. cal Based on the previously defined parameter B1, the threshold LV4 is calculated (step S805).

[0132] The threshold LV4[%] is the currently required torque LP cal The value is the median, and the parameter B1 is a fixed value. The upper and lower values ​​are calculated using the following formula. [Number 12] LV4=LP cal ±B1 ···(12)

[0133] The current threshold generation unit 53 generates the upper value (LP) in threshold LV4. cal +B1) and the lower value (LP cal The absolute value of the difference between -B1) and is used as the bandwidth of the threshold LV4 (step S806).

[0134] The bandwidth of threshold LV4 is calculated using the following formula. [Number 13] LV4 bandwidth = |(LP cal +B1)-(LP cal -B1)| ···(13)

[0135] The current threshold generation unit 53 uses the wider of the bandwidth of threshold LV3 calculated in step S804 and the bandwidth of threshold LV4 calculated in step S806 to generate the current threshold LV2. sel Select as (step S807).

[0136] For example, the difference between current tension and TP dif If it is small, the tension set value difference TS difSimilar to the case above, the bandwidth of the threshold LV3 becomes narrow, making it impossible to properly perform the determination process in step S607 shown in Figure 6. In contrast, the current tension difference TP dif Even when the value is small, the bandwidth of the threshold LV4 does not narrow, so the determination process in step S607 shown in Figure 6 can be performed appropriately.

[0137] This will result in the current threshold LV2 sel In the generation process (step S603), two thresholds, LV3 and LV4, are calculated, and the one with the wider bandwidth is the current threshold LV2. sel As a result of being selected, in step S607 shown in Figure 6, the actual torque L3 is the current threshold LV2 sel The process of determining whether or not it is within the bandwidth can be performed appropriately.

[0138] <Tension detector and other abnormality detection processing (step S608)> Next, an example of the tension detector and other abnormality detection process shown in step S608 of Figure 6 will be described. Figure 9 is a flowchart showing an example of the tension detector and other abnormality detection process (step S608).

[0139] In this tension detector abnormality detection process, in step S607 of Figure 6, the actual torque L3 is determined to be the current threshold LV2 sel Processing when it is determined that the actual torque L3 is not within the bandwidth, i.e., when the actual torque L3 is set to threshold LV1 sel The range indicated is not met, and the current threshold LV2 sel This is the process to be taken when the specified range is not met and the condition is judged to be abnormal.

[0140] The abnormality determination unit 55 determines whether or not a motor load abnormality signal for motor 7-3 (M3) is output by the abnormality determination unit 54 provided in the abnormality detection unit 12, which targets the motor 7-3 that controls the tension of the inlet section s2 (step S901).

[0141] In other words, the abnormality detection unit 55 determines, based on the abnormality detection unit 12-3 for M3, that the actual torque L3 (actual inlet torque, which in this case is also the target actual torque) of the motor 7-3 corresponding to the inlet section s2 (roll 4-2, which is the inlet roll) corresponds to a setting threshold LV1 corresponding to the inlet section s2. sel It is determined whether the range indicated by is not met, that is, whether a motor load abnormality signal is output for motor 7-3. In this example, the actual torque L3 is set to the threshold LV1. sel It has been determined that the range indicated is not met, and the abnormality detection unit 54 has already output a motor load abnormality signal for motor 7-3 (M3).

[0142] Furthermore, the abnormality determination unit 55 determines whether or not a motor load abnormality signal for motor 7-4 (M4) is output by the abnormality determination unit 54 provided in the abnormality detection unit 12, in the abnormality detection unit 12, which targets the motor 7-4 that controls the tension of the exit section s3 (step S902).

[0143] In other words, the abnormality detection unit 55, using the abnormality detection unit 12-4 for M4, determines that the actual torque L4 (actual outlet torque) of the motor 7-4 corresponding to the outlet section s3 (roll 4-3, which is the outlet roll) is set to a threshold value LV1 corresponding to the outlet section s3. sel It is determined whether the range indicated is not met, that is, whether a motor load abnormality signal for motor 7-4 is being output.

[0144] If the abnormality detection unit 55 determines in step S901 that a motor load abnormality signal for motor 7-3 has been output (step S901:Y), it determines that an abnormality has occurred in the tension detector 6-2 of section s2 and outputs a tension detector abnormality signal for section s2 (step S903).

