Description

APPARATUS AND METHOD FOR ALIGNING SHEETS TO PRODUCING CORRUGATED CARDBOARD SHEETS.

Technical Field

[1] The invention relates to an alignment apparatus and a method thereof for bonding plural layers of webs, and more particularly to an apparatus and a method to align the position of web being supplied into double facing unit(double backer) so as to produce multi-layer board comprised of bonding plural layers of webs, such as corrugated board.

[2]

Background Art

[3] In general,multi-layer board such as corrugated board is a raw material of enhancing shock-absorbing, heat insulation or durabilities depending upon deformation profiles thereof by bonding three or more papers or boards, which is formed by sticking them together with adhesive or by heat adhesion method and is normally said as corrugated board or web of corrugated board.

[4] The corrugated board is widely used as the packaging material. Depending upon the application and using environments, single wall corrugated board, double wall corrugated board and the like are used. In some cases, triple wall corrugated board may be used.

[5] A process of unwinding and sending paper in the shape of roll into a corrugating machine in which the flute formation is made, and then discharging after putting and sticking another roll paper to one side of the flute tips is called as a single face web manufacturing process. A process of adhering liner roll paper to the other side of this single face web or a process of adhering liner roll paper to the web after adding another single face web is called as a double face web or double wall web manufacturing process. The web of corrugated board is made through the two processes.

[6] In case of the latter, when the liner roll paper or the single face web and the roll paper are simultaneously being put in line with the other side of the single face web so that the single face web is made into the web of corrugated board, the input position of the web or roll paper is needed to be consistently aligned for preventing a loss of the web or roll paper. The productivity and quality depends upon the alignment method. An apparatus for performing the above process is called as a double facing machine, which uses a bonding method by heat.

[7] The materials of the multi-layer board may include all types of paper such as machine glazed paper, glassine paper, normal paper, kraft paper, board paper and the

like, films such as plastic film, i.e., cellophane, vinyl chloride, polyethylene, polypropylene and the like, metal such as aluminum, steel plate and the like, and fabrics such as processed fabric raw material and the like.

[8] The reason to bond and process plural layers of paper as above is for increasing the thickness and strength or for enhancing the shock-resistance and strength such as the corrugated board. Such multi-layer board includes a packaging box, a beverage receptacle for milk, juice and the like, a board having a multi-layered structure, and the like.

[9] As shown in Fig. 1, the laminator for bonding the plural layers of web comprises a web supply unit (10) that supplies with web, an alignment device (13) that aligns the web supplied with from the web supply unit, and a double facing unit (16) that bonds the webs aligned by the alignment device.

[10] The web supply unit (10) comprises a liner supply unit (11) that supplies with liner roll paper consisting of one surface of the web of corrugated board, a dryer (1 Ia) that dries the liner roll paper supplied from the liner supply unit (11), a corrugated core paper supply unit (12) that supplies corrugated medium paper, a single face web producing unit(single-facer)(12a), which is also referred to as a corrugator, that makes flute formation in the medium paper being supplied from the corrugated core paper supply unit and adheres the corrugated medium paper to the liner roll paper to form single face web and a bottom liner roll paper supply unit(14) that supplies bottom liner roll paper consisting of a outer surface of the corrugated board.

[11] Thealignment device(13) relates to the invention herein, which is to align two single face webs(13a, 13b) that are being supplied from the single face web producing machine (single facer) (11, 11a, 12, 12a) and another single facer of the web supply unit(lθ).

[12] When each single face web and the bottom liner roll paper are pre-heated by a pre- heater (14a) and then supplied under the condition of being pasted to the flute tips, the double facing unit (16) bonds and dries them each other while heating at temperatures of which viscosity of the adhesive is activated.

[13] The adhesive hereinis made of starch in ingredient. The viscosity of adhesive is activated to stick to the bottom liner paper when heated with being pasted to the flute tips as above-mentioned, since the viscosity is activated when heating the adhesive with being melted in water.

[14] Thecorrugated board formed by the double facing unit(16) passes to a device (17) that scores the folding line and slits the widths at a pre-designed position, and a cutter(17a) that cuts out the length, and then is stacked by a stacker(18).

[15] To do these,the alignment device (13) aligns positions of the single face webs being put into the double facing unit (16) on the basis of center line or edge of each single

face web. In the traditional system, guiding plates are fitted to the both edge positions which the single face web passes through so that the plates can contact the both edges of the web and the alignment can be made by means of moving the guiding plates from side to side to adjust input position of the web when passes through between the plates.

