Patent Application
20130160947
The present invention relates to a gravure plate-making processing system, and more particularly, to a fully automatic gravure plate-making processing system capable of performing an unattended operation even in the nighttime.
Conventionally, gravure plate-making plants described in Patent Documents 1 to 6 have been known.
As can be seen from the drawings of Patent Documents 1 to 3, a manufacturing line for a gravure plate-making roll has conventionally been constructed of an industrial robot and a stacker crane used in combination.
In the manufacturing line using the stacker crane, processing is performed in each of various processing units under a state in which a plate-making roll to be processed (hereinafter referred to as “unprocessed plate-making roll”) is chucked at the stacker crane with use of a cassette-type roll chuck rotary transportation unit.
However, in the case of such a manufacturing line using the stacker crane, the unprocessed plate-making roll is sequentially transferred to the various processing units under the state in which the unprocessed plate-making roll is chucked with use of the cassette-type roll chuck rotary transportation unit, and hence there arises a problem in that a longer time period is required accordingly.
In addition, in the case of the manufacturing line using the stacker crane, the unprocessed plate-making roll is sequentially transferred to the processing units under the state in which the unprocessed plate-making roll is chucked with use of the cassette-type roll chuck rotary transportation unit, and hence there arises a problem in that the various processing units need to be juxtaposed to one another and thus a large installation space is required therefor.
Further, in the case of the manufacturing line using the stacker crane, the unprocessed plate-making roll is sequentially transferred to the various processing units under the state in which the unprocessed plate-making roll is chucked with use of the cassette-type roll chuck rotary transportation unit, and hence there arises another problem in that dust may be generated.
The present invention has been made in view of the above-mentioned circumstances of the conventional technologies, and it is therefore an object thereof to provide a fully automatic gravure plate-making processing system capable of manufacturing a gravure plate-making roll more quickly as compared to a conventional case, achieving space saving, performing an unattended operation even in the nighttime, and reducing dust between individual processes.
In order to solve the above-mentioned problems, according to the present invention, there is provided a fully automatic gravure plate-making processing system, including: a first industrial robot for chucking and handling an unprocessed plate-making roll; a second industrial robot for chucking and handling the unprocessed plate-making roll; a roll stock apparatus, a photosensitive film coating apparatus, a laser exposure apparatus, an ultrasonic cleaning apparatus with a drying function, a grinding wheel polishing apparatus, and a paper polishing apparatus, which serve as processing apparatus arranged in a handling area of the first industrial robot; and a degreasing apparatus, a copper plating apparatus, a developing apparatus, an etching apparatus, a resist removal apparatus, a surface hardening film forming apparatus, and an ultrasonic cleaning apparatus, which serve as processing apparatus arranged in a handling area of the second industrial robot, in which the first industrial robot and the second industrial robot are configured to transfer the unprocessed plate-making roll therebetween to perform plate-making processing.
In this manner, the unprocessed plate-making roll is transferred between the first industrial robot and the second industrial robot, and thus the gravure plate-making roll can be manufactured more quickly as compared to the conventional manufacturing line for a gravure plate-making roll using a stacker crane. Further, the unprocessed plate-making roll is transferred between the first industrial robot and the second industrial robot, and hence the stacker crane becomes unnecessary, which leads to such an advantage that space saving can be achieved. Further, the series of processing can be performed fully automatically based on predetermined programs, and hence there is also such an advantage that an unattended operation can be performed even in the nighttime. Further, the generation of dust can be prevented more reliably as compared to the case of using the stacker crane.
