Film-winding device, film manufacturing device, control method, and program

Abstract

Provided is a film-winding device with which it is possible to suppress slippage of a film on a feed roll. A winding shaft rotates to wind the film. The feed roll rotates to convey the film to the winding shaft, and is provided with a suction mechanism for suctioning the film. A slippage amount estimation unit estimates the amount of slippage of the film on the surface of the feed roll on the basis of at least one measurement parameter, which is a parameter that can be measured with respect to the conveyance of the film. A suction control unit performs a process for dynamically controlling the suction force in the suction mechanism on the basis of the estimated amount of slippage.

Description

Film winding device, film manufacturing device, control method and program

[0001] This disclosure relates to a film winding device, a film manufacturing device, a control method, and a program.

[0002] A technique for winding film is known. In relation to this technique, Patent Document 1 discloses a winding machine for sheet-like materials that winds the sheet-like material onto a winding core while pressing it with a pressing roll. The winding machine according to Patent Document 1 includes a pressing force generating means that applies elastic pressing force to the pressing roll via a bearing means in order to generate pressing force on the pressing roll. Furthermore, the winding machine according to Patent Document 1 includes a control means that controls the elastic pressing force of the pressing force generating means so that the pressing force of the pressing roll becomes a preset pressing force.

[0003] Japanese Patent Publication No. 2002-316752

[0004] The technology described in Patent Document 1 does not take into consideration the slippage of the film in the feed roll that supplies the film to the core. Therefore, with the technology described in Patent Document 1, it is difficult to suppress film slippage even in situations where film slippage occurs on the surface of the feed roll.

[0005] This disclosure is made to solve these problems and aims to provide a film winding device, a film manufacturing device, a control method, and a program that can suppress film slippage in the feed roll.

[0006] The film winding device according to this disclosure comprises a winding shaft that winds a film by rotating, a feed roll equipped with a suction mechanism that conveys the film to the winding shaft by rotating and sucks the film, and a control device, the control device comprising a slip amount estimation unit that estimates the amount of film slip on the surface of the feed roll based on at least one measurement parameter which is a measurable parameter with respect to the conveyance of the film, and a suction control unit that performs processing for dynamically controlling the suction force in the suction mechanism based on the estimated slip amount.

[0007] The film manufacturing apparatus described herein is a film manufacturing apparatus that uses a film winding device.

[0008] The control method according to this disclosure estimates the amount of film slip on the surface of the feed roll based on at least one measurement parameter which is a parameter measured in relation to the transport of film by a film winding device having a winding shaft that winds up the film by rotating and a feed roll equipped with a suction mechanism that transports the film to the winding shaft by rotating and sucks up the film, and performs processing to dynamically control the suction force in the suction mechanism based on the estimated amount of slip.

[0009] The program according to this disclosure causes a computer to perform the following steps: estimate the amount of film slip on the surface of a feed roll based on at least one measurement parameter which is a parameter measured in relation to the transport of a film by a film winding device having a winding shaft that winds up a film by rotating, and a feed roll equipped with a suction mechanism that transports the film to the winding shaft by rotating and sucks up the film; and perform processing to dynamically control the suction force in the suction mechanism based on the estimated amount of slip.

[0010] According to this disclosure, a film winding device, a film manufacturing device, a control method, and a program capable of suppressing film slippage in the feed roll can be provided.

[0011] This is a diagram showing the configuration of a film manufacturing apparatus according to Embodiment 1. This is a diagram showing the schematic configuration of a film winding device according to Embodiment 1. This is a diagram illustrating the details of a film winding device according to Embodiment 1. This is a diagram illustrating the configuration of a suction mechanism provided on a feed roll according to Embodiment 1. This is a diagram showing the configuration of a control device according to Embodiment 1. This is a diagram illustrating the method for calculating the winding diameter by the winding diameter calculation unit according to Embodiment 1. This is a diagram illustrating the processing of the tension control unit according to Embodiment 1. This is a diagram illustrating the processing of the slip amount estimation unit according to Embodiment 1. This is a flowchart illustrating the operation of a film winding device according to Embodiment 1. This is a diagram showing the configuration of a control device according to Embodiment 2. This is a diagram illustrating the method for measuring the slip amount according to Embodiment 2. This is a diagram illustrating a database stored in a database storage unit according to Embodiment 2. This is a flowchart illustrating the operation of a film winding device according to Embodiment 2. This is a diagram illustrating a modified example of Embodiment 2.

[0012] (Embodiment 1) Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. For clarity of explanation, the following descriptions and drawings have been omitted and simplified as appropriate. In each drawing, the same elements are denoted by the same reference numerals, and redundant explanations have been omitted as necessary. In addition, hatching has been omitted in some parts of the drawings to avoid clutter.

[0013] In the following embodiments, when necessary for convenience, the description will be divided into multiple sections or embodiments. Unless otherwise specified, these are not unrelated, and one may be a modification, application, detailed explanation, or supplementary explanation of part or all of the other. Furthermore, in the following embodiments, when referring to the number of elements (including number, numerical value, quantity, range, etc.), unless otherwise specified or clearly limited to a specific number in principle, it is not limited to that specific number, and may be greater than or less than that number.

[0014] Furthermore, in the following embodiments, the components (including operation steps, etc.) are not necessarily essential unless specifically stated or considered to be clearly essential in principle. Similarly, in the following embodiments, when referring to the shape, positional relationship, etc. of the components, etc., it shall include those that substantially approximate or resemble the shape, etc., unless specifically stated or considered to be not in principle. The same applies to the numbers, etc. (including the number of items, numerical values, quantities, ranges, etc.).

[0015] <Configuration of Film Manufacturing Apparatus> Figure 1 shows the configuration of the film manufacturing apparatus 1 according to Embodiment 1. The film manufacturing apparatus 1 according to Embodiment 1 produces a sheet-like film by molding a thermoplastic resin such as BOPP (Biaxially Oriented Polypropylene). The resin may be, for example, PET (Polyethylene Terephthalate). The film manufacturing apparatus 1 includes an extruder 2, a cast molding machine 4, a longitudinal stretcher 6, a transverse stretcher 8, and a film winding device 10. The film winding device 10 can function as a winding machine.

[0016] The extruder 2 melts and plasticizes a resin such as polypropylene resin. Next, the casting machine 4 cools the molten and plasticized resin with a cooling roll and forms it into a sheet. After that, the longitudinal stretcher 6 stretches the sheet (resin film) in the resin transport direction (film transport direction; MD). The transverse stretcher 8 stretches the sheet (resin film) in the width direction (film width direction; TD). As a result, the sheet is formed into a film 90 with a thickness of about 20 μm. The film winding device 10 then winds up the formed film 90. The transverse stretcher 8 may also have a heat treatment machine for heating the transported resin film. Note that the longitudinal stretcher 6 and transverse stretcher 8 are not required in the film manufacturing apparatus 1.

[0017] <Configuration of the film winding device> Figure 2 is a diagram showing the schematic configuration of the film winding device 10 according to Embodiment 1. The film winding device 10 includes a feed roll 20, a feed motor 22, a winding shaft 50, a winding motor 52, and a control device 100. Hereafter, unless otherwise specified, "upstream" means upstream in the film transport direction (the direction of MD in Figure 1 and the direction indicated by arrow A3 in Figure 2), and "downstream" means downstream in the film transport direction.

[0018] The feed roll 20 transports the film 90, which has been conveyed from the preceding process of the film winding device 10, toward the winding shaft 50. The feed motor 22 rotates the feed roll 20. Driven by the feed motor 22, the feed roll 20 rotates in the direction indicated by arrow A1. As a result, the feed roll 20 feeds out the film 90 in the direction indicated by arrow A3.

[0019] Furthermore, the feed roll 20 has at least one suction mechanism 30. The suction mechanism 30 is configured to suck the film 90 onto the surface 20a of the feed roll 20. Thus, the feed roll 20 functions as a suction roll. Details of the suction mechanism 30 will be described later.

[0020] The winding shaft 50 winds up the film 90 that has been conveyed by the feed roll 20. The winding motor 52 rotates the winding shaft 50. The winding shaft 50 rotates in the direction indicated by arrow A2, driven by the winding motor 52. As a result, the winding shaft 50 winds up the film 90. As a result, a wound film 92, which is the film 90 wound up on the winding shaft 50, is formed around the winding shaft 50.

