Abstract:
A peripheral length correction device with a metal ring wrapped around a pair rollers of a rotating driver side and a follower side, wherein, while regulating the separation distance of the pair of rollers and exerting a predetermined tension to the metal ring, corrects the metal ring peripheral length by strengthening the predetermined tension; a peripheral length measurement device which measures the separation distance to provide a measurement value and calculates the metal ring peripheral length from the measurement value; and a surface defect inspection device, wherein, while regulating the separation distance of the pair of rollers and exerting the predetermined tension to the metal ring, inspects for an existing surface defect on the metal ring, which comprise a scraper, wherein each of the pair of rollers has its outer circumferential surface in contact with a blade edge of the scraper.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates to a peripheral length correction device, a peripheral length measurement device and a surface defect inspection device of a metal ring which constitutes one of the components in a V-belt for a Continuously Variable Transmission (hereinafter denoted as “CVT belt”).  
         [0003]     2. Description of the Related Art  
         [0004]     Conventionally, there is a known CVT belt structure in which a plurality of layered thin metal rings of approximately 0.2 mm (0.0008 in.) in thickness are laminated together and unified by consecutively attached steel elements.  
         [0005]      FIG. 5  is an outline view diagram of a CVT belt in conventional prior art. As shown in this diagram, a CVT belt  1  is constructed by assembling two laminated belts  2  containing a plurality of metal rings  2   a  (for example, a stack of about 12 endless layers) which are supported by thin trapezoidal layered elements  3  composed of a large number of steel elements  3   a  (for example, about 400 consecutive elements).  
         [0006]     Such a CVT belt  1  structure is manufactured in the following steps:  
         [0007]     (1) Initially, a ring-shaped drum is formed by welding together the ends of a thin sheet of ultrahigh strength steel, such as maraging steel, etc.  
         [0008]     (2) Next, the drum is cut into round slices of a predetermined width and rolled to create the metal rings  2   a  of a basic peripheral length.  
         [0009]     (3) Subsequently, after performing a solution treatment, etc. to each of the above-mentioned metal rings  2   a , the required peripheral length relative to the CVT belt  1  stacked layer position is supplied using a “peripheral length correction device.” Here, “peripheral length” denotes the ring length of a metal ring  2   a , namely the length of one revolution. The peripheral length of a metal ring  2   a  is subtly different for each CVT belt  1  stacked layer position. In particular, the outermost periphery side is slightly longer and the innermost periphery side is slightly shorter.  
         [0010]     (4) Next, while inspecting whether or not the proper peripheral length for each stacked layer position has been provided with the “peripheral length measuring device,” the existence of surface defects in the metal rings  2   a  is inspected using a “surface defect inspection device.” 
         [0011]     (5) Lastly, after performing aging treatment, nitride treatment, etc. to increase surface hardness of the metal rings  2   a  which pass a quality control inspection, a metal ring  2   a  with the proper peripheral length difference applied for every layer are sequentially laminated together to form a laminated belt  2 . The steel elements  3   a  are consecutively attached and the CVT belt  1  is completed.  
         [0012]     In the process of manufacturing the CVT belt  1 , the above-mentioned three devices (a peripheral length correction device, a peripheral length measurement device and a surface defect inspection device) are necessary. Although these devices are independent apparatus or devices which execute concurrently a portion or all of peripheral length correction, peripheral length measurement and surface defect inspection, all are common in that peripheral length correction, peripheral length measurement and surface defect inspection are performed with a metal ring  2   a  wrapped around between two rollers while exerting the required tension to a metal ring  2   a  as the rollers are rotated.  
         [0013]      FIG. 6  is a substantial part conceptual diagram of a peripheral length correction device, a peripheral length measurement device and a surface defect inspection device. As seen in the diagram, a pair of metallic rollers  4 ,  5  with one as a driver side rotating in a constant direction and the other as a follower side are arranged individually at a predetermined separation distance L on the same level surface. A predetermined tension (tensile force) is exerted relative to a metal ring  2   a  wrapped around the pair of rollers  4 ,  5  as a correction object, a measurement object or an inspection object by slightly expanding the separation distance L of the pair of rollers  4 ,  5 .  
