Patent Application
20180127225
This application claims priority under 35 U.S.C. § 119 to Japanese Patent Application No. 2016-219116 filed on Nov. 9, 2016, the entire content of which is hereby incorporated by reference.
The present invention relates to a corrugated paperboard box making machine, and more particularly to a corrugated paperboard box making machine configured to enable a counter-ejector thereof to reliably separate a batch consisting of a given number of box-structured corrugated paperboard sheets.
Heretofore, a corrugated paperboard box making machine equipped with a counter-ejector has been well known. For example, a corrugated paperboard box making machine described in JP 2011-230432A (Patent Document 1) comprises a sheet feeding apparatus for feeding corrugated paperboard sheets one-by-one, a plurality of type of processing apparatuses for subjecting each of the corrugated paperboard sheets to given processings such as printing and creasing, and a folder-gluer for applying glue onto a joint flap and folding and gluing the glue-applied corrugated paperboard sheet along creases and through the joint flap to form a box structure. The corrugated paperboard box making machine further comprises a counter-ejector disposed downstream of the folder-gluer and configured to count the number of the resulting folded and glued (i.e., box-structured) corrugated paperboard sheets to form a batch consisting of a given number of the box-structured corrugated paperboard sheets and eject the batch therefrom. The counter-ejector comprises a hopper for receiving therein the box-structured corrugated paperboard sheets, a main ledge, an auxiliary ledge, and an elevator.
The box-structured corrugated paperboard sheets are fed out from a folder-gluer outlet roll pair toward the hopper while being counted. In conjunction with operation of feeing out the last box-structured corrugated paperboard sheet in the preceding batch into the hopper, the main ledge starts to move downwardly from a standby position located above an installation height of the outlet roll pair. The main ledge further continues to move downwardly while allowing a next batch of box-structured corrugated paperboard sheets fed out from the output roll pair after the start of the downward movement to be sequentially stacked thereon. Then, when the main ledge moves downwardly to an installation position of the auxiliary ledge, the box-structured corrugated paperboard sheets stacked on the main ledge are passed to and stacked on the auxiliary ledge. When the given number of box-structured corrugated paperboard sheets are stacked on the auxiliary ledge, they are passed to the elevator located below the auxiliary ledge.
After the box-structured corrugated paperboard sheets stacked on the main ledge are passed to the auxiliary ledge, the main ledge continues to move further downwardly to a given lower position while clamping the preceding batch in cooperation with the elevator. When the main ledge is moved downwardly to the given lower position and fed out the preceding batch to an ejection conveyer, the main ledge is returned from the given lower position to the upper standby position so as to form a next batch on the auxiliary ledge. By enabling the main ledge to repeat the downward and upward movements between the standby position and the given lower position, the batch consisting of the given number of box-structured corrugated paperboard sheets will be continuously formed.
There have been proposed a variety of corrugated paperboard box making machine capable of feeding a plurality of corrugated paperboard sheets during a given processing period of time in which a processing rotator such as a printing cylinder is rotated 360 degrees to thereby increase a processible number of corrugated paperboard sheets per unit time. For example, in a corrugated paperboard box making machine described in JP 2003-127251A (Patent Document 2), a feeding unit comprises a feeding drive device such as a servomotor to drive a feeding device such as feeding rollers. A feeding unit drive controller is operable to control the feeding drive device to enable the feeding unit to perform one of a first feeding operation of feeding one corrugated paperboard sheet during a given processing period of time, and a second feeding operation of feeding a plurality of corrugated paperboard sheets during the given processing period of time.
In the case where the operation of feeding a plurality of corrugated paperboard sheets during the given processing period of time is performed as in the corrugated paperboard box making machine described in the Patent Document 2, time intervals at which box-structured corrugated paperboard sheets are sequentially fed out from the outlet roll pair of the folder-gluer into the hopper of the counter-ejector are shortened, even when a rotational speed of the processing rotator is maintained at a value equal to that during the operation of feeding one corrugated paperboard sheet during the given processing period of time. When the time intervals are shortened, the main ledge tends to become failing to accurately enter between a last one of box-structured corrugated paperboard sheets in a previous batch and a first one of box-structured corrugated paperboard sheets in a next, new, batch. This is likely to lead to a situation where the first box-structured corrugated paperboard sheet in the new batch comes into collision with the main ledge, resulting in occurrence of jam-up. This is also likely to lead to a situation where the first box-structured corrugated paperboard sheet in the new batch falls in the hopper without being loaded on the main ledge, and thus the box-structured corrugated paperboard sheets being stacked are not separated as a given number of the box-structured corrugated paperboard sheets.
It is an object of the present invention to provide a corrugated paperboard box making machine capable of reliably separating the box-structured corrugated paperboard sheets being stacked, as a batch of a given number of the box-structured corrugated paperboard sheets, even when a sheet feeding operation of feeding one corrugated paperboard sheet is performed plural time during a period of time in which a processing rotator is rotated 360 degrees, and to provide a sheet feeding control apparatus for the corrugated paperboard box making machine.
In order to achieve the above object, according to a first aspect of the present invention, there is provided a corrugated paperboard box making machine which comprises: a sheet feeding apparatus capable of repeatedly performing a sheet feeding operation of feeding one corrugated paperboard sheet; a processing apparatus comprising a processing rotator capable of being rotated so as to subject each of the corrugated paperboard sheets fed from the sheet feeding apparatus to a given processing; a folder-gluer for folding and gluing each of the corrugated paperboard sheets subjected to the given processing to form a box structure; a counter-ejector for stacking the box-structured corrugated paperboard sheets fed out from the folder-gluer and separating the box-structured corrugated paperboard sheets being stacked, as a batch consisting of a given number of the box-structured corrugated paperboard sheets; a feeding control mode setting unit for setting a feeding control mode to one of a first feeding control mode for controlling the sheet feeding apparatus such that the sheet feeding operation is performed once during a period of time in which the processing rotator is rotated 360 degrees, and a second feeding control mode for controlling the sheet feeding apparatus such that the sheet feeding operation is performed plural times during the period of time in which the printing rotor is rotated 360 degrees; and a control apparatus for controlling the sheet feeding apparatus according to the feeding control mode set by the feeding control mode setting unit, wherein the control apparatus is operable to execute a sheet feeding control processing of controlling the sheet feeding apparatus such that the sheet feeding operation is successively repeated a number of times corresponding to a given batch-forming sheet number which is the number of the given number of box-structured corrugated paperboard sheets in the batch, and a sheet feeding stop control processing of, when the second feeding control mode is set by the feeding control mode setting unit, controlling the sheet feeding apparatus such that the sheet feeding operation is stopped at least once after execution of the sheet feeding control processing. In the first aspect of the present invention, the sheet feeding stop control processing is configured to, when the second feeding control mode is set by the feeding control mode setting unit, control the sheet feeding apparatus such that the sheet feeding operation is stopped at least once after execution of the sheet feeding control processing. This makes it possible to enable the counter-ejector to reliably separate the box-structured corrugated paperboard sheets being stacked, as a batch consisting of a given number of the box-structured corrugated paperboard sheets, even when the sheet feeding operation is performed plural time during the period of time in which the processing rotator is rotated 360 degrees.
In the first aspect of the present invention, the sheet feeding apparatus may have any configuration as long as it has a function of feeding corrugated paperboard sheets one-by-one. For example, the sheet feeding apparatus may be configured to feed out corrugated paperboard sheets one-by-one while catching a rear end of each of the corrugated paperboard sheets by a claw of a kicker. Alternatively, the sheet feeding apparatus may comprise a raisable-lowerable member raisable and lowerable with respect to a plurality of feeding rollers, wherein it may be configured such that, every time the raisable-lowerable member is lowered, corrugated paperboard sheets are placed on and fed out by the plurality of feeding rollers one-by-one.
In the first aspect of the present invention, the sheet feeding stop control processing may be configured to, when the second feeding control mode is set by the feeding control mode setting unit, control the sheet feeding apparatus such that one of the plurality of sheet feeding operations during the period of time in which the processing rotator is rotated 360 degrees is stopped, or control the sheet feeding apparatus such that at least two of the plurality of sheet feeding operations during the period of time in which the processing rotator is rotated 360 degrees are successively stopped.
In the first aspect of the present invention, the number of times the sheet feeding operation is stopped may be a constant number, or may be a variable number which varies depending on the number of times of the sheet feeding operation to be performed during the period of time in which the processing rotator is rotated 360 degrees, or the given batch-forming sheet number.
In the first aspect of the present invention, in the case where the sheet feeding apparatus comprises the raisable-lowerable member raisable and lowerable with respect to the plurality of feeding rollers, the control apparatus may be configured to control a drive section of the raisable-lowerable member such that the raisable-lowerable member is stopped at a position above the plurality of feeding rollers, or may be configured to control a drive section of the plurality of feeding rollers such that rotation of the plurality of feeding rollers is stopped.
In the first aspect of the present invention, the feeding control mode setting unit may be configured to automatically set the feeding control mode according to a mode instruction designating one of the feeding control modes in specifications of each order. Alternatively, the feeding control mode setting unit may comprise a manipulation unit manipulatable by an operator. In this case, the feeding control mode is set according to manipulation of the manipulation unit.
In the first aspect of the present invention, the control apparatus may be configured such that, when the first feeding control mode is set by the feeding control mode setting unit, the control processing of controlling the sheet feeding apparatus such that the sheet feeding operation is stopped at least once after execution of the sheet feeding control processing is not executed, or may be configured such that, when the first feeding control mode is set by the feeding control mode setting unit, the control processing is executed in conformity to the sheet feeding speed and the sheet length.
In a specific embodiment of the first aspect of the present invention, the corrugated paperboard box making machine comprises a storage unit for storing therein a plurality of types of feeding stop control patterns each for deciding a timing at which the sheet feeding operation is stopped in the period of time in which the processing rotator is rotated 360 degrees, wherein the control apparatus is operable to execute a selection processing of selecting at least one of the plurality of types of feeding stop control patterns stored in the storage unit, depending on whether the given batch-forming sheet number specified in accordance with an order is an even number or an odd number, wherein the sheet feeding stop control processing is configured to control the sheet feeding apparatus such that the sheet feeding operation is stopped at least one after execution of the sheet feeding control processing, according to the feeding stop control pattern selected by the selection processing.
In this specific embodiment, the selection processing is configured to select at least one of the plurality of types of feeding stop control patterns stored in the storage unit, depending on whether the given batch-forming sheet number specified in accordance with an order is an even number or an odd number. Further, the sheet feeding stop control processing is configured to control the sheet feeding apparatus such that the sheet feeding operation is stopped at least one after execution of the sheet feeding control processing, according to the feeding stop control pattern selected by the selection processing. This makes it possible to easily set a timing at which the sheet feeding operation is stopped, e.g., a stop start time or a stop time period, and thus easily execute the sheet feeding stop control processing.
In this specific embodiment, the control apparatus may be configured to execute a determination processing of determining whether the given batch-forming sheet number specified in accordance with an order is an even number or an odd number. Alternatively, the corrugated paperboard box making machine may be configured to preliminarily store designation information for designating, in specifications of each other, whether the given batch-forming sheet number specified in accordance with an order is an even number or an odd number. The selection processing is configured to select at least one of the plurality of types of feeding stop control patterns stored in the storage unit, according to a determination result based on the determination processing, or the designation information.
In another specific embodiment of the first aspect of the present invention, the second feeding control mode is configured to control the sheet feeding apparatus such that the sheet feeding operation is performed twice during the period of time in which the processing rotator is rotated 360 degrees, wherein the sheet feeding stop control processing is configured to, when the second feeding control mode is set by the feeding control mode setting unit, and the given batch-forming sheet number is an even number, control the sheet feeding apparatus such that the sheet feeding operation is stopped twice, and to, when the second feeding control mode is set by the feeding control mode setting unit, and the given batch-forming sheet number is an odd number, control the sheet feeding apparatus such that the sheet feeding operation is stopped only once.
In this specific embodiment, one of the first feeding control mode and the second feeding control mode is set by the feeding control mode setting unit. The sheet feeding stop control processing is configured to, when the second feeding control mode is set by the feeding control mode setting unit, and the given batch-forming sheet number is an even number, control the sheet feeding apparatus such that the sheet feeding operation is stopped twice, and to, when the second feeding control mode is set by the feeding control mode setting unit, and the given batch-forming sheet number is an odd number, control the sheet feeding apparatus such that the sheet feeding operation is stopped only once. Thus, in the second feeding control mode, irrespective of whether the number of the given batch-forming sheet is an even number or an odd number, a positional relationship between each of two corrugated paperboard sheets fed by the first and second sheet feeding operations during the period of time in which the printing cylinder is rotated 360 degrees, and a printing die of the printing cylinder, is kept constant. This makes it possible to form a given printing pattern with good positional accuracy.
In yet another specific embodiment of the first aspect of the present invention, the sheet feeding apparatus comprises: a plurality of feeding rollers rotatable to feed a bottommost one of a plurality of stacked corrugated paperboard sheets; a raisable-lowerable member raisable and lowerable with respect to the plurality of feeding rollers; a roller drive motor for rotating the plurality of feeding rollers, individually; a raising-lowering drive motor; a motion conversion mechanism configured to convert a rotation of the raising-lowering drive motor into a motion for causing the raisable-lowerable member to be raised and lowered, and transmit the converted motion to the raisable-lowerable member, wherein the sheet feeding stop control processing is configured to stop the sheet feeding operation by stopping the roller drive motor.
In this specific embodiment, the sheet feeding apparatus comprises the raisable-lowerable member raisable and lowerable with respect to the plurality of feeding rollers, the raising-lowering drive motor, and the motion conversion mechanism configured to convert a rotation of the raising-lowering drive motor into a motion for causing the raisable-lowerable member to be raised and lowered, and transmit the converted motion to the raisable-lowerable member. The sheet feeding stop control processing is configured to stop the sheet feeding operation by stopping the roller drive motor. In this case, a required accuracy in stop position of the roller drive motor or in adjusted position of a cam or the like is not so high as compared to processing of stopping the raising-lowering drive motor or adjustment operation for a cam or the like. Thus, it becomes possible to stop the sheet feeding operation by simple control processing.
In this specific embodiment, the sheet feeding apparatus may be configured such that a plurality of roller drive shafts are rotated by one roller drive motor, or may be configured such that the plurality of roller drive shafts are rotated, respectively, by a plurality of roller drive motors.
In this specific embodiment, a lowering timing and a raising timing of the raisable-lowerable member may be adjusted by controlling activation and deactivation of the raising-lowering drive motor. Further, the motion conversion mechanism may comprise a stationary cam and a movable cam each configured to be rotated by the raising-lowering drive motor. In this case, the lowering timing and the raising timing of the raisable-lowerable member may be adjusted by adjusting a rotational phase of the movable cam with respect to the stationary cam.
