U.S. patent application number 09/774972 was filed with the patent office on 2001-09-27 for film running device.
Invention is credited to Koyama, Satoru, Saito, Takeshi, Takahashi, Kazuo.
Application Number | 20010023906 09/774972 |
Document ID | / |
Family ID | 18550161 |
Filed Date | 2001-09-27 |
United States Patent
Application |
20010023906 |
Kind Code |
A1 |
Saito, Takeshi ; et
al. |
September 27, 2001 |
Film running device
Abstract
A film running device which enables the film to run stably,
which as a whole is small in size, simple in construction and
requires easy maintenance. A long film 1 is delivered from a
delivery roll 2. A drive rotor R of the delivery roll incorporates
an outer rotor-type electric motor 25M therein, and is rotated by
the motor.
Inventors: |
Saito, Takeshi; (Miyagi,
JP) ; Takahashi, Kazuo; (Tochigi, JP) ;
Koyama, Satoru; (Miyagi, JP) |
Correspondence
Address: |
SONNENSCHEIN NATH & ROSENTHAL
P.O. BOX 061080
WACKER DRIVE STATION
CHICAGO
IL
60606-1080
US
|
Family ID: |
18550161 |
Appl. No.: |
09/774972 |
Filed: |
February 1, 2001 |
Current U.S.
Class: |
242/414.1 ;
242/418; 242/420.5; 242/535; 242/541.1; 242/546; 242/564 |
Current CPC
Class: |
G03B 27/587
20130101 |
Class at
Publication: |
242/414.1 ;
242/564; 242/546; 242/535; 242/541.1; 242/420.5; 242/418 |
International
Class: |
B65H 018/10; B65H
016/10; B65H 020/02; B65H 023/185; B65H 023/192; B65H 023/198; B65H
018/16 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 1, 2000 |
JP |
P2000-024102 |
Claims
1. A film running device for running a long film delivered from a
delivery roll, wherein a rotary shaft of said delivery roll is a
drive rotor which incorporates an outer rotor-type electric motor
therein, and said drive rotor is rotated by said motor.
2. A film running device for running a long film delivered from a
delivery roll so as to be taken up by a take-up roll, wherein a
rotary shaft of said take-up roll is a drive rotor which
incorporates an outer rotor-type electric motor therein, and said
drive rotor is rotated by said motor.
3. A film running device in which a region where a long film runs
at a different speed is arranged via a feed roll on a passage along
which the long film runs, wherein said feed roll is a drive rotor
which incorporates an outer rotor-type electric motor therein, and
said drive rotor is rotated by said motor.
4. A film running device in which a pinch roll is disposed on a
passage along which a long film runs, wherein said pinch roll is a
drive rotor which incorporates an outer rotor-type electric motor
therein, and said drive rotor is rotated by said motor.
5. A film running device for running a long film delivered from a
delivery roll so as to be taken up by a take-up roll, and including
a touch roll so disposed as to come into rotational contact with
the film taken up by the take-up roll, wherein said touch roll is a
drive rotor which incorporates an outer rotor-type electric motor
therein, and said drive rotor is rotated by said motor.
6. A film running device according to claim 1, wherein said motor
is controlled by controlling the frequency to bring the peripheral
speed of said delivery roll into nearly agreement with a
predetermined film running speed.
7. A film running device according to claim 2, wherein said motor
is controlled by controlling the frequency to bring the peripheral
speed of said take-up roll into nearly agreement with a
predetermined film running speed.
8. A film running device according to claim 3, wherein said motor
is controlled by controlling the frequency to bring the peripheral
speed of said drive rotor into nearly agreement with a
predetermined film running speed.
9. A film running device according to claim 4, wherein said motor
is controlled by controlling the frequency to bring the peripheral
speed of said drive rotor into nearly agreement with a
predetermined film running speed.
10. A film running device according to claim 5, wherein said motor
is controlled by controlling the frequency to bring the peripheral
speed of said drive rotor into nearly agreement with a
predetermined film running speed.