         [0014]     In such a configuration, by strengthening the above-stated tension, a metal ring  2   a  is extended and that peripheral length can be corrected (longer than the basic peripheral length). Likewise, by measuring the separation distance L while exerting the predetermined tension, the peripheral length of a metal ring  2   a  can be calculated from that measured result. Furthermore, while observing the surface of a metal ring  2   a  with a camera, etc. during circumvolution (rotation), the existence of surface defects can be inspected.  
         [0015]     Apart from that, when circumvolutory movement is performed with a metal ring  2   a  wrapped around the pair of rollers  4 ,  5 , a flaw may be scarred to the inner circumferential surface of a metal ring  2   a  (contact surface with the rollers  4 ,  5 ). One of those causes can be attributed to foreign matter (a substance or an object) adhering to the surface of the rollers  4 ,  5 . For example, such foreign matter can be waste material (metal scraps, etc.) adhered on the belt conveyor for transporting a metal ring  2   a  or processing residue from a metal ring  2   a  (metal powder, etc.) floating in the air. In order to prevent such problems, even though each CVT belt  1  is checked by visual examination to determine whether or not there is foreign matter adhered to the surface of the rollers  4 ,  5 , considerable manpower is needed to perform these manual inspections.  
         [0016]     Furthermore, in order to remove foreign matter adhered to the surface of the rollers  4 ,  5 , for example, various methods have been devised such as placing a brush against the surface of the rollers  4 ,  5  or placing a suction nozzle close to the surface of the rollers  4 ,  5  for suction removal of foreign matter, etc. Nevertheless, while foreign matter loosely adhered to the surface of the rollers  4 ,  5  can be removed by these methods, foreign matter firmly adhered is difficult to remove and frequently necessitates replacement of the rollers  4 ,  5  themselves to a fresh set.  
       SUMMARY OF THE INVENTION  
       [0017]     Therefore, the present invention provides a peripheral length correction device, a peripheral length measurement device and a surface defect inspection device for enabling removal of foreign matter firmly adhered to the surface of rollers in view of achieving damage avoidance to the inner circumferential surface (the contact surface with the rollers) of a metal ring.  
         [0018]     The present invention is a peripheral length correction device with a metal ring wrapped around a pair of rollers of a rotating driver side and a follower side, wherein, while regulating a separation distance of the pair of rollers and exerting a predetermined tension to the metal ring, corrects the metal ring peripheral length by strengthening the predetermined tension, comprising a scraper, wherein each of the pair of rollers has its outer circumferential surface in contact with a blade edge of the scraper.  
         [0019]     As a preferred embodiment in the present invention of the peripheral length correction device, the scraper blade edge has an angle of less than 90 degrees relative to a tangential line of the outer circumferential surface of the rollers.  
         [0020]     Also, the scraper blade edge may have an angle of substantially less than 90 degrees divided equally relative to a perpendicular line of the outer circumferential surface of the rollers.  
         [0021]     Furthermore, the scraper blade edge may have an angle of substantially 90 degrees or more than 90 degrees divided equally relative to a perpendicular line of the outer circumferential surface of the rollers.  
         [0022]     The present invention is a peripheral length measurement device with a metal ring wrapped around a pair of rollers of a rotating driver side and a follower side, wherein, while regulating a separation distance of the pair of rollers and exerting a predetermined tension to the metal ring, measures the separation distance to provide a measurement value and calculates the metal ring peripheral length from the measurement value, comprising a scraper, wherein each of the pair of rollers has its outer circumferential surface in contact with a blade edge of the scraper.  
         [0023]     As a preferred embodiment in the present invention of the peripheral length measurement device, the scraper blade edge has an angle of less than 90 degrees relative to a tangential line of the outer circumferential surface of the rollers.  
         [0024]     Also, the scraper blade edge may have an angle of less than 90 degrees divided equally relative to a perpendicular line of the outer circumferential surface of the rollers.  
         [0025]     Furthermore, the scraper blade edge may have an angle of substantially 90 degrees or more than 90 degrees divided equally relative to a perpendicular line of the outer circumferential surface of the rollers.  
