Wound body manufacturing device

Abstract

This wound body manufacturing device comprises: a winding core capable of winding a foil material in the form of a wound body; an adjustment part capable of adjusting the supply amount of the foil material to be supplied toward the winding core; a guiding surface that is provided between the winding core and the adjustment part and that guides the foil material from the adjustment part side to the winding core side, and a guide capable of making an adjustment so as to bring the foil material into contact with the guiding surface; and a control unit. The control unit disposes, from the beginning till the end of the winding of the foil material by the winding core, the guiding surface at a first position where a surface provided by virtually extending the guiding surface to the downstream side would be kept intersecting the winding core. After the winding of the wound body is finished, the control unit presses the foil material such that the foil material can be supplied toward the guide by the adjustment part, and then moves and disposes the guiding surface at a second position where the surface provided by virtually extending the guiding surface to the downstream side would be in contact with the wound body.

Description

Manufacturing apparatus for a wound body

[0001] The present invention relates to a manufacturing apparatus for a wound body.

[0002] For example, Japanese Patent Application Laid-Open No. 2005-021989 discloses a manufacturing process for a wound body such as a honeycomb body obtained by winding a corrugated plate of a predetermined length and a flat foil material supplied from a roll, for example, in an overlapping manner. The wound body is obtained by cutting the flat foil material after winding the corrugated plate around the axis of the core.

[0003] At this time, it is desirable to cut the foil material with a cutter arranged orthogonally or substantially orthogonally to the foil material rather than cutting the foil material from a direction inclined with respect to the cutter. For this reason, for example, after winding the corrugated plate and stopping the rotation of the core, the guide position of the flat foil material is shifted so that the tangential direction of the wound body and the direction in which the foil material is supplied coincide or substantially coincide, and the foil material is cut with a cutter from a direction orthogonal or substantially orthogonal to the foil material.

[0004] However, when the guide position of the foil material is shifted so that the tangential direction of the wound body and the direction in which the foil material is supplied coincide or substantially coincide, the distance between the end of the guide surface and the tangent of the wound body approaches as compared with before shifting the guide surface. For this reason, the foil material may be bent, and it may be difficult to cut the desired position of the foil material with the cutter.

[0005] An object of the present invention is to provide a manufacturing apparatus for a wound body that can hardly cause the foil material to be bent and can cut the foil material at a desired position when performing a process of cutting the foil material after winding the supplied foil material to form a wound body.

[0006] A winding body manufacturing apparatus according to one aspect of the present invention comprises: a winding core that extends in the Y-axis direction when defining an XYZ Cartesian coordinate system, is rotatable around an axis at that position, and capable of winding a supplied foil material as a winding body; an adjustment unit that is spaced apart from the winding core in the upstream -X-axis direction and can adjust the amount of the foil material supplied downstream in the +X-axis direction toward the winding core; a base provided between the winding core and the adjustment unit, having a guide surface that follows the XY plane in the +Z-axis direction and guides the foil material from the adjustment unit side toward the winding core, and a guide that can adjust the foil material supplied downstream in the +X-axis direction through the adjustment unit to contact the guide surface according to the Z-axis position of the guide surface; an actuator provided on the base that moves the guide surface and the guide together in a direction along the ±Z-axis direction; a cutter provided between the guide on the base and the winding core and capable of cutting the foil material wound in the winding body; and a control unit that controls the movement of the winding core, the adjustment unit, the actuator and the cutter. The control unit controls the actuator to position the guide surface at a first position such that, from the start to the end of winding the foil material on the winding core, the surface obtained by virtually extending the XY plane of the guide surface in the downstream +X axis direction intersects the winding core or is brought within a predetermined distance range from the winding core in the Z axis direction. After winding the winding body is completed, the adjustment unit controls the adjustment unit to press the foil material so that it can be supplied toward the guide, and then controls the actuator to move the guide surface in the -Z axis direction to a second position such that the surface obtained by virtually extending the XY plane of the guide surface in the downstream +X axis direction is in contact with the winding body or is in a nearby position, thereby applying tension to the foil material. With the tension applied, the cutter controls the cutter to cut the foil material between the guide and the winding body.

[0007] A schematic perspective view of a wound body wound using a manufacturing apparatus. A schematic top view of the winding body manufacturing apparatus. A schematic front view of the winding body manufacturing apparatus viewed from the direction indicated by arrow III in Figure 2. A schematic front view of the winding body manufacturing apparatus showing a series of operations following Figure 3. A schematic front view of the winding body manufacturing apparatus showing a series of operations following Figure 4. A schematic front view of the winding body manufacturing apparatus showing a series of operations following Figure 5. A schematic front view of the winding body manufacturing apparatus showing a series of operations following Figure 6. A schematic front view of the winding body manufacturing apparatus showing a series of operations following Figure 7. A schematic block diagram of the winding body manufacturing apparatus shown in Figures 2 to 8. A flowchart showing an example of a series of operations of the winding body manufacturing apparatus. A schematic diagram to explain the distance from the adjustment section to the end of the corrugated sheet of the winding body manufacturing apparatus shown in Figures 5 and 6.

[0008] The following describes embodiments for carrying out this invention with reference to the drawings.

[0009] A manufacturing apparatus 10 for a wound body (metal substrate) 110 according to one embodiment will be described with reference to Figures 1 to 11.

[0010] Figure 1 shows a schematic perspective view of a wound body 110 wound using the manufacturing apparatus 10. The wound body 110 is formed by winding a strip-shaped flat plate 120 and a corrugated plate 130 placed on top of the flat plate 120 in a roll shape around an axis of a winding core 14 that is perpendicular to the conveying direction of the flat plate 120 and the corrugated plate 130. The flat plate 120 is formed as a flat plate. The corrugated plate 130 is formed, for example, as a plate with a substantially sinusoidal wave curvature of a predetermined pitch and predetermined amplitude.

[0011] In this embodiment, the flat plate 120 and the corrugated plate 130 may or may not have through holes (ventilation passages) formed therein. For example, through holes may be formed only in the flat plate 120.

[0012] An example of the wound body 110 according to this embodiment is a honeycomb body that supports a catalyst for exhaust gas purification. The wound body (honeycomb body) 110 is used, for example, as a component housed inside the cylindrical outer casing of an exhaust gas purification catalytic converter.