11. A film running device according to claim 1, wherein the
frequency is controlled by an inverter.
12. A film running device according to claim 2, wherein the
frequency is controlled by an inverter.
13. A film running device according to claim 3, wherein the
frequency is controlled by an inverter.
14. A film running device according to claim 4, wherein the
frequency is controlled by an inverter.
15. A film running device according to claim 5, wherein the
frequency is controlled by an inverter.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a film running device for
handling long films in a step of producing, for example, magnetic
recording media, photographic films, film capacitors, collector
films of film electrodes in the secondary cells, etc.
[0003] 2. Prior Art
[0004] In the production of, for example, magnetic recording media,
photographic films, film capacitors and collector films in the
secondary cells, use is made of long films such as various resin
films or metal films as base films for constituting the above
films. While the long films are running at a predetermined speed,
various operations are executed such as applying a magnetic coating
material, evaporating a metal magnetic material, sputtering,
calender treatment, heat treatment, forming a surface protection
layer, forming a back layer, applying a photographic emulsion,
depositing an electrode layer, and applying an activated
depolarizing mix for cell of an electrode-constituting agent.
[0005] The film running device usually includes a delivery roll for
delivering and feeding a film, a take-up roll for taking up the
film, and regions for varying the running speed or the tension
along a passage where the film runs in order to accomplish a
running speed or a tension adapted to executing various treatments
along the passage between the above rolls. In this case, a feed
roll is often arranged between the regions to cut the tension or to
execute a so-called connection cutting. There are further provided
many rolls such as pinch rolls, touch rolls and guide rolls.
[0006] It is desired that these rolls are rotated at a peripheral
speed in agreement with the running speed of the film from the
standpoint of controlling the running speed of the film, and
avoiding damages to the surfaces of the films or to the coated
films formed on the surfaces of the films, that may be caused by
slip between the films and the rolls.
[0007] When the film running device is so constituted that the
individual rolls rotate by themselves, provision is made of
electric motors for the rolls to rotate them, and their rotational
motions are transmitted to the rolls by pulley-belt mechanisms.
[0008] This, however, is accompanied by many problems such as noise
due to the pulley-belt mechanisms, dispersion in the rotational
speed due to slipping causing a change in the tension of the
running film and developing wrinkles.
[0009] Further, large space is required for arranging the electric
motors and rotation transmission mechanisms, the number of parts
increases, the device as a whole becomes bulky occupying increased
areas and space, and requiring cumbersome maintenance.
SUMMARY OF THE INVENTION
[0010] The present invention is to provide a film running device
which enables the film to run stably, features a decrease in the
size of the device as a whole, simplicity and easy maintenance
avoiding the above inconvenience.
[0011] The present invention is concerned with a film running
device for running a long film delivered from a delivery roll,
wherein a rotary shaft of the delivery roll is a drive rotor which
incorporates an outer rotor-type electric motor therein, and the
drive rotor is rotated by the motor.
[0012] The invention is further concerned with a film running
device for running a long film delivered from a delivery roll so as
to be taken up by a take-up roll, wherein a rotary shaft of the
take-up roll is a drive rotor which incorporates an outer
rotor-type electric motor therein, and the drive rotor is rotated
by the motor.
[0013] The invention is further concerned with a film running
device in which a region where a long film runs at a different
speed is arranged via a feed roll on a passage along which the long
film runs, wherein the feed roll is a drive rotor which
incorporates an outer rotor-type electric motor therein, and the
drive rotor is rotated by the motor.
[0014] The invention is further concerned with a film running
device in which a pinch roll is disposed on a passage along which a
long film runs, wherein the pinch roll is a drive rotor which
incorporates an outer rotor-type electric motor therein, and the
drive rotor is rotated by the motor.
[0015] The invention is further concerned with a film running
device for running a long film delivered from a delivery roll so as
to be taken up by a take-up roll, and including a touch roll so
disposed as to come into rotational contact with the film taken up
by the take-up roll, wherein the touch roll is a drive rotor which
incorporates an outer rotor-type electric motor therein, and the
drive rotor is rotated by the motor.