In still another specific embodiment of the first aspect of the present invention, the corrugated paperboard box making machine comprises: a speed setting unit for, when the second feeding control mode is set by the feeding control mode setting unit, setting a sheet feeding speed representing the number of corrugated paperboard sheets to be fed from the sheet feeding apparatus per unit time, to an initial sheet feeding speed; and a speed changing unit for changing the sheet feeding speed from the initial sheet feeding speed, wherein the second feeding control mode is configured to control the sheet feeding apparatus such that the sheet feeding operation is performed twice during the period of time in which the processing rotator is rotated 360 degrees, and the initial sheet feeding speed is set to a sheet feeding speed which is equal to or greater than a maximum sheet feeding speed corresponding to a maximum rotational speed at which the processing rotator can be rotated per unit time so as to subject each of the corrugated paperboard sheets fed from the sheet feeding apparatus to the given processing, when the first feeding control mode is set by the feeding control mode setting unit, and wherein the sheet feeding apparatus is operable, when the second feeding control mode is set by the feeding control mode setting unit, to feed corrugated paperboard sheets, at the initial sheet feeding speed, or the sheet feeding speed changed by the speed changing unit.
In this specific embodiment, the speed setting unit is configured to, when the second feeding control mode is set by the feeding control mode setting unit, set the sheet feeding speed to an initial sheet feeding speed. The speed changing unit is configured to change the sheet feeding speed from the initial sheet feeding speed. In the second feeding control mode, the sheet feeding operation is performed twice during the period of time in which the processing rotator is rotated 360 degrees. The initial sheet feeding speed is set to a sheet feeding speed which is equal to or greater than the maximum sheet feeding speed corresponding to the maximum rotational speed of the processing rotator in the first feeding control mode. The sheet feeding apparatus is operable, when the second feeding control mode is set by the feeding control mode setting unit, to feed corrugated paperboard sheets, at the initial sheet feeding speed, or the sheet feeding speed changed by the speed changing unit. Thus, when the second feeding control mode is set, it is possible to initialize the sheet feeding speed to an value which is equal to or greater than the maximum sheet feeding speed in the first feeding control mode.
In this specific embodiment, when the initial sheet feeding speed is set to a relatively high value equal to greater than the maximum rotational speed of the processing rotator, the speed setting unit may be configured to set the sheet feeding speed to a value which is two times the maximum rotational speed of the processing rotator.
In this specific embodiment, when the initial sheet feeding speed is set to a value which is less than two times the maximum rotational speed of the processing rotator, the speed setting unit may be configured to change the sheet feeding speed to a value which is greater than or less than the initial sheet feeding speed.
According to a second aspect of the present invention, there is provided a sheet feeding control apparatus for use in a corrugated paperboard box making machine, wherein the corrugated paperboard box making machine comprises: a sheet feeding apparatus capable of repeatedly performing a sheet feeding operation of feeding one corrugated paperboard sheet; a processing apparatus comprising a processing rotator capable of being rotated so as to subject each of the corrugated paperboard sheets fed from the sheet feeding apparatus to a given processing; a folder-gluer for folding and gluing each of the corrugated paperboard sheets subjected to the given processing to form a box structure; a counter-ejector for stacking the box-structured corrugated paperboard sheets fed out from the folder-gluer and separating the box-structured corrugated paperboard sheets being stacked, as a batch consisting of a given number of the box-structured corrugated paperboard sheets; and a feeding control mode setting unit for setting a feeding control mode to one of a first feeding control mode for controlling the sheet feeding apparatus such that the sheet feeding operation is performed once during a period of time in which the processing rotator is rotated 360 degrees, and a second feeding control mode for controlling the sheet feeding apparatus such that the sheet feeding operation is performed plural times during the period of time in which the printing rotor is rotated 360 degrees. The sheet feeding control apparatus is configured to execute a sheet feeding control processing of controlling the sheet feeding apparatus such that the sheet feeding operation is successively repeated a number of times corresponding to the number of the given number of box-structured corrugated paperboard sheets in the batch, and a sheet feeding stop control processing of, when the second feeding control mode is set by the feeding control mode setting unit, controlling the sheet feeding apparatus such that the sheet feeding operation is stopped at least once after execution of the sheet feeding control processing.
In the second aspect of the present invention, the sheet feeding stop control processing is configured to, when the second feeding control mode is set by the feeding control mode setting unit, control the sheet feeding apparatus such that the sheet feeding operation is stopped at least once after execution of the sheet feeding control processing. This makes it possible to enable the counter-ejector to reliably separate the box-structured corrugated paperboard sheets being stacked, as a batch consisting of a given number of the box-structured corrugated paperboard sheets, even when the sheet feeding operation is performed plural time during the period of time in which the processing rotator is rotated 360 degrees.
In the second aspect of the present invention, the sheet feeding stop control processing of controlling a sheet feeding apparatus having any of various configurations can be embodied in various control configurations, as with the first aspect of the present invention and the specific embodiments thereof.
With reference to accompanying drawings, a corrugated paperboard box making machine according to one embodiment of the present invention will now be described. A sheet feeding apparatus comprised in the corrugated paperboard box making machine 1 according to this embodiment is capable of feeding corrugated paperboard sheets in a designated one of a one-sheet feeding mode for feeding one corrugated paperboard sheet in a given processing cycle during which a printing cylinder of a printer is rotated 360 degrees, and a two-sheet feeding mode for sequentially feeding two corrugated paperboard sheets in the given processing cycle.
As depicted in
The sheet feeding apparatus 2 comprises a table 20. A large number of corrugated paperboard sheets SH produced by a corrugating machine are stacked on the table 20 while being positioned between a front gate 21 and a back guide 22. The front gate 21 is disposed to allow the corrugated paperboard sheets SH to be fed out one-by-one through a gap between the front gate 21 and the table 20. The back guide 22 is configured to be movable with respect to the front gate 21, in a direction parallel to a feeding (conveyance) direction FD, so as to receive a plurality of types of corrugated paperboard sheets having different sheet lengths in the feeding direction FD. The sheet feeding apparatus 2 comprises a large number of feeding rollers, a raisable-lowerable grate, and a pair of feed rolls 23, 24. The feeding rollers are configured to, when the grate is lowered below the feeding rollers, come into contact with a bottommost one of the corrugated paperboard sheets SH, whereby the stacked corrugated paperboard sheets SH are fed out one-by-one toward the pair of feed rolls 23, 24. The pair of feed rolls 23, 24 is configured to feed the corrugated paperboard sheets SH one-by-one toward the printer 3. The pair of feed rolls 23, 24 is drivenly coupled to a main drive motor MT.
The sheet feeding apparatus 2 comprises a sheet sensor SN1 for counting the number of corrugated paperboard sheets SH fed out therefrom. The sheet sensor SN1 is composed of a heretofore-known optical sensor comprising a light-emitting section and a light-receiving section, and disposed in adjacent relation to the front gate 21. The sheet sensor SN1 is operable to detect a leading edge of each of the corrugated paperboard sheets SH passing through the front gate 21 to generate a sheet detection signal ST1. A detailed configuration of the sheet feeding apparatus 2 comprising the large number of feeding rollers and the grate will be described later.
The printer 3 comprises two printing units 25, 26. Each of the printing units 25, 26 comprises a printing cylinder (25A, 26A), a printing die (25B, 26B), an ink application mechanism (25C, 26C), and a press roll (25D, 26D). Each of the printing dies 25B, 26B has a given printing pattern, and is attached to an outer peripheral surface of a corresponding one of the printing cylinders 25A, 26A. In the one-sheet feeding mode, only one printing die is attached to each of the printing cylinders. Each of the ink application mechanisms 25C, 26C is configured to apply ink having a color which is different in each of the printing units. The printer 3 is configured to subject the fed corrugated paperboard sheet SH to two-color printing by using the two printing units 30, 31, and supply the printed corrugated paperboard sheet SH to the creaser-slotter 4. Each of the printing units 25, 26 is drivenly coupled to the main drive motor MT. The printing cylinders 25A, 26A have the same diameter Dp. Each of the ink application mechanisms 25C, 26C comprises an anilox roll (25E, 26E) and a rubber-covered roll (25F, 26F). Each of the anilox rolls 25E, 26E is configured to be movable between a contactable position for applying ink and a spaced-apart position for keeping ink from being applied, with respect to a corresponding one of the printing dies 25B, 26B attached, respectively, to the printing cylinders 25A, 26A. Two air cylinders 25G, 26G are provided as a means to move respective ones of the anilox rolls 25E, 26E between the contactable position and the spaced-apart position. A configuration for moving an anilox roll between the contactable position and the spaced-apart position by an actuating unit such as an air cylinder has heretofore been known, as described, for example, in JP 2000-006362A.
The creaser-slotter 4 comprises one creaser unit 30, and two slotter units 31, 32. The creaser unit 30 serves as a means to subject the printed corrugated paperboard sheet SH to creasing, and comprises a pair of creasing rolls arranged one above the other. Each of the slotter units 31, 32 serves as a means to subject the creased corrugated paperboard sheet SH to slotting, and comprises an upper slotter (31B, 32B) to which a slotter blade (31A, 32A) is attached, and a lower slotter (31C, 32C) formed with a groove fittable with the slotter blade (31A, 32A). In the one-sheet feeding mode, only one slotter blade is attached to each of the upper slotters. The creaser-slotter 4 is configured to subject the printed corrugated paperboard sheet SH to creasing and slotting to form a joint flap, by using the creaser unit 30 and the slotter units 31, 32, and supply the processed corrugated paperboard sheet SH to the die cutter 5. Each of the creaser unit 30 and the slotter units 31, 32 is drivenly coupled to the main drive motor MT.
The die cutter 5 comprises a die cylinder 33 and an anvil cylinder 34 which are disposed across a conveyance path. One punching die 35 for subjecting the processed corrugated paperboard sheet SH to punching is attached to a plate-like body made of veneer-core plywood or the like, and the plate-like body with the punching die is wound around an outer peripheral surface of the die cylinder 33. On the occasion of order change, the punching die 35 can be replaced with another punching die having a punching pattern conforming to a new order. Each of the die cylinder 33 and the anvil cylinder 34 is drivenly coupled to the main drive motor MT.
The folder-gluer 6 is operable to convey the punched corrugated paperboard sheet SH, and, during the conveyance, apply glue onto the joint flap of the punched corrugated paperboard sheet SH and then fold and glue the glue-applied corrugated paperboard sheet SH along the creases or the like and through the joint flap. The folder-gluer 6 comprises a guide rail 36 along the feeding direction FD of the corrugated paperboard sheet SH. A loop-shaped conveyance belt 37 is provided just above the guide rail 36 in a circulatingly (endlessly) movable manner. A glue supply device 38, a bending bar 39 and a folding belt 40 are arranged along the guide rail 36 and the conveyance belt 37.
The folder-gluer 6 is operable to support and convey the punched corrugated paperboard sheet SH formed with the creases and the joint flap, by using the guide rail 36 and the conveyance belt 37. During the conveyance of the punched corrugated paperboard sheet SH, the folder-gluer 6 is operable to apply glue onto the joint flap the glue supply device 38, and then bend the glue-applied corrugated paperboard sheet SH by using the bending bar 39. Then, the folder-gluer 6 is operable to fold the bent corrugated paperboard sheet SH and glue the folded corrugated paperboard sheet SH through the joint flap, by using the folding belt 40, thereby preparing a folded and glued (i.e., box-structured) corrugated paperboard sheet SH. The conveyance belt 37 is drivenly coupled to a non-depicted conveyance drive motor, and the folding belt 40 is drivenly coupled to a non-depicted folding drive motor.
The sheet transfer apparatus 7 primarily comprises a transfer conveyer 41 and an upper conveyance roll 42. The transfer conveyer 41 is operable to receive the box-structured corrugated paperboard sheet SH from the folder-gluer 6 and convey the received corrugated paperboard sheet SH. The upper conveyance roll 42 is disposed above and in opposed relation to a lower conveyance roll 43 disposed on an outlet side of the transfer conveyer 41. The upper conveyance roll 42 is operable to nip the box-structured corrugated paperboard sheet SH in cooperation with the transfer conveyer 41, and convey the box-structured corrugated paperboard sheet SH toward the counter-ejector 8. Each of the transfer conveyer 41 and the upper conveyance roll 42 is drivenly coupled to a non-depicted conveyer drive motor.
The counter-ejector 8 is operable to count the number of the box-structured corrugated paperboard sheets SH sequentially supplied from the sheet transfer apparatus 7 to form a batch BT consisting of a given number of the box-structured corrugated paperboard sheets SH. The counter-ejector 8a primarily comprises a front contact plate 44, a correction plate 45, a main ledge 46, a pair of auxiliary ledges 47A, 47B, an elevator 48, and a lower conveyer 49. The lower conveyer 49 is operable to feed out the batch BT toward the bundler 9. A detailed configuration of the counter-ejector 8 will be described later.
With reference to
A raising-lowering motor 80 composed of an AC servomotor is fixed to the motor mounting plate 64. Two paired bearings 81, 82 are individually fixed to the bearing mounting plate 65 so as to rotatably support an intermediate drive shaft 83. The raising-lowering motor 80 has a rotary shaft coupled to the intermediate drive shaft 83 via a coupler 84. An encoder 85 is coupled to the rotary shaft of the raising-lowering motor 80.
A first roller motor 90 and a second roller motor 91 each composed of an AC servomotor are individually fixed to the motor mounting plate 64. Two paired bearings 92, 93 are individually fixed to the bearing mounting plate 65 to rotatably support a first roller drive shaft 94. The first roller motor 90 has a rotary shaft coupled to the first roller drive shaft 94 via a coupler 95. Two paired bearings 96, 97 are individually fixed to the bearing mounting plate 65 to rotatably support a second roller drive shaft 98. The second roller motor 91 has a rotary shaft coupled to the second roller drive shaft 98 via a coupler 99. Two encoders 100, 101 are coupled, respectively, to the rotary shaft of the first roller motor 90 and the rotary shaft of the second roller motor 91.
A third roller motor 102 and a fourth roller motor 103 each composed of an AC servomotor are individually fixed to the motor mounting plate 66. Two paired bearings 104, 105 are individually fixed to the bearing mounting plate 67 to rotatably support a third roller drive shaft 106. The third roller motor 102 has a rotary shaft coupled to the third roller drive shaft 106 via a coupler 107. Two paired bearings 108, 109 are individually fixed to the bearing mounting plate 67 to rotatably support a fourth roller drive shaft 110. The fourth roller motor 103 has a rotary shaft coupled to the fourth roller drive shaft 110 via a coupler 111. Two encoders 112, 113 are coupled, respectively, to the rotary shaft of the third roller motor 102 and the rotary shaft of the fourth roller motor 103.
As depicted in
The first roller drive shaft 94 is coupled to the first roller support shaft 120 via a coupler 128, and the second roller drive shaft 98 is coupled to the second roller support shaft 121 via a coupler 129. The third roller drive shaft 106 is coupled to the third roller support shaft 122 via a coupler 130, and the fourth roller drive shaft 110 is coupled to the fourth roller support shaft 123 via a coupler 131.
The sheet feeding apparatus 2 comprises a motion conversion mechanism 140. The motion conversion mechanism 140 is configured to convert a unidirectional rotation of the raising-lowering motor 80 into a raising-lowering motion of an aftermentioned grate 141. In
The motion conversion mechanism 140 comprises a plurality of support mechanisms 142 supporting the grates 141 in a raisable and lowerable manner, and a swing mechanism 143. The swing mechanism 143 is configured to convert the unidirectional rotation of the raising-lowering motor 80 to a swinging motion, and transmit the swinging motion to the support mechanisms 142.
