Glass roll manufacturing apparatus and method

Abstract

This glass roll manufacturing apparatus 2 for winding a glass ribbon 1 and obtaining a glass roll 25 comprises a winding unit 12 to be integrally move comprising a winding core support part 16 that supports a winding core 10 for winding the glass ribbon 1 in a roll shape in a state of being overlapped with a protection sheet 5 in a winding area 3 disposed at a downstream end of a conveyance path of the glass ribbon 1, and a sheet roll support part 17 that supports a sheet roll 11 in which the protection sheet 5 is wound in the roll shape. The glass roll manufacturing apparatus 2 further comprises a transfer mechanism 38 that transfers the winding unit 12 on a unit-by-unit basis between the winding area 3 and a retreat area 39 separated from the winding area 3.

Description

Glass roll manufacturing apparatus and manufacturing method

[0001] The present disclosure relates to a glass roll manufacturing apparatus and manufacturing method.

[0002] A glass roll is manufactured from an ultra-thin glass ribbon (for example, having a thickness of 200 μm or less). Patent Document 1 discloses an example of a mode for manufacturing a glass roll from a glass ribbon.

[0003] In this method, an ultra-thin glass ribbon is first formed using the downdraw method. Next, the conveying direction of the formed glass ribbon is changed from vertical to horizontal. After that, unnecessary portions are cut off and removed from the glass ribbon as it is conveyed horizontally. Finally, in a winding area located at the downstream end of the glass ribbon conveying path, the glass ribbon is superimposed on a protective sheet and wound around a winding core to form a glass roll. The protective sheet is supplied from a sheet roll on which the protective sheet before being superimposed on the glass ribbon is wound.

[0004] JP 2015-63450 A

[0005] When a glass roll is manufactured by winding a glass ribbon in the above-described manner, there is a problem that productivity of the glass roll decreases due to poor maintainability of the manufacturing equipment arranged in the winding area.

[0006] An example of the manufacturing equipment is a power unit that is connected to the shaft of the winding core and applies torque to rotate the winding core. A member for supporting the winding core (hereinafter referred to as a winding core support member), a member for supporting a sheet roll (hereinafter referred to as a sheet roll support member), and the like are arranged near the power unit. The winding core support member is a member on which the winding core is placed before the start of winding the glass ribbon and after the winding is completed. The sheet roll support member is a member on which the sheet roll is placed before the start of winding the glass ribbon and after the winding is completed.

[0007] During maintenance work on the power unit, it is necessary to retract all of the cores, core support members, sheet rolls, and sheet roll support members from the winding area (near the power unit) so as not to interfere with the work. However, no means has been provided for retracting all of these items at once, which lengthens the time required for retraction and ultimately reduces the maintainability of the power unit. This has led to a decrease in the productivity of glass rolls.

[0008] In view of the above circumstances, a technical problem to be solved is to increase the productivity in manufacturing glass rolls.

[0009] The glass roll manufacturing device for solving the above problem is a glass roll manufacturing device for winding a glass ribbon to obtain a glass roll, and is characterized in that it includes a winding unit that is integrally movable in a winding area located at the downstream end of a conveying path for the glass ribbon, and includes a winding core support section that supports a winding core for winding the glass ribbon into a roll while overlapping it with a protective sheet, and a sheet roll support section that supports a sheet roll on which the protective sheet is wound into a roll, and further includes a transport mechanism that transports the winding unit unit by unit between the winding area and an evacuation area separated from the winding area.

[0010] This glass roll manufacturing apparatus includes a winding unit that includes a core support section that supports a core and a sheet roll support section that supports a sheet roll, and these support sections are movable as a unit. The winding unit can be transported unit-by-unit between the winding area and a retreat area away from the winding area by a transport mechanism that transports the unit. This improves the maintainability of manufacturing equipment (e.g., the power unit described above) located in the winding area. Specifically, when performing maintenance work on the manufacturing equipment, the core, core support section, sheet roll, and sheet roll support section can all be retreated from the winding area (near the manufacturing equipment) as a unit so as not to interfere with the work. This reduces the time required for retreat and improves the maintainability of the manufacturing equipment. As a result, the productivity of glass rolls can be increased.

[0011] In the above configuration, it is preferable to provide a plurality of winding units.