[0016] According to the film running device of the present
invention, the motor is controlled by controlling the frequency to
control the rotational speed of the drive rotor in order to bring
the circumferential speed of the delivery roll, circumferential
speed of the take-up roll or circumferential speed of the feed
roll, pinch roll or touch roll into nearly agreement with the
predetermined film running speed.
[0017] As described above, the present invention deals with a film
running device having at least any one of a delivery roll for
delivering the film, a take-up roll, a feed roll, a pinch roll or a
touch roll, wherein the drive rotor of these rolls is rotated by an
electric motor incorporated therein, avoiding a structure in which
a motor is arranged at a position separate from the roll and the
rotational motion thereof is transmitted via a rotation
transmission mechanism.
[0018] The rotational speed of the roll is controlled by
controlling the drive motor relying upon the frequency, so that the
rotation of the roll is brought into agreement with the film
running speed at all times to stably run the film.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a diagram schematically illustrating the
constitution of a film running device according to the present
invention;
[0020] FIG. 2 is a sectional view schematically illustrating the
constitution of a drive rotor in the film running device according
to the present invention;
[0021] FIG. 3 is a sectional view schematically illustrating a roll
for delivering or taking up a long film in the film running device
according to the present invention;
[0022] FIG. 4 is a diagram illustrating the constitution of a
control circuit device in the device of the present invention;
[0023] FIG. 5 is a flowchart of the control circuit device in the
device of the present invention;
[0024] FIG. 6 is a diagram illustrating the control circuit device
in the device of the present invention; and
[0025] FIG. 7 is a diagram illustrating the constitution of the
control circuit device in the device of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The film running device according to an embodiment of the
present invention is used in a form of executing various production
line works by running various long films such as resin films or
metal films which are base films in the production of, for example,
magnetic recording media, photographic films, film capacitors and
collector films in the secondary cells, and applying a magnetic
coating material, evaporating a metal magnetic material, effecting
the sputtering, calender treatment, heat treatment, forming a
surface protection layer, forming a back layer, applying a
photographic emulsion, depositing an electrode layer, and applying
an activated depolarizing mix for cell of an electrode-constituting
agent.
[0027] FIG. 1 is a view schematically illustrating the constitution
of a film running device according to an embodiment of the present
invention to which only, however, the invention is in no way
limited.
[0028] In a step of producing a magnetic recording medium according
to this embodiment, a long film 1 constituting a magnetic recording
medium having, for example, a magnetic coating material formed on a
nonmagnetic film such as PET (polyethylene terephthalate) film, is
delivered from a delivery roll 2 on which the long film 1 is wound
and runs toward a take-up roll 3 being guided by a plurality of
guide rollers 4.
[0029] The delivery roll 2 and the take-up roll 3 have rotary
shafts that are constituted by drive rotors R1 and R2.
[0030] On a passage along which the long film 1 runs, a treating
unit 5 is provided to execute various treatments such as calender
treatment for the long film 1 to produce the magnetic recording
medium.
[0031] The treating unit 5 has a pair of elastic rolls 15 that come
into rotational contact with, for example, a metal roll 14, and the
long film 1 runs passing through the metal roll 14 and the elastic
rolls 15 being pressed thereby so as to be calender-treated.
[0032] In a running portion between, for example, the treating unit
5 and the take-up roll 3, there are provided a drive rotor R3
constituting a so-called feed roll 6 which execute the so-called
connection cutting of tension of the long film 1 and a drive rotor
R4 constituting a pinch roll 7 that comes into rotational contact
therewith to nip the long film 1.
[0033] On the subsequent stage of the drive rotor R3 which is the
feed roll, there are provided a pair of guide rolls 4 and a
tension-adjusting roll 8 between them.
[0034] Further, a so-called touch roll 9, i.e., a drive rotor R5
that constitutes the touch roll 9 is provided to come into
rotational contact with the take-up peripheral surface of the
take-up roll 3, so that the long film 1 is taken up by the take-up
roll 3 under a predetermined take-up pressure without developing
slackness.