[16] In other words, it is to set up a pair of guiding plates, which are movable from side to side, at both ends of an entrance path through which web passes, and then to have the web passed through between the guiding plates so that edge of the advancing web can be forcibly aligned by the guiding plates and then moved to the double facing unit(16).

[17] However, there may be the problems of deformation (folded or crushed) or tearing away at the contacting sides which are pushed by the guiding plates moving from side to side, because the web is made of a material having a mechanically weak strength (paper, film).

[18] As described above, if any deformation at the edges of the web arises in the course of contacting with and passing through guiding plates, the adhesive can not be uniformly applied to the edges deformed, thereby causing poor bonding between web and web or roll paper.

[19] The poorbonding as described above leads to waste at the same time, because not only the relating part but also the web of the finished product containing the inferior part should be cut away.

[20] Furthermore, the traditional way of aligning by guiding plates requires to frequently change the positions of the guiding plates according to the continual change of the web widths. In particular, the end portion of the preceding web where the width changes are consecutively made and the starting portion of the succeeding web cannot be aligned during the bonding at high speed because of the different web widths in most cases, and thereby the production speed should be lowered.

[21] Another steeringapparatus invented to make up for the problems in the traditional way of aligning by the guiding plates is designed to incorporate about 8-10 steering rolls, made of urethane, having a diameter of 160 mm and a width of 50 mm, fitted in a row on an rotating axis and the rotating axis is provided over a center of the single face web so that it maintains 90 degree angle to an advancing direction of the web. A pneumatic apparatus is attached to the rotating axis so that the steering rolls can apply predetermined pressure force to the web. And a supporting lever of the rotating axis is again connected to a steering axis that steers the rotating axis so that the steering rolls are located over the center of the advancing web so as to move the advancing direction of the web from side to side. At this time, a DC motor controls the steering axis.

[22] In other words, the steering apparatus features that both ends of the axis of the steering rolls being rotating are connected to the steering axis fixed by an extended shaft. The pneumatic apparatus is mounted to vertically move the steering roll axis

pivoting on the connected point. The steering rolls press the center of the web being put in and the fixed axis connected to the controller rotates from side to side, enabling the advancing direction of the web being pulled out from the double facing unit(16) to be adjusted. However, in the aligning method by means of the single steering axis which adjusts the position at the center of the web, the paper tension in pulling web is so high even with its own weights when the single face web weighs heavy or alignment is made at high speed, i.e., when the roll paper used is of heavy weight or of wide width, because a length of the web to be pulled is 20 meters or more for the web on the upper bridge that it requires to enhance the basic pressure of the steering roll pressing the center of the web for ensuring a proper steering ability.

[23] Therefore, it causes serious defect that the bonding at the center of the web is not made due to the flute deformation(crushed) caused in the pressed center of the single face web when the higher pressure to the web is applied.

[24] In other words, in order to move the position of the web, it is required to apply the optimum force to the web while adjusting the direction of the steering roll, thereby twisting the direction and moving the position of the web by means of friction force between the web and the steering roll.

[25] The steering roll is consisted of one steering axis. Accordingly, when the advancing speed of the web is high or the web weighs heavy, the force of pulling the web by the steering roll is strongly applied to the contact point (contact point between the steering roll and the web), so that the contact surface where the steering rolls press the web must be increased as much as that.

[26] By the way, if the pressing force of the steering roll is weakened, it makes the steering of the web unavailable due to slippage caused by reduced contact surface between the steering roll and the web. To the contrary, if the pressure on the web is applied too much to increase the contact surface, the flute deformation on the pressing surface of the web is made.

[27] Reduced pressing force should be applied to the web for preventing the poor bonding which might be caused by the flute deformation and production speed should be lowered for ensuring smooth movement of the position of the web.

[28] In the meantime,the above-mentioned way of steering via steering rolls of single steering axis at the center of the web, designed to eliminate the problems appeared in the conventional aligning apparatus by means of the guiding plates, comprises control method as follows: white/black cameras are fitted at an uniform distance away to right and left side ends towards an advancing direction of the single face web and a pair of high frequency lamps is fitted towards the cameras at the locations of rear right and left sides of the web being supplied. And then after detecting the positions of right and left edges of the web by means of taking image of brightness and darkness line shown in

the camera screen, thereby the position of the web is adjusted (a model by means of cameras offered from E&L Company). However, as for this method concerned, only the positions of the side ends of the web in the camera screen are detected. Accordingly, when the edges of the web is bent, there occurs a deflection between an actual position of the web and a position of the contrast line in the process of taking images(refer to the description relating to FIG. 13) and it is not available to calculate a width of the single face web being advancing, so that an operator may encounter difficulties to cope with an emergency. In addition, the communication between the adjustment unit and the controller is made in a manner of CAN communication that is relatively slow, so that it is difficult to apply the method to a real-time control corresponding to the moving speed of the web.