[0145] On the other hand, if the abnormality determination unit 55 determines in step S902 that a motor load abnormality signal for motor 7-4 has been output (step S902:Y), it determines that an abnormality has occurred in the tension detector 6-3 of section s3 and outputs a tension detector abnormality signal for section s3 (step S904).

[0146] Furthermore, if the abnormality determination unit 55 determines in step S901 that no motor load abnormality signal is output for motor 7-3 (step S901:N), and in step S902 that no motor load abnormality signal is output for motor 7-4 (step S902:N), it determines that an abnormality has occurred in the bearings, etc., used in the machinery (connecting part) connected to motor 7-3, which is the target motor, and outputs a motor machinery abnormality signal for motor 7-3 (step S905).

[0147] As a result, the actual torque L3 is set to threshold LV1 sel The range indicated is not met, and the current threshold LV2 sel If the range indicated is not met, the tension detector abnormality determination process (step S608) outputs a tension detector abnormality signal for section s3, a tension detector abnormality signal for section s2, or a motor mechanical abnormality signal for motor 7-3.

[0148] <Slip occurrence and other abnormality detection processing (step S609)> Next, an example of the slip occurrence and other abnormality detection process shown in step S609 of Figure 6 will be explained. Figure 10 is a flowchart showing an example of the slip occurrence and other abnormality detection process (step S609).

[0149] This slip occurrence and other abnormality detection process occurs in step S607 of Figure 6, when the actual torque L3 is at the current threshold LV2 sel Processing when it is determined that the actual torque L3 is within the bandwidth of the setting threshold LV1 sel The range indicated is not met, and the current threshold LV2 sel This is the procedure to be followed when the specified range is met and it is determined to be abnormal.

[0150] The abnormality determination unit 55 calculates the absolute value of the control deviation EP2 of the inlet section s2 input from the tension control unit 23 of the control unit 11, and determines whether the absolute value is greater than the preset parameter B2 (step S1001).

[0151] Furthermore, the abnormality determination unit 55 calculates the absolute value of the control deviation EP3 of the outlet section s3 input from the tension control unit 23 of the control unit 11, and determines whether the absolute value is greater than the preset parameter B2 (step S1002).

[0152] If the abnormality detection unit 55 determines in step S1001 that the absolute value of the control deviation EP2 is greater than that of parameter B2 (step S1001:Y), or if it determines in step S1002 that the absolute value of the control deviation EP3 is greater than that of parameter B2 (step S1002:Y), it determines that motor slip has occurred (or the material has stretched) for motor 7-3 (M3), which is the target motor of the abnormality detection unit 12-3 for M3, and outputs a slip occurrence abnormality signal for motor 7-3 (M3) (step S1003).

[0153] Here, the state in which motor slip occurs refers to a state in which slip occurs between the roll 4-2 connected to motor 7-3 and the material, or a state in which slip occurs between motor 7-3 and the roll 4-2 connected to motor 7-3, when motor 7-3 is the target motor.

[0154] On the other hand, if the abnormality determination unit 55 determines in step S1001 that the absolute value of the control deviation EP2 is not greater than that of parameter B2 (step S1001:N), it determines whether or not a dancer is installed in the inlet section s2 (step S1004). Whether or not a dancer is installed in the inlet section s2 is predetermined.

[0155] Furthermore, if the abnormality determination unit 55 determines in step S1002 that the absolute value of the control deviation EP3 is not greater than the parameter B2 (step S1002:N), it determines whether or not a dancer is installed in the exit section s3 (step S1005). Whether or not a dancer is installed in the exit section s3 is predetermined.

[0156] If the abnormality detection unit 55 determines in step S1004 that a dancer is installed in the inlet section s2 (step S1004:Y), it determines that an abnormality (including an abnormal air pressure) has occurred in the dancer installed in the inlet section s2 and outputs a dancer abnormality signal for the inlet section s2 (step S1006).

[0157] Furthermore, if the abnormality detection unit 55 determines in step S1005 that a dancer is installed in the outlet section s3 (step S1005:Y), it determines that an abnormality (including an abnormal air pressure) has occurred in the dancer installed in the outlet section s3 and outputs a dancer abnormality signal for the outlet section s3 (step S1007).

[0158] On the other hand, if the abnormality detection unit 55 determines in step S1004 that no dancer is installed in the entrance section s2 (step S1004:N), and in step S1005 that no dancer is installed in the exit section s3 (step S1005:N), it determines that there is no corresponding abnormality.