With reference to
As depicted in
The coupling rod 154 is horizontally disposed below the four roller support shafts 120 to 123. The coupling rod 154 is disposed such that a right end thereof extends through a through-hole 161 formed in the right frame 69. In this state, a left end of the coupling rod 154 is coupled to the other arm 152B the left two-arm lever 152 via a coupling pin 162. An intermediate portion of the coupling rod 154 is coupled to the other arm 153B of the right two-arm lever 153 via a coupling pin 163, at a position adjacent to the right frame 69.
With reference to
As depicted in
As depicted in
Referring to
A rotational position sensor 190 is provided as a means to detect a given rotational position of the raising-lowering drive shaft 170. The rotational position sensor 190 comprises an optical sensor 191, and a light-blocking member 192. The optical sensor 191 has a heretofore-known configuration comprising a light-emitting section and a light-receiving section, wherein it is fixed to the bearing mounting plate 65, as depicted in
In
With reference to
The correction plate 45 is located in adjacent relation to the transfer conveyer 41 and the upper conveyance roll 42, and disposed to be contactable with a trailing edge of the box-structured corrugated paperboard sheet SH. The box-structured corrugated paperboard sheets SH are stacked in a receiving space defined by the front contact plate 44, the correction plate 45 and others. The correction plate 45 is configured to perform a heretofore-known corrective motion, i.e., to be reciprocatingly moved in the rightward-leftward direction, so as to enable the edges of the stacked box-structured corrugated paperboard sheets SH to be arranged in order. The correction plate 45 is disposed in a certain positional relationship with the transfer conveyer 41 and the upper conveyance roll 42, which allows contact with the trailing edges of the stacked box-structured corrugated paperboard sheets SH according to the corrective motion.
The main ledge 46 has an L shape, and comprises a horizontally extending portion 46A and a vertically standing portion 46B. A drive pulley 202 and a driven pulley 203 are rotatably supported by the frame of the counter-ejector 8. A ledge drive belt 204 is disposed to extend horizontally in the rightward-leftward direction while being wound around between the drive pulley 202 and the driven pulley 203. The drive pulley 202 is coupled to an output shaft of a belt drive motor 205. A guide rail 206 is horizontally supported by the frame of the counter-ejector 8 at a position adjacent to the ledge drive belt 204. The guide rail 106 supports a ledge support member 207 movably in the rightward-leftward direction. The ledge support member 207 has an upper end fixed to the ledge drive belt 204. A ledge raising-lowering motor 208 is fixed onto the ledge support member 207. A pinion 209 is fixed to an output shaft of the ledge raising-lowering motor 208. A rack 210 is fixed to the vertically standing portion 46B of the main ledge 46, and meshed with the pinion 109. The vertically standing portion 46B of the main ledge 46 is supported movably in an upward-downward direction by a support mechanism provided on the ledge support member 207. The main ledge 46 is positioned in the rightward-leftward direction according to a rotational direction and a rotational amount of the belt drive motor 205, and positioned in the upward-downward direction according to a rotational direction and a rotational amount of the ledge raising-lowering motor 208.
The auxiliary ledge 47A is disposed to be movable forwardly and backwardly in the rightward-leftward direction with respect to the front contact plate 44. The auxiliary ledge 47B is disposed to be movable forwardly and backwardly in the rightward-leftward direction with respect to the correction plate 45. The two auxiliary ledges 47A, 47B are configured to be moved in directions causing them to come close to each other so as to support a lower surface of the stacked box-structured corrugated paperboard sheet SH, and to be moved in directions causing them to come away from each other so as to pass the stacked box-structured corrugated paperboard sheet SH to the elevator 48. The two auxiliary ledges 47A, 48B are coupled to a non-depicted ledge drive motor via a heretofore-known coupling mechanism.
The elevator 48 has an upper portion formed as a table 48A and a lower portion formed as a support rod 48B. The table 48A has a size capable of being loaded with a box-structured corrugated paperboard sheet SH having a maximum size producible by the corrugated paperboard box making machine 1. Specifically, a dimension LE of the table 48A in the rightward-leftward direction is approximately equal to a length of the maximum-size box-structured corrugated paperboard sheet in the rightward-leftward direction.
A drive pulley 212 and a driven pulley 213 are rotatably supported by the frame of the counter-ejector 8. An elevator drive belt 214 is disposed to extend horizontally in the rightward-leftward direction while being wound around between the drive pulley 212 and the driven pulley 213. The drive pulley 212 is coupled to an output shaft of a table displacement motor 215. A guide rail 216 is horizontally supported by the frame of the counter-ejector 8 at a position adjacent to the elevator drive belt 214. An elevator support member 217 is supported movably in the rightward-leftward direction by the guide rail 216. The elevator support member 217 has a lower end fixed to the elevator drive belt 214. A table raising-lowering motor 218 is fixed onto the elevator support member 217. A pinion 219 is fixed to an output shaft of the table raising-lowering motor 218. A rack 220 is fixed to the support rod 48B of the elevator 48, and meshed with the pinion 219. The support rod 48B of the elevator 48 is supported movably in the upward-downward direction by a support mechanism provided on the elevator support member 217.
The elevator 48 is positioned in the rightward-leftward direction according to a rotational direction and a rotational amount of the table displacement motor 215, and positioned in the upward-downward direction according to a rotational direction and a rotational amount of the table raising-lowering motor 218. In other words, the table 48A of the elevator 48 is configured to be displaced in the rightward-leftward direction with respect to a position of the correction plate 45 in the rightward-leftward direction, and to be displaced in the upward-downward direction between a height position of a lower edge of each of the front contact plate 44 and the correction plate 45, and a height position of the lower conveyor 49.
The lower conveyor 49 comprises a drive pulley 221, a driven pulley 222, a conveyor drive belt 223, and a belt drive motor 224. The drive pulley 221 and the driven pulley 222 are rotatably supported by the frame of the counter-ejector 8. The conveyor drive belt 223 is disposed to extend horizontally in the rightward-leftward direction while being wound around between the drive pulley 221 and the driven pulley 222. The drive pulley 221 is coupled to an output shaft of the belt drive motor 224.
An upper conveyor 225 is disposed with a distance from the lower conveyor 49. The upper conveyor 225 is configured to be moved in the upward-downward direction by a non-depicted servo motor, such that the distance between the upper conveyor 225 and the lower conveyor 49 becomes approximately equal to a thickness of the batch BT in the upward-downward direction, and then positioned with respect to the lower conveyor 49. The upper conveyor 225 is coupled to the output shaft of the belt drive motor 224 via a heretofore-known coupling mechanism. According to rotation of the belt drive motor 224, the lower conveyor 49 is operable to eject the batch BT in a given ejection direction TD toward the bundler 9, in cooperation with the upper conveyor 225. The given ejection direction TD is a direction parallel to the feeding (conveyance) direction FD, and identical to a direction causing the front contact plate 44 to come away from the correction plate 45.
The counter-ejector 8 comprises a sheet sensor SN2 for counting the number of the box-structured corrugated paperboard sheets SH supplied from the sheet transfer apparatus 7. The sheet sensor SN2 is composed of a heretofore-known optical sensor comprising a light-emitting section and a light-receiving section, and disposed in adjacent relation to the transfer conveyer 41 and the upper conveyance roll 42. The sheet sensor SN2 is operable to detect the leading edge of each of the box-structured corrugated paperboard sheets SH passing through the upper conveyance roll 42 to generate a sheet detection signal ST2.
As regards a corrugated paperboard box making machine 1 depicted in
As depicted in
Two slotter blades 31A1, 31A2 are attached to an outer peripheral surface of the upper slotter 31B of the slotter unit 31. Similarly, two slotter blades 32A1, 32A2 are attached to an outer peripheral surface of the upper slotter 32B of the slotter unit 32. The slotter blades 31A1, 31A2 are operable to subject front and rear ends of an initial or first one of two creased corrugated paperboard sheets SH fed in the processing cycle, to slotting. The slotter blades 32A1, 32A2 are operable to subject front and rear ends of a next or second one of the two creased corrugated paperboard sheets SH fed in the processing cycle, to slotting.
Two punching dies 35A1, 35A2 are attached to the outer peripheral surface of the die cylinder 33 in a point symmetrical positional relation. The punching die 35A1 is operable to subject an initial or first one of two slotted corrugated paperboard sheets SH fed in the processing cycle, to punching. The punching die 35A2 is operable to subject a next or second one of the two slotted corrugated paperboard sheets SH fed in the processing cycle, to punching.
With reference to
The lower-level management device 310 is operable, according to the control instruction information sent from the upper-level management device 300, to control operations of drive sections such as the main drive motor MT, and perform a management control, for example, of counting the number of processed corrugated paperboard sheets SH and sending the obtained data to the upper-level management device 300. The lower-level management device 310 is connected to a first program memory 320 and a working memory 330, thereby making up a computer for controlling the corrugated paperboard box making machine 1 in cooperation with these memories. The first program memory 320 is a memory fixedly storing therein a control program for controlling an entirety of the corrugated paperboard box making machine 1, a program for executing a feeding control processing depicted in
The lower-level management device 310 is connected to the manipulation panel 340. The manipulation panel 340 comprises a feeding button 341, an order termination button 342, a sheet feeding speed change button 343, and an information display 344. The feeding button 341 is configured to be manipulated to cause the sheet feeding apparatus 2 to start feeding of corrugated paperboard sheets SH. The manipulation panel 340 is operable, upon manipulation of the feeding button 341, to generate a feeding start signal SF. The order termination button 342 is configured to be manipulated to terminate a currently executed order. The sheet feeding speed change button 343 is configured to be manipulated to change a sheet feeding speed to an arbitrary value. The sheet feeding speed change button 343 comprises a speed increasing button for increasing the sheet feeding speed, and a speed reducing button for reducing the sheet feeding speed. The information display 344 is configured to display information such as a numerical value representing a changed value of the sheet feeding speed.
The lower-level management device 310 is connected to each of a drive control device 350, a printing control device 351, a creaser-slotter control device 352, a die cutter control device 353, a folder-gluer control device 354, a counter-ejector control device 355, and a roller motor control device 356. The drive control device 350 is operable, according to the control instruction information from the lower-level management device 310, to control activation and deactivation of the main drive motor MT, and a rotational speed thereof. The rotational speed of the main drive motor MT is controlled according to the sheet feeding speed contained in the control instruction information. The printing control device 351 is operable, according to the control instruction information from the lower-level management device 310, to control an operation of the printing units 25, 26. The creaser-slotter control device 352 is operable, according to the control instruction information from the lower-level management device 310, to control an operation of the creaser unit 30 and to control an operation of the slotter units 31, 32. The die cutter control device 353 is operable, according to the control instruction information from the lower-level management device 310, to control an operation of the die cutter 5. The folder-gluer control device 354 is operable, according to the control instruction information from the lower-level management device 310, to control operations of the glue supply device 38, the conveyance drive motor, the folding drive motor and others. The counter-ejector control device 355 is connected to the sheet sensor SN2, and operable, based on the sheet detection signal ST2 received from the sheet sensor SN2, to count the number of the box-structured corrugated paperboard sheets SH fed from the sheet transfer apparatus 7. Further, the counter-ejector control device 355 is operable, according to the control instruction information from the lower-level management device 310, to control activation and deactivation of each of the motors provided in the counter-ejector 8, such as the belt drive motor 205 and the ledge raising-lowering motor 208. For example, the counter-ejector control device 355 is operable to control the activation of the ledge raising-lowering motor 208 such that, when the sheet sensor SN2 detects a leading edge of a last one of the box-structured corrugated paperboard sheets SH forming one batch, the main ledge 46 starts to move downwardly from the given standby position toward the given lower position. In
The rotational position sensor 190 and the sheet sensor SN1 are individually connected to the lower-level management device 310. The lower-level management device 310 is operable, upon manipulation of the feeding button 341, to send control instruction information containing a feeding start instruction to the roller motor control device 356. After sending the feeding start instruction, the lower-level management device 310 is operable, every time it receives the detection signal SD from the rotational position sensor 190, to send control instruction information containing a synchronization instruction to the roller motor control device 356. Further, the lower-level management device 310 is operable, based on the sheet detection signal ST1 received from the sheet sensor SN1, to count the number of corrugated paperboard sheets SH fed from the sheet feeding apparatus 2.
The roller motor control device 356 is operable, according to the control instruction information from the lower-level management device 310, to control a sequence of operations of a first motion controller 360. A basic roller drive pattern memory 361 is connected to the roller motor control device 356. The basic roller drive pattern memory 361 stores therein two basic roller drive patterns BRP11, BRP12 preliminarily set for the one-sheet feeding mode, and three basic roller drive patterns BRP21 to BRP23 preliminarily set for the two-sheet feeding mode, in order to control the rotational speed of each of the roller motors 90, 91, 102, 103. The lower-level management device 310 is operable, upon receiving control instruction information for carrying out preparation for execution of the next (new) order, from the upper-level management device 300, to send control instruction information containing an order preparation instruction to the roller motor control device 356. The roller motor control device 356 is operable, upon receiving the control instruction information containing the order preparation instruction, from the lower-level management device 310, to read out one of a combination of the basic roller drive patterns BRP11, BRP12, and a combination of the basic roller drive patterns BRP21 to BRP23, from the basic roller drive pattern memory 361, to generate a roller speed control pattern creation instruction. The roller motor control device 356 is operable to send the roller speed control pattern creation instruction to the first motion controller 360. The roller speed control pattern creation instruction contains the sheet feeding speed contained in the control instruction information from the lower-level management device 310, and the read-out combination of basic roller drive patterns BRP. Further, the roller motor control device 356 is operable, in response to the feeding start instruction or the synchronization instruction contained in the control instruction information from the lower-level management device 310, to send a motion start instruction to the first motion controller 360.
The first motion controller 360 comprises a built-in motion CPU, and is connected to a second program memory 362 and a first speed control pattern memory 363. The second program memory 362 preliminarily stores therein a roller speed control pattern creation program for creating a roller speed control pattern RT, and a phase-difference set value DPP. The phase-difference set value DPP is a value for setting a phase difference by which a start phase of an acceleration region (BR11, BR21) in each of the basic roller drive patterns BRP11, BRP21 depicted in
Then, the first motion controller 360 is operable, upon receiving the motion start instruction from the roller motor control device 356, to read out the speed control instructions from the first speed control pattern memory 363 at intervals of a given control cycle, and sequentially send the speed control instructions to a first drive control circuit 364. For example, the given control cycle is 1 msec, which is a time period during which the first motion controller 360 can reliably execute processing such as read-out of the speed control instructions, even in a situation where the sheet feeding speed is set to an upper limit speed which is a maximum sheet feeding speed realizable in the corrugated paperboard box making machine 1. A basic configuration of the first motion controller 360 is commonly known, as disclosed, for example, in JP 2006-072399A, JP 11-272312A and JP 05-050329A. Thus, detailed description thereof will be omitted.