[0013] As an example, metal foil materials such as stainless steel can be used as the material for the flat plate 120 and the corrugated plate 130. The thickness of the metal foil material can range from several tens of micrometers to a few millimeters or less.

[0014] Although not shown in the diagram, the corrugated sheet 130 is supplied in a pre-defined state, for example, as a corrugated sheet winding, with the total length of the corrugated sheet 130 or the number of waves (number of peaks) of the corrugated sheet 130 predetermined to be within a specified range. The corrugated sheet 130 is supplied, for example, cut to a certain length in the longitudinal direction. One corrugated sheet winding is required for the manufacture of one winding 110, and they are supplied sequentially in an interchangeable manner. The corrugated sheet 130 may also be cut to an appropriate length by a cutter 20, for example, if it is long enough to be sufficient for the length required for one winding 110, as is the case with the flat sheet roll 82 described later.

[0015] Figure 2 is a schematic top view of the winding body 110 manufacturing apparatus 10. Figure 3 is a front view of the winding body 110 manufacturing apparatus 10 as seen from the direction indicated by arrow III in Figure 2. Figures 4 to 8 sequentially show a series of operations following the manufacturing apparatus 10 in Figure 3. Note that the cutter 16 and corrugated sheet supply unit 28 are not shown in Figure 2.

[0016] Here, we adopt an XYZ Cartesian coordinate system in Figures 2 through 8. The +X axis direction is the direction in which the winding flat plate 120 is guided (conveyed) when it is wound with the corrugated plate 130. That is, the +X axis direction is the direction in which the winding flat plate 120 moves from the upstream side to the downstream side. The +Y axis direction is the direction toward the top of Figure 2 and also along the depth direction (width direction) perpendicular to the plane of the paper in Figures 3 through 8. The +Z axis direction is the direction toward the top of the plane of the paper in Figure 2 and also the direction toward the top of the paper in Figures 3 through 8.

[0017] Figure 9 shows a schematic block diagram of the manufacturing apparatus 10 for the wound body 110 shown in Figures 2 to 8.

[0018] As shown in Figures 2 to 9, the manufacturing apparatus 10 for the wound body 110 includes a first housing 12, a winding core 14, a cutter 16, a second housing 18, an adjustment unit 20, a base unit 22, a flat plate presser 24, a flat plate supply unit 26, a corrugated plate supply unit 28, and a control unit 30.

[0019] The first housing 12 is fixed, for example, to the lower surface (XY plane) of the paper in Figure 2, or to the depth surface (ZX plane) of the paper in Figure 2.

[0020] The first housing 12 is provided with, for example, a winding core 14 and a cutter 16.

[0021] The core 14 is formed as a metal rod with a diameter of, for example, about 5 mm, by processing a highly rigid and tough steel material such as SUS440C or SKD11. The core 14 is supported on the housing 12 so as to be rotatable around a predetermined central axis C. The predetermined central axis C is provided parallel to the Y axis. The length of the core 14 in the Y axis direction is formed to be greater than the width of the flat plate 120 and the corrugated plate 130 in the Y axis direction. The core 14 may be a pair that can move closer to and further apart in the Y axis direction. It is preferable that the position of the core 14 in the X axis direction and the position in the Z axis direction remain unchanged.

[0022] The winding core 14 has, for example, a slit 14a extending in the Y-axis direction. For example, with the corrugated sheet 130 placed on the flat sheet 120, the flat sheet 120 is positioned in the slit 14a of the winding core 14 from the +X-axis end side of the flat sheet 120, and the +X-axis end of the corrugated sheet 130 is brought into contact with or close to the winding core 14 on the +Z-axis side of the flat sheet 120. Then, the winding core 14 is rotated around its axis to form a substantially cylindrical metal base material (winding body) 110. Therefore, the winding core 14 can wind the supplied foil material (flat sheet 120 and / or corrugated sheet 130) as the winding body 110. Alternatively, the +X-axis end of the corrugated sheet 130 may be positioned in the slit 14a of the winding core 14.

[0023] The manufacturing apparatus 10 shown in Figures 2 to 8 has a first drive source (actuator) 15 provided on the winding core 14. The first drive source 15 is a motor or the like that rotates the winding core 14 around a predetermined central axis C. The first drive source 15 is controlled by a control unit 30, for example, by torque or rotational speed.

[0024] In this embodiment, the cutter (movable blade) 16 is used together with the receiving part (fixed blade) 16a. The cutter 16 and the receiving part 16a are provided on the -X-axis side of the winding core 14. The cutter 16 and the receiving part 16a are supported on the first housing 12 so as to be movable in the Z-axis direction, that is, in a direction perpendicular to the X-axis and Y-axis directions. The length of the receiving part 16a in the depth direction (Y-axis direction) is formed to be greater than the width of the corrugated sheet 130 and the flat sheet 120 in the width direction (Y-axis direction). Normally, the cutter 16 does not interfere with the movement of the flat sheet 120 and the corrugated sheet 130 in the X-axis direction and is stationary on the front or back side of the flat sheet 120 in the Y-axis direction. The cutter 16 is formed as, for example, a circular blade that is movable in the Y-axis direction, and can cut the flat sheet (foil material) 120 with the blade by, for example, a shear force applied between it and the receiving part 16a. Furthermore, the length of the receiving portion 16a in the depth direction (Y-axis direction) may be formed to be smaller than the width in the width direction (Y-axis direction) of the corrugated sheet 130 and the flat sheet 120.

[0025] Furthermore, the cutter 16 may be formed as a so-called guillotine cutter with a continuous blade that is larger in the Y-axis direction than the width direction (Y-axis direction) of the corrugated sheet 130 and the flat sheet 120, and can cut the flat sheet 120 (and corrugated sheet 130) by moving in the Z-axis direction. Alternatively, a laser cutter may be used for the cutter 16. If a laser cutter is used for the cutter 16, the receiving portion 16a may be unnecessary.

[0026] The manufacturing apparatus 10 shown in Figures 2 to 8 is provided in the first housing 12 and has a second-first drive source (actuator) 17a that moves the cutter 16 and the receiving part 16a, and a second-second drive source (actuator) 17b that moves the cutter 16 so that it can reciprocate in the Y-axis direction. The second-first drive source 17a can be an air cylinder that moves the cutter 16 and the receiving part 16a along the Z-axis direction, or a linear actuator (electric cylinder) using a motor and a ball screw, etc. The second-first drive source 17a may move the cutter 16 and the receiving part 16a not only along the Z-axis direction, but also along the X-axis direction. The second-second drive source 17b can be an air cylinder that moves the cutter 16 along the Y-axis direction, or a linear actuator (electric cylinder) using a motor and a ball screw, etc. The second-first drive source 17a and the second-second drive source 17b are controlled by the control unit 30.