[0021] The control device 100 can be implemented, for example, by a computer. Note that the control device 100 does not need to consist of a single physical device. The control device 100 controls the operation of the film winding device 10. The control device 100 may also control the operation of, for example, the feed motor 22 or the winding motor 52. The control device 100 estimates the amount of slip S of the film 90 on the surface 20a of the feed roll 20 based on at least one measurement parameter, which is a measurable parameter related to the transport of the film 90. Furthermore, the control device 100 performs processing to dynamically control the suction force in the suction mechanism 30 based on the estimated amount of slip S. More details will be described later.

[0022] Figure 3 is a diagram illustrating the details of the film winding device 10 according to Embodiment 1. As described above, the film winding device 10 includes a feed roll 20, a feed motor 22, a winding shaft 50, a winding motor 52, and a control device 100. The film winding device 10 also includes a guide roll 12, a tension detector 14, a feed roll 16, a feed motor 16a, a nip roll 18, a nip roll 40, a tension detector 44, a near roll 60, and a sensor 70.

[0023] The feed roll 16 is located upstream of the feed roll 20. The nip roll 18 is located near the feed roll 16. The tension detector 14 is located upstream of the feed roll 16. The guide roll 12 is located upstream of the tension detector 14. The nip roll 40 is located near the feed roll 20. The tension detector 44 is located downstream of the feed roll 20, between the feed roll 20 and the winding shaft 50. The near roll 60 is located near the winding shaft 50.

[0024] The guide roll 12 guides the film 90 that has been transported from the preceding process of the film winding device 10, as indicated by arrow F. The tension detector 14 detects the tension applied to the film 90 as it is transported between the guide roll 12 and the feed roll 16. In other words, the tension detector 14 detects the tension of the film 90 upstream of the feed roll 16 and the feed roll 20 as a measurement parameter. The tension detector 14 may have a roll-shaped structure in which a load cell is built into the bearing portion, for example.

[0025] The feed roll 16 transports the film 90 that has passed through the guide roll 12 to the downstream feed roll 20. The feed roll 16 is driven by the feed motor 16a. The feed roll 16 rotates in the direction indicated by arrow B1, driven by the feed motor 16a. The nip roll 18, together with the feed roll 16, grips the film 90 being transported by the feed roll 16. In other words, the film 90 is transported while being gripped by the feed roll 16 and the nip roll 18. The nip roll 18 rotates in accordance with the movement of the transported film 90. Furthermore, the gripping of the film 90 between the feed roll 16 and the nip roll 18 causes a tension cut at this point. In other words, the tension of the film 90 differs between the upstream and downstream sides of the position where it is gripped by the feed roll 16 and the nip roll 18 (nip position).

[0026] Furthermore, the feed roll 20 is driven by the feed motor 22 and rotates in the direction indicated by arrow B2. The nip roll 40, together with the feed roll 20, grips the film 90 being conveyed by the feed roll 20. In other words, the film 90 conveyed by the feed roll 16 is conveyed while being gripped by the feed roll 20 and the nip roll 40. The nip roll 40 rotates in accordance with the movement of the conveyed film 90. This means that the tension of the film 90 will be different on the upstream and downstream sides of the position where it is gripped by the feed roll 20 and the nip roll 40 (nip position).

[0027] The tension detector 44 detects the tension applied to the film 90 as it is transported between the feed roll 20 and the winding shaft 50. In other words, the tension detector 44 detects the tension of the film 90 downstream of the feed roll 16 and the feed roll 20 as a measurement parameter. The tension detector 44 may have a roll-shaped structure in which a load cell is built into the bearing portion, for example.

[0028] The winding shaft 50 is driven by the winding motor 52 and rotates in the direction indicated by arrow B3. This causes the winding shaft 50 to wind up the film 90, forming a wound film 92 around the winding shaft 50. The near roll 60 presses the winding film 90 toward the winding shaft 50. This prevents air from being drawn in when the film 90 is wound up by the winding shaft 50.

[0029] The sensor 70 detects one or more measurement parameters. The sensor 70 can be installed at various locations inside and outside the film winding device 10 and detect various conditions. The sensor 70 may include, for example, a temperature sensor, humidity sensor, torque sensor, pressure sensor, acceleration sensor, photoelectric sensor, laser sensor, displacement sensor, ultrasonic sensor, image sensor, Doppler sensor, or encoder. The sensor 70 may detect measurement parameters related to the environment inside and near the film winding device 10 (e.g., temperature and humidity). The sensor 70 may also detect the transport speed of the film 90 as a measurement parameter. The sensor 70 may also detect the torque applied to the feed roll 16, feed roll 20 and winding shaft 50 as measurement parameters. The sensor 70 may also detect the rotation speed and rotation angle of the feed roll 16 as measurement parameters. The sensor 70 may also detect the rotation speed and rotation angle of the feed roll 20 as measurement parameters. Furthermore, the sensor 70 may detect the rotational speed and rotational angle of the winding shaft 50 as measurement parameters. The rotational speed and rotational angle of the feed roll 20 may be detected by the feed motor 22. Similarly, the rotational speed and rotational angle of the winding shaft 50 may be detected by the winding motor 52. In addition, the rotational speed and rotational angle of the feed roll 16 may be detected by the feed motor 16a.

[0030] Further, the film winding device 10 has a width detector 72. The width detector 72 is provided upstream of the feed roll 20. The width detector 72 may be provided, for example, between the feed roll 20 and the feed roll 16. The width detector 72 detects the film width, which is the width of the film 90 being conveyed, as a detection parameter. For example, the width detector 72 may be composed of a laser irradiator installed on one side of the conveyed film 90 and a laser receiver installed so as to face the laser irradiator on the other side of the film 90. In this case, in the range where the film 90 exists between the laser irradiator and the laser receiver, the laser receiver cannot receive the laser irradiated from the laser irradiator. On the other hand, in the range where the film 90 does not exist between the laser irradiator and the laser receiver, the laser receiver can receive the laser irradiated from the laser irradiator. Then, the width detector 72 detects the range where the laser receiver cannot receive the laser irradiated from the laser irradiator as the film width.

[0031] The control device 100 controls the operation of the film winding device 10 using the measurement parameters detected by the tension detectors 14, 44, the sensor 70, the width detector 72, etc. The control device 100 may control, for example, the operations of the feed motor 16a, the feed motor 22, and the winding motor 52. Further, the control device 100 may control the operation of the suction mechanism 30 of the feed roll 20. The control device 100 is communicably connected to the tension detectors 14, 44, the sensor 70, the width detector 72, the feed motor 16a, the feed motor 22, and the winding motor 52 by wire or wirelessly.

[0032] <Configuration of the suction mechanism> FIG. 4 is a diagram illustrating the configuration of the suction mechanism 30 provided on the feed roll 20 according to the first embodiment. The left diagram of FIG. 4 shows a cross section in a plane perpendicular to the rotation axis of the feed roll 20. The right diagram of FIG. 4 shows a state in which the curved surface 20a of the feed roll 20 is developed into a plane.

[0033] The suction mechanism 30 includes a suction portion 32, an opening portion 34, an opening / closing portion 36, and a drive portion 38. Further, the feed roll 20 has an outer cylinder portion 24 provided outside the suction mechanism 30. The outer cylinder portion 24 is configured to be rotatable by a feed motor 22. That is, when the outer cylinder portion 24 rotates by the feed motor 22, the feed roll 20 rotates. On the other hand, the suction mechanism 30 provided inside the outer cylinder portion 24 in the feed roll 20 does not necessarily have to rotate. Therefore, "the feed roll 20 rotates" may mean that the outer cylinder portion 24 rotates. A number of holes are provided in the outer cylinder portion 24 so as to enable communication between the suction mechanism 30 and the surface 20a of the feed roll 20. The outer cylinder portion 24 may be formed in a porous mesh shape. By the suction mechanism 30 performing suction on the surface 20a of the feed roll 20 through a number of holes provided in the outer cylinder portion 24, the film 90 can be adsorbed to the outer cylinder portion 24 (the surface 20a of the feed roll 20).