[0012] In this way, it is possible to further improve the productivity of glass rolls. This is for the following reason. When a glass roll on which a glass ribbon of a desired length has been wound is completed, in order to start the production of a new glass roll, it is necessary to perform preparatory work such as the following (1) to (3), for example: (1) The winding core on which the glass ribbon has been wound is removed from the winding unit, and an empty winding core for starting a new winding of the glass ribbon is attached to the winding unit. (2) The sheet roll used for winding the glass ribbon is removed from the winding unit, and an unused sheet roll for use in newly winding the glass ribbon is attached to the winding unit. (3) The end of the protective sheet of the unused sheet roll is fixed to the empty winding core, and then the protective sheet is wound around the empty winding core while applying tension (for example, several turns). Completing all of the above preparatory work (1) to (3) requires a considerable amount of time. Therefore, if only a single winding unit is present, the production of the glass roll must be suspended for a long period of time until all of the preparatory work is completed. In this case, productivity of the glass roll is likely to decrease. In contrast, if multiple winding units are present, while one of the multiple winding units is being used to manufacture a glass roll in the winding area, the other winding units can perform the above-mentioned preparation work in the retreat area. This makes it possible to complete the preparation work for the other winding units when a glass roll is completed in one winding unit. Therefore, after retreating one winding unit from the winding area, production of a new glass roll can be started simply by advancing the other winding units into the winding area. As a result, productivity of the glass roll can be further improved. Of course, the time required to retreat one winding unit from the winding area and then advance the other winding units into the winding area is significantly shorter than the time required to complete all of the preparation work (1) to (3) described above.

[0013] In the above configuration, it is preferable that a plurality of evacuation areas are provided corresponding to the plurality of winding units, respectively, and that the transport mechanism has a plurality of transport paths connecting the winding area and the plurality of evacuation areas, respectively.

[0014] In this way, since multiple evacuation areas are provided and the transport mechanism has multiple transport paths, the winding unit being transported from the winding area to the evacuation area and the winding unit being transported from the evacuation area to the winding area can pass through different transport paths, thereby making it possible to smoothly replace the winding units arranged in the winding areas.

[0015] In the above configuration, each of the multiple transport paths has a shared section through which any of the multiple winding units can pass, and a dedicated section connected to the shared section and through which only one of the multiple winding units can pass, and it is preferable that a winding area is provided at one end of the shared section and a connection point with the dedicated section is provided at the other end of the shared section, and that a connection point is provided at one end of the dedicated section and an evacuation area is provided at the other end of the dedicated section.

[0016] In this way, each of the multiple transfer paths has a shared section through which all of the multiple winding units can pass, thereby minimizing the space required to provide the multiple transfer paths. Furthermore, while each transport path has a shared section, it also has a dedicated section through which only one winding unit can pass, thereby avoiding interference with smooth replacement of winding units placed in the winding area. More specifically, because each transport path has a dedicated section, when a winding unit being transferred from the winding area to the evacuation area passes through the shared section and enters the dedicated section, another winding unit can enter the shared section from the dedicated section and head toward the winding area. This avoids interference with smooth replacement of winding units placed in the winding area. As described above, this configuration makes it possible to achieve both space saving and smooth replacement of winding units.

[0017] In the above configuration, the transfer mechanism has a first track extending along the shared section, a second track extending along the dedicated section, a carriage running on one of the first and second tracks, and a third track provided on the carriage, and when the carriage runs on one of the tracks and reaches the connection point, the third track and the other of the first and second tracks are continuous, and it is preferable that the winding unit further has a running body for running on the third track and the other track.

[0018] In this configuration, when the carriage travels on one of the first track extending along the shared section and the second track extending along the dedicated section, the third track provided on the carriage also moves along the first track. Then, when the carriage traveling on the first track reaches the connection point between the shared section and the dedicated section, the third track on the carriage becomes continuous with the other track of the first and second tracks. From the above, when the carriage travels on the first track with the winding unit loaded on the third track provided on the carriage, the winding unit can be transported along the first track. Furthermore, when the carriage reaches the connection point, the third track and the other track become continuous, allowing the winding unit having the traveling body to be transferred from the third track to the other track. Then, the winding unit can be transported along the other track. Thus, being able to transport the winding unit along both the first track and the other track means that the winding unit can be transported along both the first track and the second track, and ultimately means that it can be transported along both the shared section and the dedicated section. According to this configuration, simply by transferring the winding unit between the third track and the other track, which are connected to each other, it is possible to quickly transfer the winding unit from the shared section to the dedicated section, or from the dedicated section to the shared section. Furthermore, using the track to transport the winding unit makes it easy to position the winding unit. As a result, it is even more advantageous for smoothly replacing the winding unit placed in the winding area.

[0019] In the above configuration, it is preferable that the shared section extends in the same direction as the conveying path of the glass ribbon.

[0020] In this way, at the same time that the transfer of the winding unit from the winding area to the evacuation area begins, the winding unit starts moving further downstream from the winding area located at the downstream end of the conveying path of the glass ribbon. This makes it possible to quickly secure a space between the winding unit and the downstream end of the conveying path of the glass ribbon. For example, this space can be used by an operator to inspect the condition of the glass ribbon being continuously conveyed to the downstream end of the conveying path.

[0021] In the above configuration, the winding unit may further include a guide portion for guiding the feeding of the protection sheet along the supply path from the sheet roll to the core.