[0159] As a result, the actual torque L3 is set to threshold LV1 sel The range indicated is not met, and the current threshold LV2 sel If the conditions within the specified range are met, the slip occurrence abnormality detection process (step S609) outputs a slip occurrence abnormality signal for motor 7-3, a dancer abnormality signal for the inlet section s2, or a dancer abnormality signal for the outlet section s3.

[0160] In the above embodiment, motor 7-2 was described as the reference motor, but any of motors 7-1, 7-3, 7-4, or 7-5 may be used as the reference motor. The position of the reference motor is changed according to the overall configuration of the material transport system 1, etc.

[0161] As described above, the abnormality detection unit 12 of the embodiment of the present invention determines whether the actual torques L1,...,L5 of motors 7-1,...,7-5 are abnormal, and if it is determined that they are abnormal, it determines the location that caused the abnormality and generates an abnormality signal that reflects it.

[0162] Specifically, for example, the setting threshold generation unit 52 of the M3 abnormality detection unit 12-3 that controls the motor 7-3 generates a setting threshold LV1 for the torque within the normal range from the tension setting values ​​ts2, ts3 of the inlet and outlet sections s2, s3 of the roll 4-2. sel Calculate.

[0163] The current threshold generation unit 53 generates a current threshold value LV2 of torque within the normal range from the current tension values ​​tp2, tp3 of the inlet and outlet sections s2, s3 of the roll 4-2. sel Calculate.

[0164] The abnormality detection unit 54 sets the threshold value LV1 sel Based on the actual torque L3, if it is determined that the actual torque L3 is abnormal, a motor load abnormality signal is output for motor 7-3, and an abnormality check is performed on PG8-3. If an abnormality is found, a PG abnormality signal is output for PG8-3.

[0165] The abnormality determination unit 55 is determined by the abnormality determination unit 54 to be abnormal in actual torque L3, and the current threshold LV2 sel Based on the actual torque L3, if it is determined that the actual torque L3 is abnormal, a tension detector abnormality signal for the inlet and outlet sections s2 and s3, or a motor mechanical abnormality signal for motor 7-3, is output depending on whether or not there is a motor load abnormality signal for motors 7-3 and 7-4 in the inlet and outlet sections s2 and s3.

[0166] Furthermore, the abnormality detection unit 55 outputs a slip occurrence abnormality signal for the motor 7-3, a dancer abnormality signal for the inlet section s2, or a dancer abnormality signal for the outlet section s3, based on the control deviations EP2, EP3 of the inlet and outlet sections s2, s3, and the presence or absence of dancers in the inlet and outlet sections s2, s3.

[0167] This allows the operator to narrow down the cause of the anomaly based on the anomaly signal output from the anomaly detection unit 12. In other words, in a material transport system 1 that moves materials at a constant speed and controls the material to maintain constant tension, if the material tension is abnormal, the cause of the anomaly can be identified.

[0168] Therefore, the time required to identify the cause of an abnormality after it occurs can be shortened. In addition, by constantly monitoring the abnormality signal output from the abnormality detection unit 12, the operator can detect signs of an abnormality and, by prompting action such as issuing an alarm before an abnormality occurs, can avoid the unexpected shutdown of the material transport system 1 while it is in operation.

[0169] Although the present invention has been described above with reference to embodiments, the present invention is not limited to the above embodiments and can be modified in various ways without departing from the technical concept.

[0170] For example, in the above embodiment, the abnormality determination unit 54 performs a PG abnormality determination of PG8-3 in step S606 of Figure 6, and if it determines that an abnormality has occurred in PG8-3, it outputs a PG abnormality signal for PG8-3.

[0171] Alternatively, the abnormality determination unit 55 may perform a PG abnormality determination of PG8-3 during the processing between steps S607 and S608 in Figure 6, or between steps S607 and S609, and if it determines that an abnormality has occurred in PG8-3, it may output a PG abnormality signal for PG8-3.

[0172] Furthermore, for example, in the above embodiment, in the processing example shown in Figure 6, the abnormality determination unit 54 determines in step S604 that the actual torque L3 is set to threshold LV1 sel If it is determined that the actual torque L3 is within the bandwidth of the setting threshold LV1 sel Based on this, as long as it is normal, the actual torque L3 is updated and the determination process in step S604 is repeated. Then, the abnormality determination unit 55 determines that the actual torque L3 is set to threshold LV1 by the abnormality determination unit 54. sel If it is determined that the actual torque L3 is not within the bandwidth, in step S607, the current threshold LV2 sel Determine whether or not it is within the bandwidth.