[0034] The suction portion 32 may be provided inside the feed roll 20 so as to extend in the axial direction. The suction portion 32 has a hollow structure. The suction portion 32 may have a piping structure. The inside of the suction portion 32 is depressurized so that the pressure is lower than the atmospheric pressure. Therefore, the suction portion 32 functions as a decompression chamber. Note that the inside of the suction portion 32 is depressurized by a suction device such as a vacuum pump, for example. Also, a number of holes for communicating the inside of the suction portion 32 with the opening portion 34 are provided on the surface of the suction portion 32.

[0035] The opening portion 34 may be provided on the downstream side of the nip position of the feed roll 20. The opening portion 34 communicates the inside of the suction portion 32 with the surface 20a of the feed roll 20 via the outer cylinder portion 24. Thereby, the film 90 contacting the surface 20a of the feed roll 20 is sucked by the suction portion 32 through the opening portion 34. Therefore, the suction mechanism 30 is configured to suck the film 90 through the opening portion 34.

[0036] The opening / closing section 36 is configured to adjust the opening area A, which is the area of ​​the opening 34 on the surface 20a of the feed roll 20. Specifically, the opening / closing section 36 may adjust the opening length L and the opening width W. Here, A = W × L. The opening length L corresponds to the length of the opening 34 in the circumferential direction. The opening width W corresponds to the length of the opening 34 in the width direction. Therefore, the opening 34 is configured such that the area on the surface 20a of the feed roll 20 is variable by the opening / closing section 36. In addition, the suction mechanism 30 is configured such that the length of the opening 34 in the circumferential direction and the length of the opening 34 in the width direction are variable. Here, "length in the circumferential direction" corresponds to the length of the feed roll 20 in the circumferential direction. "Circumferential direction" corresponds to the direction of rotation around the rotation axis of the feed roll 20. Also, "length in the width direction" corresponds to the length of the feed roll 20 in the width direction. "Width direction" corresponds to the direction along the rotation axis of the feed roll 20. The opening / closing section 36 may be, for example, a shutter. The opening / closing section 36 may be provided, for example, between the outer cylinder section 24 and the suction section 32.

[0037] The opening / closing section 36 is configured to be openable and closable by a drive unit 38, which will be described later. When the opening / closing section 36 moves in the direction of opening in the circumferential direction, the opening length L of the opening 34 increases. On the other hand, when the opening / closing section 36 moves in the direction of closing in the circumferential direction, the opening length L of the opening 34 decreases. Also, when the opening / closing section 36 moves in the direction of opening in the width direction, the opening width W of the opening 34 increases. On the other hand, when the opening / closing section 36 moves in the direction of closing in the width direction, the opening width W of the opening 34 decreases. In this way, the opening / closing section 36 adjusts the opening area A.

[0038] The drive unit 38 drives the opening / closing section 36. The drive unit 38 drives the opening / closing section 36 to open or close in the circumferential direction under the control of the control device 100. The drive unit 38 also drives the opening / closing section 36 to open or close in the width direction under the control of the control device 100. The drive unit 38 may be, for example, a motor. Note that if the opening area A is large, the suction force of the suction mechanism 30 may be large. On the other hand, if the opening area A is small, the suction force of the suction mechanism 30 may be small. The drive unit 38 may also perform control to adjust the suction pressure (degree of depressurization) in the suction section 32. For example, the drive unit 38 may operate a pressure regulating valve that controls the suction pressure in the suction section 32. Note that the suction force F of the suction mechanism 30 on the surface 20a of the feed roll 20 is expressed by the following equation (1). Note that Ps represents the suction pressure. Furthermore, c is a predetermined constant (proportionality constant), which can be determined, for example, by the diameter and density of the holes provided in the outer cylinder portion 24, and the thickness of the outer cylinder portion 24. Therefore, the suction force F in the suction mechanism 30 is controlled by the operation of the drive unit 38. F = c × Ps × A = c × Ps × W × L ... (1)

[0039] In the above example, the outer cylinder portion 24 of the feed roll 20 rotates, and the suction mechanism 30 provided inside the outer cylinder portion 24 does not rotate. However, the configuration is not limited to this. The entire feed roll 20, including the suction mechanism 30, may be configured to rotate. In this case, the outer cylinder portion 24 may not be provided. Also in this case, the opening / closing portion 36 may be provided on the surface 20a of the feed roll 20. Also in this case, the suction mechanism 30 may be provided at multiple locations on the feed roll 20. In other words, the suction mechanism 30 may be capable of sucking the film 90 at multiple locations on the surface 20a of the feed roll 20. To put it another way, the surface 20a of the feed roll 20 may have multiple openings 34. By providing the suction mechanism 30 at multiple locations on the feed roll 20, the suction mechanism 30 rotates in conjunction with the rotation of the feed roll 20, and at all times, one of the suction mechanisms 30 is capable of sucking the film 90. Therefore, the suction mechanism 30 rotates in conjunction with the rotation of the feed roll 20, and is always able to suck up the film 90 that is in contact with the surface 20a of the feed roll 20. In this case, the number of locations where the suction mechanism 30 is provided can be appropriately determined according to the area on the surface 20a of the feed roll 20 that is in contact with the film 90. Specifically, as shown in Figure 3, if the film 90 is in contact with half of the surface 20a of the feed roll 20, the suction mechanism 30 can be provided at two locations symmetrical with respect to the rotation axis of the feed roll 20. If the film 90 is in contact with one-third of the surface 20a of the feed roll 20, the suction mechanism 30 can be provided at three locations symmetrical with respect to the rotation axis of the feed roll 20. Note that if two or more suction mechanisms 30 are provided, the suction section 32 may be common to all of the multiple suction mechanisms 30.

[0040] <Configuration of the control device> Figure 5 shows the configuration of the control device 100 according to Embodiment 1. The control device 100 has as its main hardware components a control unit 102, a storage unit 104, a communication unit 106, and an interface unit 108 (IF; Interface). The control unit 102, storage unit 104, communication unit 106, and interface unit 108 are interconnected via a data bus or the like.

[0041] The control unit 102 is a processor, such as a CPU (Central Processing Unit). The control unit 102 has the function of an arithmetic unit that performs control processing and arithmetic processing. The control unit 102 may have multiple processors. The storage unit 104 is a storage device, such as a memory or a hard disk. The storage unit 104 is, for example, a ROM (Read Only Memory) or RAM (Random Access Memory). The storage unit 104 has the function of storing control programs and arithmetic programs executed by the control unit 102. In other words, the storage unit 104, which is a memory, stores one or more instructions. The storage unit 104 also has the function of temporarily storing processing data. The storage unit 104 may include a database. The storage unit 104 may also have multiple memories.

[0042] The communication unit 106 performs the necessary processing for the control device 100 to communicate with other devices via a network. The communication unit 106 may include a communication port, router, firewall, etc. The interface unit 108 is, for example, a user interface (UI). The interface unit 108 has an input device such as a keyboard, touch panel, or mouse, and an output device such as a display or speaker. The interface unit 108 may be configured such that the input device and the output device are integrated, for example, a touchscreen or touch panel. The interface unit 108 accepts data input operations from a user such as an operator or worker, and outputs information to the user.

[0043] Furthermore, the control device 100 according to Embodiment 1 includes, as its components, a target tension receiving unit 110, a measurement parameter acquisition unit 112, a slip amount estimation unit 120, a suction control unit 130, a winding diameter calculation unit 150, and a tension control unit 160. The slip amount estimation unit 120 also includes a detected tension acquisition unit 122, an ideal model storage unit 124, an ideal tension acquisition unit 126, and an estimated slip amount calculation unit 128. The control device 100 uses these components to control the suction mechanism 30 and perform processing to control the tension applied to the film 90.

[0044] As mentioned above, the control device 100 does not need to be composed of a single physical device. In this case, each of the above-mentioned components may be realized by multiple physically separate devices. This is also true in other embodiments described later.