Further, it is preferred that the fully automatic gravure plate-making processing system further include a roll transfer placement table provided at a position at which the handling area of the first industrial robot overlaps with the handling area of the second industrial robot, that the ultrasonic cleaning apparatus with a drying function be provided in proximity to the roll transfer placement table, that, in the handling area of the first industrial robot, the grinding wheel polishing apparatus and the paper polishing apparatus, the roll stock apparatus, and the photosensitive film coating apparatus and the laser exposure apparatus be arranged in this order clockwise with respect to a position of the ultrasonic cleaning apparatus with a drying function, that the developing apparatus be provided in proximity to the roll transfer placement table, that, in the handling area of the second industrial robot, the etching apparatus and the resist removal apparatus, the surface hardening film forming apparatus and the ultrasonic cleaning apparatus, and the copper plating apparatus and the degreasing apparatus be arranged in this order clockwise with respect to a position of the developing apparatus, and that the first industrial robot and the second industrial robot be configured to transfer the unprocessed plate-making roll therebetween to perform the plate-making processing.
Through the arrangement as described above, it is possible to achieve higher work efficiency due to the reduction in movement time between the individual processes, and to achieve further space saving.
Further, the following configuration may be employed: that is, an IC tag that is wirelessly readable and writable is attached to the unprocessed plate-making roll, and a main computer for managing roll stock and plate-making that checks the record on the IC tag and outputs necessary signals to the individual roll processing apparatus for processing the roll, thereby assigning desired works to the individual roll processing apparatus. Further, a record of completion of the processing is written onto the IC tag and also recorded onto the main computer, thereby managing the process from the roll stock to the plate-making method and shipment. As such a technology of managing the process from the roll stock to the plate-making method and shipment with use of an IC tag that is wirelessly readable and writable, the technology disclosed in, for example, Patent Document 8 may be employed.
One or both of the processing rooms, in which the first industrial robot and the second industrial robot are arranged, may be set as clean rooms. Accordingly, the generation of dust can further be reduced.
It is preferred that the surface hardening film forming apparatus be a chromium plating apparatus, a DLC film forming apparatus, or a silicon dioxide film forming apparatus. For example, the diamond-like carbon (DLC) film forming apparatus for forming a DLC film as described in Patent Document 2, the silicon dioxide film forming apparatus for forming a silicon dioxide film as described in Patent Document 3, or the chromium plating apparatus as described in Patent Document 1 is applicable.
Further, it is more preferred that the processing apparatus be a two-stage processing apparatus including two processing apparatus arranged vertically. With this configuration, more processing apparatus can be arranged in the turnable range of the robotic arm.
It is preferred that one of the two processing apparatus which is arranged on a lower stage of the two-stage processing apparatus include a roll loading and unloading opening portion in a top surface of the one of the two processing apparatus so that a robotic arm is allowed to enter through the top surface of the one of the two processing apparatus.
It is preferred that one of the two processing apparatus which is arranged on an upper stage of the two-stage processing apparatus include a roll loading and unloading opening portion in a side surface facing corresponding one of the first industrial robot and the second industrial robot so that a robotic arm is allowed to enter through the side surface of the one of the two processing apparatus.
The present invention has a remarkable effect of providing the fully automatic gravure plate-making processing system capable of manufacturing a gravure plate-making roll more quickly as compared to the conventional case, achieving space saving, performing an unattended operation even in the nighttime, and reducing dust between the individual processes.
Further, there is no need to employ the conventional cassette-type roll chuck rotary transportation unit and the like. Thus, space saving can be achieved as a matter of course, and further, there are produced such effects that the rotation accuracy of the unprocessed plate-making roll is improved and that the sealability of the unprocessed plate-making roll is improved when the unprocessed plate-making roll is set onto the processing apparatus.
In the following, embodiments of the present invention are described. However, these embodiments are described for illustrative purposes. Therefore, it is understood that various modifications can be made thereto within the scope of the technical idea of the present invention.
A fully automatic gravure plate-making processing system for a gravure plate-making roll according to the present invention is described with reference to the accompanying drawings. In
A configuration of the processing room-A is described. In the processing room-A, reference symbol 16 represents a first industrial robot, which includes a turnable multi-axis robotic arm 18. The first industrial robot 16 is controlled by operating a control panel 28a for an industrial robot. Reference symbol Q represents a turnable range of the robotic arm 18, which corresponds to a handling area of the first industrial robot 16.