[0022] Typically, the protective sheet is guided from the sheet roll to the core by a guide section (e.g., multiple rollers). In this case, among the preparatory work for starting the production of a new glass roll described above, in work (3), the protective sheet pulled out from the sheet roll is wound around the guide section, and then the end of the protective sheet is fixed to the empty core. As described above, when a guide section is present, the preparatory work newly includes the work of winding the protective sheet around the guide section. Therefore, if each of the multiple winding units has a guide section, while one of the multiple winding units is being used to produce a glass roll, the preparatory work, including the work of winding the protective sheet around the guide section, can be performed in the other winding units.

[0023] In the above configuration, the guide section may have a just-before-winding guide arranged adjacent to the upstream side of the winding core on the supply path, and the just-before-winding guide may guide the feeding of the protective sheet so that the glass ribbon that has reached the winding area and the protective sheet moving along the just-before-winding guide are in the same position.

[0024] In the above configuration, the immediately preceding winding guide may guide the feeding of the protective sheet while the protective sheet is in a horizontal position.

[0025] In the above configuration, the sheet roll support portion may be positioned lower than the core support portion in the winding unit, and the protective sheet may be superimposed on the outer peripheral surface side of the glass ribbon wound around the core.

[0026] The glass roll manufacturing apparatus can be used to carry out a glass roll manufacturing method, which includes a winding step of winding a glass ribbon, with a protective sheet superimposed thereon, around a winding core to produce a glass roll.

[0027] According to this manufacturing method, it is possible to obtain the same functions and effects as those already described for the glass roll manufacturing apparatus.

[0028] The above manufacturing method preferably includes a replacement step of replacing the winding units arranged in the winding area by transferring, after the winding step is completed, the winding units supporting the winding cores on which the glass ribbon has already been wound from the winding area to an evacuation area, and transferring the winding units supporting the winding cores before the glass ribbon has been wound from the evacuation area to the winding area.

[0029] According to this manufacturing method, it is possible to obtain the same functions and effects as those already described for the glass roll manufacturing apparatus.

[0030] According to the glass roll manufacturing apparatus and manufacturing method of the present disclosure, it is possible to increase productivity when manufacturing glass rolls.

[0031] 4 is a plan view showing a part of a glass roll manufacturing apparatus and a winding step in the glass roll manufacturing method. FIG. 1 is a cross-sectional view showing the A-A section in FIG. 1. FIG. 2 is an enlarged plan view showing the periphery of a pin and a locking mechanism. FIG. 3 is a plan view showing a glass roll manufacturing apparatus. FIG. 4 is a cross-sectional view showing the B-B section in FIG. 4. FIG. 5 is a cross-sectional view showing a part of a glass roll manufacturing apparatus. FIG. 6 is a plan view schematically showing a replacement step in the glass roll manufacturing method. FIG. 7 is a plan view schematically showing a replacement step in the glass roll manufacturing method.

[0032] Hereinafter, embodiments of a glass roll manufacturing apparatus and a manufacturing method will be described with reference to the accompanying drawings. Note that the X direction, Y direction, and Z direction shown in each drawing referred to in the description of the embodiments are directions that are perpendicular to one another.

[0033] First, the glass ribbon handled by the glass roll manufacturing apparatus and manufacturing method will be described.

[0034] <Glass Ribbon> The glass ribbon 1 shown in Figs. 1 and 2 is a long glass continuously formed by a known forming method such as a downdraw method typified by an overflow downdraw method, a slot downdraw method, or the like, or a float method.

[0035] During molding, ear portions (portions thicker than other portions) formed at locations corresponding to both widthwise end edges of the glass ribbon 1 have already been cut off and removed from the glass ribbon 1. The thickness of the glass ribbon 1 is set to a level that can impart flexibility to the glass ribbon 1, and is, for example, 200 μm or less, 100 μm or less, or 50 μm or less.

[0036] The glass ribbon 1 is typically an alkali-free glass that does not substantially contain an alkali metal oxide component. Alternatively, the glass ribbon 1 may be an alkali aluminosilicate glass that contains an alkali metal oxide component.

[0037] Next, a glass roll manufacturing apparatus will be described.

[0038] <Glass roll manufacturing apparatus> As shown in Figures 1 and 2 , a glass roll manufacturing apparatus 2 (hereinafter simply referred to as the manufacturing apparatus 2) includes a conveying mechanism 4 for conveying the glass ribbon 1 toward a winding area 3 arranged at the downstream end of the conveying path of the glass ribbon 1, and a winding mechanism 6 for winding the glass ribbon 1 that has reached the winding area 3 into a roll while overlapping it with a protective sheet 5.