[29] In particular, when the web moves at a high speed of 300 mpm (meter per min) for ensuring the productivity maximized, it is required to increase the communication speed and to enhance a steering ability so as to achieve the real-time alignment of the positions of the web, which is advancing at high speed. However, due to the technical problems, it is used a method of widening an alignment limit of differences or a manner of further providing another camera device in a row in addition to the apparatus using the cameras, which means double-adjusting the position of the web moving at the high speed, resulting to expensive costs in comparison with the performance thereof.

[30] Furthermore, regarding the measurement of the position of the web under the condition in which the edges of the web are bent in a varied form or in different shapes, it is technically problematic to measure the precise position in a manner of the camera by means of taking images for the brightness and darkness contrast line of the edges of the web.

[31] Inother words, as for the single face web, there occurs a warp due to a difference in humidity between the upper and the lower surface or a difference in tension forces between the respective roll papers. As to the manner of camera concerned, the detection of the position of the web edges are judged via a back light device fitted to the opposite side across the web. Therefore, even when the web is warped with the edge thereof being bent, its position warped is misjudged as an actual position, so that an alignment error of the web can be caused.

[32]

Disclosure of Invention Technical Problem

[33] Theobject of the invention is to solve the problems as above described in the conventional web alignment apparatus and to provide an alignment apparatus and method

for bonding plural layers of webs, wherein distance measuring meters using laser beams are provided over the upper side of both ends of each webs, which are putting into a double facing unit in a process of manufacturing a corrugated board consisted of multiple roll papers, a predetermined limit is set on a traverse line from an advancing direction of the web being put in, the laser beams are consecutively illuminated within the preset limit to measure a distance of an object within the predetermined limit from the illuminating position, a surface profile of the web is recognized by data collected along the distance measuring line within the predetermined limit to calculate a position and a width of the web and position values of a center line and both side end lines of the advancing web and thereby controlling a position of the web in a real time by a manner of TCP/IP communication.

[34] Anotherobject of the invention is to provide an alignment apparatus and method for bonding plural layers of webs, minimizing the number of steering rolls contacting with the web to adjust a position thereof so as not to affect a quality of the web and adjusting a position of the web correctly and quickly without making any deformation in quality of the web even at the web advancing speed of 300 mpm or more.

[35] Still another object of the invention is to provide an alignment apparatus and method for bonding plural layers of webs, capable of minimizing a damage of web in the course of correcting a position of the web and thereby increasing an economic efficiency.

[36]

Technical Solution

[37] In order toachieve the above objects, the invention offers an alignment apparatus for bonding of multi-layer web which makes a feature of comprising a base unit that is supplied with web from a web supply unit and maintains a established height thereof ; a sensing device that senses at least one side end of the web passing through on the base unit; an adjustment device that consists of at least two pieces separated from each other, enabling to move a position of web by contacting the face thereof passing through on the base unit and by acting with a synchronized steering angle for moving web ; and a controller that makes it available to move the corresponding position of the web to base position through the adjustment device by setting a base position at a predetermined position and measuring via the sensing device at least one side end of the web passing through on the base unit.

[38] Thebase position features a position which a center of a traverse width of or an edge of the web passes.

[39] Thebase unit makes a feature of comprising a lead-in roll for preventing a damage in the underneath of the web being put in, a fixed round-bar established for maintaining

constant tension against the lead-in roll and a support plate for supporting the underneath of the web towards the adjustment device.

[40] The sensing device consists of a laser-type distance measuring apparatus positioned at a rear end of the adjustment device and at upper ends of left and right sides of a center of the base plate.

[41] The sensing device comprises a light source unit that emits laser beam, a light receiving unit that receives the laser beam reflected from the web, a reflection unit having a plurality of reflectors that illuminates the laser beam of the light source unit to a traverse direction of the web being put in within a preset limit and at the same time reflects the reflected light from the web to the light receiving unit; and a sensing controller that receives, in a uniform interval within a preset limit, the reflected light of the laser beam which is illuminated in a uni-direction within a predetermined limit from the light source unit, measures distances up to the web through a time gap between the illuminated light and the received light and recognizes a surface profile of the web by arithmetic data collected along the distance measuring line to calculate a width and a position of the web.

[42] The controller illuminates the laser beam from the sensing device to a limited area in a traverse direction towards an advancing direction of the web being put in, receives distance data measured at a preset interval within a preset measuring limit and thus to make a measurement line and recognizes a surface profile of the web along the measurement line ; measures distances up to the both edges of the surface profile of the web from a distance center- line between the sensing devices installed on the right and left to calculate a width of the web ; and measures deflections in position with a preset alignment line according to the value calculated to determine a movement distance of the web being put in.