The first drive control circuit 364 is operable to receive the speed control instructions from the first motion controller 360 and rotation pulses from the group of encoders 100, 101, 112, 113, to control the rotational speed and the activation-deactivation of each of the roller motors 90, 91, 102, 103. That is, the first drive control circuit 364 is operable to control supply of electricity to the roller motors, such that the rotational speed of each of the roller motors becomes equal to a value conforming to the speed control instruction, during the given control cycle. According to rotation of the roller motors 90, 91, 102, 103, the feeding rollers 124 to 127 are rotated in the counterclockwise direction as indicated by the arrowed lines in
A basic grate raising-lowering pattern memory 370 and an order-specific grate raising-lowering pattern memory 371 are connected to the lower-level management device 310. The basic grate raising-lowering pattern memory 370 stores therein: a basic grate raising-lowering pattern BGS1 preliminarily set in conformity to a minimum sheet length in the one-sheet feeding mode; a basic grate raising-lowering pattern BGL1 preliminarily set in conformity to a maximum sheet length in the one-sheet feeding mode; a basic grate raising-lowering pattern BGS2 preliminarily set in conformity to a minimum sheet length in the two-sheet feeding mode; and a basic grate raising-lowering pattern BGL2 preliminarily set in conformity to a maximum sheet length in the two-sheet feeding mode, in order to control the rotational speed of the raising-lowering motor 80. The order-specific grate raising-lowering pattern memory 371 is operable to temporarily store an order-specific grate raising-lowering pattern DGP, as mentioned below.
The lower-level management device 310 is operable, upon receiving control instruction information for carrying out preparation for execution of the next (new) order, from the upper-level management device 300, to execute the grate raising-lowering pattern creation program stored in the first program memory 320. According to the execution of the grate raising-lowering pattern creation program, the lower-level management device 310 is operable, based on one of the basic grate raising-lowering patterns BGS1, BGL1, BGS2, BGL2 stored in the basic grate raising-lowering pattern memory 370, to create an order-specific grate raising-lowering pattern DGP conforming to a sheet length of the next order, and temporarily store the created order-specific grate raising-lowering pattern DGP in the order-specific grate raising-lowering pattern memory 371. Subsequently, the lower-level management device 310 is operable to read out the order-specific grate raising-lowering pattern DGP from the order-specific grate raising-lowering pattern memory 371 to generate a grate raising-lowering speed control pattern creation instruction. The grate raising-lowering speed control pattern creation instruction contains a sheet feeding speed set by manipulation of the sheet feeding speed change button 343 or the like, and the order-specific grate raising-lowering pattern DGP.
The lower-level management device 310 is operable, upon manipulation of the feeding button 341, to receive the feeding start signal SF from the manipulation panel 340, and send, as the motion start instruction, control instruction information containing the feeding start instruction, to a second motion controller 380. After sending the feeding start instruction, the lower-level management device 310 is operable, every time it receives the detection signal SD from the rotational position sensor 190, to send, as the motion start instruction, control instruction information containing the synchronization instruction, to the second motion controller 380.
The second motion controller 380 is connected to the lower-level management device 310. The second motion controller 380 comprises a built-in motion CPU, and is connected to a third program memory 381 storing therein a program, and a second speed control pattern memory 382. The third program memory 381 preliminarily stores therein a grate raising-lowering speed control pattern creation program for creating a grate raising-lowering speed control pattern GT. The second speed control pattern memory 382 is operable to temporarily store therein a grate raising-lowering speed control pattern GT created by the second motion controller 380. The grate raising-lowering speed control pattern GT contains a series, large number of speed control instructions for designating the rotational speed of the raising-lowering motor 80. The second motion controller 380 is operable, upon receiving the grate raising-lowering speed control pattern creation instruction from the lower-level management device 310, to execute the grate raising-lowering speed control pattern creation program. According to the execution of the grate raising-lowering speed control pattern creation program, the second motion controller 380 is operable, based on the sheet feeding speed and the order-specific grate raising-lowering pattern DGP contained in the grate raising-lowering speed control pattern creation instruction, to create a grate raising-lowering speed control pattern GT and temporarily store the created grate raising-lowering speed control pattern GT in the second speed control pattern memory 382.
Then, the second motion controller 380 is operable, upon receiving the motion start instruction from the lower-level management device 310, to read out the speed control instructions from the second speed control pattern memory 382 at intervals of a given control cycle, and sequentially send the speed control instructions to a second drive control circuit 383. For example, the given control cycle is 1 msec, which is a time period during which the second motion controller 380 can reliably perform processing such as read-out of the speed control instructions even in a situation where the sheet feeding speed is set to an upper limit speed which is a maximum sheet feeding speed realizable in the corrugated paperboard box making machine 1. The second motion controller 380 has the same basic configuration as that of the first motion controller 360.
The second drive control circuit 383 is operable to receive the speed control instructions from the second motion controller 380, and rotation pulses from the encoder 85, to control the rotational speed and the activation-deactivation of the raising-lowering motor 80. That is, the second drive control circuit 383 is operable to control supply of electricity to the raising-lowering motor 80 such that the rotational speed of the raising-lowering motor 80 becomes equal to a rotational speed conforming to the speed control instruction, during the given control cycle. While the rotary shaft of the raising-lowering motor 80 is rotated 360 degrees, the eccentric member 171 is rotated 360 degrees in the clockwise direction as indicated by the arrowed lines in
With reference to
As depicted in
A rate of change of speed per unit time (speed change rate per unit time) at which each of the roller motors 90, 91, 102, 103 is rotationally accelerated in the acceleration region BR11 is preliminarily set based on a maximum speed change rate per unit time for each of the roller motors, so as to allow an amount of change of the rotational angle θp in the acceleration region BR11 to be minimized. In particular, the speed change rate per unit time in acceleration region BR11 needs to be set such that the circumferential speed Vr of each of the feeding rollers is accelerated from the stopped state to a value equal to the circumferential speed Vp of each of the printing cylinders, within a time period after a leading edge of a corrugated paperboard sheet SH passes through the front gate 21 through until the corrugated paperboard sheet SH is fed by a distance LF depicted in
A maximum time period during which one corrugated paperboard sheet SH is fed by the feeding rollers 124 to 127, in a processing cycle where each of the printing cylinders is rotated 360 degrees, i.e., in a time period during which the rotational angle θp changes from 0 degree to 360 degrees, is a sum of a duration of the acceleration region BR11 and a duration of the constant-speed region BR12. Thus, an amount of change of the rotational angle θp in the acceleration region BR11 and the constant-speed region BR12 is preliminarily set based on a maximum sheet length processible by the corrugated paperboard box making machine 1 under the condition that the feeding mode is set to the one-sheet feeding mode. In the constant-speed region BR12, the circumferential speed Vp of each of the printing cylinders and the circumferential speed Vr of each of the feeding rollers need to become equal to each other and set to a value corresponding to the sheet feeding speed, i.e., the speed ratio Rf needs to be 1. In order to reliably stop the roller motors in the stop region BR 14, a rate of change of speed per unit time (speed change rate per unit time) at which each of the roller motors is rotationally decelerated in the deceleration region BR13 is set to be less than the speed change rate per unit time in the acceleration region BR11.
An upper surface of each of the grates 141 undergoes wear due to frictional contact with corrugated paperboard sheets SH. When the upper surface of the grate 141 is worn away, a height position of the upper surface of the grate 141 is lowered by a distance corresponding to an amount of the wear, and a timing at which a lower surface of a corrugated paperboard sheet SH comes into contact with the feeding rollers is changed according to the wear amount. In order to allow the corrugated paperboard sheet SH to reliably come into contact with the feeding rollers in the stopped state, at a start time point of the processing cycle, a duration of the stop region BR14 is preliminarily set by taking into account a predetermined allowable wear amount. In this embodiment, the allowable wear amount is set to 0.4 mm.
In
As depicted in
A speed change rate per unit time at which each of the roller motors 90, 91, 102, 103 is rotationally accelerated in the acceleration region BR21 is preliminarily set based on a maximum speed change rate per unit time for each of the roller motors, so as to allow an amount of change of the rotational angle θp in the acceleration region BR21 to be minimized. Specifically, it is preliminarily set to be greater than the speed change rate per unit time in the acceleration region BR11. In particular, the speed change rate per unit time in acceleration region BR21 needs to be set such that the circumferential speed Vr of each of the feeding rollers is accelerated from the stopped state to a value equal to the circumferential speed Vp of each of the printing cylinders, within a time period after a leading edge of a corrugated paperboard sheet SH passes through the front gate 21 through until the corrugated paperboard sheet SH is fed by the distance LF depicted in
Two corrugated paperboard sheets SH need to be sequentially fed in a processing cycle where each of the printing cylinders is rotated 360 degrees, i.e., in a time period during which the rotational angle θp changes from 0 degree to 360 degrees. Thus, a maximum time period during which each of two corrugated paperboard sheets SH is fed by the feeding rollers 124 to 127 is a sum of a duration of the acceleration region BR21 and a duration of the constant-speed region BR22, so that an amount of change of the rotational angle θp in the acceleration region BR21 and the constant-speed region BR22 is preliminarily set based on a maximum sheet length processible by the corrugated paperboard box making machine 1 under the condition that the feeding mode is set to the two-sheet feeding mode. In the constant-speed region BR22, the circumferential speed Vp of each of the printing cylinders and the circumferential speed Vr of each of the feeding rollers need to become equal to each other and set to a value corresponding to the sheet feeding speed, i.e., the speed ratio Rf needs to be 1. In order to reliably stop the roller motors in the stop region BR 24, a speed change rate per unit time at which each of the roller motors is rotationally decelerated in the deceleration region BR23 is set to be less than the speed change rate per unit time in the acceleration region BR21.
In order to enable the corrugated paperboard sheet SH to reliably come into contact with the feeding rollers in the stopped state, at a start time point of the processing cycle, a duration of the stop region BR24 is preliminarily set by taking into account the predetermined allowable wear amount.
The basic roller drive sub-pattern BRP2B has the same pattern shape as that of the basic roller drive sub-pattern BRP2A, as depicted in
In
In
With reference to
With reference to
As depicted in
The minimum sheet length can be set to a smaller value, as an amount of change of the rotational angle θp in the acceleration sub-regions BS11A, BS13A and the deceleration sub-regions BS11B, BS13B is set to a smaller value as much as possible. Thus, each of the speed change rate per unit time in the acceleration sub-regions BS11A, BS13A and the speed change rate per unit time in the deceleration sub-regions BS11B, BS13B is preliminarily set based on a maximum speed change rate per unit time for the raising-lowering motor 80.
In
As depicted in
With reference to
As depicted in
The maximum sheet length can be set to a larger value, as an amount of change of the rotational angle θp in the acceleration sub-regions BL11A, BL13A and the deceleration sub-regions BL11B, BL13B is set to a smaller value as much as possible. Thus, each of the speed change rate per unit time in the acceleration sub-regions BL11A, BL13A and the speed change rate per unit time in the deceleration sub-regions BL11B, BL13B is preliminarily set based on the maximum speed change rate per unit time for the raising-lowering motor 80.
As depicted in
With reference to
As depicted in
Each of the variable-speed lowering regions BS21 of the basic grate raising-lowering sub-patterns BGS2A, BGS2B is composed of an acceleration sub-region BS21A and a deceleration sub-region BS21B. Similarly, each of the variable-speed raising regions BS23 of the basic grate raising-lowering sub-patterns BGS2A, BGS2B is composed of an acceleration sub-region BS23A and a deceleration sub-region BS23B. In this embodiment, a speed change rate per unit time at which the raising-lowering motor 80 is accelerated in the acceleration sub-regions BS21A, BS23A is set to be equal to a speed change rate per unit time at which the raising-lowering motor 80 is decelerated in the deceleration sub-regions BS21B, BS23B. The variable-speed lowering region BS21 and the variable-speed raising region BS23 in each of the basic grate raising-lowering sub-patterns BGS2A, BGS2B are arranged at a time interval conforming to the minimum sheet length, in a direction causing an increase in the rotational angle θp, i.e., in the arrowed direction along the horizontal axis in
The minimum sheet length can be set to a smaller value, as an amount of change of the rotational angle θp in the acceleration sub-regions BS21A, BS23A and the deceleration sub-regions BS21B, BS23B is set to a smaller value as much as possible. Thus, each of the speed change rate per unit time in the acceleration sub-regions BS21A, BS23A and the speed change rate per unit time in the deceleration sub-regions BS21B, BS23B is preliminarily set based on the maximum speed change rate per unit time for the raising-lowering motor 80. The speed change rate per unit time in the acceleration sub-regions and the deceleration sub-regions, and a maximum value of the speed ratio Rg in the acceleration sub-regions, are set such that a total area of two regions surrounded by two polygonal lines indicative of respective shapes of the basic grate raising-lowering sub-patterns BGS2A, BGS2B and the horizontal axis representing the rotational angle θp in
The lower-position control region BS22 is set in the same manner as that for the lower-position control region BS12 of the basic grate raising-lowering pattern BGS 1 depicted in
The basic grate raising-lowering sub-pattern BGS2B has the same pattern shape as that of the basic grate raising-lowering sub-pattern BGS2A, as depicted in
With reference to
As depicted in
Each of the variable-speed lowering regions BL21 of the basic grate raising-lowering sub-patterns BGL2A, BGL2B is composed of an acceleration sub-region BL21A and a deceleration sub-region BL21B. Similarly, each of the variable-speed raising regions BL23 of the basic grate raising-lowering sub-patterns BGL2A, BGL2B is composed of an acceleration sub-region BL23A and a deceleration sub-region BL23B. In this embodiment, a speed change rate per unit time at which the raising-lowering motor 80 is accelerated in the acceleration sub-regions BL21A, BL23A is set to be equal to a speed change rate per unit time at which the raising-lowering motor 80 is decelerated in the deceleration sub-regions BL21B, BL23B. The variable-speed lowering region BL21 and the variable-speed raising region BL23 in each of the basic grate raising-lowering sub-patterns BGL2A, BGL2B are arranged at a time interval conforming to the maximum sheet length, in a direction causing an increase in the rotational angle θp, i.e., in the arrowed direction along the horizontal axis in
The maximum sheet length can be set to a larger value, as an amount of change of the rotational angle θp in the acceleration sub-regions BL21A, BL23A and the deceleration sub-regions BL21B, BL23B is set to a smaller value as much as possible. Thus, each of the speed change rate per unit time in the acceleration sub-regions BL21A, BL23A and the speed change rate per unit time in the deceleration sub-regions BL21B, BL23B is preliminarily set based on the maximum speed change rate per unit time for the raising-lowering motor 80. The speed change rate per unit time in the acceleration sub-regions and the deceleration sub-regions, and a maximum value of the speed ratio Rg in the acceleration sub-regions, are set such that a total area of four regions surrounded by four polygonal lines indicative of respective shapes of the basic grate raising-lowering sub-patterns BGL2A, BGL2B and the horizontal axis representing the rotational angle θp in
As depicted in
The basic grate raising-lowering sub-pattern BGL2B has the same pattern shape as that of the basic grate raising-lowering sub-pattern BGL2A, as depicted in
With reference to the drawings, an operation and functions of the corrugated paperboard box making machine 1 according to the above embodiment will be described below. As regards the operation and functions of the corrugated paperboard box making machine 1, a control operation pertaining to a feeding operation of the sheet feeding apparatus 2, a control operation of the printing control device 351 and a control operation of the counter-ejector control device 355 will be described. On the other hand, since respective control operations of the creaser-slotter control device 352, the die cutter control device 353 and the folder-gluer control device 354 are well known, detailed description thereof will be omitted.
When an operator manipulates the order termination button 342 or when a processing of a given number of corrugated paperboard sheets designated by a production plan has been completed in a previous order, the lower-level management device 310 sends a feeding termination instruction to the control devices 350 to 356. Subsequently, the lower-level management device 310 receives the order preparation instruction for directing preparation for execution of the next (new) order. The lower-level management device 310 sends the order preparation instruction containing specifications of the next order to each of the control devices 350 to 356.