[0027] The second housing 18 is positioned upstream (towards the -X-axis) of the first housing 12. The second housing 12 is fixed, for example, to the lower surface (XY plane) in Figures 3 to 8, or to the depth surface (ZX plane) in Figures 3 to 8.

[0028] The second housing 18 is provided with, for example, an adjustment unit 20, a base unit 22, and a flat plate holder 24.

[0029] The adjustment unit 20 can adjust the supply amount of the flat plate 120 along the X-axis direction. The adjustment unit 20 includes a fixed part 42 having a sliding surface 42a, a third drive source 44, and a pad 46 provided on the third drive source 44.

[0030] The fixing portion 42 is fixed to the floor or the second housing 18. The sliding surface 42a of the fixing portion 42 is located on the +Z axis side of the fixing portion 42 and guides the flat plate 120 horizontally, for example, in the +X axis direction. At this time, the flat plate 120 can slide on the sliding surface 42a. A material with excellent wear resistance is used for the sliding surface 42a. For example, die steel (SKD11) is preferably used for the sliding surface 42a.

[0031] The third drive source 44 is controlled by the control unit 30. The third drive source 44 can be an air cylinder or a linear actuator that moves the pad 46 in the Z-axis direction. For example, an air cylinder can be used as the third drive source 44. The air cylinder 44 has a cylinder portion 44a fixed to the second housing 18 and a rod portion 44b that is extendable (movable) in the Z-axis direction relative to the cylinder portion 44a.

[0032] A pad 46 is fixed to the -Z axis end of the rod portion 44b. The pad 46 is made of a material that has sliding properties against the flat plate 120. For example, ultra-high molecular weight polyethylene (UHPE) can be used for the pad 46.

[0033] Furthermore, it is preferable that the sliding surface 42a is supported along the entire length of the flat plate 120 in the width direction. The pad 46 only needs to support a part of the flat plate 120 in the width direction; for example, it may support the center of the flat plate 120 in the width direction. Of course, the pad 46 may also support the entire length of the flat plate 120 in the width direction.

[0034] The base unit 22 is provided between the winding core 14 and the adjustment unit 20. The base unit 22 has a base 52 and a fourth drive source (actuator) 54.

[0035] The base 52 comprises a plate-shaped member 62 having a guide surface 62a and a guide 64.

[0036] The guide surface 62a of the plate-shaped member 62 of the base 52 is aligned with the XY plane on the +Z axis side and guides the flat plate 120 from the adjustment section 20 side to the winding core 14 side.

[0037] The guide 64 of the base 52 is supported by a plate-shaped member 62. The guide 64 is positioned on the +Z axis side of the guide surface 62a. The flat plate 120 is then guided towards the winding core 14 through the space between the guide surface 62a and the guide 64. Preferably, the guide 64 is formed as a roller (guide roller) that is long in the Y axis direction and rotatable around the axis of a central axis extending in the Y axis direction. The length of the guide 64 in the Y axis direction is formed to be greater than the width of the flat plate 120. The guide 64 can then guide the flat plate 120, which is supplied in the +X axis direction downstream through the adjustment part 20, so as to be in contact with the guide surface 62a, depending on the Z axis position of the guide surface 62a of the plate-shaped member 62.

[0038] The fourth drive source (actuator) 54 is provided on the plate-shaped member 62 of the base 52, and is capable of moving the guide surface 62a and the guide 64 together in a direction along the ±Z axis.

[0039] The fourth drive source 54 is an air cylinder or a linear actuator that moves the plate-shaped member 62 in the Z-axis direction. For example, an air cylinder is used as the fourth drive source 54. The air cylinder 54 has a cylinder portion 54a fixed to the second housing 18 and a rod portion 54b that is extendable (movable) in the Z-axis direction relative to the cylinder portion 54a. The plate-shaped member 62 is fixed to the end of the rod portion 54b in the +Z-axis direction.

[0040] The rod portion 54b relative to the cylinder portion 54a is provided such that, when the rod portion 54b is extended to its maximum extent relative to the cylinder portion 54a, the surface of the guide surface 62a, which is virtually extended in the downstream +X axis direction, intersects with the winding core 14 or is kept within a predetermined distance range relative to the winding core 14 in the Z axis direction. Furthermore, the rod portion 54b relative to the cylinder portion 54a is positioned at a second position where, when the rod portion 54b is moved to its maximum extent relative to the cylinder portion 54a in the -Z axis direction, the surface of the guide surface 62a, which is virtually extended in the downstream +X axis direction relative to the XY plane, is in contact with the winding body 110, or is in a nearby position.

[0041] The flat presser 24 is provided, for example, on the +Z-axis direction side facing the guide surface 62a of the plate-like member 62. And it is preferable that the flat presser 24 is provided at the end portion on the +X-axis direction side of the guide surface 62a. The flat presser 24 has a fifth drive source 72 and a pad (presser member) 74 provided on the fifth drive source 72.

[0042] The fifth drive source 72 is controlled by the control unit 30. As the fifth drive source 72, an air cylinder, a linear actuator, or the like that moves the pad 74 in the Z-axis direction is used. For example, an air cylinder is used as the fifth drive source 72. The air cylinder 72 has a cylinder portion 72a fixed to the second housing 18 and a rod portion 72b that can expand and contract (move) in the Z-axis direction with respect to the cylinder portion 72a.

[0043] The pad 74 is fixed to the end portion of the rod portion 72b in the -Z-axis direction. The pad 74 preferably presses the flat plate 120 against the guide surface 62a over the entire length in the width direction or a region longer than the entire length. For this reason, the pad (presser member) 74 can press the foil material (flat plate 120) against the guide surface 62a. When the foil material (flat plate 120) is pressed against the guide surface 62a by the pad (presser member) 74, the foil material (flat plate 120) is immovable with respect to the guide surface 62a.

[0044] The flat plate supply unit 26 has a flat plate roll 82, a sixth drive source 84 that rotates the flat plate roll 82, and a guide 86.