[0035] In the film running device, the drive rotors R (R1 to R5)
are rotated by outer rotor type motors incorporated therein, and
their rotational speeds are controlled by controlling the frequency
so as to come into agreement with the film running speed.
[0036] Referring to FIG. 2 which is a sectional view schematically
illustrating the constitution, each of the drive rotors R (R1 to
R5) is constituted by a cylinder 20 having a fixed shaft 21 along
the center axis thereof.
[0037] Rotary bearings 22, 23 and 24 which are ball bearings, for
example, are provided between the cylinder 20 and the fixed shaft
21 at both ends and, as required, at an intermediate portion
thereof, enabling the cylinder 20 to rotate about the fixed shaft
21.
[0038] Outer rotor-type electric motors 25M (25M1 to 25M5) are
disposed on the fixed shafts 21 of the drive rotors R (R1 to R5).
That is, a stator or a coil 26 of the motor 25M is secured onto the
fixed shaft 21, and a rotor or a magnet 27 along the outer
circumference thereof is secured to the cylinder 20.
[0039] The coil terminals of the motor 25M in the drive rotor R are
connected to the inner ends of a power cable 28 that is guided from
an end of the cylinder 20 running through a hole perforated in the
fixed shaft 21 in the axial direction thereof. The outer end of the
power cable 28 is electrically connected to a power cable connector
29c (29c1 to 29c5).
[0040] The fixed shaft 21 of the drive rotor R (R1 to R5) is
provided with a pulse generator 30PG (30PG1 to 30PG5) to generate
pulses in a required number depending upon the rotation of the
cylinder 20. The pulse generator 30PG is a known one placed in the
market, and has, for example, a source of light and a light
detector element, and shuts off light and transmits light depending
upon the rotation of the cylinder 20, so that electric signals of a
required frequency are picked up from the light detector element.
The pulse generator 30PG is guided to an external unit through a
cable (PG cable) 31 guided along the fixed shaft 21 and is
connected to a PG cable connector 32c (32c1 to 32c5).
[0041] As required, further, a gas introduction port 37 is formed
at one end of the cylinder 20 to introduce the external air or the
cooling gas into the cylinder 20, and a gas outlet port 38 is
formed at the other end, so that heat generated by the motor 25M
and the pulse generator 30PG can be radiated.
[0042] Referring to FIG. 3 which schematically illustrates the
constitution, the roll 2 or 3 for delivering or taking up the long
film 1 is detachably attached to the drive rotor R1 or R2, and
rotates, in its mounted state, together with the drive rotor R1 or
R2 constituting a chucking mechanism.
[0043] For example, the drive rotor R1 or R2 is chucked on at least
the one end of the delivery roll 2 or the take-up roll 3. The drive
rotors R1 and R2 incorporate outer rotor-type motors 25M1 and 25M2
in a manner as described with reference to FIG. 2, and include
pulse generators 30PG1 and 30PG2.
[0044] Here, the drive rotor R of a similar constitution may be
chucked on the ends on the other side of the delivery roll 2 and
the take-up roll 3. Here, however, rotary shafts that freely rotate
without rotary drive function may be fitted to the ends on the
other side.
[0045] There are provided chucking mechanisms 36 for detachably and
rotatably coupling the delivery roll 2 and the take-up roll 3, the
rotary drive shaft R provided for at least either one of them, and
the freely rotating shaft.
[0046] The chucking mechanism 36 may be constituted by spline
shafts 34 provided at the ends of the drive rotor R or of the
rotary shaft at both ends of the delivery roll 2 or of the take-up
roll 3, and bosses 35 that fit to the spline shafts 34 at both ends
of the delivery roll 2 or of the take-up roll 3.
[0047] In the constitution of FIG. 1, some or all guide rolls 4 may
incorporate the outer rotor-type motor as explained with reference
to FIG. 2.