[0045] Each of the above-described components can be realized, for example, by executing a program under the control of the control unit 102. More specifically, each component can be realized by the control unit 102 executing a program (instruction) stored in the memory unit 104. Alternatively, each component can be realized by recording the necessary program on any non-volatile recording medium and installing it as needed. Furthermore, each component is not limited to being realized by software programs, but may also be realized by any combination of hardware, firmware, and software. In addition, each component may be realized using a user-programmable integrated circuit, such as an FPGA (field-programmable gate array) or a microcontroller. In this case, the program composed of the above-described components may be realized using this integrated circuit. These points are also true in other embodiments described later.

[0046] The target tension receiving unit 110 receives the target tension of the film 90. The target tension receiving unit 110 receives the target tension, which is the target value of the tension applied to the film 90 as it is transported between the feed roll 20 and the winding shaft 50. The target tension receiving unit 110 may receive the target tension input by, for example, a user operation to the interface unit 108. Alternatively, the target tension receiving unit 110 may receive the target tension from another device (such as a user terminal) via the communication unit 106. The target tension can be set appropriately depending on the film 90 being manufactured.

[0047] The measurement parameter acquisition unit 112 acquires the measurement parameters described above. For example, the measurement parameter acquisition unit 112 may acquire the detected tension, which is the tension detected by the tension detector 44, as a measurement parameter. Alternatively, for example, the measurement parameter acquisition unit 112 may acquire the measurement parameters detected by the sensor 70. Alternatively, for example, the measurement parameter acquisition unit 112 may acquire the rotation speed and rotation angle of the feed roll 20, detected by the sensor 70 or the feed motor 22, as measurement parameters. Alternatively, for example, the measurement parameter acquisition unit 112 may acquire the rotation speed and rotation angle of the winding shaft 50, detected by the sensor 70 or the winding motor 52, as measurement parameters. Alternatively, the measurement parameter acquisition unit 112 may acquire measurement parameters that will be input into the ideal model described later. Alternatively, the measurement parameter acquisition unit 112 may acquire the film width detected by the width detector 72 as a measurement parameter.

[0048] The slip amount estimation unit 120 estimates the slip amount S of the film 90 on the surface 20a of the feed roll 20 based on at least one measurement parameter. Details of the processing of the slip amount estimation unit 120 will be described later. In Embodiment 1, the slip amount estimation unit 120 estimates the slip amount S using the detected tension, which is the tension detected by the tension detector 44, as a measurement parameter. The detected tension acquisition unit 122 acquires the detected tension detected by the tension detector 44. The detected tension acquisition unit 122 may also acquire the detected tension acquired by the measurement parameter acquisition unit 112.

[0049] The ideal model storage unit 124 stores the ideal model. Here, the ideal model is a simulation model that simulates the operation of the film winding device 10. The ideal model is a model that can perform a simulation under the same operating conditions as the film winding device 10 in operation, such that no slippage of the film 90 occurs on the surface of the feed roll 20. The ideal model is configured to accept operating conditions as input and output the ideal tension under those conditions. Here, the ideal tension is the tension applied to the film 90 being transported between the winding shaft 50 and the feed roll 20 in a situation where no slippage of the film 90 occurs on the surface of the feed roll 20. The operating conditions include the film tension and film transport speed immediately before the film winding device 10. The operating conditions can also be determined by, for example, the physical properties of the film 90 and the distance between the rolls (distance between the feed roll 20 and the winding shaft 50).

[0050] The ideal tension acquisition unit 126 acquires the ideal tension using an ideal model. Specifically, the ideal tension acquisition unit 126 performs a simulation using the ideal model and acquires the ideal tension output by the simulation. The estimated slip amount calculation unit 128 calculates the estimated slip amount S, which is the estimated slip amount S, based on the difference between the detected tension and the ideal tension obtained by the simulation using the ideal model, as will be described later.

[0051] The suction control unit 130 performs processing to dynamically control the suction force in the suction mechanism 30 based on the slip amount S estimated by the slip amount estimation unit 120. In other words, the suction control unit 130 performs dynamic suction control. The suction control unit 130 also performs processing to control the operation of the drive unit 38. The suction control unit 130 outputs a suction control instruction to the drive unit 38 indicating that the suction force should be controlled. Therefore, the suction control unit 130 functions as a suction control instruction output unit.

[0052] Specifically, the suction control unit 130 performs the following process to control the suction force F as shown in equation (2) below. In other words, the suction control unit 130 sets the suction force F in the suction mechanism 30 to the suction force F represented by the following equation (2): F = β × S ... (2)

[0053] Here, S represents the amount of slip, and β represents the proportionality constant. β is determined by factors such as the tension of the film 90, the frictional characteristics between the surface 20a of the feed roll 20 and the film 90, and the allowable value of mechanical loss generated in the feed roll 20. From equation (2), it can be seen that the larger the amount of slip, the greater the required suction force F. Therefore, the suction control unit 130 controls the system so that the suction force in the suction mechanism 30 increases as the estimated amount of slip increases.

[0054] Furthermore, the suction control unit 130 may control the drive unit 38 to control the opening area A. In other words, the suction control unit 130 may control the opening area A to increase as the estimated slip amount S increases, thereby increasing the suction force F. The slip amount can change dynamically depending on the surrounding environment, etc. Therefore, the suction control unit 130 may dynamically control the suction force in the suction mechanism 30 by dynamically controlling the opening area A, which is the area of ​​the opening 34. The suction control unit 130 may also dynamically control the suction force in the suction mechanism 30 by dynamically controlling at least one of the opening length L and the opening width W.

[0055] Furthermore, the suction control unit 130 may dynamically control the opening width W according to the film width detected by the width detector 72. Specifically, the suction control unit 130 outputs a suction control instruction to the drive unit 38 so that the opening width W becomes a length corresponding to the detected film width. As a result, the drive unit 38 operates the opening / closing unit 36 ​​in the width direction so that the opening width W is as indicated by the suction control instruction. The suction control unit 130 may also control the drive unit 38 so that the opening width W becomes longer as the detected film width increases. For example, the suction control unit 130 may output a suction control instruction to the drive unit 38 indicating that the opening width W should be the same length as the film width. Alternatively, the suction control unit 130 may output a suction control instruction to the drive unit 38 indicating that the opening width W should be longer than the film width by a predetermined length. Alternatively, the suction control unit 130 may output a suction control instruction to the drive unit 38 indicating that the opening width W should be shorter than the film width by a predetermined length. As a result, the film 90 is sucked up in a region corresponding to the film width on the surface 20a of the feed roll 20, making it possible to efficiently suck up the film 90. Furthermore, the film width can be dynamically varied depending on the condition of the film 90, etc. Therefore, with the above configuration, the opening width W can be dynamically controlled in accordance with the variation in film width. Moreover, the opening width W does not have to depend on the film width. As long as the amount of slip can be suppressed, the opening width W may be wider or narrower than the film width.

[0056] Furthermore, the suction control unit 130 controls the opening length L so that the suction force in the suction mechanism 30 becomes the suction force F represented by the above equation (2). Specifically, as shown in the above equation (1), the suction force F can be defined by the opening area A. The opening area A is defined by the opening width W and the opening length L. Here, as described above, the opening width W can be adjusted according to the film width. Therefore, the suction control unit 130 calculates the opening length L such that the suction force in the suction mechanism 30 becomes the suction force F represented by the above equation (2). The suction control unit 130 then outputs a suction control instruction to the drive unit 38 so that the opening length L becomes the calculated opening length L. As a result, the drive unit 38 operates the opening / closing unit 36 ​​in the circumferential direction so that the opening length L is the opening length L indicated by the suction control instruction.

[0057] The suction control unit 130 may also control the operation of the drive unit 38 to control the suction pressure P. In other words, the suction control unit 130 may control the system so that the suction pressure P decreases as the estimated slip amount S increases, thereby increasing the suction force F.

[0058] As described above, the suction control unit 130 is configured to dynamically control the suction force in the suction mechanism 30 based on the estimated slip amount S. As a result, the film 90 is drawn towards the feed roll 20 according to the estimated slip amount S. Therefore, with the above configuration, slip of the film 90 on the feed roll 20 can be suppressed. The slip amount S of the film 90 on the feed roll 20 may change from time to time due to the winding diameter of the film 90 on the winding shaft 50, and external disturbances such as humidity, temperature, or static electricity in the film winding device 10. The slip amount S changes dynamically due to the above factors.