Reference symbol 20 represents an unprocessed plate-making roll, and reference symbols 22a and 22b represent roll stock apparatus, respectively. As the roll stock apparatus, for example, the roll stock apparatus disclosed in Patent Documents 4 to 6 may be used.
Chuck means 72 is provided at a distal end of the robotic arm 18. The chuck means 72 is capable of releasably chucking the unprocessed plate-making roll 20.
Reference symbol 24 represents a photosensitive film coating apparatus, and reference symbol 26 represents a laser exposure apparatus. In the example of
Reference symbol 50 represents a roll transfer placement table, on which the unprocessed plate-making roll 20 is placeable for transfer. The roll transfer placement table 50 is provided at a position at which the handling area Q of the first industrial robot 16 overlaps with a handling area of second industrial robot 30. Reference symbol 70 represents an ultrasonic cleaning apparatus with a drying function, which is configured to perform ultrasonic cleaning processing and drying processing for the unprocessed plate-making roll 20. The ultrasonic cleaning apparatus 70 with a drying function is provided in proximity to the roll transfer placement table 50.
The ultrasonic cleaning apparatus 70 includes a reservoir for storing cleaning water, and an ultrasonic transducer provided below the reservoir. The ultrasonic cleaning apparatus 70 is capable of performing cleaning by vibrating the cleaning water through ultrasonic vibration of the ultrasonic transducer. A drying function is further provided to the ultrasonic cleaning apparatus 70 with a drying function. The ultrasonic cleaning apparatus 70 with a drying function is capable of performing ultrasonic cleaning and drying for each processing as necessary.
Further, in the processing room-A, a main control panel 52 is provided so as to control the fully automatic gravure plate-making processing system 10.
Next, a configuration of the processing room-B is described. In the processing room-B, reference symbol 30 represents a second industrial robot, which includes a turnable multi-axis robotic arm 32. The second industrial robot 30 is controlled by operating a control panel 28b for an industrial robot. Reference symbol P represents a turnable range of the robotic arm 32, which corresponds to a handling area of the second industrial robot 30.
Chuck means 74 is provided at a distal end of the robotic arm 32. The chuck means 74 is capable of releasably chucking the unprocessed plate-making roll 20.
Reference symbol 42 represents a developing apparatus, and for example, the developing apparatus as disclosed in Patent Documents 4 to 6 may be used.
Reference symbol 38 represents a degreasing apparatus, and reference symbol 40 represents a copper plating apparatus. In the example of
Reference symbol 44 represents an etching apparatus, and reference symbol 46 represents a resist removal apparatus. In the example of
Reference symbol 48 represents a chromium plating apparatus, and reference symbol 36 represents an ultrasonic cleaning apparatus. As the chromium plating apparatus, a conventionally known apparatus may be used, and for example, the chromium plating apparatus as disclosed in Patent Document 1 may be used. Further, in the example of
Further, the ultrasonic cleaning apparatus 36 includes a reservoir for storing cleaning water, and an ultrasonic transducer provided below the reservoir. The ultrasonic cleaning apparatus 36 is capable of performing cleaning by vibrating the cleaning water through ultrasonic vibration of the ultrasonic transducer.
Next, a configuration of the processing room-C is described. In the processing room-C, reference symbol 21 represents a paper polishing apparatus for performing paper polishing, and reference symbol 34 represents a grinding wheel polishing apparatus. As the grinding wheel polishing apparatus 34, a conventionally known apparatus is applicable, and for example, the grinding wheel polishing apparatus as disclosed in Patent Documents 4 to 6 may be used. In the example of
The processing room-A and the processing room-C are communicable to each other via the shutter 14, and hence the grinding wheel polishing apparatus 34 and the paper polishing apparatus 21 are arranged in the handling area of the first industrial robot 16.