[0045] The flat plate roll 82 is formed by rolling a foil material (flat plate) 120 having a length sufficiently longer than the length of the flat plate 120 required for one winding body 110.

[0046] As the sixth drive source 84, a motor or the like that rotates the central axis 82a of the flat plate roll 82 around its axis is used. The sixth drive source 84 is controlled by the control unit 30, for example, in terms of torque or rotational speed.

[0047] The guide 86 is provided, for example, on the second housing 18. The guide 86 guides the flat plate 120 supplied from the flat plate roll 82 toward the adjustment unit 20. The guide 86 is preferably formed as a roller (guide roller) that is long in the Y-axis direction and rotatable about the central axis extending in the Y-axis direction. Note that the guide 86 may not be provided depending on the situation where the flat plate 120 is guided from the flat plate roll 82 to the guide 64 of the base unit 22.

[0048] Note that the flat plate roll 82 and the sixth drive source 84 of the flat plate supply unit 26 may be provided, for example, on the second housing 18, similar to the guide 86.

[0049] The corrugated plate supply unit 28 is provided, for example, on the second housing 18. The corrugated plate supply unit 28 has a corrugated plate roll (not shown).

[0050] The corrugated plate roll is, for example, a roll formed by winding a corrugated plate 130 of a predetermined length or a predetermined number of peaks. Here, for manufacturing one wound body 110, one corrugated plate roll is used, and after the corrugated plate 130 of one corrugated plate roll is supplied from the corrugated plate supply unit 28, it is to be exchanged.

[0051] Note that the corrugated plate supply unit 28 may supply a flat plate and supply it, for example, toward the winding core (mandrel) 14 while processing the flat plate into the corrugated plate 130, similar to the flat plate 120 supplied from the flat plate roll 82. In this case, the corrugated plate supply unit 28 or the cutter 20 may cut the flat plate to be processed into the corrugated plate 130 supplied from the corrugated plate supply unit 28 or the corrugated plate 130 after the flat plate is processed at a determined position.

[0052] The control unit 30 is composed of, for example, a computer and includes a processor (processing circuit) and a storage medium. The processor may include any of the following: CPU (Central Processing Unit), ASIC (Application Specific Integrated Circuit), microcontroller, FPGA (Field Programmable Gate Array), and DSP (Digital Signal Processor). The storage medium may include a main memory such as memory, as well as an auxiliary storage device. Examples of storage media include HDD (Hard Disk Drive), SSD (Solid State Drive), magnetic disk, optical disk (CD-ROM, CD-R, DVD, etc.), magneto-optical disk (MO, etc.), and non-volatile memory such as semiconductor memory that allows writing and reading at any time.

[0053] In the control unit 30, there may be only one processor and one storage medium, or there may be multiple processors and storage mediums. In the control unit 30, the processor performs processing by executing programs stored in the storage medium, etc. Furthermore, the programs executed by the processor of the control unit 30 may be stored on a computer (server) connected to the control unit 30 via a network such as the Internet, or on a server in a cloud environment. In this case, the processor downloads the programs via the network.

[0054] In the control unit 30, the control of each drive source 15, 17a, 17b, 44, 54, 72, and 84 is performed by a processor or the like, and the storage medium functions as a data storage unit.

[0055] Furthermore, at least a portion of the processing performed by the control unit 30 may be executed by a cloud server configured in the cloud environment. The infrastructure of the cloud environment consists of virtual processors such as virtual CPUs and cloud memory. In one example, the control of each drive source 15, 17a, 17b, 44, 54, 72, 84 is performed by a virtual processor, and the cloud memory functions as a data storage unit.

[0056] As shown in Figure 9, the manufacturing apparatus 10 for the wound body 110 according to this embodiment has a transport unit 32 that transports the wound body 110 to a predetermined position, for example. An example of the transport unit 32 is a hand robot. The transport unit 32 is controlled by a control unit 30.

[0057] The following describes a series of operations of the manufacturing apparatus 10 for the wound body 110 according to this embodiment. Figure 10 shows a flowchart of the series of operations of the manufacturing apparatus 10 for the wound body 110 according to this embodiment.

[0058] Figure 11 shows a schematic diagram illustrating the distance from the adjustment section of the winding body manufacturing apparatus shown in Figures 5 and 6 to the end of the corrugated sheet.

[0059] As shown in Figures 2 and 3, the flat plate 120 is used, for example, by being pulled out from the flat plate roll 82. The control unit 30 controls the sixth drive source 84 and supplies the flat plate 120 to the winding core 14 from the flat plate supply unit 26 through the guide 86, the sliding surface 42a of the adjustment unit 20 and the pad 46, the guide 64, and the guide surface 62a. In addition, the corrugated sheet 130 is supplied from the corrugated sheet supply unit 28 to the +Z axis side of the flat plate 120. For example, with the corrugated sheet 130 positioned on the +Z axis side of the flat plate 120, the flat plate 120 is placed in the slit 14a of the winding core 14 from the +X axis end side of the flat plate 120, and the +X axis end of the corrugated sheet 130 is brought into contact with or close to the winding core 14 on the +Z axis side of the flat plate 120. Therefore, the tip of the corrugated sheet 130 (the end on the +X axis side) is positioned between the flat sheet 120 and the winding core 14, for example, on the -Z axis side (step S10).

[0060] One end face of the flat plate 120 in the width direction (Y-axis direction) (the end face on the +Y-axis side) and one end face of the corrugated sheet 130 in the width direction (Y-axis direction) (the end face on the +Y-axis side) lie on the same ZX plane. Also, the other end face of the flat plate 120 in the width direction (Y-axis direction) (the end face on the -Y-axis side) and the other end face of the corrugated sheet 130 in the width direction (Y-axis direction) (the end face on the -Y-axis side) lie on the same ZX plane. For this reason, it is preferable that both ends of the flat plate 120 and the corrugated sheet 130 in the width direction are aligned.

[0061] At this time, there is a gap between the sliding surface 42a and the pad 46, and a gap between the guide surface 62a and the pad 74. The cutter 16 and the receiving portion 16a are not in contact with either the flat plate 120 or the corrugated plate 130, due to the control of the second-first drive source 17a and the second-second drive source 17b by the control unit 30.