[0059] Therefore, the film winding device 10 according to this embodiment is configured to estimate the amount of slip S and dynamically control the suction mechanism 30 according to the estimated amount of slip S. As a result, the film winding device 10 according to this embodiment is configured to suppress slip of the film 90 on the feed roll 20 by a suction force F corresponding to the dynamically estimated amount of slip S. Therefore, the film winding device 10 according to this embodiment can more appropriately suppress slip of the film 90 on the feed roll 20, regardless of the cause of the slip.

[0060] The winding diameter calculation unit 150 calculates the winding diameter D of the wound film 92, which is the film 90 wound on the winding shaft 50, based on the slip amount S estimated by the slip amount estimation unit 120. Ｗ Calculate the winding diameter D using Figure 6 below. Ｗ The calculation method will be explained.

[0061] <Method for Calculating Winding Diameter> Figure 6 shows the winding diameter D calculated by the winding diameter calculation unit 150 according to Embodiment 1. Ｗ This is a diagram illustrating the calculation method. When no slippage of the film 90 occurs on the surface of the feed roll 20, the winding diameter D Ｗ This can be expressed by the following equation (3). ... (3)

[0062] Here, t represents time. Also, D Ｗ (t) indicates the winding diameter at the time the winding diameter is calculated. Also, f(x) includes the diameter and angular velocity of the feed roll 20.

[0063] If no slippage of the film 90 occurs on the surface of the feed roll 20, the length of film 90 that the feed roll 20 has fed to the winding shaft 50 during one rotation of the winding shaft 50 is expressed by the following equation (4). ... (4)

[0064] On the other hand, when slip of the film 90 occurs on the surface of the feed roll 20, actually, the film 90 will not be wound around the take-up shaft 50 by the amount of the slip S. In other words, when slip of the film 90 occurs on the surface of the feed roll 20, the length of the film 90 wound around the take-up shaft 50 becomes shorter than the amount represented by the above formula (4). Therefore, when slip of the film 90 occurs on the surface of the feed roll 20, let the winding diameter be D Ｗ ’ and let the amount of slip generated be S, then the following formula (5) holds. ・・・(5)

[0065] Therefore, when slip of the film 90 occurs on the surface of the feed roll 20, the winding diameter D Ｗ ’ is expressed as in the following formula (6). The winding diameter calculation unit 150 calculates D Ｗ ’ as shown in formula (6). ・・・(6)

[0066] Here, as described above, the suction control unit 130 controls the suction force F in the suction mechanism 30 so as to suppress the occurrence of slip. Therefore, in the present embodiment, it is not necessary to consider the occurrence of the slip amount S as in the above formulas (5) and (6). Therefore, the winding diameter calculation unit 150 calculates D Ｗ as shown in formula (3). Thus, since the winding diameter calculation unit 150 can calculate the winding diameter D Ｗ without considering the slip amount S, the calculation accuracy of the winding diameter can be improved. Note that the diameter D ｆ of the feed roll 20 is predetermined. Also, θ ｆｐｖ can be calculated by detecting the rotation angle of the take-up shaft 50 and the rotation angle of the feed roll 20.

[0067] The tension control unit 160 is based on the winding diameter D calculated by the winding diameter calculation unit 150 ＷBased on this, processing is performed to control the tension applied to the film 90 being conveyed between the feed roll 20 and the winding shaft 50. Specifically, the tension control unit 160 controls the torque of the winding motor 52 so that the tension applied to the film 90 being conveyed between the feed roll 20 and the winding shaft 50 becomes the target tension received by the target tension receiving unit 110.

[0068] The tension control unit 160 calculates the torque value to be instructed to the winding motor 52 using a method described later with reference to Figure 7, and outputs a torque command to the winding motor 52. In this way, the tension control unit 160 controls the tension applied to the film 90 by controlling the winding motor 52. Since the tension control unit 160 controls the tension by outputting a torque command, which is a control signal, to the winding motor 52, it functions as a control signal output unit.

[0069] <Tension Control> Figure 7 is a diagram illustrating the processing of the tension control unit 160 according to Embodiment 1. The tension control unit 160 of the control device 100 calculates the torque command τ to be output to the winding motor 52. For example, the torque command τ is expressed as τ = T × r. Here, r is the radius of the winding film 92 wound on the winding shaft 50. The radius r is the winding diameter D Ｗ It is 1 / 2 of that. That is, r = D Ｗ It is / 2. In addition, it is also possible to calculate the command value from the difference between the target tension and the actual tension. Therefore, the tension control unit 160 sets the target tension T ０ And the winding diameter D calculated by the winding diameter calculation unit 150 Ｗ Using this, the torque command τ is calculated using the following equation (7): τ = T ０ ×D Ｗ / 2 ... (7)

[0070] The tension control unit 160 then outputs a control signal indicating the calculated torque command τ to the winding motor 52. Alternatively, the tension control unit 160 may transmit the control signal to a servo amplifier built into the winding motor 52. This brings the tension applied to the film 90 to the target tension T. ０ The torque of the winding motor 52 is controlled to achieve this.

[0071] As described above, the winding diameter of the film 90 wound on the winding shaft 50 is used to control the tension applied to the film 90. Therefore, if the accuracy of the calculated winding diameter is poor, the accuracy of the torque command value will also be poor, and tension control may become unstable. Furthermore, as mentioned above, the amount of slip of the film 90 affects the calculation of the winding diameter. In contrast, in this embodiment, as described above, the occurrence of slip of the film 90 is suppressed by sucking the film 90 with the suction mechanism 30. Therefore, the winding diameter can be calculated with high accuracy. Consequently, the control device 100 according to this disclosure can perform tension control stably.

[0072] <Method for Estimating Slip Amount> Figures 8 and 9 are diagrams illustrating the processing of the slip amount estimation unit 120 according to Embodiment 1. Figure 8 shows an example of film tension results obtained from an actual film winding device 10 in operation. Graph G1 illustrated in Figure 8 shows the time course of the detected tension T, which is detected by the tension detector 44 and obtained by the detected tension acquisition unit 122. As illustrated in Figure 8, even after some time has passed since the start of operation, the detected tension T fluctuates, as indicated by arrow E1. One possible cause of this fluctuation is that film 90 is slipping on the surface of the feed roll 20.

[0073] Figure 9 illustrates the film tension results obtained from the simulation. Graph G2 in Figure 9 shows the time course of the ideal tension T' obtained by the ideal tension acquisition unit 126 performing a simulation using the ideal model stored in the ideal model storage unit 124. The ideal tension acquisition unit 126 inputs data representing the same conditions as the actual machine into the ideal model and performs the simulation. This allows for obtaining the ideal tension T' when no slip occurs under the same conditions as the actual machine. As illustrated in Figure 9, after some time has passed since film winding began in the simulation, the ideal tension T' becomes largely stable, as indicated by arrow E2.

[0074] The estimated slip amount calculation unit 128 calculates the slip amount S based on the difference between the detected tension T and the ideal tension T'. Specifically, the estimated slip amount calculation unit 128 calculates the estimated slip amount S using the following equation (8): S = α1 × ΔT ... (8)

[0075] Here, S represents the estimated slip amount at a certain time t. ΔT represents the difference between the detected tension T and the ideal tension T' at a certain time t. Furthermore, α1 can be set appropriately depending on the operating conditions of the actual machine. Specifically, α1 can be set appropriately according to the physical properties of the film 90, the distance between rolls, the angular velocity of the feed roll 20 and the winding shaft 50, and the amount of air trapped in the winding shaft 50. In this way, the slip amount estimation unit 120 estimates the slip amount S on the surface of the feed roll 20.

[0076] <Operation of the Film Winding Device> Figure 10 is a flowchart showing the operation of the film winding device 10 according to Embodiment 1. Figure 10 mainly shows the control method executed by the control device 100 according to Embodiment 1. The target tension receiving unit 110 of the control device 100 receives the target tension of the film 90 as described above (step S102). The measurement parameter acquisition unit 112 of the control device 100 acquires the measurement parameters as described above (step S104).