In the example of
Doors 58 and 60 are provided on a wall 56 of the processing room-A, through which a processed plate-making roll is carried outside and a unprocessed plate-making roll (plate-making base material) is newly carried inside. The processed plate-making roll is placed on any one of the roll stock apparatus 22a and 22b, and the unprocessed plate-making roll is placed on the other roll stock apparatus. A computer 62 is installed outside the processing room-A so as to check and manage various kinds of information, and to perform settings for various kinds of programs. Reference symbol 64 represents a processed plate-making roll that is manufactured.
In the example of
As described above, the fully automatic gravure plate-making processing system 10 according to the present invention includes: the first industrial robot 16; the second industrial robot 30; the roll stock apparatus 22a and 22b, the photosensitive film coating apparatus 24, the laser exposure apparatus 26, the ultrasonic cleaning apparatus 70 with a drying function, the grinding wheel polishing apparatus 34, and the paper polishing apparatus 21, which are arranged in the handling area of the first industrial robot 16; and the degreasing apparatus 38, the copper plating apparatus 40, the developing apparatus 42, the etching apparatus 44, the resist removal apparatus 46, the chromium plating apparatus 48 as the surface hardening film forming apparatus, and the ultrasonic cleaning apparatus 36, which are arranged in the handling area of the second industrial robot 30. The first industrial robot 16 and the second industrial robot 30 are configured to transfer the unprocessed plate-making roll therebetween to perform plate-making processing.
Note that, a single apparatus may serve as both the copper plating apparatus 40 and the chromium plating apparatus 48 to perform copper plating and chromium plating through only the replacement of the plating solution.
More specifically, in the example of
Referring to
When a degreasing work is finished at the degreasing apparatus 38, the second industrial robot 30 chucks the plate-making roll 20, and transports the unprocessed plate-making roll 20 to the copper plating apparatus 40. Then, the second industrial robot 30 releases the unprocessed plate-making roll 20, and sets the unprocessed plate-making roll 20 onto the copper plating apparatus 40.
When a plating work is finished at the copper plating apparatus 40, the second industrial robot 30 chucks the unprocessed plate-making roll 20, and transports and places the unprocessed plate-making roll 20 onto the roll transfer placement table 50 so that the unprocessed plate-making roll 20 is transferred to the first industrial robot 16. The first industrial robot 16 chucks the unprocessed plate-making roll 20, and transports the unprocessed plate-making roll 20 to the grinding wheel polishing apparatus 34. Then, the first industrial robot 16 releases the unprocessed plate-making roll 20, and sets the unprocessed plate-making roll 20 onto the grinding wheel polishing apparatus 34.
When a grinding wheel polishing work is finished at the grinding wheel polishing apparatus 34, the first industrial robot 16 chucks the unprocessed plate-making roll 20, and transports the unprocessed plate-making roll 20 to the ultrasonic cleaning apparatus 70. Then, the first industrial robot 16 releases the unprocessed plate-making roll 20, and sets the unprocessed plate-making roll 20 onto the ultrasonic cleaning apparatus 70.
When an ultrasonic cleaning work is finished at the ultrasonic cleaning apparatus 70, the first industrial robot 16 chucks the unprocessed plate-making roll 20, and transports the unprocessed plate-making roll 20 to the photosensitive film coating apparatus 24. Then, the first industrial robot 16 releases the unprocessed plate-making roll 20, and sets the unprocessed plate-making roll 20 onto the photosensitive film coating apparatus 24.
When a photosensitive film coating work is finished at the photosensitive film coating apparatus 24, the first industrial robot 16 chucks the unprocessed plate-making roll 20, and transports the unprocessed plate-making roll 20 to the laser exposure apparatus 26. Then, the first industrial robot 16 releases the unprocessed plate-making roll 20, and sets the unprocessed plate-making roll 20 onto the laser exposure apparatus 26.