[43] The adjustment device comprises at least two steering rollers that contact the surface of the web passing through on the base unit and are separated from each other; at least two steering axes each of which steers the steering rollers, respectively; an elevation unit that adjusts a vertical position of the steering rollers; and an angle adjusting unit that adjusts a steering angle of the steering rollers, and simultaneously adjusts at least the two steering axes via the angle adjusting unit to adjust a position of the web while the steering rollers are contacting the upper surface of the web via the elevation unit by the controller.

[44] Thesteering rollers consist of numbers of sub-rollers that are respectively installed to at least two rotating axes and are rotating independently. And the rotating axes, consisting of at least two pieces, have a separate steering axis respectively, are connected to the angle adjusting unit and are steered with synchronized angle.

[45] The elevation unit consists of a pneumatic cylinder.

[46] The angle adjusting unit consists of a servo motor.

[47] The sensing device and the controller communicate with each other by means of

TCP/IP.

[48] The invention also provides an alignment method for bonding plural layers of web comprising the steps of:

[49] (a) detecting webs, having different widths respectively, being supplied with to adhere each other and measuring at least one of the preset measurement positions;

[50] (b) calculating a movement distance for moving an alignment position obtained from the measurement position of the webs being supplied with to a preset base position; and

[51] (c) moving and checking the alignment position for the webs being supplied with to the base position.

[52] The alignment position for the web in the step of (a) is set by means of measuring a width of web in a traverse direction of 9O ⁰ C angle towards an advancing direction of the web being supplied and calculating a center line or guide line of the web.

[53] Thealignment position of the step (a) is aligned either by a manner of aligning an assumed center line or guide line, which is set to each of the web being supplied, with a preset base line or aligning another assumed center line with a specific assumed center line, or by a manner of aligning on the basis of side end of preset specific web out of the webs being supplied with.

[54] Thecalculation of the movement distance in the step of (b) is made by means of sensing side positions of the web through the surface profile of a measurement line obtained by repeatedly measuring distances to the positions of the web at a uniform interval, calculating the width of the web being supplied with by measuring distances of the sensed edge positions of the web from a center line of the base unit, and figuring out distance of the web being supplied with from a center line of the base unit or from a preset guide line after establishing a guide line.

[55] Thedistance is measured by means of obtaining time gaps between the illuminated laser beam and a reflected light that is reflected at a preset uniform interval in angle.

[56] In the step (c),the alignment position of each of the webs being supplied is made to be in line with a preset base position and the position of the web is to be controlled so that the web moves to the alignment position by calculating movement distance between an alignment position of the web being supplied and the base position to convert a value thereof into an angle.

[57]

Advantageous Effects

[58] The apparatus and a method thereof for bonding plural layers of web relating to the

invention offers to prevent losses of the web caused due to alignment error by providing precise and rapid real-time alignment of the each webs being supplied for producing corrugated board or multi-layered web consisted of bonding webs and by sending them to the double facing unit, to make it available to change the widths of the web in keeping the state of alignment at a normal running speed which differs from the conventional method obliged to reduce the production speed whenever width changes of the web are made, and to make increased productivity remarkably effective by providing easy operation thanks to automation. [59]

Brief Description of Drawings

[60] FIG.1 illustrates a structure of a bonding apparatus for bonding a corrugated board consisted of a plurality of webs; [61] FIG.2illustrates a perspective view of an alignment apparatus for bonding multiple webs according to an embodiment of the invention; [62] FIG.3 illustrates a side view of an alignment apparatus for bonding multiple webs according to an embodiment of the invention; [63] FIG.4illustrates a front view of an alignment apparatus for bonding multiple webs according to an embodiment of the invention; [64] FIG.5illustrates a plain view of an alignment apparatus for bonding multiple webs according to an embodiment of the invention; [65] FIG.6illustrates a perspective view of a steering roller related apparatus out of the alignment apparatus for bonding multiple webs according to an embodiment of the invention; [66] FIG.7illustrates a front view of a steering roller related apparatus out of the alignment apparatus for bonding multiple webs according to an embodiment of the invention; [67] FIG.8illustrates a side view of a steering roller related apparatus out of the alignment apparatus for bonding multiple webs according to an embodiment of the invention; [68] FIG.9is a block diagram illustrating a structure of the alignment apparatus for bonding multiple webs according to an embodiment of the invention; [69] FIG.10 is a flow chart illustrating a control method of the alignment apparatus for bonding multiple webs according to an embodiment of the invention; [70] FIG.11 illustrates an example of a control method of the alignment apparatus for bonding multiple webs according to an embodiment of the invention; [71] FIG.12 illustrates an example of a change in adjusting angle of an adjustment roller in a control method of the alignment apparatus for bonding multiple webs according to an embodiment of the invention;