[0077] As described above, the slip amount estimation unit 120 of the control device 100 estimates the slip amount (step S110). Specifically, as described above, the detected tension acquisition unit 122 of the slip amount estimation unit 120 acquires the detected tension (step S112). As described above, the ideal tension acquisition unit 126 of the slip amount estimation unit 120 acquires the ideal tension by performing a simulation using an ideal model (step S114). As described above, the estimated slip amount calculation unit 128 of the slip amount estimation unit 120 calculates the estimated slip amount based on the difference between the detected tension and the ideal tension (step S116).

[0078] As described above, the suction control unit 130 of the control device 100 controls the suction mechanism 30 (step S120). Specifically, the suction control unit 130 controls the suction force in the suction mechanism 30 according to the amount of slip S estimated in the process of S110. As described above, the winding diameter calculation unit 150 of the control device 100 calculates the winding diameter (step S130). As described above, the tension control unit 160 performs a process to control the tension applied to the film 90 using the winding diameter calculated in the process of S130 (step S132).

[0079] As described above, the film winding device 10 according to Embodiment 1 is configured to dynamically control the suction force in the suction mechanism 30 according to the estimated amount of slip. Therefore, it is possible to suppress the occurrence of film 90 slip on the surface 20a of the feed roll 20. This improves the accuracy of calculating the winding diameter on the winding shaft 50. Therefore, it becomes possible to control the tension of the film 90 with high precision. Furthermore, because it is possible to suppress the occurrence of film 90 slip, a wound film 92 with a stable winding appearance, such as fewer wrinkles and aligned end faces, is produced on the winding shaft 50. Therefore, the film winding device 10 according to Embodiment 1 makes it possible to manufacture high-quality film products.

[0080] Furthermore, as described above, the film winding device 10 according to Embodiment 1 is configured to detect the film width and dynamically control the opening width W of the opening 34 in the suction mechanism 30 according to the detected film width. This allows the suction force in the suction mechanism 30 to be controlled in accordance with minute changes in the width direction of the film 90. Therefore, it becomes possible to stably wind the film 90 on the winding shaft 50.

[0081] Furthermore, by controlling the suction force in the suction mechanism 30 according to the estimated slip amount S, it is possible to suppress mechanical loss caused by the feed roll 20. In other words, if the film 90 is always sucked with a strong suction force regardless of the estimated slip amount, that suction force may become a load on the rotation of the feed roll 20. Therefore, it may not be desirable to make the suction force too strong in order to completely prevent slip. In contrast, in the above-described embodiment, by adjusting the coefficient β in equation (2), it is possible to suppress the occurrence of slip of the film 90 while suppressing the occurrence of mechanical loss.

[0082] (Embodiment 2) Next, Embodiment 2 will be described. In the film winding device 10 according to Embodiment 2, the method for estimating the amount of slip differs from that according to Embodiment 1. The other configurations of the film winding device 10 according to Embodiment 2 are substantially the same as those of Embodiment 1, so their description will be omitted. Accordingly, the configurations of the film winding device 10 other than the control device 100 in Embodiment 2 are substantially the same as those of Embodiment 1, so their description will be omitted.

[0083] <Configuration of the control device> Figure 11 shows the configuration of the control device 100 according to Embodiment 2. Similar to Embodiment 1, the control device 100 according to Embodiment 2 has as its main hardware components a control unit 102, a storage unit 104, a communication unit 106, and an interface unit 108. The control device 100 according to Embodiment 2 also has as its components a target tension receiving unit 110, a measurement parameter acquisition unit 212, a slip amount estimation unit 220, a suction control unit 130, a winding diameter calculation unit 150, and a tension control unit 160. The slip amount estimation unit 220 also has a database construction unit 222, a database storage unit 224, and an estimated slip amount calculation unit 228. The control device 100 uses these components to control the suction mechanism 30 and perform processing to control the tension applied to the film 90. Unless otherwise specified, the functions of the components other than the measurement parameter acquisition unit 212 and the slip amount estimation unit 220 are substantially the same as those in Embodiment 1, and therefore their explanation will be omitted.

[0084] The measurement parameter acquisition unit 212 acquires the measurement parameters described above. The measurement parameter acquisition unit 212 acquires measurement parameters related to the database constructed by the database construction unit 222, which will be described later. For example, the measurement parameter acquisition unit 212 may acquire the detected tension, which is the tension detected by the tension detector 44, as a measurement parameter. Alternatively, for example, the measurement parameter acquisition unit 212 may acquire measurement parameters detected by the sensor 70. Alternatively, for example, the measurement parameter acquisition unit 212 may acquire the rotation speed and rotation angle of the feed roll 20, detected by the sensor 70 or the feed motor 22, as measurement parameters. Alternatively, for example, the measurement parameter acquisition unit 212 may acquire the rotation speed and rotation angle of the winding shaft 50, detected by the sensor 70 or the winding motor 52, as measurement parameters. Alternatively, the measurement parameter acquisition unit 212 may acquire the film width detected by the width detector 72 as a measurement parameter.

[0085] The slip amount estimation unit 220, similar to the slip amount estimation unit 120 in Embodiment 1, estimates the slip amount S of the film 90 on the surface 20a of the feed roll 20 based on at least one measurement parameter. Details of the processing of the slip amount estimation unit 220 will be described later. In Embodiment 2, the slip amount estimation unit 220 estimates the slip amount S using a database that shows the relationship between previously measured measurement parameters and the slip amount of the film at the time the measurement parameters were measured. The slip amount estimation unit 220 also estimates the slip amount S at a timing after the database has been generated. The database may be constructed before the operation of the film winding device 10. In this case, "timing after the database has been generated" may be a timing during the operation of the film winding device 10.

[0086] The database construction unit 222 constructs a database showing the relationship between pre-measured measurement parameters and the amount of film slip at the time those parameters were measured. Note that the database construction unit 222 may be implemented by a device different from the control device 100. In other words, the database may be constructed by a device separate from the control device 100.

[0087] For example, the database construction unit 222 may, but is not limited to, construct the database before the film winding device 10 is put into operation. The database construction unit 222 may also construct the database by updating the contents of the database while the film winding device 10 is in operation. The following description will describe an example in which the database is constructed before the film winding device 10 is put into operation.

[0088] Before operating the film winding device 10, the database construction unit 222 acquires one or more measurement parameters detected in a certain state. Furthermore, as will be described later using Figure 12, before operating the film winding device 10, the database construction unit 222 acquires the amount of slip detected in that state. For example, the database construction unit 222 may acquire, but is not limited to, the tension of the film 90 (detected tension), the rotational speed of the feed roll 20, and the rotational speed of the winding shaft 50 as measurement parameters. The database construction unit 222 then associates one or more measurement parameters with the amount of slip for this state. The database construction unit 222 then performs the above processing for various states. As a result, the database construction unit 222 constructs a database showing the relationship between measurement parameters and the amount of slip in a large number of states.

[0089] Figure 12 is a diagram illustrating a method for measuring slip amount according to Embodiment 2. Figure 12 illustrates, for example, the state of the film winding device 10 before operation. In Embodiment 2, before operation of the film winding device 10, various films 90 having different physical properties are transported between the feed roll 20 and the winding shaft 50. A Doppler sensor 80 is also installed near the transported films 90. The Doppler sensor 80 measures the transport speed of the films 90. Note that it is often difficult to install the Doppler sensor 80 in the film winding device 10 during operation due to space and other factors. Therefore, the Doppler sensor 80 does not need to be installed in the film winding device 10 during operation.

[0090] The database construction unit 222 acquires the transport speed of the film 90 measured by the Doppler sensor 80 in a certain state, and the rotation speed of the feed roll 20 measured in that state. Then, the database construction unit 222 uses the transport speed of the film 90 and the rotation speed of the feed roll 20 to calculate the slip amount S in that state using the following equation (9). ... (9)

[0091] Here, V Ｆ This indicates the peripheral speed of the feed roll 20. Note that the peripheral speed of the feed roll 20 is determined by the rotational speed of the feed roll 20 and the diameter D of the feed roll 20. ｆ It can be obtained from V. ｆ This indicates the transport speed of the film 90.