[0048] According to the present invention as described above, the
delivery roll 2, take-up roll 3, feed roll 6, pinch roll 7, touch
roll 9 and, depending upon the cases, guide rolls 4 have drive
motors 25M incorporated in the drive rotors R thereof, and the
drive rotors R are directly rotated by the motors 25M, avoiding
slipping, vibration and increased space for arrangement that are
inherent in the rotation transmission mechanism in which motors are
arranged separately from the rotary members to drive them, i.e.,
that are inherent in the rotation transmission mechanism in which
the rotary members are rotated relying upon the belt-pulley
mechanisms.
[0049] In the present invention, in particular, a control circuit
device is provided for controlling the rotational speed of the
drive rotor R by controlling the frequency so as to be brought into
agreement with the desired running speed of the long film 1.
[0050] FIG. 4 is a view schematically illustrating the constitution
of the control circuit device 300, and FIG. 5 is a control
flowchart thereof. The invention, however, is in no way limited
thereto only.
[0051] For simplicity, FIGS. 4 and 5 representatively illustrate
three drive rotors R1, R2 and R3, i.e., delivery roll 2, take-up
roll 3 and feed roll 6. By using this control circuit device,
however, it is allowable to control many drive rotors R, e.g.,
fourteen drive rotors R.
[0052] The control circuit device 300 includes a controller (CPU)
100, an analog input device (analog input module) 80, first to
third drive amplifiers 61 to 63 for driving the motors 25M of the
drive rotors R, and encoder signal converters 71 to 73.
[0053] Except the motors 25M and the drive rotors R, the
circuitries may be those placed in the market.
[0054] Outputs of the first to third amplifiers 61 to 63 are fed to
power cable connectors 29c1 to 29c3 of the motors 25M1 to 25M3
through power cables 41 to 43.
[0055] The encoder signal converters 71 to 73 are connected to the
PG cable connectors 32c1 to 32c3 of the drive rotors R1 to R3
through the PG cables 51 to 53.
[0056] The controller 100, analog input device and amplifiers 61 to
63 are connected together through a communication cable LC, and the
encoder signal converters 71 to 73 and the corresponding amplifiers
61 to 63 are connected together through connection cables 91 to
93.
[0057] The operation of the control circuit device 300 will now be
described with reference to FIG. 5 wherein the portions
corresponding to those of FIG. 4 are denoted by the same reference
numerals but their description is not repeated.
[0058] The operation instruction, stop instruction and speed
adjustment instruction are issued from the controller 100 of FIG.
4. In case an abnormally occurs, an abnormal signal detecting this
fact is transmitted from the controller 100 to the host controller
200, then, host controller 200 issues predetermined operation
instruction such as on/off instruction or emergency stop.
[0059] Thus, a so-called multi-axis control is executed in which an
operation instruction issued from the controller 100 and data
signals representing the contents of instructions such as speed
instructions as a result of operating changes in the outer diameter
caused by the running of the long film 1 in relation to the
delivery roll 2 and take-up roll 3, are transmitted to their
respective addresses of the first to third drive amplifiers 61 to
63 through the communication cable LC. Accordingly, the motors 25M1
to 25M3 of the drive rotors R1 to R3 are driven by the outputs of
the drive amplifiers 61 to 63, and the drive rotors R1 to R3 are
rotated.
[0060] When the operator wishes to suitably set reference speeds of
the drive rotors R1 to R3, he sets desired numerical data as
reference speeds through the analog input device 80.
[0061] Then, the numerical data that are input are fed to the
controller 100 and are, then, sent, through the communication cable
LC to the first to third drive amplifiers 61 to 63 to drive the
drive rotors R1 to R3.
[0062] As described above, predetermined signal data are sent to
execute desired operation.
[0063] The rotational speeds or the rotational peripheral speeds
from the pulse generators 30PG1 to 30PG3 provided in the drive
rotors R1 to R3, i.e., detection pulse signals based on the
rotational speeds of the motors 25M1 to 25M3, are input to the
first to third encoder signal converters 71 to 73 and are
converted, usually, through commercially available amplifiers into
signals that are adapted as inputs to the first to third drive
amplifiers 61 to 63, and are input to the first to third drive
amplifiers 61 to 63.