[72] FIG.13 illustrates an example of a method of detecting side positions of web by the alignment apparatus for bonding multiple webs according to an embodiment of the invention;

[73] FIG.14 illustrates an example of a method of determining a center line of abnormal web in the alignment apparatus for bonding multiple webs according to an embodiment of the invention;

[74] FIG.15 illustrates an example of a method of setting a center line of the alignment apparatus for bonding multiple webs according to an embodiment of the invention;and

[75] FIG.16 illustrates an example of an alignment method when different widths of papers are connected in the alignment apparatus for bonding multiple webs according to an embodiment of the invention;

[76]

Best Mode for Carrying out the Invention

[77] With reference to the accompanying drawings figuring examples, an alignment apparatus for bonding multiple webs and a method thereof according to an embodiment of the invention will be hereinafter described in details.

[78] In the drawings, FIG. 2 is a perspective view of an alignment apparatus for bonding multiple webs according to an embodiment of the invention; FIG. 3 is a side view of an alignment apparatus for bonding multiple webs according to an embodiment of the invention; FIG. 4 is a front view of an alignment apparatus for bonding multiple webs according to an embodiment of the invention; FIG. 5 is a plain view of an alignment apparatus for bonding multiple webs according to an embodiment of the invention; FIG. 6 is a perspective view of a steering roller related apparatus out of an alignment apparatus for bonding multiple webs according to an embodiment of the invention; FIG. 7 is a front view of a steering roller related apparatus out of an alignment apparatus for bonding multiple webs according to an embodiment of the invention; FIG. 8 is a side view of a steering roller related apparatus out of an alignment apparatus for bonding multiple webs according to an embodiment of the invention; FIG. 9 is a block diagram for illustrating a structure of an alignment apparatus for bonding multiple webs according to an embodiment of the invention; FIG. 10 is a flow chart for illustrating a control method of an alignment apparatus for bonding multiple webs according to an embodiment of the invention; FIG. 11 illustrates an example of a control method of an alignment apparatus for bonding multiple webs according to an embodiment of the invention; FIG. 12 illustrates an example of a change in adjusting angle of an adjustment roller in a control method of an alignment apparatus for bonding multiple webs according to an embodiment of the invention; FIG. 13 illustrates an example of a method of detecting side positions of web by an alignment

apparatus for bonding multiple webs according to an embodiment of the invention; FIG. 14 illustrates an example of a method of determining a center line of abnormal web in an alignment apparatus for bonding multiple web according to an embodiment of the invention; FIG. 15 illustrates an example of a method of setting a center line in an alignment apparatus for bonding multiple webs according to an embodiment of the invention, and FIG. 16 illustrates an example of an alignment method when different widths of papers are connected in the alignment apparatus for bonding multiple webs according to an embodiment of the invention.

[79] As shown in FIG. 2 to FIG. 8, an alignment apparatus for bonding multiple webs according to an embodiment of the invention is an apparatus for aligning double webs.

[80] Tothis end, the apparatus for aligning a position of each web are installed at upper and lower bridges as shown in FIG. 2 to FIG. 5 and each of the aligning apparatus has same structure and do same operation.

[81] In FIG. 2 to FIG. 5, reference numerals are given to structural elements for upper bridge only. The structural elements without given reference numerals for the lower bridge are as same as the upper.

[82] Inorder to supply each webs to the alignment apparatus of the invention, rolled paper

(90) is supplied from a supply unit (10), as shown in FIG. 1.

[83] The alignment apparatus of the invention that is supplied with the web (90), aligns it at a predetermined position and delivers it to a double facing unit (16) of FIG. 1 comprises a base device that maintains the web(90) supplied at a established height; sensing devices (62, 64) that sense both edge positions of the web (90) passing the base device, an adjustment device that contacts one surface of the web(90) passing the base device to adjust a position of the web (90), a controller (60) that figures out the distance of both edge positions of the web (90) passing the base device from a center line(refer to FIG. 15) calculated through the positions of the sensing devices (62, 64) and thus adjusts a position of the web by the adjustment device, and a frame (20) which the above structural elements are mounted to.

[84] As shown in FIG. 3, the base device comprises a lead-in roll (37) that is mounted to a front end of the supply unit so as to make rotation possible, a fixed roll (37a) that supports the web passing the lead-in roll (37) and a base unit (35) that supports the underneath of the web (90) passing the fixed roll (37a).