[0039] The conveying mechanism 4 is configured to convey the glass ribbon 1 in a flat position (a horizontal position in the illustrated example). The conveying mechanism 4 includes a belt conveyor 7 for sending the glass ribbon 1 downstream. In the present embodiment, a strip-shaped resin sheet 9 is supplied to a conveying surface 8 of the belt conveyor 7 from a supply device (not shown), and the glass ribbon 1 is conveyed while placed on the resin sheet 9. The resin sheet 9 has a width dimension (dimension along the X direction) larger than that of the glass ribbon 1. The resin sheet 9 that has reached the downstream end of the belt conveyor 7 is guided downward from the conveying surface 8 of the belt conveyor 7 to be separated from the glass ribbon 1. Note that the conveying mechanism 4 may be configured so that the resin sheet 9 is omitted and the glass ribbon 1 is directly supported and conveyed by the belt conveyor 7.

[0040] The winding mechanism 6 includes a winding unit 12, which is a unit made up of multiple components including a winding core 10 and a sheet roll 11, a power unit 13 that applies torque to rotate the winding core 10, a bearing member 14 that cooperates with the power unit 13 to support the rotating winding core 10, and a pair of bearing members 15, 15 that support the rotating sheet roll 11.

[0041] The winding unit 12 has, as its constituent elements, a winding core 10 that serves as a core for winding the glass ribbon 1, a winding core support section 16 that can support the winding core 10, a sheet roll 11 in which the protective sheet 5 is wound into a roll before being superimposed on the glass ribbon 1, a sheet roll support section 17 that can support the sheet roll 11, and a guide section 18 that guides the feeding of the protective sheet 5 along a supply path from the sheet roll 11 to the winding core 10.

[0042] The components 10, 11, 16, 17, and 18 of the winding unit 12 are mounted on a common base 19, and the winding unit 12 can transport all of the components 10, 11, 16, 17, and 18 together.

[0043] The winding core 10 has a winding core body 20 and a shaft 21. The winding core body 20 is formed in a columnar or cylindrical shape, and the glass ribbon 1 can be wound around it. Note that a protective sheet 5 is wound around the circumferential surface of the winding core body 20 in advance before the winding of the glass ribbon 1 starts (see FIG. 6 ). The shaft 21 is assembled with the winding core body 20, and the winding core body 20 can be rotated in conjunction with the rotation of the shaft 21. One end of the shaft 21 is attached to the power unit 13, and the other end of the shaft 21 is attached to the bearing member 14.

[0044] The core support parts 16 are elements that function when the winding unit 12 is transported. Two core support parts 16 are provided, one on one end side and the other end side of the shaft 21 of the core 10. Each core support part 16 has a support groove 22 at its top.

[0045] The support groove 22 is formed so that the opening width (width along the Y direction) gradually increases toward the upper side. When the winding unit 12 is transported, the support groove 22 can support the winding core 10 from below by supporting both side walls of the groove in contact with the shaft 21 of the winding core 10 (see FIGS. 5 and 6 ). Note that when the glass ribbon 1 is wound, the shaft 21 supported by the power unit 13 and the bearing member 14 rotates without contacting the support groove 22.

[0046] The sheet roll 11 can continuously unwind the protective sheet 5 to be superimposed on the glass ribbon 1 and supply it to the winding core 10.

[0047] The sheet roll 11 has a shaft 23, a core 24, and a strip-shaped protective sheet 5 wound around the core 24. The shaft 23 is assembled with the core 24. Both ends of the shaft 23 are attached to bearing members 15, 15, respectively. The core 24 is formed in a columnar or cylindrical shape. The protective sheet 5 is a sheet for protecting the glass ribbon 1 from scratches and the like, and is, for example, a resin sheet (PET sheet, etc.). The protective sheet 5 has a width dimension larger than that of the glass ribbon 1. As a result, in the glass roll 25 being produced, both ends of the protective sheet 5 in the width direction protrude from the glass ribbon 1.

[0048] The sheet roll 11 and the sheet roll support section 17 are disposed below the winding core 10 and the winding core support section 16 in the winding unit 12. The protective sheet 5 unwound from the sheet roll 11 is configured to be superimposed on the outer peripheral surface side of the glass ribbon 1 wound around the winding core 10.

[0049] The protective sheet 5 may also be configured to be superimposed on the inner peripheral surface side of the glass ribbon 1 that is wound around the winding core 10. In this case, it is preferable that the sheet roll 11 and the sheet roll support part 17 are disposed above the winding core 10 and the winding core support part 16 in the winding unit 12.

[0050] The sheet roll support portion 17 is an element that functions when the winding unit 12 is transported. Two sheet roll support portions 17 are provided, one at one end and the other at the shaft 23. Each sheet roll support portion 17 has a support groove 26 at its top.

[0051] The support groove 26 is formed so that the opening width (width along the Y direction) gradually increases toward the upper side. When the winding unit 12 is transported, the support groove 26 can support the sheet roll 11 from below by supporting both side walls of the groove in contact with the shaft 23 of the sheet roll 11 (see Figures 5 and 6 ). Of the both side walls of the support groove 26, the side wall on the side in the direction in which the protective sheet 5 is pulled out from the sheet roll 11 is higher than the other side wall. When the glass ribbon 1 is wound, the shaft 23 supported by the pair of bearing members 15, 15 rotates without contacting the support groove 26.