[0064] The outputs from the first to third drive amplifiers 61 to
63 are fed back as, for exmaple, abnormal signals and are
transmitted to the controller 100.
[0065] Thus, the drive rotors R1 to R3 can be controlled to rotate
at desired speeds.
[0066] FIGS. 4 and 5 have illustrated the case of driving three
drive rotors R1 to R3, i.e., delivery roll 2 for feeding the long
film 1, take-up roll 3, and feed roll 6. When the drive rotors R4
and R5 of the pinch roll 7 and touch roll 9 are to be driven or
when the guide rolls 4, too, are to be driven in addition to those
described above, the drive amplifiers and encoder converters may be
connected to the controller 100 through the cable LC to realize
four-stage or more-stage constitution. Or, conversely, only one or
more of these drive members may be controlled.
[0067] In the above-mentioned constitution, further, the controller
100 may be provided with a graphic panel GP to make it possible to
visually monitor the rotational speeds of the drive rotors R, to
set the draw and to display abnormal condition, so that the
setpoint value can be quickly transmitted to the controller 100 and
that manual operation signals can be transmitted.
[0068] That is, the plural drive rotors R can be separately
operated, and a difference in the speed of the drive rotors R can
be set by setting the draw in operating the line. In operating the
line, however, it is desired that the speed that serves as a
reference is given from the analog input module as described
above.
[0069] As a control circuit device for the drive rotor R, a
commercially available inverter 400 may be used as shown in, for
example, FIG. 6.
[0070] In this case, a pulse generator may or may not be used.
[0071] Referring, for example, to FIG. 7, the inverter 400 includes
a converter 401 and an inverter 402, inputs an alternating current
from an AC power source S which may be a commercial power source of
50 Hz or 60 Hz, controls the inverter 402 by a voltage-frequency
instruction signal based on a preset speed of the drive rotor R,
produces an output of which the voltage and frequency are
controlled, and controls the motor 25M of the drive rotor R, i.e.,
controls the rotational speed by controlling the frequency.
[0072] FIG. 1 has dealt with the case where the long film 1 was a
magnetic recording medium and the treating unit 5 has executed the
calender treatment. Not being limited to the case of executing the
calender treatment, however, the film running device can be used
for forming, for example, magnetic layer, i.e., for applying a
magnetic coating material, evaporating a metal magnetic material,
for effecting the sputtering, for forming a surface layer, a
protection layer, a back layer, or for executing the drying. Not
being limited to the production of magnetic recording medium,
further, the running device of the invention can be used for
executing various works such as applying a photographic emulsion,
depositing an electrode layer or applying an activated depolarizing
mix for cell of the electrode-constituting agent in the step of
producing, for example, photographic films, film capacitors,
collector films of film electrodes in the secondary cells and the
like.
[0073] As described above, the present invention deals with a film
running device having at least any one of a delivery roll for
delivering the film, a take-up roll, a feed roll, a pinch roll or a
touch roll, wherein the drive rotor which is the roll is rotated by
an electric motor incorporated therein, avoiding a structure in
which a motor is arranged at a position separate from the roll and
the rotational motion thereof is transmitted via a rotation
transmission mechanism. This saves space for providing motors and
rotation transmission mechanisms, makes it easy to design the
facilities and installation thereof, to decrease the number of
parts, to eliminate vibration and slipping caused by the rotation
transmission mechanism and, hence, to accomplish stable drive.
[0074] Besides, the rotation of the drive rotors such as delivery
roll, take-up roll, feed roll, pinch roll and touch roll are
controlled by controlling the frequency, and the long film is
brought into agreement with the running speeds that are suitably
set in each of the operation regions. Accordingly, the long film is
not damaged and can be stably worked at optimum speeds in each of
the working portions.
[0075] The frequency can be easily controlled by using a
commercially available inverter, and the device can be simply
constructed and produced at a reduced cost, offering a great
industrial effect.
* * * * *