Sheet Feeding Device Rotation Count Calculation
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Solution Overview
Problem
Conventional sheet feeding devices struggle to accurately calculate the remaining amount of sheets in rolls, leading to insufficient storage and increased waste during the joining process, as the outer diameter calculation method is less reliable when the storage amount exceeds the reference amount.
Innovation Solution
A sheet feeding device with a calculation unit that calculates the outer diameter and remaining sheet amount based on conveyance speed and rotations, and a shaft control unit that adjusts rotation speed to maintain optimal storage and conveyance speeds, ensuring precise sheet remaining amount calculation and storage before joining processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the storage amount of sheet using the storage mechanism is increased to more than the reference storage amount, then the sheet can be continuously supplied during joining processing, but the outer diameter calculation becomes inaccurate and the sheet remaining amount cannot be grasped
Solution Approach 1:
The invention changes the calculation parameters from relying on outer diameter measurements to using rotation counts and a predetermined sheet width. When storage amount exceeds the reference, the system switches to a calculation method based on counting roll rotations and multiplying by the known sheet width, which remains accurate regardless of storage amount variations.
Solution Approach 2:
The invention replaces the mechanical measurement system (outer diameter sensors) with a computational system based on rotation counting. Instead of physically measuring the changing outer diameter, the system uses a rotation count detection unit to track how many times the roll rotates, providing accurate sheet remaining amount calculation without mechanical measurement errors.
2Reliability
If the sheet remaining amount is increased to perform joining processing, then the joining can be completed without supply interruption, but the sheet waste after joining increases
Solution Approach 1:
The invention implements a feedback control system where the sheet remaining amount is continuously calculated and fed back to the control unit. The control unit compares the calculated remaining amount against target values and dynamically adjusts the acceleration amount and storage amount settings, enabling precise control of sheet remaining amount to minimize waste while ensuring continuous joining processing.
Solution Approach 2:
The invention makes the acceleration amount and storage amount dynamic rather than fixed. The control unit adjusts these parameters based on real-time sheet remaining amount calculations, allowing the system to optimize the balance between maintaining sufficient sheet for continuous joining and minimizing excess sheet waste after joining completion.
3Quantity of substance
If the rotation speed of the supply roll is accelerated to store large amount of sheet, then the storage amount increases, but the peripheral speed becomes unequal to conveyance speed and outer diameter cannot be calculated
Solution Approach 1:
The invention extracts the outer diameter measurement from the calculation process during acceleration phases. Instead of attempting to measure or calculate outer diameter when the roll is accelerating and storage amount is changing, the system separates this measurement function and relies solely on rotation counting, which remains valid regardless of speed variations.
Data Source
AI summary
In steady control, a shaft control unit (922) adjusts rotation speed of a first support shaft (31) to cause a first roll (R1) to have peripheral speed equal to predetermined conveyance speed by maintaining a sheet storage amount in a storage mechanism (5) in a first storage amount as a reference. In storage amount adjustment control, the shaft control unit (922) accelerates the rotation speed of the first support shaft (31) to increase the peripheral speed of the first roll (R1) higher than the conveyance speed, until the sheet storage amount in the storage mechanism (5) reaches a predetermined second storage amount that is larger than the first storage amount. A calculation unit (911) calculates an outer diameter of the first roll (R1) based on the conveyance speed when the steady control is performed, and calculates the outer diameter of the first roll (R1) based on the sheet thickness calculated from a decrease amount of the outer diameter of the first roll (R1) in the steady control when the storage amount adjustment control is performed.