[0052] The guide unit 18 has a pre-winding guide 27 arranged adjacent to the upstream side of the winding core 10 (the glass roll 25 being manufactured) on the supply path of the protective sheet 5. In this embodiment, the pre-winding guide 27 is configured with a plurality of rollers 28 (three in the illustrated example) arranged along the Y direction. However, this is not limitative, and as a modified example of this embodiment, the pre-winding guide 27 can be configured with, for example, a belt conveyor instead of the plurality of rollers 28.

[0053] The pre-winding guide 27 is configured to guide the feeding of the protective sheet 5 so that the glass ribbon 1 that has reached the winding area 3 and the protective sheet 5 that is moving along the pre-winding guide 27 have the same posture. In the present embodiment, the protective sheet 5 and the glass ribbon 1 that is superimposed on the protective sheet 5 are made to assume a horizontal posture on the pre-winding guide 27. Of course, this is not limitative, and as a modification of the present embodiment, the protective sheet 5 and the glass ribbon 1 may be made to assume an inclined posture inclined with respect to the horizontal plane. In this case, as an example, of the above-mentioned plurality of rollers 28, the rollers 28 that are arranged closer to the winding core 10 may be arranged higher.

[0054] The power unit 13 includes a drive source such as a motor (not shown), and is capable of rotating the shaft 21 of the winding core 10 while holding one end of the shaft 21. The power unit 13 and the bearing member 14 cooperate to adjust the vertical position of the rotating winding core 10 (shaft 21). Due to this function, in the present embodiment, the orientation of the glass ribbon 1 immediately before winding is maintained horizontal.

[0055] To explain the above-mentioned adjustment function in more detail, as the glass ribbon 1 is wound around the winding core 10, the diameter of the glass roll 25 being produced gradually increases. Therefore, in order to maintain the orientation of the glass ribbon 1 immediately before winding in a horizontal orientation, it is necessary to gradually move the winding core 10 upward in accordance with the increase in the diameter of the glass roll 25. The above-mentioned adjustment function is utilized for this upward movement of the winding core 10.

[0056] A block 31 is attached to the underside of the base 19 as a running body for causing the winding unit 12 to run on a first rail 29 and a third rail 30, which will be described later. Linear guides, for example, can be used as the first rail 29 and the third rail 30. On the other hand, a block for a linear guide, for example, can be used as the block 31. A pin 32 is provided on the upper surface of the base 19 for fixing the position of the winding unit 12 on the first rail 29. Two pins 32 are provided, and the two pins 32 are arranged with a gap in the X direction.

[0057] As shown in Figures 2 and 3, the pin 32 can fix the position of the winding unit 12 in cooperation with a locking mechanism 33. The locking mechanism 33 has a shaft 35 arranged on a base 34 on which the first rail 29 is laid, and an arm 36 that rotates around the shaft 35. A recess 37 for hooking onto the pin 32 is formed in the arm 36. When the recess 37 hooks onto the pin 32 as the arm 36 rotates, the position of the winding unit 12 on the first rail 29 is fixed. Of course, when the glass ribbon 1 is being wound, the position of the winding unit 12 is fixed. On the other hand, when the recess 37 disengages from the pin 32 as the arm 36 rotates, the above-mentioned fixation is released, and the winding unit 12 can travel on the first rail 29. To rotate the arm 36, for example, a cylinder mechanism connected to the arm 36 may be used.

[0058] As shown in Fig. 4, the manufacturing apparatus 2 further includes a transfer mechanism 38 for transferring the winding unit 12. Note that the winding unit 12 is not shown in Fig. 4 to make it easier to understand the structure of the transfer mechanism 38. The transfer mechanism 38 is a mechanism for transferring the winding unit 12 unit by unit between the winding area 3 and a retreat area 39 separated from the winding area 3.

[0059] In the present manufacturing apparatus 2, two evacuation areas 39 are provided for one winding area 3. The transfer mechanism 38 has two transfer paths 40 that respectively connect the winding area 3 and the two evacuation areas 39. The number of evacuation areas 39 and the number of transfer paths 40 correspond to the number of winding units 12 provided in the present manufacturing apparatus 2. In other words, the present manufacturing apparatus 2 is provided with two of the above-mentioned winding units 12 (see FIGS. 8 to 10).

[0060] In the following description, one of the two evacuation areas 39 may be distinguished from the other by being referred to as a first evacuation area 41 and the other by being referred to as a second evacuation area 42. Furthermore, one of the two transfer paths 40 may be distinguished from the other by being referred to as a first transfer path 43 and the other by being referred to as a second transfer path 44. Furthermore, one of the two winding units 12 may be distinguished from the other by being referred to as a first winding unit 45 and the other by a second winding unit 46 (see FIGS. 8 to 10).