[0062] The control unit 30 then controls the fourth drive source (actuator) 54 to maintain a state in which the XY plane of the guide surface 62a is virtually extended in the downstream +X axis direction, intersects with the winding core 14, for example. Alternatively, the control unit 30 controls the fourth drive source (actuator) 54 to maintain a state in which the XY plane of the guide surface 62a is virtually extended in the downstream +X axis direction, and is brought within a predetermined distance range in the Z axis direction relative to the winding core 14. This position of the guide surface 62a is called the first position. The first position does not necessarily require the XY plane of the guide surface 62a to be virtually extended in the downstream +X axis direction, and intersect with the winding core 14.

[0063] The control unit 30 then controls the first drive source 15 and the sixth drive source 84 to feed out the flat plate 120 toward the winding core 14, while rotating the winding core 14 around its axis (step S20). As the flat plate 120 is wound onto the winding core 14, the corrugated sheet 130 supplied from the corrugated sheet roll follows. As a result, as shown in Figure 4, a winding body 110 is formed in which the flat plate 120 and the corrugated sheet 130 overlap. Here, the length of the flat plate 120 and the length of the corrugated sheet 130 in one winding body 110 are approximately constant. Therefore, if the required amount of flat plate 120 is supplied to the winding body 110, the supply of the corrugated sheet 130 is completed before or approximately simultaneously with that. Then, when the control unit 30 determines, for example, that a predetermined amount of flat plate 120 has been supplied from the flat plate roll 82, it controls the first drive source 15 and the sixth drive source 84 to stop the rotation of the winding core 14 and the rotation of the flat plate roll 82. As a result, a substantially cylindrical metal base material (winding body) 110 (see Figure 1) is formed. After the rotation of the winding core 14 is stopped, the winding core 14 does not rotate around its axis but remains stopped in that position, and the shape of the winding body 110 does not change.

[0064] After this operation, the corrugated sheet roll of the corrugated sheet supply unit 28 is replaced (step S21). Preferably, this replacement of the corrugated sheet roll is also performed automatically by an appropriate device controlled by the control unit 30. Note that the timing of the replacement of the corrugated sheet roll does not have to be the timing in step S21, and any appropriate timing is acceptable.

[0065] As shown in Figure 5, the control unit 30 controls the third drive source 44 of the adjustment unit 20 to move the pad 46 in the -Z axis direction, and the pad 46 presses against the sliding surface 42a (step S30). At this time, the pad 46 presses against, for example, the center of the flat plate 120 in the width direction.

[0066] After the winding core 14 stops rotating, the winding body 110 does not change shape, but the flat plate roll 82 can still feed out the flat plate 120. When the flat plate (foil material) 120 is sandwiched between the pad 46 and the sliding surface 42a of the adjustment unit 20, the space between the pad 46 and the sliding surface 42a has sliding properties relative to the flat plate (foil material) 120. Therefore, if the flat plate 120 is pulled from the winding body 110 side (+X axis side), the flat plate 120 can move in the +X axis direction through the space between the pad 46 and the sliding surface 42a. In this way, after winding the winding body 110, the control unit 30 controls the adjustment unit 20 and holds the flat plate (foil material) 120 so that it can be supplied toward the guide 64. In other words, the adjustment unit 20 can adjust the amount of flat plate (foil material) 120 supplied toward the winding core 14 in the downstream +X axis direction. Furthermore, when tension is applied to the flat plate (foil material) 120, the amount of flat plate (foil material) 120 supplied may be adjusted by adjusting the thrust of the drive source 44, thereby adjusting the tension applied to the flat plate (foil material) 120.

[0067] As shown in Figure 6, the control unit 30 controls the fourth drive source 54 of the base unit 22 to move the guide surface 62a and guide 64 of the plate-shaped member 62 in the -Z axis direction (step S40). The amount of movement at this time is, for example, the same as the assumed radius r of the winding body 110. Then, the flat plate 120 is aligned with the tangent to the winding body 110 in the -Z axis direction.

[0068] In this manner, the control unit 30 controls the fourth drive source (actuator) 54 to move the guide surface 62a in the -Z axis direction relative to the first position, thereby positioning the surface obtained by virtually extending the XY plane of the guide surface 62a in the downstream +X axis direction to a position in contact with the winding body 110, or a position near it. This position of the guide surface 62a is designated as the second position.

[0069] Furthermore, when the control unit 30 moves the guide surface 62a from the first position to the second position, it controls the second-first drive source 17a to move the cutter 16 and the receiving part 16a together to a predetermined position in the Z-axis direction. The timing of the Z-axis movement of the cutter 16 and the receiving part 16a is preferably performed simultaneously with the movement of the guide surface 62. At this time, the control unit 30 moves the receiving part 16a to the -Z-axis side of the flat plate 120. The cutter 16 is positioned in a position where it could cut the flat plate 120 if it were moved in the +Y-axis direction or the -Y-axis direction in the Z-axis direction, but it is kept positioned on the -Y-axis side or the +Y-axis side of the flat plate 120 so that the cutter 16 does not touch the flat plate 120.

[0070] Using Figure 11, we compare the distance L0 from the adjustment unit 20 shown in Figure 5 to the end position of the corrugated sheet 130 with the distance L1 from the adjustment unit 20 to the end position of the corrugated sheet 130 shown in Figure 6. In Figure 11, the path for distance L0 is shown with a solid line, and the path for distance L1 is shown with a dashed line.

[0071] For the sake of simplicity, in Figure 11, let's assume that the end position 130a of the corrugated sheet 130 is at the outermost -Z-axis position of the winding body 110. Distances L0 and L1 can be rephrased as the length of the flat plate 120 from the adjustment section 20 through the guide 64 and guide surface 62a to the end position 130a of the corrugated sheet 130. In this case, the flat plate 120 that is the outermost periphery where the corrugated sheet 130 does not overlap extends in the -X-axis direction from the end position 130a of the corrugated sheet 130.

[0072] The distance L0 shown in Figure 11 is the sum of the distance α0 from the adjustment unit 20 to the guide 64, the distance (length) β in the X-axis direction on the guide surface 62a, and the distance γ0 from the downstream end 62b of the guide surface 62a to the end position 130a of the corrugated sheet 130 of the winding body 110 (= α0 + β + γ0). The distance L1 shown in Figure 11 is the sum of the distance α1 from the adjustment unit 20 to the guide 64, the distance (length) β in the X-axis direction on the guide surface 62a, and the distance γ1 from the downstream end 62b of the guide surface 62a to the end position 130a of the corrugated sheet 130 of the winding body 110 (= α1 + β + γ1).