         [0026]     The present invention is a surface defect inspection device with a metal ring wrapped around a pair of rollers of a rotating driver side and a follower side, wherein, while regulating a separation distance of the pair of rollers and exerting a predetermined tension to the metal ring, inspects for an existing surface defect on the metal ring, comprising a scraper, wherein each of the pair of rollers has its outer circumferential surface in contact with a blade edge of the scraper.  
         [0027]     As a preferred embodiment in the present invention of the surface defect inspection device, the scraper blade edge has an angle of less than 90 degrees relative to a tangential line of the outer circumferential surface of the rollers.  
         [0028]     Also, the scraper blade edge may have an angle of less than 90 degrees divided equally relative to a perpendicular line of the outer circumferential surface of the rollers.  
         [0029]     Furthermore, the scraper blade edge may have an angle of substantially 90 degrees or more than 90 degrees divided equally relative to a perpendicular line of the outer circumferential surface of the rollers.  
         [0030]     According to the present invention with a metal ring wrapped around a pair of rollers for a rotating driver side and a follower side, while regulating the separation distance of the pair of rollers and exerting a predetermined tension, that metal ring peripheral length can be corrected by strengthening the tension.  
         [0031]     Likewise, with a metal ring wrapped around a pair of rollers for a rotating driver side and a follower side, while regulating the separation distance of the pair of rollers and exerting a predetermined tension to that metal ring for measuring the separation distance to provide a measurement value, the metal ring peripheral length can be calculated from the measurement value.  
         [0032]     Likewise, with a metal ring wrapped around a pair of rollers for a rotating driver side and a follower side, while regulating the separation distance of the pair of rollers and exerting a predetermined tension to that metal ring, the existence of a surface defect on the metal ring can be inspected.  
         [0033]     Furthermore, the present invention comprises a scraper having the blade edge in contact with each outer circumferential surface of the pair of rollers. Even in cases where foreign matter, such as waste material on the belt conveyor for transporting a metal ring or processing residue from a metal ring (metal powder, etc.) floating in the air, adheres to the surface of a roller, this foreign matter can be “scraped off” by the scraper blade edge which follows the rotation of the rollers. Consequently, a flaw is not scarred to the inner circumferential surface (contact surface with the rollers) of a metal ring.  
         [0034]     Also, when the scraper blade edge has an angle of less than 90 degrees, the removal effect of foreign matter can be increased. On the other hand, when the scraper blade edge has an angle of substantially 90 degrees or more than 90 degrees, abrasion of the blade edge can be controlled.  
         [0035]     Besides, when the scraper blade edge has an angle “divided equally” relative to a perpendicular line of the outer circumferential surface of the rollers, the removal effect of foreign matter also can be acquired in either direction for correction reversal of the rollers.  
         [0036]     The above and further objects and novel features of the present invention will more fully appear from the following detailed description when the same is read in conjunction with the accompanying drawings. It is to be expressly understood, however, that the drawings are for the purpose of illustration only and are not intended as a definition of the limits of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0037]      FIG. 1  is a conceptual configuration diagram of an apparatus which encompasses three apparatus in the preferred embodiments: a peripheral length correction device, a peripheral length measurement device and a surface defect inspection device;  
         [0038]      FIG. 2  is a related view of the rollers  12 ,  13  and the scrapers  18 ,  19 ;  
         [0039]      FIG. 3  is a preferred form view of the blade edges  18   a ,  19   a  for the scrapers  18 ,  19 ;  
         [0040]      FIG. 4A  is another preferred form view of the blade edges  18   a ,  19   a  for the scrapers  18 ,  19 ;  
         [0041]      FIG. 4B  is another preferred form view of the blade edges  18   a ,  19   a  for the scrapers  18 ,  19 ;  
         [0042]      FIG. 5  is an outline view diagram of a CVT belt in conventional prior art; and  
         [0043]      FIG. 6  is a substantial part conceptual diagram of a peripheral length correction device, a peripheral length measurement device and a surface defect inspection device. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0044]     Hereinafter, the preferred embodiments of the present invention with a surface defect inspection device as an example will be explained with reference to the drawings.  
         [0045]     Additionally, illustration of specific or example numerical values for various details in the following explanation or character strings and other symbols are merely references for a clear understanding of the concept of the present invention. Accordingly, the concept of the present invention should not be limited explicitly to this terminology entirely or in part.  