In response to receiving the order preparation instruction from the upper-level management device 300, the lower-level management device 310 starts a program for executing a feeding control processing depicted in
Count values such as a fed-sheet number are initialized (S1). For example, a fed-sheet number indicative of the number of corrugated paperboard sheets SH fed from the sheet feeding apparatus 2 to form one batch is set to an initial value of “0”. As an example other than the fed-sheet number, a cumulative number of corrugated paperboard sheets SH fed from the sheet feeding apparatus 2 in each order is set to an initial value of “0”.
Subsequently, the sheet length, the batch-forming sheet number and the feeding mode of the next order are set (S2). Specifically, information for designating the sheet length, the batch-forming sheet number and the feeding mode determined as specifications of the next order is stored and set in a given storage area of the working memory 330. The sheet length means the length of a corrugated paperboard sheet SH in the feeding direction FD. The batch-forming sheet number means a given number of corrugated paperboard sheets SH forming one batch.
Subsequently, it is determined whether or not the feeding mode in the next order is the one-sheet feeding mode (S3). Specifically, it is determined whether the feeding mode-designating information stored in the working memory 330 in the step S2 indicates the one-sheet feeding mode or the two-sheet feeding mode. When the feeding mode is determined to be the one-sheet feeding mode (S3: YES), the processing routine proceeds to step S4. On the other hand, when the feeding mode is determined to be not the one-sheet feeding mode, i.e., to be the two-sheet feeding mode (S3: NO), the processing routine proceeds to step S7.
In the former case where the feeding mode is determined to be the one-sheet feeding mode, an allowable speed is calculated based on the designated sheet length (S4). Specifically, the allowable speed Sa (sheets/min) is calculated based on an outer peripheral length Cp (mm) of each of the printing cylinders 25A, 26A, a given downward-movement time period Td (sec) of the main ledge 46, and a sheet length Ls (mm). The outer peripheral length Cp (mm) of each of the printing cylinders 25A, 26A is calculated by multiplication of the diameter Dp of each of the printing cylinders and pi (π). The given downward-movement time period Td (sec) of the main ledge 46 means a time period necessary for the main ledge 46 to move downwardly from the standby position slightly above a height position where the box-structured corrugated paperboard sheet SH is fed out by the transfer conveyer 41 and the upper conveyance roll 42, to the given lower position slightly above a height position where the auxiliary ledges 47A, 47B are installed. The given downward-movement time period Td is determined by performance of the ledge raising-lowering motor 208, and a mechanical configuration of an up-down mechanism comprising the pinion 209 and the rack 210. The sheet length Ls means the length of the corrugated paperboard sheet SH in the feeding direction FD, set in conformity to an order intended to be executed.
For example, the allowable speed Sa (sheets/min) is calculated by the following formula:
Sa=60×(π×Dp−Ls)/(Td×π×Dp)
Subsequently, the allowable speed is set as a sheet feeding speed (S5). Specifically, the allowable speed Sa calculated in the step S4 is stored and set in a given storage area of the working memory 330, as a sheet feeding speed Sf at which the sheet feeding apparatus 2 feeds the corrugated paperboard sheet SH.
Subsequently, a first upper limit speed, the allowable speed and the sheet feeding speed are displayed (S6). Specifically, the first upper limit speed S1max, the allowable speed Sa and the sheet feeding speed Sf are individually displayed on the information display 344, in the form of a numerical value defined as the number of the corrugated paperboard sheets SH to be fed per minute. The first upper limit speed S1max means a maximum sheet feeding speed at which the corrugated paperboard box making machine 1 can feed the corrugated paperboard sheet SH in the one-sheet feeding mode. The first upper limit speed S1max is determined by a mechanical configuration of the corrugated paperboard box making machine 1. When the step S5 is executed for the first time after start of the feeding control processing, the sheet feeding speed Sf is displayed on the information display 344 as the same numerical value as that of the allowable speed Sa.
On the other hand, when the feeding mode is determined, in the step S3, to be not the one-sheet feeding mode, a second upper limit speed S2max is calculated as the sheet feeding speed (S7). The second upper limit speed S2max means a maximum sheet feeding speed at which the corrugated paperboard box making machine 1 can feed the corrugated paperboard sheet SH in the two-sheet feeding mode, and has a value which is two times the first upper limit speed S1max.
The second upper limit speed and the sheet feeding speed are displayed (S8). Specifically, the second upper limit speed S2max and the sheet feeding speed Sf are individually displayed on the information display 344, in the form of a numerical value defined as the number of the corrugated paperboard sheets SH to be fed per minute.
Subsequently, it is determined whether or not the batch-forming sheet number is an even number (S5). Specifically, it is determined whether the batch-forming sheet number-designating information stored in the working memory 330 in the step S2 indicates an even sheet number or an odd sheet number. When the batch-forming sheet number is determined to be an even number (S9: YES), the processing routine proceeds to step S10. On the other hand, when the batch-forming sheet number is determined to be not an even number, i.e., to be an odd number (S9: NO), the processing routine proceeds to step S11.
In the former case where the designated batch-forming sheet number is determined to be an even number, the control value XC is set to a numerical value NB representing the batch-forming sheet number (S10).
In the latter case where the designated batch-forming sheet number is determined to be not an even number, the control value XC is set to a numerical value (NB−1) derived from subtracting “1” from the numerical value NB representing the batch-forming sheet number (S11). Specifically, according to the batch-forming sheet number-designating information stored in the working memory 330 in the step S2, the control value XC is set to the numerical value derived from subtracting “1” from the numerical value NB representing the batch-forming sheet number. Then, this numerical value (NB−1) is stored in a given storage area of the working memory 330.
After execution of the processing in the step S10 or S11, it is determined whether or not a sheet feeding speed changing manipulation has been performed (S12). Specifically, it is determined whether or not the sheet feeding speed change button 343 has been manipulated by an operator. When the sheet feeding speed change button 343 is determined to have been manipulated (S12: YES), the processing routine proceeds to step S13. On the other hand, when the sheet feeding speed change button 343 is determined to be not manipulated (S12: NO), the processing routine proceeds to step S17.
In the former case where the sheet feeding speed change button 343 is determined to have been manipulated, the sheet feeding speed is changed (S13). Specifically, when the speed increasing button of the sheet feeding speed change button 343 is manipulated, the sheet feeding speed is increased depending on a duration time of the manipulation of the speed increasing button. On the other hand, when the speed reducing button of the sheet feeding speed change button 343 is manipulated, the sheet feeding speed is reduced depending on a duration time of the manipulation of the speed reducing button. The changed sheet feeding speed Sf is stored in the given area of the working memory 330 in an updating manner. In this embodiment, an operator can change the sheet feeding speed Sf within a speed range equal to or less than the first upper limit speed S1max in the one-sheet feeding mode, or within a speed range equal to or less than the second upper limit speed S2max in the two-sheet feeding mode, while taking into account specifications of an order intended to be executed, and a state of corrugated paperboard sheets, such as warpage. For example, in a situation where a solid print area in a printing pattern is relatively small, an operator is apt to change the sheet feeding speed Sf to a value greater than the allowable speed Sa, when the feeding mode is set to the one-sheet feeding mode. On the other hand, in a situation where warpage occurs in the corrugated paperboard sheets SH, an operator is apt to change the sheet feeding speed Sf to a value less than the allowable speed Sa, when the feeding mode is set to the one-sheet feeding mode, and to change the sheet feeding speed Sf to a value less than the second upper limit speed S2max, when the feeding mode is set to the two-sheet feeding mode.
Subsequently, it is determined whether or not the feeding mode in the next order is the one-sheet feeding mode (S14). Specifically, it is determined whether the feeding mode-designating information stored in the working memory 330 in the step S2 indicates the one-sheet feeding mode or the two-sheet feeding mode. When the feeding mode is determined to be the one-sheet feeding mode (S14: YES), the processing routine proceeds to step S15. On the other hand, when the feeding mode is determined to be not the one-sheet feeding mode, i.e., to be the two-sheet feeding mode (S14: NO), the processing routine proceeds to step S16.
In the former case where the feeding mode is determined to be the one-sheet feeding mode, the first upper limit speed, the allowable speed and the sheet feeding speed are displayed (S15). Specifically, the first upper limit speed S1max, the allowable speed Sa and the sheet feeding speed Sf are individually displayed on the information display 344, in the form of a numerical value defined as the number of the corrugated paperboard sheets SH to be fed per minute. This sheet feeding speed Sf is the sheet feeding speed changed in the step S13.
On the other hand, when the feeding mode is determined to be not the one-sheet feeding mode, the second upper limit speed S2max and the sheet feeding speed Sf are individually displayed on the information display 344, in the form of a numerical value defined as the number of the corrugated paperboard sheets SH to be fed per minute. This sheet feeding speed Sf is the sheet feeding speed changed in the step S13.
The operator can look at contents displayed on the information display 344 to figure out a specific numerical value of the changed sheet feeding speed Sf, and a relative magnitude of the changed sheet feeding speed Sf with respect to the first upper limit speed S1max and the allowable speed Sa. On the other hand, when the processing in the step S16 is executed, the operator can look at contents displayed on the information display 344 to figure out a specific numerical value of the changed sheet feeding speed Sf, and a relative magnitude of the changed sheet feeding speed Sf with respect to the second upper limit speed S2max.
On the other hand, when the sheet feeding speed change button 343 is determined, in the step S12, to be not manipulated, it is determined whether or not the feeding mode in the next order is the one-sheet feeding mode (S17). Specifically, it is determined whether the feeding mode-designating information stored in the working memory 330 in the step S2 indicates the one-sheet feeding mode or the two-sheet feeding mode. When the feeding mode is determined to be the one-sheet feeding mode (S17: YES), the processing routine proceeds to step S18. On the other hand, when the feeding mode is determined to be not the one-sheet feeding mode, i.e., to be the two-sheet feeding mode (S17: NO), the processing routine proceeds to step S19.
In the former case where the feeding mode is determined to be the one-sheet feeding mode, it is determined whether or not the sheet feeding speed is greater than the allowable speed (S18). When the sheet feeding speed is determined to be greater than the allowable speed (S18: YES), the processing routine proceeds to step S19. On the other hand, when the sheet feeding speed is determined to be equal to or less than the allowable speed (S18: NO), the processing routine proceeds to step S20.
In the former case where the sheet feeding speed is determined to be greater than the allowable speed, a sheet feeding stop control is set (S19). Specifically, a control instruction for directing execution of the sheet feeding stop control is stored and set in a given storage area of the working memory 330. Further, the control instruction for directing execution of the sheet feeding stop control is sent to each of the printing control device 351 and the roller motor control device 356.
On the other hand, in the latter case where the sheet feeding speed is determined to be equal to or less than the allowable speed, a sheet feeding control is set (S20). Specifically, a control instruction for directing execution of the sheet feeding control is stored and set in a given storage area of the working memory 330. Further, the control instruction for directing execution of the sheet feeding control is sent to each of the printing control device 351 and the roller motor control device 356.
After execution of the processing in the step S19 or S20, it is determined whether or not a sheet feeding start manipulation has been performed (S21). Specifically, it is determined whether or not the feeding start signal SF generated from the manipulation panel 340 in response to manipulation of the feeding button 341 by an operator has been received. When the sheet feeding start manipulation is determined to have been performed (S21: YES), the processing routine proceeds to step S22. On the other hand, when the sheet feeding start manipulation is determined to be not performed (S21: NO), the processing routine returns to the step S12 and thus the processings in the steps S12 to S20 will be executed again.
In the former case where the sheet feeding start manipulation is determined to have been performed, an instruction for directing start of feeding is issued (S22). Specifically, according to the feeding start signal SF, control instruction information containing the feeding start instruction and the motion start instruction is sent to the drive control device 350 and the roller motor control device 356. Further, the control instruction information is also sent to the second motion controller 380 as the motion start instruction. Detailed control operations of the roller motor control device 356 and the second motion controller 380 during the sheet feeding operation will be described later.
Subsequently, it is determined whether the leading edge of the corrugated paperboard sheet SH has been detected (S23). Specifically, it is determined whether or not the sheet detection signal ST1 generated from the sheet sensor SN1 detecting the leading edge of the corrugated paperboard sheet SH fed from the sheet feeding apparatus 2 has been received. When the leading edge of the corrugated paperboard sheet SH is determined to have been detected (S23: YES), the processing routine proceeds to step S24. On the other hand, when the leading edge of the corrugated paperboard sheet SH is determined to be not detected (S23: NO), the processing routine returns to the step S22.
In the former case where the leading edge of the corrugated paperboard sheet SH is determined to have been detected, the fed-sheet number is incremented by “1” (S24). The fed-sheet number means a given number of corrugated paperboard sheets SH fed from the sheet feeding apparatus 2 to form one butch, as mentioned above.
After execution of the processing in the step S24, it is determined whether or not the fed-sheet number is identical to the control value XC (S25). When the fed-sheet number is determined to be identical to the control value XC (S25: YES), the processing routine proceeds to step S26. On the other hand, when the fed-sheet number is determined to be not identical to the control value XC (S25: NO), the processing routine returns to the step S22.
In the former case where the fed-sheet number is determined to be identical to the control value XC, it is further determined whether or not the sheet feeding stop control is set (S26). When the sheet feeding stop control is determined to be set (S26: YES), the processing routine proceeds to step S27. On the other hand, when the sheet feeding stop control is determined to be not set (S26: NO), the processing routine proceeds to step S28.
In the former case where the sheet feeding stop control is determined to be set, an instruction for directing temporary stop of feeding is issued (S27). Specifically, when the feeding mode is the one-sheet feeding mode, a one-sheet feeding temporary stop instruction CS1 for directing temporary stop of one cycle of sheet feeding operation is issued. On the other hand, when the feeding mode is the two-sheet feeding mode, and the batch-forming sheet number is an even number, a two-sheet feeding temporary stop instruction CS21 for directing temporary stop of two cycles of sheet feeding operation is issued. Further, when the feeding mode is the two-sheet feeding mode, and the batch-forming sheet number is an odd number, a two-sheet feeding temporary stop instruction CS22 for directing temporary stop of one cycle of sheet feeding operation is issued. One of the feeding temporary stop instructions CS1, CS21, CS22 is sent to each of the printing control device 351 and the roller motor control device 356. Detailed control operations of the printing control device 351 and the roller motor control device 356 during the feeding temporary stop operation will be described later.
On the other hand, in the latter case where the sheet feeding stop control is determined, in the step S26, to be not set, the fed-sheet number is reset to “0” (S28). That is, the fed-sheet number is reset so as to count the number of corrugated paperboard sheets fed to form a next batch.
After execution of the step S28, it is determined whether or not the current order has been completed (S29). Specifically, it is determined whether or not the order termination button 342 has been manipulated by an operator, or a processing of a given number of corrugated paperboard sheets designated by a production plan has been completed in the current order. When the order is determined to have been completed (S29: YES), the processing routine proceeds to step S30. On the other hand, when the order is determined to be not completed (S29: NO), the processing routine returns to the step S22.
In the former case where the order is determined to have been completed, an instruction for directing termination of feeding is issued (S30). Specifically, the feeding termination instruction for directing termination of the sheet feeding operation is sent to each of the control devices 350 to 356 and the second motion controller 380. After execution of the processing in the step S30, the feeding control processing is terminated.