[0173] In response, the abnormality detection unit 54 determines that the actual torque L3 is set to threshold LV1 sel The abnormality determination unit 55 determines whether the actual torque L3 is within the bandwidth and whether the actual torque L3 is within the current threshold LV2 sel It is determined whether or not the actual torque L3 is within the bandwidth, and if in both determinations it is determined that the actual torque L3 is within the respective bandwidth, that is, the actual torque L3 is within the setting threshold LV1 sel and current threshold LV2 sel Based on this, as long as the condition is normal, the actual torque L3 may be updated and these determination processes may be repeated.

[0174] Furthermore, in the above embodiment, for example, Figures 5 to 10 illustrate an M3 abnormality detection unit 12-3 that detects abnormalities using the tension of the inlet section s2 and the tension of the outlet section s3. The configuration and processing shown in Figures 5 to 10 are applicable not only to the M2 abnormality detection unit 12-2 and the M4 abnormality detection unit 12-4 that target the inlet and outlet sections, but also to the M1 abnormality detection unit 12-1 that targets the outlet section s1 and the M5 abnormality detection unit 12-5 that targets the inlet section s4.

[0175] In this case, the abnormality detection unit 12-1 for M1 only has an outlet section s1 and no inlet section, so in step S701 of Figure 7, the tension set value ts2=0 and the tension set value difference TS of the inlet section are set. dif Treated as =-ts3, in step S801 of Figure 8, the current tension value tp2=0 and the difference in current tension values ​​TP dif It is treated as =-tp3. Also, the abnormality detection unit 12-1 for M1 does not perform the processing in steps S901 and S903 in Figure 9 and steps S1001, S1004, and S1006 in Figure 10.

[0176] The abnormality detection unit 12-5 for M5 only has an inlet section s4 and no outlet section. Therefore, in step S701 of Figure 7, the tension set value ts3=0 and the tension set value difference TS of the outlet section are set. dif Treated as =ts2, in step S801 of Figure 8, the current tension value tp3=0 and the difference in current tension values ​​TP of the exit section dif It is treated as =tp2. Also, the abnormality detection unit 12-5 for M5 does not perform the processes in steps S902 and S904 in Figure 9 and steps S1002, S1005 and S1007 in Figure 10.

[0177] Furthermore, in the above embodiment, for example, in Figure 1, motor 7-2 is used as the reference motor, and the tension of section s1 is controlled by motor 7-1, the tension of section s2 is controlled by motor 7-3, the tension of section s3 is controlled by motor 7-4, and the tension of section s4 is controlled by motor 7-5.

[0178] Alternatively, any of motors 7-1, 7-3, 7-4, or 7-5 may be used as the reference motor. For example, if motor 7-4 is used as the reference motor, the tension of section s1 is controlled by motor 7-1, the tension of section s2 is controlled by motor 7-2, the tension of section s3 is controlled by motor 7-3, and the tension of section s4 is controlled by motor 7-5. [Explanation of symbols]

[0179] 1. Material handling system 2. Unwinding roll (roll for unwinding) 3. Winding roll (a roll for winding) 4-1, 4-2, 4-3 Roll 5-1, 5-2 Processing device 6-1, 6-2, 6-3, 6-4 Tension detectors 7-1, 7-2, 7-3, 7-4, 7-5 Motors 8-1, 8-2, 8-3, 8-4, 8-5 PG (Pulse Generator) 9-1, 9-2, 9-3, 9-4, 9-5 CT (Current Detector) 10. Material conveying device 11 Control Unit 12 Anomaly detection unit (anomaly detection device) 12-1 Anomaly detection unit for M1 12-2 Anomaly detection unit for M2 12-3 Anomaly detection unit for M3 12-4 Anomaly detection unit for M4 12-5 Anomaly detection unit for M5 21 Reference Speed ​​Control Unit 22 Tracking Speed ​​Control Unit Tracking speed control unit for 22' M3 23 Tension control unit 23' Tension control section for M3(s2) 24 Actual Torque Calculation Unit 41,44 Converter 42, 46, 48 Subtractors 43, 47, 49 Controllers 45 Adder 51 Tension calculation unit at rated torque 52 Setting threshold generation unit 53 Current threshold generation unit 54,55 Abnormality determination section Sections s1, s2, s3, s4 MC1, MC2, MC3, MC4, MC5 Motor Command p1, p2, p3, p4, p5 pulse signals i1, i2, i3, i4, i5 Current values tp1, tp2, tp3, tp4 Current tension values ts1, ts2, ts3, ts4 Tension setting values VS Driving speed setting value EP1, EP2, EP3, EP4 Control deviation L1, L2, L3, L4, L5 Actual Torque T mtr Tension at rated torque TS dif Tension set value difference TP dif Current tension difference LS cal Required torque for setting (motor load factor) LP cal Current required torque (motor load factor) LV1, LV2, LV3, LV4 thresholds LV1 sel Setting threshold LV2 sel Current threshold B1, B2, C parameters FL magnetic flux ratio P Motor Capacity N base Base rotations i Reduction ratio D Roll diameter