[0092] Alternatively, the peripheral speed of the winding shaft 50 may be used to calculate the slip amount S. In this case, a winding diameter sensor is installed near the wound film 92 wound by the winding shaft 50. The winding diameter sensor measures the winding diameter of the winding shaft 50. The peripheral speed may then be calculated from the winding diameter and angular velocity of the winding shaft 50. The database construction unit 222 uses the angular velocity and winding diameter of the winding shaft 50 and the rotational speed of the feed roll 20 to calculate the slip amount S using the following equation (10). ... (10)

[0093] Here, VＦ This indicates the peripheral speed of the feed roll 20. Also, ω Ｗ This indicates the angular velocity of the winding shaft 50, and D Ｗ This indicates the winding diameter of the winding shaft 50.

[0094] The database storage unit 224 stores the database constructed by the database construction unit 222. Note that the database storage unit 224 may be implemented by a device different from the control device 100. In other words, the database may be stored in a device separate from the control device 100.

[0095] As described above, the database associates slip amounts with one or more measurement parameters that have been measured in advance for various conditions. In other words, the database shows the correspondence between one or more measurement parameters and slip amounts for various conditions. The database may also be, for example, a table-formatted data showing the relationship between slip amount and one or more measurement parameters.

[0096] Figure 13 illustrates a database stored in the database storage unit 224 according to Embodiment 2. In the database, a state, a slip amount S, and one or more measurement parameters A, B, and C are associated with each other. For example, the measurement parameters A, B, and C may be the tension of the film 90 (detected tension), the rotational speed of the feed roll 20, and the rotational speed of the winding shaft 50, respectively. Note that the number of measurement parameters is not limited to three.

[0097] Figure 13 shows that in state #1, the slip amount value S1, the value of measurement parameter A PA1, the value of measurement parameter B PB1, and the value of measurement parameter C PC1 were measured. Figure 13 also shows that in state #2, the slip amount value S2, the value of measurement parameter A PA2, the value of measurement parameter B PB2, and the value of measurement parameter C PC2 were measured. Figure 13 also shows that in state #3, the slip amount value S3, the value of measurement parameter A PA3, the value of measurement parameter B PB3, and the value of measurement parameter C PC3 were measured.

[0098] The estimated slip amount calculation unit 228 calculates the estimated slip amount during operation of the film winding device 10 using the database stored in the database storage unit 224. In other words, the estimated slip amount calculation unit 228 calculates the estimated slip amount at a time after the database has been generated. The estimated slip amount calculation unit 228 calculates the estimated slip amount using the database and measurement parameters measured during operation. Note that "measurement parameters measured during operation" correspond to one or more measurement parameters measured in advance when the database is constructed before operation. In other words, the estimated slip amount calculation unit 228 estimates the slip amount using the database and measurement parameters measured at a time after the database has been generated, corresponding to the measurement parameters measured in advance. For example, the estimated slip amount calculation unit 228 estimates the slip amount using the database and measurement parameters measured during operation, corresponding to the measurement parameters measured before operation. In the example shown in Figure 13, the estimated slip amount calculation unit 228 estimates the slip amount using the database illustrated in Figure 13 and the measurement parameters A, B, and C measured during operation.

[0099] Specifically, the estimated slip amount calculation unit 228 uses a database to calculate an estimated slip amount corresponding to the measurement parameters measured during operation. For example, the estimated slip amount calculation unit 228 may calculate the slip amount S corresponding to the value of the measurement parameter measured during operation in the database as the estimated slip amount. In the example in Figure 13, when the values ​​of the measurement parameters A, B, and C measured during operation are PA1, PB1, and PC1, respectively, the estimated slip amount calculation unit 228 calculates S1 as the estimated slip amount. Also, for example, if the value of the measurement parameter measured during operation does not match the value shown in the database, the estimated slip amount calculation unit 228 may calculate the estimated slip amount corresponding to the measurement parameter measured during operation by performing data interpolation using the value shown in the database.

[0100] Furthermore, for example, the estimated slip amount calculation unit 228 may calculate the estimated slip amount corresponding to the measurement parameters measured during operation using a function obtained using a database. This function takes the measurement parameters measured during operation as input and outputs the estimated slip amount. For example, the estimated slip amount calculation unit 228 may calculate the estimated slip amount by performing multiple regression analysis on the database and calculating a regression equation. In this case, the estimated slip amount calculation unit 228 may calculate a regression equation using the slip amount in the database as the dependent variable and other measurement parameters (measurement parameters A, B, and C in the example of Figure 13) as independent variables. The estimated slip amount calculation unit 228 may then calculate the estimated slip amount by substituting the values ​​of the measurement parameters measured during operation into the calculated regression equation. Note that calculating the regression equation by multiple regression analysis may be performed by a device other than the control device 100.

[0101] Furthermore, for example, the estimated slip amount calculation unit 228 may calculate the estimated slip amount using a trained model obtained through machine learning performed using a database. In this case, machine learning is performed so that the measurement parameters in the database (measurement parameters A, B, and C in the example of Figure 13) are input and the corresponding slip amounts are output. As a result, the trained model is trained so that the slip amounts are output when the measurement parameters are input. The estimated slip amount calculation unit 228 inputs the measurement parameters measured during operation into the trained model and calculates the output slip amounts as the estimated slip amount. Note that machine learning may be performed by a device other than the control device 100.

[0102] <Operation of the Film Winding Device> Figure 14 is a flowchart showing the operation of the film winding device 10 according to Embodiment 2. Figure 14 mainly shows the control method executed by the control device 100 according to Embodiment 2. As described above, the database construction unit 222 constructs a database before the operation of the film winding device 10 (step S202). The constructed database is stored in the database storage unit 224.

[0103] As described above, the target tension receiving unit 110 of the control device 100 receives the target tension of the film 90 (step S204). As described above, the measurement parameter acquisition unit 212 of the control device 100 acquires the measurement parameters (step S206).

[0104] As described above, the slip amount estimation unit 120 of the control device 100 estimates the slip amount (step S210). Specifically, the estimated slip amount calculation unit 228 of the slip amount estimation unit 220 calculates the estimated slip amount using the database as described above (step S216).

[0105] As described above, the suction control unit 130 of the control device 100 controls the suction mechanism 30 (step S220). As described above, the winding diameter calculation unit 150 of the control device 100 calculates the winding diameter using the slip amount estimated in the process of S210 (step S230). As described above, the tension control unit 160 performs a process to control the tension applied to the film 90 using the winding diameter calculated in the process of S230 (step S232).

[0106] As described above, the film winding device 10 according to Embodiment 2 is configured to dynamically control the suction force in the suction mechanism 30 according to the estimated amount of slip. Therefore, substantially the same as in Embodiment 1, it is possible to suppress the occurrence of film 90 slip on the surface 20a of the feed roll 20.

[0107] <Modification of Embodiment 2> Figure 15 is a diagram illustrating a modification of Embodiment 2. In the example of Figure 15, before the operation of the film winding device 10, a database DB is constructed consisting of actual measurement results obtained by operating the actual film winding device 10 and analysis results obtained by performing a simulation using the actual measurement results. During operation, the control device 100 uses the constructed database DB to predict the amount of film 90 slip that may occur in the feed roll 20. The control device 100 then controls the suction force in the suction mechanism 30 according to the predicted amount of slip. This allows slip to be suppressed before it occurs. Therefore, in the example of Figure 15, the suction mechanism 30 is controlled by feedforward control. The database DB shown in Figure 15 may indicate how much slip occurs under what conditions. The database DB may also indicate what the suction force should be under what conditions. Furthermore, the database DB may consist of either actual measurement results or analysis results, or both.

[0108] The database construction unit 222 stores pre-operation data as measured results. These "measured results" show the relationship between measurement parameters measured under various conditions and the amount of slip measured under those conditions, as illustrated in Figure 13 above. The measured results also include various parameters that can define the amount of slip of the film 90 on the feed roll 20. For example, the measured results may include the physical properties of the film 90, the detected tension of the film 90, the transport speed of the film 90, the torque of the winding motor 52, and the operating environment (temperature, humidity, etc.). The measured results may also include control parameters, which are parameters for suction control and tension control. Control parameters related to suction control may include, for example, the opening length L and the opening width W. Control parameters related to tension control may include, for example, the torque command τ.