[0073] Note that the length β is constant, and the distances α0 and α1 change as the guide surface 62a and guide 64 move between the position shown in Figure 5 and the position shown in Figure 6. Similarly, the distances γ0 and γ1 change as the guide surface 62a and guide 64 move between the position shown in Figure 5 and the position shown in Figure 6. In this case, α0 < α1 and γ0 > γ1.

[0074] Then, when the guide surface 62a and guide 64 of the plate-shaped member 62 move from the first position shown in Figure 5 to the second position shown in Figure 6, and the distance between the downstream end 62b of the guide surface 62a and the winding body 110 changes from distance γ0 to distance γ1, since γ0 > γ1, the flat plate 120 between the guide 64 and the winding body 110 tends to loosen, and deflection may occur. Similarly, when the guide surface 62a and guide 64 of the plate-shaped member 62 move from the first position shown in Figure 5 to the second position shown in Figure 6, and the distance between the adjustment part 20 and the guide 64 changes from distance α0 to distance α1, since α0 < α1, tension tends to be applied to the flat plate 120 between the adjustment part 20 and the guide 64.

[0075] Furthermore, the static friction force between the sliding surface 42a and the pad 46 is greater than the static friction force between the guide 64 and the flat plate 120, and the kinetic friction force between the sliding surface 42a and the pad 46 is greater than the kinetic friction force between the guide 64 and the flat plate 120. For this reason, the flat plate 120 moves or attempts to move along the guide 64 more easily than it moves or attempts to move through the space between the sliding surface 42a and the pad 46.

[0076] When α1 - α0 > γ0 - γ1, at the end of winding the flat plate 120 by the winding core 14, the distance L0 of the guide surface 62a at the first position is shorter than the distance L1 at the second position.

[0077] At this time, the distance of the flat plate 120 between the adjustment section 20 and the guide 64 becomes larger than the amount of slack in the flat plate 120 between the guide 64 and the winding body 110. As a result, the flat plate 120 moves through the adjustment section 20 by a length of (α1 - α0) - (γ0 - γ1) in the +X axis direction relative to the adjustment section 20. At this time, as shown in Figure 6, the flat plate 120 between the downstream end 62b of the guide surface 62a and the end position of the corrugated sheet 130 is taut with appropriate tension.

[0078] The relationship between distances L0 and L1 will be explained in more detail below.

[0079] Let θ1 be the angle between α0 and α1 shown in Figure 11. In this case, α1 = α0 / cos(θ1) (0 < θ1 < 90°).

[0080] In Figure 11, the angle between the center 112a of the circle 112 schematically representing the wound body 110 and the tangent line T of the flat plate 120 to the circle 112 is denoted as θ2. The radius of the circle 112 is denoted as r. The distance between the downstream end 62b of the guide surface 62a and the center of the winding core 14 is denoted as d. In this case, γ0 can be expressed as dsin(θ2) + Δγ (0 < θ2 < 90°). Also, Δγ can be expressed as 2πr × (θ3) / 360°, where (θ3) = 90° - (θ2).

[0081] Therefore, γ0 = dsin(θ²) + 2πr × ((90° - (θ²)) / 360°.

[0082] On the other hand, γ1 = d.

[0083] Therefore, L0 can be expressed as L0 = α0 + β + dsin(θ2) + 2πr × ((90° - (θ2)) / 360°, and L1 can be expressed as L1 = α0 / cos(θ1) + β + d.

[0084] When distance L0 < distance L1, the rotational position of the winding body 110 does not change, and the flat plate 120 is pulled from the flat plate roll 82. At this time, as shown in Figure 6, the flat plate 120 between the downstream end 62b of the guide surface 62a and the end position of the corrugated plate 130 is taut with appropriate tension.

[0085] Then, the control unit 30 controls the fifth drive source 72 to extend the rod portion 72b relative to the cylinder portion 72a. Then, the pad 74 provided on the -Z axis side of the rod portion 72b presses against the guide surface 62a (step S50).

[0086] In this case, the pad 74 of the flat plate retainer 24 is positioned on the guide surface 62a at a location close to the downstream end 62b along the +X axis direction, and on the +Z axis direction side with respect to the guide surface 62a. In this case, the flat plate 120 can be prevented from moving within the narrower region between the position of the pad 74 closest to the +X axis direction and the winding body 110. For this reason, the flat plate 120 is subjected to appropriate tension.

[0087] The control unit 30 controls the second-second drive source 17b and moves the cutter 16 in the Y-axis direction while maintaining the position of the receiving portion 16a (step S60). At this time, as shown in Figure 8, the Y-axis direction, which is the direction in which the cutter 16 moves, and the X-axis direction, which is the direction in which the flat plate 120 extends, are perpendicular. For this reason, the flat plate 120 can be cut more easily with a cutter 16 having a circular blade, for example. Accordingly, when cutting the flat plate (foil material) 120, the control unit 30 controls the cutter 16 with tension applied to the flat plate (foil material) 120 between the guide 64 and the winding body 110, and causes the cutter 16 to cut the flat plate (foil material) 120. The cutter 16 may move in one direction in the Y-axis direction to cut the flat plate 120, or it may reciprocate to return to a predetermined position. After the cutter 16 moves in one direction in the Y-axis direction to cut the flat plate 120, the cutter 16 is positioned so as not to interfere with subsequent flat plates 120 and corrugated plates 130 that are guided toward the winding core 14. The cutter 16 and the receiving part 16a may be provided as a pair of units that can move together in the Y-axis direction. In this embodiment, the cutter 16 is positioned above the flat plate 120 on the winding core side of the winding body 110, and the receiving part 16a is positioned below the flat plate 120, but the cutter 16 may also be positioned below the flat plate 120, and the receiving part 16a may be positioned above the flat plate 120 on the winding core side of the winding body 110. Generally, the cutter 16 is larger than the receiving part 16a, so by positioning the cutter 16 below the foil material, interference with the winding body 110 is reduced, and the flat plate 120 can be cut at a position closer to the winding body 110.