         [0046]     Furthermore, explanation has been omitted which describes details of well-known methods, well-known procedures, well-known architecture, well-known circuit configurations, etc. (hereinafter denoted as “common knowledge”) for the purpose of a concise explanation, but does not intentionally exclude this common knowledge entirely or in part. Therefore, relevant common knowledge already known by persons skilled in the art at the time of filing the present invention is naturally included in the following description.  
         [0047]      FIG. 1  is a conceptual configuration diagram of an apparatus which encompasses three apparatus in the preferred embodiments: a peripheral length correction device, a peripheral length measurement device and a surface defect inspection device (hereinafter collectively denoted as “the apparatus”).  
         [0048]     The apparatus  10  configuration comprises a fixed position driver side roller  12  which is rotary driven by a motor  11 ; a variable position follower side roller  13  in which the spacing arrangement is on the same rotational level (plane of rotation) as the roller  12 ; and a load  14  with a predetermined mass (for example, 80 kg (176 lbs.)). Additionally, when operated as a peripheral length correction device, the apparatus  10  comprises a peripheral length correction section  15 . Also, when operated as a peripheral length measurement device, the apparatus  10  comprises a peripheral length measurement section  16 . Further, when operated as a surface defect inspection device, the apparatus  10  comprises a defect inspection section  17 .  
         [0049]     In such a configuration, initially, the follower side roller  13  is placed in an initial position (position of the dashed and dotted line “A” in  FIG. 1 ) and a metal ring  2   a  is wrapped around between (bridged between) the rollers  12 ,  13 . Next, the required tension is exerted on that metal ring  2   a  by furnishing the load  14  to the follower side roller  13  and moving the roller  13  to the lower side as seen in  FIG. 1 .  
         [0050]     Subsequently, while driving the motor  11  in that state for executing circumferential rotation of a metal ring  2   a  in a constant direction (the direction of arrow “B”), peripheral length correction, peripheral length measurement or defect inspection of the concerned metal ring  2   a  is performed using the peripheral length correction section  15 , peripheral length measurement section  16  or the defect inspection section  17 .  
         [0051]     Here, the peripheral length correction section  15  guides the operation to increase and decrease the tension (under or over tension) exerted on a metal ring  2   a , that is, the object for correcting the metal ring  2   a  peripheral length. For example, this function (peripheral length correction) is actualized by executing variable control of the load amount in the load  14 . Also, the peripheral length measurement section  16  performs estimated measurement of the current metal ring  2   a  peripheral length from the movement amount of the follower side roller  13 . For example, this function (peripheral length measurement) is implemented by comprising a linear sensor for measuring the movement amount of the roller  13 . Additionally, the defect inspection section  17  inspects for the existence of a surface defect on an object (metal ring  2   a ) by an optical technique, for example, image processing and laser beam reflection processing or a magnetic technique, such as the Eddy Current (EC) technique, etc.  
         [0052]     Furthermore, as a distinctive constituent element of the embodiment, the scrapers  18 ,  19  are placed at each of the rollers  12 ,  13 .  
         [0053]      FIG. 2  is a related view of the rollers  12 ,  13  and the scrapers  18 ,  19 . As shown in this diagram, the blade edges  18   a ,  19   a  of the scrapers  18 ,  19  are in contact with the outer circumferential surface so that the axial direction traverses each of the rollers  12 ,  13 , as well as the outer circumferential upper surface of the rollers  12 ,  13  are displaced relatively in the circumferential direction and follow the rotation of each of the rollers  12 ,  13 .  
         [0054]      FIG. 3  is a preferred form view of the blade edges  18   a ,  19   a  for the scrapers  18 ,  19 . In the case of the diagram example, the blade edges  18   a ,  19   a  of the scrapers  18 ,  19  have an angle α 1  of less than 90 degrees in relation to a tangential line  20  of the outer circumferential surface of the rollers  12 ,  13 .  
         [0055]     Also, the blade edges  18   a ,  19   a  of this angle α  1  are used to “scrape off” foreign matter  22  adhered to the outer circumferential surface by being displaced relatively in the circumferential direction along the outer circumferential surface of the rollers  12 ,  13  and follow the rotational direction according to the arrow  21  of the rollers  12 ,  13 .  