Claims

1. An abnormality detection device for detecting an abnormality in a material transport system in which an unwinding roll unwinds and moves a sheet-like material, each of a plurality of rolls inserts and passes the material, and a winding roll winds up the material after it has passed through the plurality of rolls, Based on the preset tension setting value ts of the material, a setting threshold LV1 indicates the normal range of torque for the motor that rotates the roll. sel A threshold generation unit for setting the threshold, The current tension value tp of the material is input from a tension detector installed in the material transport system, and a current threshold value LV2 indicating the normal range of the torque is set based on the current tension value tp. sel A current threshold generation unit that calculates the threshold, The actual torque L calculated based on the current i flowing through the motor, and the setting threshold LV1 obtained by the setting threshold generation unit. sel and the current threshold value LV2 obtained by the current threshold value generation unit. sel Based on this, an abnormality determination unit determines the abnormality, An anomaly detection device characterized by being equipped with the following features.

2. In the abnormality detection device according to claim 1, The abnormality determination unit, The actual torque L is the setting threshold LV1 sel An abnormality detection device characterized by determining that a motor load abnormality has occurred, indicating an abnormality in the load connected to the motor, if the range indicated is not met.

3. In the abnormality detection device according to claim 2, The abnormality detection unit further, The actual torque L is the setting threshold LV1 sel An abnormality detection device characterized by determining whether or not a PG abnormality has occurred, indicating an abnormality in the PG (pulse generator) that detects the rotational position connected to the motor, if the range indicated is not met.

4. In the abnormality detection device according to claim 1, The abnormality determination unit, The actual torque L is the setting threshold LV1 sel The range indicated is not met, and the actual torque L is the current threshold LV2 sel An abnormality detection device characterized in that, if the range indicated is not met, it is determined that a tension detector abnormality has occurred, indicating an abnormality of the tension detector, or that a mechanical abnormality has occurred, indicating an abnormality of the machine connected to the motor.

5. In the abnormality detection device according to claim 1, The abnormality determination unit, When the actual torque L does not satisfy the range indicated by the setting threshold value LV1 sel and the actual torque L satisfies the range indicated by the current threshold value LV2 sel An abnormality detection device is characterized in that it determines whether slip has occurred between the roll connected to the motor and the material, or between the motor and the roll connected to the motor.

6. In the abnormality detection device according to claim 5, The control deviation EP is calculated so that the current tension value tp matches the tension set value ts, and the tension of the material is controlled based on the control deviation EP. The abnormality determination unit, The actual torque L is the setting threshold LV1 sel The range indicated is not met, and the actual torque L is the current threshold LV2 sel An abnormality detection device characterized in that, if the range indicated is met, and further if the control deviation EP is greater than a preset parameter B2, it is determined that the slip has occurred, and if the control deviation EP is less than or equal to the parameter B2 and a dancer for maintaining the tension of the material constant is installed, it is determined that a dancer abnormality indicating a dancer abnormality has occurred.