[0088] If the cutter 16 is a so-called guillotine cutter, the cutter 16, which has a blade extending in the Y-axis direction, is moved in the Z-axis direction to cut the flat plate (foil material) 120 with the cutter 16.

[0089] Subsequently, the control unit 30 controls the transport unit 32 to transport the wound body 110, which has finished winding, to a predetermined position, for example (step S70). The transport unit 32 may be a hand robot, for example. At this time, the control unit 30 controls the third drive source 44 and the fifth drive source 72 to move the pad 46 away from the sliding surface 42a of the fixing part 42 in the +Z axis direction, and move the pad (pressing member) 74 away from the guide surface 62a of the plate-shaped member 62 of the base 52 in the +Z axis direction. The control unit 30 also controls the fourth drive source 54 to move the plate-shaped member 62 and the guide 64 of the base 52 from the second position (see Figures 6-8) to the first position (see Figures 3-5). The control unit 30 also controls the second-first drive source 17a to move the cutter 16 and the receiving part 16a in the Z axis direction, and further in the X axis direction as needed. The timing of the Z-axis movement of the cutter 16 and the receiving portion 16a is preferably performed simultaneously with the movement of the plate-shaped member 62 and the guide 64. For this reason, the manufacturing apparatus 10 for the wound body 110 is arranged as shown in Figure 3.

[0090] As described above, once step S21, in which the corrugated sheet roll of the corrugated sheet supply unit 28 is replaced, the control unit 30 determines whether or not the corrugated sheet roll has been replaced (step S22). If the corrugated sheet roll has been replaced (step S22-Yes), the control unit 30 determines whether or not there is any flat sheet 120 remaining on the flat sheet roll 82 (step S80). If there is any flat sheet 120 remaining on the flat sheet roll 82 (step S80-Yes), the process returns to step S10. If there is no flat sheet 120 remaining on the flat sheet roll 82 (step S80-No), the control unit 30 terminates the manufacturing process of the wound body 110. If the corrugated sheet roll has not been replaced (step S22-No), the control unit 30 terminates the manufacturing process of the wound body 110.

[0091] Furthermore, even if step S22-No is processed earlier in time than step S70, which transports the wound body 110, the control unit 30 will not terminate the manufacturing process of the wound body 110 midway through, but will transport the wound body 110 to a predetermined location, for example.

[0092] The manufacturing apparatus 10 for the wound bodies 110 repeats the manufacturing of wound bodies 110 in this manner, thereby obtaining a large number of wound bodies 110.

[0093] Therefore, the control unit 30 controls the fourth drive source (actuator) 54 to position the guide surface 62a at a first position that maintains the surface obtained by virtually extending the XY plane of the guide surface 62a in the downstream +X axis direction from the beginning to the end of winding the flat plate (foil material) 120 by the winding core 14, so that it intersects with the winding core 14. Subsequently, after winding the winding body 110 is completed, the control unit 30 controls the adjustment unit 20 to press the flat plate (foil material) 120 so that it can be supplied toward the guide 64, and then controls the fourth drive source (actuator) 54 to move the guide surface 62a in the -Z axis direction, thereby moving the guide surface 62a to a second position where the surface obtained by virtually extending the XY plane of the guide surface 62a in the downstream +X axis direction contacts the winding body 110, and thereby applying tension to the flat plate (foil material) 120. The control unit then controls the cutter 16 while tension is applied to the flat plate (foil material) 120, causing the cutter 16 to cut the flat plate (foil material) 120 between the guide 64 and the winding body 110.

[0094] The pad 74 of the flat plate holder 24 is positioned on the guide surface 62a near the downstream end 62b along the +X axis, and on the +Z axis side relative to the guide surface 62a. In this case, the flat plate 120 can be prevented from moving within a narrower area between the position of the pad 74 of the flat plate holder 24 that is closest to the +X axis and the winding body 110. The cutter 16 is positioned downstream of the area where the pad (holding member) 74 presses the flat plate (foil material) 120 against the guide surface 62a, on the +X axis side. Therefore, the flat plate 120 can be stretched appropriately and easily cut along the Y axis using the cutter 16.

[0095] In this case, if a circular blade movable in the Y-axis direction is used as the cutter 16, the Y-axis direction, which is the direction of movement of the cutter 16, and the X-axis direction, which is the extension direction of the flat plate 120, are perpendicular to each other. Therefore, the flat plate 120 can be cut more easily with a cutter 16 that has a blade that moves in the Y-axis direction.

[0096] In this case, if a so-called guillotine cutter having a blade extending in the Y-axis direction is used as the cutter 16, the Z-axis direction, which is the direction of movement of the cutter 16, and the X-axis direction, which is the direction of extension of the flat plate 120, are perpendicular to each other.

[0097] In the adjustment section 20, when the center of the flat plate 120 in the width direction is pressed, the center of the flat plate 120 in the width direction is pulled the most, and less tension is applied to the end faces of the flat plate 120 in the width direction. If the flat plate 120 is cut with the cutter 16 in this state, the end faces of the flat plate 120 may warp into a roughly C-shape or a shape resembling part of an arc. On the other hand, in this embodiment, the pad 74 of the flat plate presser 24 presses the entire width of the flat plate 120 against the guide surface 62a. Therefore, when the flat plate 120 is cut with the cutter 16, it is possible to prevent the end faces of the flat plate 120 from warping into a roughly C-shape or a shape resembling part of an arc.

[0098] As mentioned above, the adjustment unit 20 may also press down on the entire width of the flat plate 120.

[0099] Therefore, according to this embodiment, after creating a wound body 110 by winding a supplied foil material (for example, a flat plate 120 and a corrugated plate 130), when the supplied foil material (flat plate 120) is cut to separate the wound body 110 from the foil material (flat plate 120), it is possible to provide a manufacturing apparatus 10 for a wound body 110 that is less likely to cause bending in the foil material (flat plate 120) and can cut the foil material (flat plate 120) at a desired position.

[0100] In this embodiment, an example was described in which a flat plate 120 and a corrugated plate 130 are wound as the wound body 110. For example, even when the flat plate 120 is cut to a predetermined length or a desired length, the manufacturing apparatus 10 for the wound body 110 according to this embodiment can be used.