[0061] The first evacuation area 41 is an area dedicated to evacuation of only one (first winding unit 45) of the two winding units 12. A first transfer path 43 connecting the first evacuation area 41 and the winding area 3 is a path along which the first winding unit 45 passes during transfer. In contrast, the second evacuation area 42 is an area dedicated to evacuation of only the other (second winding unit 46) of the two winding units 12. A second transfer path 44 connecting the second evacuation area 42 and the winding area 3 is a path along which the second winding unit 46 passes during transfer.

[0062] Each of the two transfer paths 40 has a shared section 47 through which both of the two winding units 12 pass, and a dedicated section 48 through which only one of the two winding units 12 passes. The shared section 47 and the dedicated section 48 are connected at a connection point 49. The shared section 47 has a winding area 3 at one end and a connection point 49 at the other end. The dedicated section 48 has a connection point 49 at one end and a retraction area 39 at the other end.

[0063] In this embodiment, the dedicated section 48 included in the first transfer path 43 and the dedicated section 48 included in the second transfer path 44 have the same length. As a result, the first transfer path 43 and the second transfer path 44 have the same length. On the other hand, when comparing the shared section 47 and the dedicated section 48, the shared section 47 is shorter than the dedicated section 48.

[0064] In the present embodiment, the common section 47 extends in the same direction as the transport path of the glass ribbon 1. On the other hand, the dedicated section 48 extends in the same direction as the width direction of the glass ribbon 1. In other words, the common section 47 and the dedicated section 48 extend in directions perpendicular to each other.

[0065] The transfer mechanism 38 has a first rail 29 as a first track extending along the shared section 47, a second rail 52 as a second track extending along the dedicated section 48, two carriages 53 running on the second rail 52, and a third rail 30 as a third track laid on the upper surface of each carriage 53. Two of each of the rails 29, 52, and 30 are laid.

[0066] Comparing the first rail 29 and the third rail 30 with the second rail 52, the distance between the two rails in the former is longer than the distance between the two rails in the latter. Here, as with the first rail 29 and the third rail 30, for example, a linear guide can be used as the second rail 52.

[0067] Each of the two carts 53 can carry a winding unit 12. Specifically, the winding unit 12 can be placed on the cart 53 by placing a block 31 attached to the base 19 of the winding unit 12 on the third rail 30 on the cart 53. One of the two carts 53 is a cart dedicated to carrying the first winding unit 45. The other of the two carts 53 is a cart dedicated to carrying the second winding unit 46.

[0068] A block 54 is attached to the underside of the carriage 53 to allow the carriage 53 to travel on the second rail 52 (see FIGS. 5 and 6). As with the block 31, a block for a linear guide, for example, can be used as the block 54.

[0069] To run the carriage 53 on the second rail 52, for example, a feed mechanism (not shown) is used. The feed mechanism may be a known mechanism. For example, a feed mechanism including a drive wheel, a driven wheel spaced apart from the drive wheel in the X direction, and a belt wound around both wheels may be used. In this case, if the belt is connected to the carriage 53, the carriage 53 runs on the second rail 52 as the belt rotates. Alternatively, a ball screw mechanism, a chain transmission mechanism, or the like may be used as the feed mechanism, or the carriage 53 may be pushed by an operator without using a feed mechanism. When a feed mechanism is used, the two carriages 53 may be run by a common feed mechanism or by different feed mechanisms.

[0070] In this embodiment, different feed mechanisms are used for the travel of the two carriages 53. The operations of the two carriages 53 are controlled so that the two carriages 53 travel on the second rail 52 in the manner exemplified below. Within the area in which the second rail 52 is laid, there are three locations spaced apart in the X direction: the first evacuation area 41, the connection point 49, and the second evacuation area 42. The operations of the two carriages 53 are controlled so that the two carriages 53 are located in two adjacent locations out of these three locations. In other words, the operations of the two carriages 53 are controlled so that both carriages 53 are not located in the evacuation area 39.

[0071] When the carriage 53 travels on the second rail 52 and reaches the connection point 49, the third rail 30 on the carriage 53 and the first rail 29 on the base 34 become continuous. At this time, the winding unit 12 can transfer from the first rail 29 to the third rail 30, or from the third rail 30 to the first rail 29. A feed mechanism (not shown) is used to run the winding unit 12 on both rails 29, 30 for transfer. The feed mechanism may be a known mechanism (for example, a chain transmission mechanism, etc.).

[0072] From the configuration described above, the manner in which the winding unit 12 is transported between the winding area 3 and the evacuation area 39 can be summarized as follows: When the winding unit 12 is transported on the dedicated section 48 of the transfer path 40 (between the evacuation area 39 and the connection point 49), the winding unit 12 is transported while being placed on a carriage 53 that receives power from the feed mechanism and travels on the second rail 52. When the winding unit 12 is transported on the shared section 47 of the transfer path 40 (between the winding area 3 and the connection point 49), the winding unit 12 receives power from the feed mechanism and travels on the first rail 29 and the third rail 30, thereby being transported.