7. In the abnormality detection device according to claim 1, One of the aforementioned plurality of rolls is designated as the target roll, the space between the target roll and the roll located next to it and provided on the unwinding roll side is designated as the entrance section, and the space between the target roll and the roll located next to it and provided on the winding roll side is designated as the exit section. The setting threshold generation unit is: The difference between the tension set value ts in the inlet section and the tension set value ts in the outlet section is called the tension set value difference TS. dif The tension T at a predetermined rated torque is calculated as follows: mtr and the difference in tension set value TS dif Based on the above, the tension set value difference TS dif The torque required to generate the desired output is set to the required torque LS. cal The threshold LV1 (=LS) is calculated using a coefficient based on the pre-set parameter C. cal The multiplication by (1±C) is calculated, the bandwidth is calculated from the upper and lower values ​​of the threshold LV1, and the fixed threshold LV2 (=LS) is calculated using the pre-set parameter B1. cal Calculate ±B1), and calculate the bandwidth from the upper and lower values ​​of the threshold LV2. The wider of the bandwidth of threshold LV1 and the bandwidth of threshold LV2 is set as the setting threshold LV1. sel As requested, The current threshold generation unit is, The difference between the current tension value tp at the inlet section and the current tension value tp at the outlet section is called the current tension value difference TP. dif The tension T at the predetermined rated torque is calculated as follows: mtr and the difference in current tension values ​​TP dif Based on the above, the difference in current tension values ​​TP dif The torque required to generate the current required torque LP cal The threshold LV3 (=LP) is calculated using the parameter C and the coefficient. cal The multiplication by (1±C) is calculated, the bandwidth is calculated from the upper and lower values ​​of the threshold LV3, and the fixed threshold LV4 (=LP) is calculated using the parameter B1. cal Calculate ±B1), and calculate the bandwidth from the upper and lower values ​​of the threshold LV4. The wider of the bandwidth of threshold LV3 and the bandwidth of threshold LV4 is set as the current threshold LV2. sel An anomaly detection device characterized by determining as such.

8. In the abnormality detection device according to claim 1, One of the aforementioned plurality of rolls is designated as the target roll, the space between the target roll and the roll located next to it and provided on the unwinding roll side is designated as the entrance section, and the space between the target roll and the roll located next to it and provided on the winding roll side is designated as the exit section. The roll located next to the target roll and provided on the unwinding roll side shall be designated as the inlet roll, and the roll located next to the target roll and provided on the winding roll side shall be designated as the outlet roll. The torque calculated based on the current value i flowing through the motor that rotates the aforementioned target roll is defined as the target actual torque La, the torque calculated based on the current value i flowing through the motor that rotates the aforementioned inlet roll is defined as the inlet actual torque Lb, and the torque calculated based on the current value i flowing through the motor that rotates the aforementioned outlet roll is defined as the outlet actual torque Lc. The abnormality determination unit, The setting threshold LV1 corresponds to the motor that rotates the target roll, where the target actual torque La is located. sel The range indicated is not met, and the target actual torque La corresponds to the current threshold LV2 of the motor that rotates the target roll. sel If it is determined that the range indicated is not met, The setting threshold LV1 corresponds to the motor that rotates the inlet roll, where the actual inlet torque Lb is located. sel If it is determined that the motor load abnormality of the motor that rotates the entrance roll has occurred because the range indicated is not met, then it is determined that a tension detector abnormality has occurred, indicating an abnormality in the tension detector installed in the entrance section. The actual outlet torque Lc corresponds to the setting threshold LV1 of the motor that rotates the outlet roll. sel An abnormality detection device characterized in that, when it has been determined that a motor load abnormality has occurred in the motor that rotates the outlet roll because the range indicated by is not met, it determines that a tension detector abnormality has occurred, indicating an abnormality in the tension detector installed in the outlet section.

9. In the abnormality detection device according to claim 1, One of the aforementioned plurality of rolls is designated as the target roll, the space between the target roll and the roll located next to it and provided on the unwinding roll side is designated as the entrance section, and the space between the target roll and the roll located next to it and provided on the winding roll side is designated as the exit section. The torque calculated based on the current value i flowing through the motor that rotates the target roll is defined as the target actual torque La. For each of the inlet and outlet sections, a control deviation EP is calculated such that the current tension value tp matches the tension set value ts, and the tension of the material is controlled based on the control deviation EP. The abnormality determination unit, The target actual torque La is the setting threshold LV1 sel The range indicated is not met, and the target actual torque La is the current threshold LV2 sel An abnormality detection device characterized in that, if the range indicated by is met, and further, if the control deviation EP of the inlet section is greater than a preset parameter B2, or if the control deviation EP of the outlet section is greater than the parameter B2, it is determined that a slip has occurred between the target roll connected to the motor and the material, or between the motor and the target roll connected to the motor.

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