[0109] The database construction unit 222 virtually executes a simulation using the physical model PM. The physical model PM is a simulation model that simulates the operation of the film winding device 10. The physical model PM is a model that can perform physical simulations under the same operating conditions as the film winding device 10 in operation, and in the same way as the actual machine, such that film 90 slip occurs on the surface of the feed roll 20. The physical model PM is configured to accept operating conditions as input and output the amount of slip and tension of the film 90 under those conditions. The database construction unit 222 constructs the physical model PM using the measured results described above. The database construction unit 222 then performs physical simulations under various operating conditions and obtains the amount of slip and tension of the film 90 under those operating conditions. The database construction unit 222 then stores the obtained amount of slip and tension in the database DB as analysis results. In this way, by performing simulations using the physical model PM, it is possible to obtain the amount of slip under conditions that could not be obtained from measured results. This configuration allows for accurate prediction of slip amounts during operation, as described later.

[0110] The estimated slip amount calculation unit 228 uses the constructed database DB to calculate a predicted slip amount, which is a predicted value of the slip amount that will occur during operation. Specifically, the estimated slip amount calculation unit 228 acquires data during operation. "Data during operation" includes the values ​​of parameters other than the slip amount from the pre-operation data described above, during operation. The data during operation includes the state during operation and the measurement parameters measured in that state. The estimated slip amount calculation unit 228 may use the database DB to calculate a predicted slip amount, which is the slip amount predicted for the state corresponding to the data during operation, in a method substantially the same as the method in Embodiment 2 described above.

[0111] Furthermore, the suction control unit 130 outputs control parameters using the predicted slip amount. Specifically, the suction control unit 130 uses the predicted slip amount as the estimated slip amount S described above and calculates the suction force F in the suction mechanism 30 using equation (2) in substantially the same manner as in the embodiment described above. The suction control unit 130 then outputs the suction pressure P, opening length L, and opening width W, which correspond to the calculated suction force F, as control parameters to the suction mechanism 30. As a result, the suction mechanism 30 can suck up the film 90 with a suction force F corresponding to the predicted slip amount before slip occurs. Therefore, it is possible to suppress the occurrence of slip.

[0112] (Modifications) The present invention is not limited to the embodiments described above, and can be modified as appropriate without departing from the spirit of the invention. For example, each process in the flowchart described above may be implemented using a trained model learned by machine learning. Also, for example, the order of each process in the flowchart described above can be changed as appropriate. Furthermore, one or more of the processes in the flowchart described above may be omitted.

[0113] Although the present disclosure has been described above with reference to embodiments, the present disclosure is not limited to the embodiments described above. Various modifications to the structure and details of the present disclosure can be made as can be understood by those skilled in the art within the scope of the present disclosure. Furthermore, each embodiment can be combined with other embodiments as appropriate.

[0114] Each drawing is merely illustrative to illustrate one or more embodiments. Each drawing may be associated with one or more other embodiments, rather than being associated with only one specific embodiment. As those skilled in the art will understand, various features or steps described with reference to any one drawing can be combined with features or steps shown in one or more other drawings, for example, to create embodiments not explicitly shown or described. Not all features or steps shown in any one drawing to illustrate an exemplary embodiment are necessarily required, and some features or steps may be omitted. The order of steps described in any of the drawings may be changed as appropriate.

[0115] The program described above, when loaded into a computer, includes a set of instructions (or software code) for causing the computer to perform one or more of the functions described in the embodiments. The program may be stored in a non-temporary computer-readable medium or a physical storage medium. Examples, but not limited to, include random-access memory (RAM), read-only memory (ROM), flash memory, solid-state drive (SSD) or other memory technologies, CD-ROM, digital versatile disk (DVD), Blu-ray® disc or other optical disc storage, magnetic cassette, magnetic tape, magnetic disk storage or other magnetic storage devices. The program may be transmitted over a temporary computer-readable medium or a communication medium. Examples, but not limited to, include electrical, optical, acoustic or other forms of propagating signals. The program may also include a program product.

[0116] This application claims priority based on Japanese Patent Application No. 2025-014434, filed on 31 January 2025, and incorporates all of its disclosures herein.

[0117] 1 Film manufacturing apparatus 2 Extruder 4 Cast molding machine 6 Longitudinal stretcher 8 Transverse stretcher 10 Film winding apparatus 20 Feed roll 22 Feed motor 24 Outer cylinder 30 Suction mechanism 32 Suction unit 34 Opening 36 Opening / closing unit 38 Drive unit 40 Nip roll 44 Tension detector 50 Winding shaft 52 Winding motor 60 Near roll 70 Sensor 72 Width detector 80 Doppler sensor 90 Film 92 Winding film 100 Control device 110 Target tension receiving unit 112 Measurement parameter acquisition unit 120 Slip amount estimation unit 122 Detected tension acquisition unit 124 Ideal model storage unit 126 Ideal tension acquisition unit 128 Estimated slip amount calculation unit 130 Suction control unit 150 Winding diameter calculation unit 160 Tension control unit 212 Measurement parameter acquisition unit 220 Slip amount estimation unit 222 Database construction unit 224 Database storage unit 228 Estimated slip amount calculation unit

Claims

1. A film winding device comprising: a winding shaft that winds a film by rotating; a feed roll equipped with a suction mechanism that conveys the film to the winding shaft by rotating and sucks the film; and a control device, wherein the control device comprises: a slip amount estimation unit that estimates the amount of film slip on the surface of the feed roll based on at least one measurement parameter which is a measurable parameter with respect to the conveyance of the film; and a suction control unit that performs processing for dynamically controlling the suction force in the suction mechanism based on the estimated slip amount.

2. The film winding device according to claim 1, wherein the suction control unit controls the suction force in the suction mechanism to increase as the estimated slip amount increases.

3. The film winding device according to claim 2, wherein the suction mechanism is configured to suck film through an opening on the surface of the feed roll having a variable area, and the suction control unit dynamically controls the suction force in the suction mechanism by dynamically controlling the opening area, which is the area of ​​the opening.

4. The film winding device according to claim 3, wherein the opening length, which is the length of the opening in the circumferential direction of the feed roll, and the opening width, which is the length of the opening in the width direction of the feed roll, are variable, and the suction control unit controls the suction force in the suction mechanism by dynamically controlling at least one of the opening length and the opening width.

5. The film winding device according to claim 4, further comprising a width detector for detecting the film width, which is the width of the film being conveyed, located upstream of the feed roll in the film conveying direction, wherein the suction control unit dynamically controls the opening width according to the film width detected by the width detector.

6. A film manufacturing apparatus using the film winding device described in any one of claims 1 to 5.

7. A control method comprising: estimating the amount of film slip on the surface of a feed roll based on at least one measurement parameter that is measured in relation to the transport of a film by a film winding device having a winding shaft that winds a film by rotating, and a feed roll equipped with a suction mechanism that transports the film to the winding shaft by rotating and sucks the film; and performing a process to dynamically control the suction force in the suction mechanism based on the estimated amount of slip.

8. The control method according to claim 7, wherein the suction force in the suction mechanism is controlled to increase as the estimated slip amount increases.

9. The control method according to claim 8, wherein the suction mechanism is configured to suck a film through an opening on the surface of the feed roll, the area of ​​the opening being variable, and the suction force in the suction mechanism is dynamically controlled by dynamically controlling the opening area.

10. The control method according to claim 9, wherein the opening length, which is the length of the opening in the circumferential direction of the feed roll, and the opening width, which is the length of the opening in the width direction of the feed roll, are variable, and the suction force in the suction mechanism is controlled by dynamically controlling at least one of the opening length and the opening width.

11. The control method according to claim 10, wherein the opening width is dynamically controlled according to the film width detected by a width detector that detects the film width, which is the width of the film being conveyed, on the upstream side of the feed roll in the film conveying direction.

12. A program that causes a computer to perform the following steps:

11. Estimate the amount of film slip on the surface of a feed roll based on at least one measurement parameter which is a parameter measured in relation to the transport of a film by a film winding device having a winding shaft that winds up a film by rotating, and a feed roll equipped with a suction mechanism that transports the film to the winding shaft by rotating and sucks up the film; and 2. Perform a process to dynamically control the suction force in the suction mechanism based on the estimated amount of slip.

Images