[0101] The adjustment section 20 is made of a material that has sliding properties relative to the flat plate (foil material) 120 when the flat plate (foil material) 120 is pressed against it, and that can supply the flat plate (foil material) 120 to the winding body 110. Therefore, the adjustment section 20 adjusts the sliding properties when the flat plate 120 moves in the X-axis direction. Thus, when the winding body 110 is not moving, the adjustment section 20, which can adjust the supply amount of the flat plate (foil material) 120, can prevent excessive tension from being applied to the flat plate 120 and maintain the tension applied to the flat plate 120 at an appropriate level. Furthermore, since the adjustment section 20 can adjust the supply amount of the flat plate (foil material) 120, additional tension may be applied to the flat plate (foil material) 120 due to the rotation of the winding core 14.

[0102] In the example shown in Figure 11 above, the case where α1 - α0 > γ0 - γ1 was described. That is, at the end of winding the flat plate (foil material) by the winding core 14, the distance from the adjustment part 20 through the guide 64 and the guide surface 62a to the outermost position in the -Z axis direction of the winding body 110 at the first position is formed to be shorter than the distance from the adjustment part 20 through the guide 64 and the guide surface 62a to the outermost position in the -Z axis direction of the winding body 110 at the second position.

[0103] For example, it is possible that α1 - α0 ≤ γ0 - γ1. In this case, the flat plate 120 will bend between the guide 64 and the winding body 110. Therefore, when α1 - α0 ≤ γ0 - γ1, it becomes more difficult to cut the flat plate 120 with the cutter 16 compared to when α1 - α0 > γ0 - γ1. Alternatively, when α1 - α0 ≤ γ0 - γ1, it is necessary to unwind the flat plate roll 82 in order to tension the flat plate 120. For this reason, it is preferable to design the manufacturing apparatus 10 for the winding body 110 such that α1 - α0 > γ0 - γ1.

[0104] Furthermore, in this embodiment, an example was described in which the flat plate 120 is pressed against the guide surface 62a using the pad 74 of the flat plate holder 24. If appropriate tension is applied to the flat plate 120, it may not be necessary to press the flat plate 120 against the guide surface 62a using the pad 74 of the flat plate holder 24. Alternatively, for example, the flat plate 120 may be cut with the cutter 16 while restricting the movement of the flat plate 120 in the X-axis and Z-axis directions using the receiving portion 16a.

[0105] In this embodiment, the corrugated sheet 130 supplied from the corrugated sheet supply unit 28 is described as being pulled out by the rotation of the winding core 14 while overlapping with the flat sheet 120 to form the wound body 110. For example, the corrugated sheet roll of the corrugated sheet supply unit 28 may be actively moved using a seventh drive source controlled by the control unit 30 to supply the corrugated sheet 130 so as to overlap with the flat sheet 120.

[0106] In this embodiment, the amount of movement of the guide surface 62a when moving it from the first position to the second position, and the amount of movement when moving it from the second position to the first position, were described as being the same amount as the assumed radius r of the winding body 110. However, the amount of movement of the guide surface 62a when moving it from the first position to the second position, and the amount of movement when moving it from the second position to the first position, do not have to be the same amount as the assumed radius r of the winding body 110. Such a amount of movement may be larger or smaller than the assumed radius r of the winding body 110. However, it is preferable that the amount of movement be 1 / 2 times or more and 3 / 2 times or less of the assumed radius r of the winding body 110.

[0107] It should be noted that the present invention is not limited to the embodiments described above, and can be modified in various ways during implementation without departing from its essence. Furthermore, each embodiment may be combined as appropriate, and in that case, the combined effects can be obtained. Moreover, the above embodiments include various inventions, and various inventions can be extracted by selecting combinations from the multiple constituent elements disclosed. For example, if the problem can be solved and effects obtained even if some constituent elements are deleted from all the constituent elements shown in the embodiment, then the configuration with these deleted constituent elements can be extracted as an invention.

Claims

1. A winding core that extends in the Y-axis direction when defining an XYZ Cartesian coordinate system, is rotatable around its axis at that position, and is capable of winding the supplied foil material as a winding body; an adjustment unit that is spaced apart from the winding core in the upstream -X-axis direction and is capable of adjusting the amount of the foil material supplied downstream in the +X-axis direction toward the winding core; a base provided between the winding core and the adjustment unit, having a guide surface that follows the XY plane in the +Z-axis direction and guides the foil material from the adjustment unit side toward the winding core side, and a guide that can adjust the foil material supplied downstream in the +X-axis direction through the adjustment unit to contact the guide surface according to the Z-axis position of the guide surface; an actuator provided on the base that moves the guide surface and the guide together in a direction along the ±Z-axis direction; a cutter provided between the guide on the base and the winding core and capable of cutting the foil material wound in the winding body; and a control unit that controls the movement of the winding core, the adjustment unit, the actuator and the cutter, wherein the control unit is An apparatus for manufacturing a winding body, comprising: controlling the actuator to position the guide surface at a first position such that, from the start to the end of winding the foil material on the winding core, the surface obtained by virtually extending the XY plane of the guide surface in the downstream +X axis direction intersects the winding core or is brought within a predetermined distance range from the winding core in the Z axis direction; controlling the adjustment unit after winding the winding body is completed to press the foil material in the adjustment unit so that the foil material can be supplied toward the guide, then controlling the actuator to move the guide surface in the -Z axis direction to a second position such that the surface obtained by virtually extending the XY plane of the guide surface in the downstream +X axis direction is in contact with the winding body or is in a nearby position, thereby applying tension to the foil material; and controlling the cutter while the tension is applied to cut the foil material between the guide and the winding body with the cutter.

2. The apparatus for manufacturing a wound body according to claim 1, wherein, at the end of winding the foil material by the winding core, the distance from the adjustment portion through the guide and the guide surface to the outermost -Z-axis position of the wound body at the first position is shorter than the distance from the adjustment portion through the guide and the guide surface to the outermost -Z-axis position of the wound body at the second position.

3. The manufacturing apparatus according to claim 1 or 2, wherein the adjustment section is formed of a material that has sliding properties relative to the foil material when tension is applied to the foil material and that can supply the foil material to the winding body.

4. The manufacturing apparatus according to any one of claims 1 to 3, wherein the control unit controls a pressing member to be able to move closer to and away from the guide surface in the Z-axis direction and to be able to press the foil material against the guide surface, and the cutter is provided in the +X-axis direction downstream of the region in which the pressing member presses the foil material against the guide surface.

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