         [0056]     Therefore, according to this embodiment, in cases where a foreign matter  22 , such as waste material, etc. on the belt conveyor for transporting a metal ring  2   a  or processing residue from a metal ring  2   a  (metal powder, etc.) floating in the air adheres to the surface of the rollers  12 ,  13  for example, these damaging causes can be eliminated. Specifically, since the foreign matter  22  can be efficiently “scraped off” by the blade edges  18   a ,  19   a  of the scrapers  18 ,  19  which follow the rotation of the rollers  12 ,  13 , a flaw is not scarred in the inner circumferential surface (contact surface with the rollers  12 ,  13 ) of a metal ring  2   a.    
         [0057]     Here, the scrapers  18 ,  19  as mentioned above requires: (A) the blade edges  18   a ,  19   a  be set to “scrape off” the foreign matter  22  adhered to the surface of the rollers  12 ,  13 , and in addition to this (B) do not damage the surface of the rollers  12 ,  13  by the contact against these blade edges  18   a ,  19   a.    
         [0058]     In order to fulfill the conditions of (A), the blade edges  18   a ,  19   a  need to have adequate angle α (fundamentally not rounded edges) and the strength (degree of hardness) of the blade edges  18   a ,  19   a  must have enough resistance (toughness) to sufficiently withstand the foreign matter  22  which is firmly adhered. Furthermore, in order to fulfill the conditions of (B), the hardness of the blade edges  18   a ,  19   a  needs to be a hardness level which does not create a flaw in the surface of the rollers  12 ,  13 .  
         [0059]     Moreover, although the blade edges  18   a ,  19   a  of the scrapers  18 ,  19  in the above-stated embodiment have the form of the angle α 1  (refer to  FIG. 3 ) relative to a tangential line  20  of the outer circumferential surface of the rollers  12 ,  13 , the present invention is not restricted to this. A suitable configuration can be selected from among various angles depending on the quality of material for the rollers  12 ,  13 , the type of foreign matter  22  adhering to the rollers  12 ,  13 , the adhesion manner, etc.  
         [0060]      FIGS. 4A and 4B  are other preferred form views of the blade edges  18   a ,  19   a  for the scrapers  18 ,  19 .  FIG. 4A  shows an example of the blade edges  18   a ,  19   a  having an angle α 2  of less than 90 degrees divided equally relative to a perpendicular line  23  of the outer circumferential surface of the rollers  12 ,  13 . Similarly,  FIG. 4B  shows an example of the blade edges  18   a ,  19   a  having an angle α 3  of substantially 90 degrees or more than 90 degrees divided equally relative to a perpendicular line  23  of the outer circumferential surface of the rollers  12 ,  13 .  
         [0061]     The difference among both is the angle (α 2 , α 3 ) of the blade edges  18   a ,  19   a . The size correlation of these angles is “α 2 &lt;α 3 .” The smaller angle α 2  has a demerit (disadvantage) of readily wearing out the blade edges  18   a ,  19   a , whereas possesses a merit (advantage) in high removal effect of the foreign matter  22 . On the other hand, the larger angle α 3  has a demerit in low removal effect of the foreign matter  22 , whereas possesses a merit of not readily wearing out the blade edges  18   a ,  19   a . In reality, it is best to consider the merit preferences in view of the quality of material for the rollers  12 ,  13  and the scrapers  18 ,  19 , along with the type of foreign matter  22  to be removed, etc. and select a suitable angle.  
         [0062]     Furthermore, in the example of these diagrams, because the blade edges  18   a ,  19   a  have an angle divided equally relative to a perpendicular line  23  of the outer circumferential surface of the rollers  12 ,  13 , the removal effect of the foreign matter  22  is not influenced by the rotational direction of the rollers  12 ,  13 . For this reason, in cases where application of the rollers  12 ,  13  is placed in forward reverse rotation, this configuration is ideal.  
         [0063]     While the present invention has been described with reference to the preferred embodiments, it is intended that the invention be not limited by any of the details of the description therein but includes all the embodiments which fall within the scope of the appended claims.