[85] Andguiding units (32, 33) that makes a position of the web adjustable by means of manual operation are installed at a rear end of the base unit (35).

[86] Theguiding units (32, 33) are provided on the upper and lower bridge separatedly and guide blocks having interacting movement are mounted at both side ends of the guiding unit. The guide blocks are designed to simultaneously move right and left while keeping a same distance away from the center line to a traverse direction of the

web by a concentric axis connected to both guide plates.

[87] Each of the sensing units (62, 64) consisting of a laser-type distance measuring device comprises a light source unit that emits laser beam; a light receiving unit that receives the laser beam reflected from the web; a reflection unit having a plurality of reflection plates that illuminate the laser beam of the light source unit to a traverse direction of the web being put in within a preset limit and at the same time reflect the reflected light from the web to the light receiving unit; and a sensing controller that receives, in a uniform interval within a preset limit, the reflected light of the laser beam which is illuminated in a uni-direction within a predetermined limit from the light source unit, measures distances up to the web using a time gap between the illuminated light and the received light and recognizes a surface shape of the web by arithmetic data collected along the distance measuring line to calculate a width and a position of the web.

[88] The controller which controls a position of the web (90) passing the base unit (35) by using the sensing units(62, 64) measures distance in a perpendicular direction towards an advancing direction of the web (90), i.e., towards an axis direction of the lead-in roll (37) and the like at a preset interval within a preset measurement limit for the edges of the web via the sensing units (62, 64), recognizes width and position of the web calculated by means of time gaps between the illuminated light and the reflecting light received, makes a guide line of the web thereon and moves the position of the web to a base line via the adjustment unit so that the guide line is in line with the preset base line.

[89] At this time, the way of calculating the width and position of the web is as follows.

[90] The measurement line (the measurement line means shapes as like 62a, 64a shown in

FIG. 11) along the distances can be made by receiving the laser beam, which consecutively illuminates from the light source unit to a traverse direction of the web (90) being put into the base unit (35), at a constant interval. From this, with eliminating the measurement line of any object being deviated from distances preset between a passing line of the web (or alignment line, i.e., a measurement line of the laser beam formed at a height which the web passes, i.e., on an upper surface of the web passing through on the base unit) and the sensing units (62, 64), a surface profile of the measurement line reflected from the upper surface of the web can be figured. Thereafter, the width of the web can be calculated by substituting the measurement line via the sensing units (62, 64), i.e., the edge position of the web (90) for the preset distance between the sensing units (62, 64), i.e., base position (C ₀ ), which is set at a center position of the preset distances between the sensing devices(62, 64), namely Li and L ₂ as shown in FIG.15. Then, if the calculated width of the web is divided into two equal parts, a position of the center line of the width of the web (90) can be calculated.

[91] In other words, as shown in FIG. 15, the sensing units (62, 64) measures a distance to the web (90) at a uniform interval of angle (for example, at 0. l°C~0.2°C interval) within a total limit of 7O ⁰ C angle for each 35°C(angle Al) towards right and left sides on the basis of the vertical center line. In such a case, it happens there are an area for which a distance is measured (inner part of the web, i.e., a section of forming a surface profile) and an area for which a distance is not measured(a section for which measurement line is not profiled) on the rightward or leftward basis from the edge position of the web (90), enabling to calculate a position of the edges of the web through a measured angle A ₂ of the part for which a distance is not measured.

[92] The edge position can be measured by using the measured angle A ₂ as follows.

[93] A distance from the center (C ₀₎ to the vertical illumination line of the laser beam of the sensing unit(62) shown in left of FIG. 15 can be obtained from a sine value of the measured distance (L) by the measured angle A ₂ to the distance L ₁ , which is obtained by dividing the distance between a pair of sensing units (62, 64) into two equal parts.

[94] In other words, the left edge position of the web is a distance obtained by adding dL to the distance Li, and the dL is calculated from Sine(A ₂ )L.

[95] On the contrary, a distance from the center (C ₀ ) to the vertical illumination line of the laser beam of the sensing unit (64) shown in right of FIG. 15 can be obtained from a sine value of the measured distance (L) by the measured angle A ₃ , in the same way as measured angle A _2, to the distance L ₂ which is obtained by dividing the distance between a pair of sensing units (62, 64) into two equal parts.

[96] In other words, the right edge position of the web is a distance obtained by deducting dL from the distances L2, and the dL is calculated from Sine(A ₃ )L.

[97] On this occasion, the positions of the left and right edge of the web (90) shown in

FIG. 15 are away same from the center and are illustrated to give an example whether the laser beam of the sensing units (62, 64) goes beyond the vertical line or not.