With reference to
A sheet feeding operation of the sheet feeding apparatus 2 will be described, on the assumption that a feeding mode set in conformity to a next order is the two-sheet feeding mode. In order to process corrugated paperboard sheets SH according to a sheet feeding operation in the two-sheet feeding mode, an operator carries out preparatory works, such as replacement of printing die members, replacement of slotter blades and replacement of punching dies.
In the step S2 depicted in
Upon detecting an input manipulation complete signal from the manipulation panel 340 after receiving from the upper-level management device 300 the order preparation instruction for directing preparation for execution of the next order, the lower-level management device 310 reads out the feeding mode-designating information and the batch-forming sheet number-designating information from the working memory 330 and sends the feeding mode designation signal, the batch-forming sheet number-designating information and the order preparation instruction to the roller motor control device 356. According to the feeding mode-designating information and the batch-forming sheet number-designating information about the next order in the order preparation instruction, the roller motor control device 356 reads out, from the basic roller drive pattern memory 361, the combination of two basic roller drive patterns for the two-sheet feeding mode, and generates a roller speed control pattern creation instruction. Specifically, when the batch-forming sheet number-designating information represents an even sheet number, the roller motor control device 356 reads out, from the basic roller drive pattern memory 361, the combination of the basic roller drive pattern BRP21 and the full cycle-stop basic roller drive pattern BRP23, and generates a roller speed control pattern creation instruction. On the other hand, when the batch-forming sheet number-designating information represents an odd sheet number, the roller motor control device 356 reads out, from the basic roller drive pattern memory 361, the combination of the basic roller drive pattern BRP21 and the half cycle-stop basic roller drive pattern BRP22, and generates a roller speed control pattern creation instruction. The roller motor control device 356 sends the roller speed control pattern creation instruction to the first motion controller 360.
Upon receiving the roller speed control pattern creation instruction from the roller motor control device 356, the first motion controller 360 reads out the roller speed control pattern creation program from the second program memory 362, and executes the roller speed control pattern creation program. According to execution of the roller speed control pattern creation program, the first motion controller 360 creates a roller speed control pattern RT2 for the two-sheet feeding mode, based on the sheet feeding speed and the basic roller drive pattern BRP21 contained in the roller speed control pattern creation instruction, and temporarily stores the roller speed control pattern RT2 in the first speed control pattern memory 363. Further, when the batch-forming sheet number-designating information represents an even sheet number, according to execution of the roller speed control pattern creation program, the first motion controller 360 also creates a full cycle-stop roller speed control pattern RT2F for the two-sheet feeding mode, based on the sheet feeding speed and the full cycle-stop basic roller drive pattern BRP23 contained in the roller speed control pattern creation instruction, and temporarily stores the full cycle-stop roller speed control pattern RT2F in the first speed control pattern memory 363. On the other hand, when the batch-forming sheet number-designating information represents an odd sheet number, according to execution of the roller speed control pattern creation program, the first motion controller 360 also creates a half cycle-stop roller speed control pattern RT2H for the two-sheet feeding mode, based on the sheet feeding speed and the half cycle-stop basic roller drive pattern BRP22 contained in the roller speed control pattern creation instruction, and temporarily stores the half cycle-stop roller speed control pattern RT2H in the first speed control pattern memory 363. Details of the full cycle-stop roller speed control pattern RT2F and the half cycle-stop roller speed control pattern RT2H will be described later.
With reference to
In the case where the sheet feeding speed contained in the roller speed control pattern creation instruction is 240 sheets/min as a value of the sheet feeding speed of corrugated paperboard sheets SH, the first motion controller 360 creates the roller speed control pattern RT21 based on the sheet feeding speed (240 sheets/min) and the basic roller drive pattern BRP21 depicted in
The roller speed control pattern RT21 is formed of two roller speed control sub-patterns RA21, RB21 each having the same pattern shape, in one processing cycle. Each of the two roller speed control sub-patterns RA21, RB21 comprises, within 0.25 sec, an acceleration region RC1, a constant-speed region RC2, a deceleration region RC3, and a stop region RC4. The acceleration region RC1, the constant-speed region RC2, the deceleration region RC3 and the stop region RC4 in each of the two roller speed control sub-patterns correspond, respectively, to the acceleration region BR21, the constant-speed region BR22, the deceleration region BR23, and the stop region BR24 in each of the basic roller drive sub-patterns BRP2A, BRP2B.
As with the creation of the roller speed control pattern RT21, through the processing of converting the rotational angle θp depicted in
Upon receiving from the upper-level management device 300 the order preparation instruction for directing preparation for execution of the next order, the lower-level management device 310 reads out the grate raising-lowering pattern creation program stored in the first program memory 320 and executes the grate raising-lowering pattern creation program. According to execution of the grate raising-lowering pattern creation program, the lower-level management device 310 creates an order-specific grate raising-lowering pattern DGP conforming to the sheet length of the next order, based on one of the two basic grate raising-lowering patterns BGS2, BGL2 stored in the basic grate raising-lowering pattern memory 370, and temporarily stores the order-specific grate raising-lowering pattern DGP in the order-specific grate raising-lowering pattern memory 371. The sheet length of the next order is designated in a range from a minimum sheet length to a maximum sheet length processible in the two-sheet feeding mode. The minimum sheet length processible in the two-sheet feeding mode is set based on the distance LF depicted in
With reference to
As depicted in
In
After creating the order-specific grate raising-lowering pattern DGP2, the lower-level management device 310 generates a grate raising-lowering speed control pattern creation instruction and sends the grate raising-lowering speed control pattern creation instruction to the second motion controller 380. Upon receiving the grate raising-lowering speed control pattern creation instruction from the lower-level management device 310, the second motion controller 380 reads out the grate raising-lowering speed control pattern creation program from the third program memory 381, and executes the grate raising-lowering speed control pattern creation program. According to execution of the grate raising-lowering speed control pattern creation program, the second motion controller 380 creates a grate raising-lowering speed control pattern GT, based on the sheet feeding speed contained in the grate raising-lowering speed control pattern creation instruction, and the order-specific grate raising-lowering pattern DGP2, and temporarily stores the grate raising-lowering speed control pattern GT in the second speed control pattern memory 382.
With reference to
In the case where the sheet feeding speed contained in the grate raising-lowering speed control pattern creation instruction is 240 sheets/min as a value of the sheet feeding speed of corrugated paperboard sheets SH, the second motion controller 380 creates the grate raising-lowering speed control pattern GT21, based on the sheet feeding speed (240 sheets/min) and the order-specific grate raising-lowering pattern DGP2 depicted in
As depicted in
Specifically, as depicted in
As depicted in
With reference to
When an operator manipulates the feeding button 341 after completion of preparation for execution of the next order, the lower-level management device 310 receives the feeding start signal SF from the manipulation panel 340. In response to the received feeding start signal SF, the lower-level management device 310 sends control instruction information containing the feeding start instruction and the sheet feeding speed to each of the drive control device 350 and the roller motor control device 356, and sends, as the motion start instruction, the control instruction information to the second motion controller 380.
In conformity to the sheet feeding speed contained in the control instruction information, the drive control device 350 rotationally drives the main drive motor MT at a rotational speed corresponding to the sheet feeding speed. Along with the rotation of the main drive motor MT, the printing cylinders 25A, 26A of the printing units 25, 26, the upper slotters of the slotter units 31, 32 and others are rotated at a speed corresponding to the sheet feeding speed, e.g., 240 sheets/min in the two-sheet feeding mode.
In response to the motion start instruction, the second motion controller 380 reads out the speed control instructions of the grate raising-lowering speed control pattern GT21 from the second speed control pattern memory 382 at intervals of a given control cycle, and sequentially send the speed control instructions to the second drive control circuit 383. Based on the speed control instructions, and a frequency of the rotation pulses from the encoder 85, the second drive control circuit 383 controls the rotational speed of the raising-lowering motor 80 to cause the rotational speed of the raising-lowering motor 80 to become equal to the rotational speed Vg according to the grate raising-lowering speed control pattern GT21 depicted in
As depicted in
In order to set start time T2 of the acceleration region RC1 of the roller speed control pattern RT21, the roller motor control device 356 calculates a time period TDP from the time T0 to the time T2, based on the sheet feeding speed contained in the control instruction information, and the phase-difference set value DPP stored in the second program memory 362. Until the elapsed time T becomes equal to the time period TDP, the roller motor control device 356 does not issue any motion start instruction. Thus, the first drive control circuit 364 keeps the roller motors 90, 91, 102, 103 in the stopped state, in the time period TDP from the time T0 just after the generation of the feeding start signal SF.
When the elapsed time T becomes equal to the time period TDP, the roller motor control device 356 generates the motion start instruction and sends it to the first motion controller 360. In response to the received motion start instruction, the first motion controller 360 reads out the speed control instructions of the roller speed control pattern RT21 from the first speed control pattern memory 363 at intervals of a given control cycle, and, after converting the speed control instructions to rotational speed control instructions for each of the roller motors, sequentially send the rotational speed control instructions to the first drive control circuit 364. Specifically, the speed control instructions are converted to rotational speed control instructions for each of the roller motors, based on the diameter Dr of each of the feeding rollers. Based on the rotational speed control instructions, and a frequency of the rotation pulses from each of the group of encoders 100, 106, 112, 113, the first drive control circuit 364 controls the rotational speed of each of the roller motors 90, 91, 102, 103 to cause the rotational speed of each of the roller motors to become equal to the rotational speed according to the roller speed control pattern RT21 depicted in
As depicted in
Among the speed control instructions for directing the rotational speed Vg of the raising-lowering motor 80, one speed control instruction at the time T3 designates a rotation speed of “0”, so that the raising-lowering motor 80 is in an approximately stopped state or in a rotating state at an extremely low speed, in a given time range around the time T3. Two or more of the speed control instructions generated in the given time range around the time T3 correspond to those for the lower-position control region in which the rotational speed of the raising-lowering motor 80 is controlled to cause the upper surface of each of the grates 141 to be located below the position PR of the uppermost point of the outer peripheral surface of each of the feeding rollers 124 to 127. The raising-lowering motor 80 is accelerated in a time period from the time T3 to time T5, according to the speed control instructions in the acceleration sub-region GC23A of the variable-speed raising region GC23, and decelerated in a time period from the time T5 to time T7, according to the speed control instructions in the deceleration sub-region GC23B of the variable-speed raising region GC23. In a time period from the time T3 to the time T7, each of the grates 141 is raised from the lowermost position and moved to the uppermost position. The upper surface of each of the grates 141 is raised to reach the position PR of the uppermost point of the outer peripheral surface of each of the feeding rollers, at a time TB1 depicted in
When the elapsed time T reaches the time T8, the rotational speed of the raising-lowering motor 80 is accelerated at the speed change rate per unit time in the acceleration sub-region GC21A of the grate raising-lowering speed control sub-pattern GA21. When the elapsed time T reaches time T10, the rotational speed of the raising-lowering motor 80 is decelerated at the speed change rate per unit time in the deceleration sub-region GC21B. When the elapsed time T reaches time T12, the rotation of the raising-lowering motor 80 is stopped. In a time period from the time T8 to the time T13, each of the grates 141 is lowered from the uppermost position and moved to the lowermost position. The upper surface of each of the grates 141 is lowered to reach the position PR of the uppermost point of the outer peripheral surface of each of the feeding rollers, at time TA2 depicted in
Among the speed control instructions for directing the rotational speed Vg of the raising-lowering motor 80, one speed control instruction at the time T12 designates a rotation speed of “0”, so that the raising-lowering motor 80 is in an approximately stopped state or in a rotating state at an extremely low speed, in a given time range around the time T12. Two or more of the speed control instructions generated in the given time range around the time T12 correspond to those for the lower-position control region in which the rotational speed of the raising-lowering motor 80 is controlled to cause the upper surface of each of the grates 141 to be located below the position PR of the uppermost point of the outer peripheral surface of each of the feeding rollers 124 to 127. The raising-lowering motor 80 is accelerated in a time period from the time T12 to time T14, according to the speed control instructions in the acceleration sub-region GC23A of the variable-speed raising region GC23, and decelerated in a time period from the time T14 to time T16, according to the speed control instructions in the deceleration sub-region GC23B of the variable-speed raising region GC23. In a time period from the time T12 to the time T16, each of the grates 141 is raised from the lowermost position and moved to the uppermost position. The upper surface of each of the grates 141 is raised to reach the position PR of the uppermost point of the outer peripheral surface of each of the feeding rollers, at time TB2 depicted in
In order to issue the speed control instructions in a time period from the time T0 to the time T17, the second motion controller 380 reads out, as a first readout operation, all of the speed control instructions in the three regions GC21, GC23, GC24 of the grate raising-lowering speed control sub-pattern GA21 and in three regions GC21, GC23, GC24 of the grate raising-lowering speed control sub-pattern GB21, from the second speed control pattern memory 382. The speed control instructions in the three regions GC21, GC23, GC24 of the grate raising-lowering speed control sub-pattern GA21 are used to feed a first one of two corrugated paperboard sheets SH in one processing cycle, and the speed control instructions in three regions GC21, GC23, GC24 of the grate raising-lowering speed control sub-pattern GB21 are used to feed a second one of the two corrugated paperboard sheets SH in the same processing cycle. In this embodiment, the sheet feeding speed in the two-sheet feeding mode is 240 sheets/min. Thus, the time period from the time T0 to the time T17 is 0.5 sec.
When the elapsed time T reaches the time T17, the lower-level management device 310 receives a first detection signal SD from the rotational position sensor 190. In response to receiving the detection signal SD, the lower-level management device 310 sends control instruction information containing the synchronization instruction and the sheet feeding speed, to each of the drive control device 350 and the roller motor control device 356, and sends, as the motion start instruction, the control instruction information to the second motion controller 380. According to the sheet feeding speed contained in the control instruction information, the drive control device 350 continues to rotationally drive the main drive motor MT at a rotational speed corresponding to the sheet conveyance speed.
In response to the motion start instruction, the second motion controller 380 reads out the speed control instructions of the grate raising-lowering speed control pattern GT21 from the second speed control pattern memory 382 at intervals of a given control cycle, and sequentially send the speed control instructions to the second drive control circuit 383. The second motion controller 380 reads out, as a second readout operation, all of the speed control instructions in the three regions GC21, GC23, GC24 of the grate raising-lowering speed control sub-patterns GA21, GB21 in the same grate raising-lowering speed control pattern GT21, from the speed control pattern memory 382. The speed control instructions in the three regions GC21, GC23, GC24 of the grate raising-lowering speed control sub-pattern GA21 are used to feed a first one of two corrugated paperboard sheets SH in the next processing cycle, and the speed control instructions in three regions GC21, GC23, GC24 of the grate raising-lowering speed control sub-pattern GB21 are used to feed a second one of the two corrugated paperboard sheets SH in the same processing cycle. After the time T17, in response to each motion start instruction based on the detection signal SD, the second motion controller 380 repeatedly performs the same control processing as that in the time period from the time T0 to the time T17.