[0073] A method for manufacturing a glass roll using the manufacturing apparatus 2 will be described below.

[0074] <Method for Manufacturing Glass Roll> The manufacturing method includes a winding step P1 and a replacement step P2.

[0075] The winding step P1 is a step of producing a glass roll 25. In the winding step P1, as already described in the description of the manufacturing apparatus 2, the glass ribbon 1 is wound around the winding core 10 in the manner shown in Figs. 1 and 2 . This produces a glass roll 25 (see Fig. 7 ) in which a glass ribbon 1 of a desired length is wound. This completes the winding step P1.

[0076] After the winding process P1 is completed, the replacement process P2 is started. The replacement process P2 is a process of replacing the winding units 12 arranged in the winding area 3. Specifically, the winding unit 12 carrying the glass roll 25 is withdrawn from the winding area 3, and a winding unit 12 carrying an empty winding core 10 (the winding unit 12 that has completed preparations for starting production of a new glass roll 25) is advanced into the winding area 3 instead.

[0077] Here, the winding unit 12 on which the glass roll 25 is placed is the winding unit 12 shown in Fig. 5. The winding unit 12 is loaded with a winding core 10 on which the glass ribbon 1 has already been wound, and a sheet roll 11 that has been used to wind the glass ribbon 1. On the other hand, the winding unit 12 on which the empty winding core 10 is placed is the winding unit 12 shown in Fig. 6. The winding unit 12 is loaded with an empty winding core 10 for newly starting winding of the glass ribbon 1, and an unused sheet roll 11 to be newly used to wind the glass ribbon 1. An end of the protective sheet 5 on the unused sheet roll 11 is fixed, and several turns of the protective sheet 5 are wound around the empty winding core 10.

[0078] In the state shown in Fig. 6, it is preferable that tension is applied to the protective sheet 5 along the path from the sheet roll 11 to the empty winding core 10. By achieving such a state, it is possible to stably wind the glass ribbon 1. The tension can be controlled, for example, by providing a dancer roller (not shown) in the guide section 18 or by providing the bearing member 15 with a torque controller that controls the rotational torque of the shaft 23, which is the rotation axis of the sheet roll 11.

[0079] The replacement of the winding unit 12 is performed according to the flow shown in Figures 8 to 10. Note that, since Figures 8 to 10 are diagrams that schematically show the replacement flow, some of the components of the manufacturing apparatus 2 described above are not shown.

[0080] First, as shown in Figure 8, the winding unit 12 (here, the first winding unit 45) carrying the glass roll 25 starts to be transported from the winding area 3 toward the connection point 49. At this time, a dedicated cart 53 for the first winding unit 45 is on standby at the connection point 49. The winding unit 12 (here, the second winding unit 46) carrying the empty winding core 10 is on standby in the second evacuation area 42.

[0081] Thereafter, the first winding unit 45 travels on the first rail 29 and the third rail 30, and as shown in Fig. 9, the first winding unit 45 arrives at the connection point 49. The first winding unit 45 that has arrived at the connection point 49 is placed on the carriage 53 (see Fig. 5).

[0082] At this time, the second winding unit 46 in the second evacuation area 42 has already completed preparations to start manufacturing a new glass roll 25. This is because, while the first winding unit 45 is being used to manufacture the glass roll 25 in the winding area 3, all of the above-mentioned preparation operations (1) to (3) (see paragraph

[0012] ) are completed for the second winding unit 46.

[0083] The first winding unit 45 that has arrived at the connection point 49 then starts to be transported from the connection point 49 toward the first evacuation area 41. At the same time, the second winding unit 46 starts to be transported from the second evacuation area 42 toward the connection point 49. At this time, the second winding unit 46 is placed on the cart 53.

[0084] Thereafter, the carriage 53 carrying the first winding unit 45 and the carriage 53 carrying the second winding unit 46 both travel on the second rail 52, and as a result, the first winding unit 45 arrives at the first evacuation area 41, as shown in Figure 10. Furthermore, the second winding unit 46 arrives at the connection point 49.

[0085] The preparatory work (1) to (3) described above is started for the first winding unit 45 that has arrived at the first evacuation area 41. In this preparatory work, the shapes of the support grooves 22 and 26 described above make it possible to quickly place the core 10 and the sheet roll 11 on the core support portion 16 and the sheet roll support portion 17, respectively.

[0086] The second winding unit 46 that has arrived at the connection point 49 then starts to be transported from the connection point 49 toward the winding area 3 (see also FIG. 6). Thereafter, the second winding unit 46 travels on the third rail 30 and the first rail 29 to arrive at the winding area 3. This switches the winding units 12 arranged in the winding area 3, completing the shunting process P2.

[0087] By repeatedly executing the above-described manufacturing method, the winding unit 12 is transported back and forth between the winding area 3 and the evacuation area 39 .