[98] The center line of the web can be obtained if dividing the both edge positions, which are calculated as described above, into two equal parts. It makes to move the web to be adjusted to the center line of the web in line with the center line of the base unit (35).

[99] As shown in FIG. 6 to FIG 8, the adjustment device comprises a pair of steering rollers (40) that contact upper surface of the web (90) passing through on the base unit (35); a pair of arms (42) to which the axis of the steering rollers (40) are respectively mounted; a pair of steering axes (50) that turn the arms (42); a pair of frames in adjustment device (46) that are mounted to both side ends of the frame(20); first and second cross members (45a, 45b), which are mounted on the front and the rear of the respective frames in adjustment device (46), movable upwards and downwards through vertical guides (47); an elevation member (48) that vertically moves the first and second cross members (45a, 45b); a pair of elevation actuators (55) that vertically

move the elevation member (48); a pair of steering members (43) that are connected to one end of each steering axis (50) toward the second cross member (45b); a steering cross bar (44) that is connected to one end of each steering member (43); and an angle adjusting actuator (52) of which one end is connected to one side of the steering cross bar (44).

[100] At this time, it is available to remarkably shorten the horizontal length of the arm (42) compared to an arm length of the conventional steering roll, because the adjustment device in the invention consists of two pieces separated from each other so as to contact both sides of the web, resulting to reduce the change in adjusting angle and to have the position adjusted enough by reduced friction with the web.

[101] Andthe steering rollers (40) consist of two sets and are mounted on a perpendicular line to the advancing direction of the web (90).

[102] And each ofthe steering rollers (40) consists of several sub-rollers (for example, four) that are fitted to one rotating axes to be freely rotatable.

[103] The reason to make each of the steering rollers (40) to be consisted of several sub- rollers is to have each of the sub-rollers freely rotatable when the angle adjustment is made by the angle adjustment unit (52), enabling to prevent the twist of the web being contacting and advancing. The rotating axes of a pair of steering rollers (40), which are separately connected to each steering axis, are designed to be connected to the steering members (43) so that they are steered at a synchronized angle each other.

[104] Andthe elevation actuator (55) consists of a pneumatic cylinder. A pneumatic line for driving the pneumatic cylinder consists of a compressor (80) and an air chamber (82), as shown in FIG. 9, so that it is running by compressed air supplied with keeping at a constant pressure.

[105] Andthe pneumatic force being supplied to the elevation actuator (55) is controlled depending upon a degree of opening of an elevation valve (85) which is controlled by the controller (60). When the steering roller (40) contacts the web (90), it should contact the web at a pressure, which dose not cause deformation of flute of the web, and the disconnection from the web (90) is made by cutting off the pneumatic force.

[106] Theangle adjusting actuator (52) consists of a servo motor. The controller (60) receives a feedback from the servo motor, recognizes a present position as an angle and thereby control an angle adjustment as much as required.

[107] Inaddition, a position (elevation height) of the elevation actuator is adjusted by a position adjusting screw (located just beside the connection place of 48 with 55) depending upon a thickness of the single face web.

[108] In the meantime, a manner of TCP/IP, a high speed communication manner, applies to the communication between sensing units (62, 64) and the controller (60) for ensuring a reliability and a real-time processing in the data communication.

[109] With reference to FIG. 10 to FIG. 12., the operation of the alignment apparatus for bonding multi-layer webs according to the invention will be described.

[110] First it is to set a base position of the assumed center line (C ₀ ) of the web (90) passing through on the base unit, i.e., the rear end of the base unit (35), a time interval for measuring positions of both edges of the web via the sensing units (62, 64) and an allowable difference limit for disregarding position adjustment in a distance between the base position through the assumed center line (C ₀ ) and the measured positions of the web.

[I l l] Further,as shown in FIG. 13(A) and FIG. 13(B), a measurement upper limit distance (UL) and a lower limit distance (LL) should be set.

[112] The reason to set the upper limit distance (UL) and the lower limit distance (LL) is as follows.

[113] The web (90) keeps in a close contact condition, i.e., a flat state with the base unit

(35) in most cases as shown in FIG. 13(A), but maintains a condition as shown in FIG. 13(B) if it may be delivered as twisted to one side by the external force and surrounding environments, particularly by humidity and the like.

[114] Therefore, In case ofa normal condition as shown in FIG. 13(A), an edge distance of the web (90) is measured as S _N (Since the measurement distance is beyond the lower limit distance (LL) when it just pass over the edge position, the distance measured just before passing over the lower limit distance (LL), i.e., the position of measuring S _N is determined as a position of a side end.), where a position of the edge is recognized.