In a time period from the time T2 to the time T4, each of the roller motors is accelerated at the speed change rate per unit time in the acceleration region RC1 of the roller speed control sub-pattern RA21, to a rotational speed corresponding to the sheet feeding speed (240 sheets/min) in the two-sheet feeding mode. Subsequently, in a time period from the time T4 to the time T6, each of the roller motors is kept at a rotational speed corresponding to the sheet feeding speed in the constant-speed region RC2. In a time period from the time T6 to the time T9, each of the roller motors is decelerated from the sheet feeding speed at the speed change rate per unit time the deceleration region RC3. In a time period from the time T9 to the time T11, each of the roller motors is kept in the stopped state in the stop region RC4.
When the elapsed time T reaches the time T11, in a time period from the time T11 to the time T13, each of the roller motors is accelerated at the speed change rate per unit time in the acceleration region RC1 of the roller speed control sub-pattern RB21, to the rotational speed corresponding to the sheet feeding speed (240 sheets/min) in the two-sheet feeding mode. Subsequently, in a time period from the time T13 to the time T15, each of the roller motors is kept at a rotational speed corresponding to the designated feeding speed, in the constant-speed region RC2. In a time period from the time T15 to the time T18, each of the roller motors is decelerated from the sheet feeding speed at the speed change rate per unit time the deceleration region RC3. In a time period from the time T18 to the time T19, each of the roller motors is kept in the stopped state, in the stop region RC4.
In order to issue the speed control instructions in a time period from the time T2 to the time T19, the first motion controller 360 reads out, as a first readout operation, all of the speed control instructions in the four regions RC1 to RC4 of each of the roller speed control sub-patterns RA21, RB21 of the roller speed control pattern RT21, from the first speed control pattern memory 363. The speed control instructions in the four regions RC1 to RC4 of the roller speed control sub-pattern RA21 are used to feed a first one of two corrugated paperboard sheets SH in one processing cycle, and the speed control instructions in the four regions RC1 to RC4 of the roller speed control sub-pattern RB21 are used to feed a second one of the two corrugated paperboard sheets SH in the same processing cycle. In this embodiment, the feeding speed in the two-sheet feeding mode is 240 sheets/min. Thus, the time period from the time T2 to the time T19 is 0.5 sec.
At the time T19 after the elapse of the time period TDP from the time T17 when receiving the synchronization instruction based on the detection signal SD, the roller motor control device 356 generates the motion start instruction and sends it to the first motion controller 360.
In response to the received motion start instruction, the first motion controller 360 reads out the speed control instructions of the roller speed control pattern RT21 from the first speed control pattern memory 363 at intervals of a given control cycle, and sequentially send the speed control instructions to the first drive control circuit 364. The first motion controller 360 reads out, as a second readout operation, all of the speed control instructions in the four regions RC1 to RC4 of each of the roller speed control sub-patterns RA21, RB21 of the roller speed control pattern RT21, from the first speed control pattern memory 363. The speed control instructions in the four regions RC1 to RC4 of the roller speed control sub-pattern RA21 are used to feed a first one of two corrugated paperboard sheets SH in the next processing cycle, and the speed control instructions in the four regions RC1 to RC4 of the roller speed control sub-pattern RB21 are used to feed a second one of the two corrugated paperboard sheets SH in the same processing cycle. After the time T19, in response to each motion start instruction based on the synchronization instruction, the first motion controller 360 repeatedly performs the same control processing as that in the time period from the time T2 to the time T19.
A first one on two corrugated paperboard sheets SH in one processing cycle starts to be fed from the time T2, and is released from the feeding rollers at the time TB1 depicted in
With reference to
In the grate raising-lowering speed control pattern GT21-1 depicted in
With reference to
In the grate raising-lowering speed control pattern GT21-2 depicted in
A sheet feeding operation of the sheet feeding apparatus 2 will be described, on the assumption that a feeding mode set in conformity to a next order is the two-sheet feeding mode. In order to process corrugated paperboard sheets SH according to a sheet feeding operation in the one-sheet feeding mode, an operator carries out preparatory works, such as replacement of printing die members, replacement of slotter blades and replacement of punching dies.
The lower-level management device 310 temporarily stores the feeding mode-designating information representing the one-sheet feeding mode, in a given storage area of the working memory 330. Further, according to the order preparation instruction and the feeding mode-designating information, the lower-level management device 310 issues an instruction for adjusting a rotational phase of each of the printing cylinders 25A, 26A, an instruction for adjusting a rotational phase of each of the upper slotters 31B, 32B, and an instruction for adjusting a rotational phase of the die cylinder 33, respectively, to the printing control device 351, the creaser-slotter control device 352 and the die cutter control device 353.
Upon detecting an input manipulation complete signal from the manipulation panel 340 after receiving from the upper-level management device 300 the order preparation instruction for directing preparation for execution of the next order, the lower-level management device 310 reads out the feeding mode-designating information from the working memory 330 and sends the feeding mode designation signal and the order preparation instruction to the roller motor control device 356. According to the feeding mode-designating information, the roller motor control device 356 reads out, from the basic roller drive pattern memory 361, the combination of the basic roller drive pattern BRP11 and the full cycle-stop basic roller drive pattern BRP12, and generates a roller speed control pattern creation instruction. The roller motor control device 356 sends the roller speed control pattern creation instruction to the first motion controller 360.
Upon receiving the roller speed control pattern creation instruction from the roller motor control device 356, the first motion controller 360 reads out the roller speed control pattern creation program from the second program memory 362, and executes the roller speed control pattern creation program. According to execution of the roller speed control pattern creation program, the first motion controller 360 creates a roller speed control pattern RT1 for the one-sheet feeding mode, based on a sheet feeding speed contained in the roller speed control pattern creation instruction, and the basic roller drive pattern BRP11, and temporarily stores the roller speed control pattern RT1 in the first speed control pattern memory 363.
A process for creating the roller speed control pattern RT1 for the one-sheet feeding mode is the same as that for creating the roller speed control pattern RT2 for the two-sheet feeding mode, and therefore its description will be omitted. In the case where the sheet feeding speed of corrugated paperboard sheets SH in the one-sheet feeding mode is 120 sheets/min, a roller speed control pattern RT11 depicted in
The roller speed control pattern RT11 is formed for each processing cycle. The roller speed control pattern RT11 comprises, within 0.5 sec, an acceleration region RC1, a constant-speed region RC2, a deceleration region RC3, and a stop region RC4. The acceleration region RC1, the constant-speed region RC2, the deceleration region RC3 and the stop region RC4 correspond, respectively, to the acceleration region BR11, the constant-speed region BR12, the deceleration region BR13 and the stop region BR14 in the basic roller drive pattern BRP1 depicted in
As with the creation of the roller speed control pattern RT11, through the processing of converting the rotational angle θp depicted in
Upon receiving from the upper-level management device 300 the order preparation instruction for directing preparation for execution of the next order, the lower-level management device 310 reads out the grate raising-lowering pattern creation program stored in the first program memory 320 and executes the grate raising-lowering pattern creation program. According to execution of the grate raising-lowering pattern creation program, the lower-level management device 310 creates an order-specific grate raising-lowering pattern DGP conforming to the sheet length of the next processing order, based on one of the two basic grate raising-lowering patterns BGS1, BGL1 stored in the basic grate raising-lowering pattern memory 370, and temporarily stores the order-specific grate raising-lowering pattern DGP in the order-specific grate raising-lowering pattern memory 371. The sheet length of the next order is designated in a range from a minimum sheet length to a maximum sheet length processible in the one-sheet feeding mode. The minimum sheet length processible in the one-sheet feeding mode is set based on the distance LF depicted in
In the case where the sheet length of the next order is an intermediate length between the minimum sheet length and the maximum sheet length, e.g., 720 mm, an order-specific grate raising-lowering pattern DGP1 is formed in conformity to the sheet length of the next order, based on the basic grate raising-lowering pattern BGL1 for the one-sheet feeding mode depicted in
After creating the order-specific grate raising-lowering pattern DGP1, the lower-level management device 310 generates a grate raising-lowering speed control pattern creation instruction and sends the grate raising-lowering speed control pattern creation instruction to the second motion controller 380. Upon receiving the grate raising-lowering speed control pattern creation instruction from the lower-level management device 310, the second motion controller 380 reads out the grate raising-lowering speed control pattern creation program from the third program memory 381, and executes the grate raising-lowering speed control pattern creation program. According to execution of the grate raising-lowering speed control pattern creation program, the second motion controller 380 creates a grate raising-lowering speed control pattern GT, based on a sheet feeding speed contained in the grate raising-lowering speed control pattern creation instruction, and the order-specific grate raising-lowering pattern DGP1, and temporarily stores the created grate raising-lowering speed control pattern GT in the second speed control pattern memory 382.
In
With reference to
After completion of preparation for execution of the next order, when an operator manipulates the feeding button 341, the lower-level management device 310 receives the feeding start signal SF from the manipulation panel 340. In response to the received feeding start signal SF, the lower-level management device 310 sends control instruction information containing the feeding start instruction and the sheet feeding speed to each of the drive control device 350 and the roller motor control device 356, and sends, as the motion start instruction, the control instruction information to the second motion controller 380.
In conformity to the sheet feeding speed contained in the control instruction information, the drive control device 350 rotationally drives the main drive motor MT at a rotational speed corresponding to the sheet feeding speed. Along with the rotation of the main drive motor MT, the printing cylinders 25A, 26A of the printing units 25, 26, the upper slotters of the slotter units 31, 32 and others are rotated at a speed corresponding to the sheet feeding speed, e.g., 120 sheets/min.
In response to the motion start instruction, the second motion controller 380 reads out the speed control instructions of the grate raising-lowering speed control pattern GT11 from the second speed control pattern memory 382 at intervals of a given control cycle, and sequentially send the speed control instructions to the second drive control circuit 383. Based on the speed control instructions, and the frequency of the rotation pulses from the encoder 85, the second drive control circuit 383 controls the rotational speed of the raising-lowering motor 80.
As depicted in
In order to set a start time point T2 of the acceleration region RC1 of roller speed control pattern RT11, the roller motor control device 356 calculates a time period TDP from the time T0 to the time T2, based on the sheet feeding speed contained in the control instruction information, and the phase-difference set value DPP stored in the second program memory 362. Until the elapsed time T becomes equal to the time period TDP, the roller motor control device 356 does not issue any motion start instruction. Thus, the first drive control circuit 364 keeps the roller motors 90, 91, 102, 103 in the stopped state, in the time period TDP from the time point T0 just after the generation of the feeding start signal SF.
When the elapsed time T becomes equal to the time period TDP, the roller motor control device 356 generates the motion start instruction and sends it to the first motion controller 360. In response to the received motion start instruction, the first motion controller 360 reads out the speed control instructions of the roller speed control pattern RT11 from the first speed control pattern memory 363 at intervals of a given control cycle, and, after converting the speed control instructions to rotational speed control instructions for each of the roller motors, sequentially send the rotational speed control instructions to the first drive control circuit 364. Specifically, the speed control instructions are converted to rotational speed control instructions for each of the roller motors, based on the diameter Dr of each of the feeding rollers. Based on the rotational speed control instructions, and the frequency of the rotation pulses from each of the group of encoders 100, 106, 112, 113, the first drive control circuit 364 controls the rotational speed of each of the roller motors.
As depicted in
According to the speed control instructions in the lower-position control region GC12, the raising-lowering motor 80 is kept in the stopped state in a time period from the time T3 to time T5. Subsequently, the raising-lowering motor 80 is accelerated in a time period from the time T5 to time T6, according to the speed control instructions in an acceleration sub-region GC13A of the variable-speed raising region GC13, and decelerated in a time period from the time T6 to time T7, according to the speed control instructions in a deceleration sub-region GC13B of the variable-speed raising region GC13. In a time period from the time T5 to the time T7, each of the grates 141 is raised from the lowermost position and moved to the uppermost position. The upper surface of each of the grates 141 is raised to reach the position PR of the uppermost point of the outer peripheral surface of each of the feeding rollers, at time TB depicted in
When the elapsed time T reaches the time T9, the lower-level management device 310 receives a first detection signal SD from the rotational position sensor 190. In response to receiving the detection signal SD, the lower-level management device 310 sends control instruction information containing the synchronization instruction and the sheet feeding speed, to each of the drive control device 350 and the roller motor control device 356, and sends, as the motion start instruction, the control instruction information to the second motion controller 380. According to the sheet feeding speed contained in the control instruction information, the drive control device 350 continues to rotationally drive the main drive motor MT at a rotational speed corresponding to the sheet feeding speed.
In response to the motion start instruction, the second motion controller 380 reads out the speed control instructions of the grate raising-lowering speed control pattern GT11 from the second speed control pattern memory 382 at intervals of a given control cycle, and sequentially send the speed control instructions to the second drive control circuit 383. The second motion controller 380 reads out, as a second readout operation, all of the speed control instructions in the four regions GC11 to GC14 of the grate raising-lowering speed control pattern GT11, from the second speed control pattern memory 382. All of the speed control instructions in the four regions GC11 to GC14 are used to feed a second corrugated paperboard sheet SH. After the time T9, in response to each motion start instruction based on the detection signal SD, the second motion controller 380 repeatedly performs the same control processing as that in the time period from the time T0 to the time T9.
In a time period from the time T2 to time T4, each of the roller motors is accelerated at the speed change rate per unit time in an acceleration region RC1, to a rotational speed corresponding to the sheet feeding speed (120 sheets/min). Subsequently, in a time period from the time T4 to time T8, each of the roller motors is kept at a rotational speed corresponding to the sheet feeding speed in a constant-speed region RC2. In a time period from the time T8 to time T10, each of the roller motors is decelerated from the sheet feeding speed, at the speed change rate per unit time a deceleration region RC3. In a time period from the time T10 to time T11, each of the roller motors is kept in the stopped state, in a stop region RC4. In order to generate the speed control instructions in a time period from the time T2 to the time T11, the first motion controller 360 reads out, as a first readout operation, all of the speed control instructions in the four regions RC1 to RC4 of the roller speed control pattern RT11, from the first speed control pattern memory 363. All of the speed control instructions in the four regions RC1 to RC4 are used to feed the first corrugated paperboard sheet SH. In this embodiment, the feeding speed is 120 sheets/min. Thus, the time period from the time T2 to the time T11 is 0.5 sec.
At the time T11 after the elapse of the time period TDP from the time T9 when receiving the synchronization instruction based on the detection signal SD, the roller motor control device 356 generates the motion start instruction and sends it to the first motion controller 360.
In response to the received motion start instruction, the first motion controller 360 reads out the speed control instructions of the roller speed control pattern RT11 from the first speed control pattern memory 363 at intervals of a given control cycle, and sequentially send the speed control instructions to the first drive control circuit 364. The first motion controller 360 reads out, as a second readout operation, all of the speed control instructions in the four regions RC1 to RC4 of the roller speed control pattern RT11, from the first speed control pattern memory 363. All of the speed control instructions in the four regions RC1 to RC4 are used to feed the second corrugated paper board sheet. After the time T11, in response to each motion start instruction based on the synchronization instruction, the first motion controller 360 repeatedly performs the same control processing as that in the time period from the time T2 to the time T11.
The first corrugated paperboard sheet SH starts to be fed from the time T2, and is released from the feeding rollers at the time TB. A distance by which the first corrugated paperboard sheet SH is fed by the feeding rollers corresponds to an area ARS of the shaded region in
With reference to
In the case where the two-sheet feeding mode is designated as the feeding mode for a current order just started to be executed, the lower-level management device 310 issues, at the step S27, the two-sheet feeding temporary stop instruction CS21 for directing temporary stop of two cycles of sheet feeding operation, when the batch-forming sheet number is an even number, or the two-sheet feeding temporary stop instruction CS22 for directing temporary stop of one cycle of sheet feeding operation, when the batch-forming sheet number is an odd number. One of the two-sheet feeding temporary stop instructions CS21, CS22 is sent to each of the printing control device 351 and the roller motor control device 356.