[0088] When performing maintenance on the power unit 13 or the like located in the winding area 3, the transport of the winding unit 12 between the winding area 3 and the evacuation area 29 is stopped, and the winding unit 12 is not present in the winding area 3 before the maintenance is performed.

[0089] Here, the following modifications can also be applied to the above embodiment.

[0090] In the above embodiment, rails 29, 52, and 30 (linear guides) are used as the first to third tracks, and blocks 31 and 54 (blocks for linear guides) are used as the running bodies for running on the rails 29, 52, and 30, but this is not limitative. As an example, the first to third tracks may be grooves formed in the floor surface of a glass manufacturing factory, and the running bodies may be wheels, caterpillar tracks, balls, etc.

[0091] In the above embodiment, the winding unit 12 is transported on the cart 53 in the dedicated section 48, and the winding unit 12 travels by itself in the shared section 47, but this is not limited to this. The winding unit 12 may be transported on the cart 53 in the shared section 47, and the winding unit 12 may travel by itself in the dedicated section 48.

[0092] REFERENCE SIGNS LIST 1 glass ribbon 2 glass roll manufacturing device 3 winding area 5 protective sheet 10 winding core 11 sheet roll 12 winding unit 16 winding core support section 17 sheet roll support section 18 guide section 25 glass roll 27 guide just before winding 29 first rail 30 third rail 31 block 38 transfer mechanism 39 evacuation area 40 transfer path 41 first evacuation area 42 second evacuation area 43 first transfer path 44 second transfer path 45 first winding unit 46 second winding unit 47 shared section 48 dedicated section 49 connection point 52 second rail 53 bogie P1 winding process P2 shunting process

Claims

1. A glass roll manufacturing apparatus for winding up a glass ribbon to obtain a glass roll, comprising: a winding unit including, in a winding area arranged at the downstream end of a conveying path of the glass ribbon, a winding core support section supporting a winding core for winding the glass ribbon into a roll while overlapping it with a protective sheet, and a sheet roll support section supporting a sheet roll around which the protective sheet is wound into a roll, the winding unit being movable as a unit; and a transport mechanism for transporting the winding unit unit by unit between the winding area and an evacuation area separated from the winding area.

2. The glass roll manufacturing apparatus according to claim 1, further comprising a plurality of said winding units.

3. The glass roll manufacturing apparatus as described in claim 2, characterized in that a plurality of the evacuation areas are provided corresponding to the plurality of winding units, and the transport mechanism has a plurality of transport paths respectively connecting the winding area and the plurality of evacuation areas.

4. A glass roll manufacturing apparatus as described in claim 3, characterized in that each of the multiple transport paths has a common section through which any of the multiple winding units can pass, and a dedicated section connected to the common section and through which only one of the multiple winding units can pass, the winding area is provided at one end of the common section and a connection point with the dedicated section is provided at the other end of the common section, the connection point is provided at one end of the dedicated section, and the evacuation area is provided at the other end of the dedicated section.

5. The glass roll manufacturing apparatus as described in claim 4, characterized in that the transport mechanism has a first track extending along the shared section, a second track extending along the dedicated section, a cart running on one of the first and second tracks, and a third track provided on the cart, and when the cart runs on the one track and reaches the connection point, the third track and the other of the first and second tracks are continuous, and the winding unit further has a running body for running on the third track and the other track.

6. A glass roll manufacturing apparatus as described in claim 4 or 5, characterized in that the shared section extends in the same direction as the conveying path of the glass ribbon.

7. A glass roll manufacturing apparatus as described in any one of claims 2 to 5, characterized in that the winding unit further has a guide section for guiding the feeding of the protective sheet along a supply path from the sheet roll to the winding core.

8. The glass roll manufacturing apparatus described in claim 7, characterized in that the guide section has a pre-winding guide arranged adjacent to the upstream side of the winding core on the supply path, and the pre-winding guide guides the feeding of the protective sheet so that the glass ribbon that has reached the winding area and the protective sheet moving along the pre-winding guide are in the same position.

9. The glass roll manufacturing apparatus according to claim 8, wherein the immediately preceding winding guide guides the feeding of the protective sheet while the protective sheet is in a horizontal position.

10. The glass roll manufacturing apparatus as described in claim 9, characterized in that the sheet roll support section is arranged lower than the core support section in the winding unit, and the protective sheet is superimposed on the outer peripheral surface side of the glass ribbon wound around the core.

11. A method for manufacturing a glass roll, comprising a winding step of producing a glass roll by using the glass roll manufacturing apparatus described in any one of claims 2 to 5 to wind the glass ribbon, overlapped with the protective sheet, around the winding core.

12. A method for manufacturing a glass roll as described in claim 11, further comprising a replacement process for replacing the winding unit arranged in the winding area by transporting, after completion of the winding process, the winding unit supporting the winding core on which the glass ribbon has been wound from the winding area to the evacuation area, and transporting the winding unit supporting the winding core before the glass ribbon is wound from the evacuation area to the winding area.

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