[115] However, in an abnormal condition as in the case of FIG. 13(B), an edge distance of the web (90) is measured as Si (At this time, the side end is determined as above described. However, the upper limit distance(UL) is disregarded by judging the case as an abrupt incoming of an object rather than the web (90)).

[116] Accordingly, the controller (60) determines the position, at which Si is measured, as a position of the side end. Such determination as above can be justifiable, even though the web(90) is in the modified position (P ₂₎ changed from the original position (P ₁₎ , which is a position in a normal condition, because dWi _, a difference between the original position (Pi ₎ and the modified position (P _2)> is deemed to be as a very slight deflection, i.e., a cosine value (dWn=cosdA*S ₁ ) of an angle difference (dA) between an angle for the original position (Pi ₎ and an angle for the modified position (P ₂ ).

[117] AndDelivery ofthe web(90) starts(S12) after driving of the alignment apparatus is started.(Sl l)

[118] Until the supply of the web (90) is completed (S 13), the controller (60) measures a deviation distance (dW) of both edges of the web by means of the laser beam via the sensing units (62, 64), as same as explained in the description on the sensing units (62, 64), and thereby determines a position of a measurement center line (C _m ), which is an

actual center line of the web (90), on the basis of the assumed center line (C ₀ ).

[119] Provided within the limit after checking whether the deviated distance (dW) of the measurement center line ( C _m ) is within allowable difference limit (S 15), since it is in the condition as the same as in (A) of FIG. 11., the web (90) remains moving to go straight (S 151) without adjusting an angle of the steering roller (40) for a predetermined time period and the process of checking a position is performed again(S19).

[120] However, if the deviated distance (dW) of the measurement center line ( C _m ) is out of the allowable limit, it is in the condition as the same as in (B) of FIG. 11 or (C) of FIG. 11 (S 16). As like as (B) or (C) of FIG.11 according to the value of dW, the steering roller (40) is to be adjusted to an angle A or an angle -A (S 17, S 171), as shown in (A) of FIG. 12 or (B) of FIG. 12.

[121] At this time, the angle of the steering roller (40) is maintained during a period of time as much as to move dL(=sinA*dS), a sine value of the angle A to the measured distance dS against the deviated distance dW. It means a period of time to move dL is the time period for which circumference of the lead-in roll (37) rotates as much as dL.

[122] Likewise as this, when the position adjustment for the deviated distance dW is completed, the angle of the steering roller (40) moves to the starting position (S 18) (in the condition of (A) of FIG. 11) by means of the angle adjustment actuator (52).

[123] The above processes are performed during the position checking period (S 19, S20), which is repeatedly performed until the delivery of the web (90) is stopped.

[124] In the meantime, the web (90) may be supplied with as in a condition of one side being torn or damaged as shown in FIG. 14, unlikely in a normal condition, or as in a condition that different widths of webs are connected as shown in FIG. 16, which means remarkable change of the web widths as like the case when the web (90) having a narrower width is connected to wider width web (90) as shown in (A) of FIG. 16 or the web (90) having a wider width is connected to the narrower width web (90) as shown in (B) of FIG. 16.

[125] Underthe situations, the change of the measured position of right edge (S^) is made in a steep slope in the damaged areas, in comparison change of the left edge position, measured in a normal condition, is made in a relatively easy slope within a predetermined time of interval. Accordingly, calculating the measurement center line (Cm) against the assumed center line (C ₀ ) by using the measured data of the left edge (S _L ), the measurement center line (Cm) of the web (90) is adjusted against the assumed center line (C ₀ .).

[126] Or If the web is deemed not in a normal condition, i.e., if the width of the web changes beyond the preset limit value, compared to the width of the web measured up to the present, the web may be kept in moving forwards for a predetermined period of time under the advancing condition as like just before (desirably, keeping in a straight

advancing condition), resulting to leave as it is without adjustment for the relevant area of the web to maintain the normal advancing condition.

[127] In the above description, the way how to adjust the position of the web is illustrated to be made in a manner of matching the measurement center line (C _m) , calculated from the positions of both edges measured by the sensing units (62, 64), to the assumed center line (C ₀ ). However, the position may be adjusted on the basis of any one side end of the web as the case may be.

[128] Inother words, the position of the web may be adjusted by comparing the assumed side end position of the web with the position of the side end actually measured.

[129] However, Provided the position of the web is adjusted by comparing the center lines as described above, even though the web is being supplied with in a condition of any one side end being damaged, the position is adjusted by using the assumed center line and the measurement center line to bond the webs, resulting to minimize the area of bad qualities in the web bonded.