(Temporary Stop Processing when Batch-Forming Sheet Number is Even Number)
With reference to
When a leading edge of the 2N-th corrugated paperboard sheet is detected by the sheet sensor SN1 and then the fed-sheet number reaches a value NB (=the control value XC) which is the batch-forming sheet number, and when the sheet feeding speed is greater than the allowable speed, the lower-level management device 310 sends, in the step S27, the two-sheet feeding temporary stop instruction CS21 for directing temporary stop of two cycles of sheet feeding operation, to the roller motor control device 356. Then, the roller motor control device 356 sends the two-sheet feeding temporary stop instruction CS21 to the first motion controller 360.
Then, when the sheet feeding period F(2N) for the 2N-th corrugated paperboard sheet which is the last corrugated paperboard sheet in the first batch is terminated, the first motion controller 360 reads the speed control instructions of the full cycle-stop roller speed control pattern RT2F from the first speed control pattern memory 363 at intervals of a given control cycle, according to the two-sheet feeding temporary stop instruction CS21. Each of the read-out speed control instructions designates that the circumferential speed of each of the feeding rollers is “0”. Thus, the first motion controller 360 converts the read-out speed control instructions to a stop instruction for directing stop of the roller motors, and sends it to the first drive control circuit 364. Based on the stop instruction and the frequency of the rotation pulses from each of the group of encoders 100, 106, 112, 113, the first drive control circuit 364 stops the rotation of each of the roller motors.
A sheet feeding stop period FP21 depicted in
In the step S27 depicted in
When a given time period adjusted in conformity to the sheet length of each order has elapsed after detection of a leading edge of the 2N-th box-structured corrugated paperboard sheet in the batch by the sheet sensor SN2, the counter-ejector control device 355 drives the ledge raising-lowering motor 208 to move the main ledge 46 downwardly from the given standby position to the given lower position. After the 2N-th corrugated paperboard sheet which is the last corrugated paperboard sheet in each batch is fed in the sheet feeding period F(2N), the sheet feeding stop period FP21 and the sheet feeding stop period FP22 are provided as mentioned above. This makes it possible to enable the main ledge 46 to be reliably moved to a given position slightly below the upper conveyance roll 42 before a first box-structured corrugated paperboard sheet in the next batch is fed out from the upper conveyance roll 42 of the sheet transfer apparatus 7.
(Temporary Stop Processing when Batch-Forming Sheet Number is Odd Number)
With reference to
When a leading edge of the 2N-th corrugated paperboard sheet is detected by the sheet sensor SN1 and then the fed-sheet number reaches a value (NB−1) (=the control value XC) which is less than the batch-forming sheet number by one, and when the sheet feeding speed is greater than the allowable speed, the lower-level management device 310 sends, in the step S37, the two-sheet feeding temporary stop instruction CS22 for directing temporary stop of one cycle of sheet feeding operation, to the roller motor control device 356. Then, the roller motor control device 356 sends the two-sheet feeding temporary stop instruction CS22 to the first motion controller 360.
Then, when the sheet feeding period F(2N) for the 2N-th corrugated paperboard sheet which is the second-last corrugated paperboard sheet in the first batch is terminated, the first motion controller 360 reads the speed control instructions of the half cycle-stop roller speed control pattern RT2H from the first speed control pattern memory 363 at intervals of a given control cycle, according to the two-sheet feeding temporary stop instruction CS22. The half cycle-stop roller speed control pattern RT2H is formed of the roller speed control sub-pattern RA21, and the roller speed control sub-pattern RC21 in which the circumferential speed Vr of each of the feeding rollers is “0”. In the sheet feeding period F(2N+1), the first motion controller 360 reads the speed control instructions of the roller speed control sub-pattern RA21 of the half cycle-stop roller speed control pattern RT2H at intervals of a given control cycle, and, after converting the speed control instructions to rotational speed control instructions for each of the roller motor, sends the rotational speed control instructions to the first drive control circuit 364. The speed control instructions are converted to the rotational speed control instructions for each of the roller motor, based on the diameter Dr of each of the feeding rollers. Based on the rotational speed control instructions and the frequency of the rotation pulses from each of the group of encoders 100, 106, 112, 113, the first drive control circuit 364 controls the rotational speed of each of the roller motors 90, 91, 102, 103 to conform to the roller speed control pattern RT21 depicted in
The sheet feeding stop period F(2N+1) depicted in
In the step S27 depicted in
When a time period equivalent to one sheet feeding period has elapsed, the printing control device 351 deactivates the air cylinder 26G to move the anilox roll 26E to the contactable position.
When a given time period adjusted in conformity to the sheet length of each order has elapsed after detection of a leading edge of the (2N+1)-th box-structured corrugated paperboard sheet in the batch by the sheet sensor SN2, the counter-ejector control device 355 drives the ledge raising-lowering motor 208 to move the main ledge 46 downwardly from the given standby position to the given lower position. After the (2N+1)-th corrugated paperboard sheet which is the last corrugated paperboard sheet in each batch is fed in the sheet feeding period F(2N+1), the sheet feeding stop period FP1 is provided as mentioned above. This makes it possible to enable the main ledge 46 to be reliably moved to a given position slightly below the upper conveyance roll 42 before a first box-structured corrugated paperboard sheet in the next batch is fed out from the upper conveyance roll 42 of the sheet transfer apparatus 7.
In the case where the one-sheet feeding mode is designated as the feeding mode for a current order which has been started to be executed, the lower-level management device 310 issues, in the step S27, the one-sheet feeding temporary stop instruction CS1 for directing temporary stop of one cycle of sheet feeding operation. The one-sheet feeding temporary stop instruction CS1 is sent to each of the printing control device 351 and the roller motor control device 356.
With reference to
When a leading edge of the N-th corrugated paperboard sheet is detected by the sheet sensor SN1 and then the fed-sheet number reaches a value NB (=the control value XC) which is the batch-forming sheet number, and when the sheet feeding speed is greater than the allowable speed, the lower-level management device 310 sends, in the step S27, the one-sheet feeding temporary stop instruction CS1 for directing temporary stop of one cycle of sheet feeding operation, to the roller motor control device 356. Then, the roller motor control device 356 sends the one-sheet feeding temporary stop instruction CS1 to the first motion controller 360.
Then, when the sheet feeding period FN for the N-th corrugated paperboard sheet which is the last corrugated paperboard sheet in the first batch is terminated, the first motion controller 360 reads the speed control instructions of the full cycle-stop roller speed control pattern RT1F from the first speed control pattern memory 363 at intervals of a given control cycle, according to the one-sheet feeding temporary stop instruction CS1. Each of the read-out speed control instructions designates that the circumferential speed of each of the feeding rollers is “0”. Thus, the first motion controller 360 converts the read-out speed control instructions to a stop instruction for directing stop of the roller motors, and sends it to the first drive control circuit 364. Based on the stop instruction and the frequency of the rotation pulses from each of the group of encoders 100, 106, 112, 113, the first drive control circuit 364 stops the rotation of each of the roller motors.
In the step S27 depicted in
When a given time period adjusted in conformity to the sheet length of each order has elapsed after detection of a leading edge of the N-th box-structured corrugated paperboard sheet in the batch by the sheet sensor SN2, the counter-ejector control device 355 drives the ledge raising-lowering motor 208 to move the main ledge 46 downwardly from the given standby position to the given lower position. After the N-th corrugated paperboard sheet which is the last corrugated paperboard sheet in each batch is fed in the sheet feeding period FN, the sheet feeding stop period FP is provided as mentioned above. This makes it possible to enable the main ledge 46 to be reliably moved to a given position slightly below the upper conveyance roll 42 before a first box-structured corrugated paperboard sheet in the next batch is fed out from the upper conveyance roll 42 of the sheet transfer apparatus 7.
Generally, when box-structured corrugated paperboard sheets are produced by processing and folding relatively short corrugated paperboard sheets each having a length of ½ of a circumferential length of the printing cylinder, the two-sheet feeding mode is set so as to produce the box-structured corrugated paperboard sheets at a higher speed than that to be set when box-structured corrugated paperboard sheets are produced in the one-sheet feeding mode. Therefore, the sheet feeding speed in the two-sheet feeding mode is set to a value greater than the first upper limit speed S1 in the one-sheet feeding mode. In the above embodiment, when the two-sheet feeding mode is set in the step S2 depicted in
In the above embodiment, the two-sheet feeding mode is set in the step S2 depicted in
In the above embodiment, when the feeding mode is the two-sheet feeding mode, and the batch-forming sheet number is an even number, two sheet feeding stop periods FP21, FP22 are provided after an elapse of the sheet feeding period F(2N) of the last corrugated paperboard sheet in each batch, as depicted in
In the above embodiment, as depicted in
The corrugated paperboard box making machine 1 and the sheet feeding apparatus 2 are, respectively, examples of a corrugated paperboard box making machine and a sheet feeding apparatus recited in the appended claims. The printer 3 and the printing cylinder (25A, 26A) are, respectively, examples of a processing apparatus and a processing rotator recited in the appended claims, and an example of a printer recited in the appended claims. The folder-gluer 6 and the counter-ejector 8 are, respectively, examples of a folder-gluer and a counter-ejector recited in the appended claims. The raising-lowering motor 80, the roller motor (90, 91, 102, 103), the feeding roller (124 to 127), the motion conversion mechanism 140 and the grate 141 are, respectively, examples of a raising-lowering motor, a roller drive motor, a feeding roller, a motion conversion mechanism and a grate recited in the appended claims. A combination of the lower-level management device 310, the roller motor control device 356 and the first and second controllers 360, 380 is an example of a control apparatus or a sheet feeding control apparatus recited in the appended claims. A combination of the lower-level management device 310 and the processing in the step S2 is an example of a feeding control mode setting unit recited in the appended claims. The processings in the steps S20 and S22 are an example of a sheet feeding control processing recited in the appended claims. A combination of the lower-level management device 310 and the processing in the step S7 is an example of a speed setting unit recited in the appended claims. A combination of the sheet feeding speed change button 343, the lower-level management device 310 and the processings in the steps S12 and S13 is an example of a speed changing unit recited in the appended claims. The basic roller drive pattern memory 361 is an example of a storage unit recited in the appended claims. The half cycle-stop basic roller drive pattern BRP22 and the full cycle-stop basic roller drive pattern BRP23 for the two-sheet feeding mode are examples of a feeding stop control pattern recited in the appended claims. The processing to be executed by the roller motor control device 356 to select and read one of the half cycle-stop basic roller drive pattern BRP22 and the full cycle-stop basic roller drive pattern BRP23 from the basic roller drive pattern memory 361 is an example of a selection processing recited in the appended claims. The second upper limit speed is an example of an initial sheet feeding speed recited in the appended claims. The first upper limit speed is an example of a maximum sheet feeding speed recited in the appended claims.
An advantageous embodiment of the present invention has been shown and described. It is obvious to a person of ordinary skill in the art that various changes and modifications may be made therein without departing from the spirit and scope thereof as set forth in appended claims.
(1) In the above embodiment, when the two-sheet feeding mode is set in the step S2 depicted in
(2) In the above embodiment, when the two-sheet feeding mode is set in the step S2 depicted in
(3) In the above embodiment, as depicted in
(4) In the above embodiment, when the feeding mode is the two-sheet feeding mode, and the batch-forming sheet number is an even number, two sheet feeding stop periods FP21, FP22 are provided after the elapse of the sheet feeding period F(2N) of the last corrugated paperboard sheet in the batch, as depicted in
(5) In the above embodiment, when a given time period adjusted in conformity to the sheet length of each order has elapsed after detection of the leading edge of the last box-structured corrugated paperboard sheet in the batch by the sheet sensor SN2, the counter-ejector control device 355 drives the ledge raising-lowering motor 208 to move the main ledge 46 downwardly from the given standby position to the given lower position. When the batch-forming sheet number becomes smaller, the main ledge 46 is more likely to become unable to return from the given lower position to the standby position before the elapse of the time period adjusted in conformity to the sheet length of each batch. Therefore, as to a batch whose sheet number is small enough to cause the situation where the main ledge 46 cannot return from the given lower position to the standby position before the elapse of the time period adjusted in conformity to the sheet length of each batch, it is necessary to provide the sheet feeding stop period. In the above embodiment, when the feeding mode is the one-sheet feeding mode, in the step S4 depicted in
(6) In the above embodiment, the lower-level management device 310 creates the order-specific grate raising-lowering pattern DGP, based on one of the basic grate raising-lowering patterns BGS1, BGL1, BGS2, BGL2, the sheet length of the next processing order, and the feeding mode-designating information. Subsequently, the second motion controller 380 creates the grate raising-lowering speed control pattern GT based on the order-specific grate raising-lowering pattern DGP and the sheet feeding speed. In the above embodiment, the lower-level management device 310 having a relatively high processing capacity has charge of a part of the processing of creating the grate raising-lowering speed control pattern GT, so that it is possible to quickly and reliably create a large variety of grate raising-lowering speed control patterns GT. In place of this configuration in the above embodiment, the second motion controller 380 may be configured to create the order-specific grate raising-lowering pattern DGP and the grate raising-lowering speed control pattern GT by itself.
(7) In the above embodiment, each of the basic roller drive patterns BRP11, BRP21 is set based on the maximum sheet length processible by the corrugated paperboard box making machine 1, and is therefore fixedly stored in the basic roller drive pattern memory 361. However, with a view to coping with various types of corrugated paperboard box making machines, the lower-level management device 310 or the roller motor control device 356 may be configured to, when a value of the maximum sheet length determined by the configuration of a corrugated paperboard box making machine used is input from the manipulation panel, create one of the basic roller drive patterns BRP11, BRP21, based on the input maximum sheet length.
(8) In the above embodiment, the basic grate raising-lowering pattern memory 370 fixedly stores therein the four basic grate raising-lowering patterns BGS1, BGL1, BGS2, BGL2. When the sheet length of an order is small so that an overlapping area is formed between the variable-speed lowering region and the variable-speed raising region, as indicated by the shaded region in
(9) In the above embodiment, creation of the roller speed control pattern RT21 and the grate raising-lowering speed control pattern GT21 has been described based on an example where the sheet feeding speed is kept constant during execution of an order. However, in the case where the sheet feeding speed is changed to a plurality of different values during execution of an order, a plurality of types of roller speed control pattern RT and a plurality of types of grate raising-lowering speed control pattern GT are created based on the plurality of different sheet feeding speeds and stored, respectively, in the first and second speed control pattern memories 363, 382.
(10) In the above embodiment, the upper-level management device 300 preliminarily stores, as a production management plan, the feeding mode-designating information for designating the feeding mode for each order, and, when preparing for execution of each order, the feeding mode-designating information is temporarily stored in the working memory 330. However, the present invention is not limited thereto. For example, the manipulation panel may comprise a feeding mode designation key, and the feeding mode-designating information for designating the feeding mode for each order may be generated in response to manipulation of the feeding mode designation key by an operator, and then temporarily stored in the working memory 330.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2016-219116 | Nov 2016 | JP | national |