When an exposure work is finished at the laser exposure apparatus 26, the first industrial robot 16 chucks the unprocessed plate-making roll 20, and places the unprocessed plate-making roll 20 onto the roll transfer placement table 50 so that the unprocessed plate-making roll 20 is transferred to the second industrial robot 30. The second industrial robot 30 chucks the unprocessed plate-making roll 20, and transports the unprocessed plate-making roll 20 to the developing apparatus 42. Then, the second industrial robot 30 releases the unprocessed plate-making roll 20, and sets the unprocessed plate-making roll 20 onto the developing apparatus 42.
When a developing work is finished at the developing apparatus 42, the second industrial robot 30 chucks the unprocessed plate-making roll 20, and transports the unprocessed plate-making roll 20 to the etching apparatus 44. Then, the second industrial robot 30 releases the unprocessed plate-making roll 20, and sets the unprocessed plate-making roll 20 onto the etching apparatus 44.
When an etching work is finished at the etching apparatus 44, the second industrial robot 30 chucks the unprocessed plate-making roll 20, and transports the unprocessed plate-making roll 20 to the resist removal apparatus 46. Then, the second industrial robot 30 releases the unprocessed plate-making roll 20, and sets the unprocessed plate-making roll 20 onto the resist removal apparatus 46.
When a resist removal work is finished at the resist removal apparatus 46, the second industrial robot 30 chucks the unprocessed plate-making roll 20, and transports the unprocessed plate-making roll 20 to the ultrasonic cleaning apparatus 36. Then, the second industrial robot 30 releases the unprocessed plate-making roll 20, and sets the unprocessed plate-making roll 20 onto the ultrasonic cleaning apparatus 36.
When an ultrasonic cleaning work is finished at the ultrasonic cleaning apparatus 36, the second industrial robot 30 chucks the unprocessed plate-making roll 20, and transports the unprocessed plate-making roll 20 to the chromium plating apparatus 48. Then, the second industrial robot 30 releases the unprocessed plate-making roll 20, and sets the unprocessed plate-making roll 20 onto the chromium plating apparatus 48. Then, chromium plating is performed at the chromium plating apparatus 48. Note that, the unprocessed plate-making roll 20 is washed and dried for each processing as necessary at the ultrasonic cleaning apparatus 70 with a drying function.
When a plating work is finished at the chromium plating apparatus 48, the second industrial robot 30 chucks the unprocessed plate-making roll 20, and places the unprocessed plate-making roll 20 onto the roll transfer placement table 50 so that the unprocessed plate-making roll 20 is transferred to the first industrial robot 16. The first industrial robot 16 chucks the unprocessed plate-making roll 20, and transports the unprocessed plate-making roll 20 to the paper polishing apparatus 21. Then, the first industrial robot 16 releases the unprocessed plate-making roll 20, and sets the unprocessed plate-making roll 20 onto the paper polishing apparatus 21. When paper polishing (automatic polishing) is performed at the paper polishing apparatus 21, the processed plate-making roll 64 is obtained and, in the example of
The processed plate-making roll 64 thus obtained is carried outside the processing room-A as a final product.
In the example of
On the other hand, there may be employed the following configuration. That is, as each of the first industrial robot and the second industrial robot, the industrial robot including drive means as disclosed in Patent Document 7 is used for transporting the unprocessed plate-making roll 20 to each processing apparatus, and setting the unprocessed plate-making roll 20 onto the processing apparatus while gripping the unprocessed plate-making roll 20. Then, the unprocessed plate-making roll is rotated by the drive means provided in the industrial robot.
Further, it is preferred, as necessary, that each processing apparatus of the fully automatic gravure plate-making processing system 10 be a two-stage processing apparatus including two processing apparatus arranged vertically. With this configuration, more processing apparatus can be arranged in the turnable range of the robotic arm.
In
In the two-stage roll transfer placement table 92, roll chuck means for gripping the unprocessed plate-making roll 20 are arranged vertically, and as illustrated in
The unprocessed plate-making roll 20 is transported from the robotic arm 18 of the first industrial robot 16 in the zone-A to the lower roll chuck means of the two-stage roll transfer placement table 92.
The unprocessed plate-making roll 20 is transported from the robotic arm 32 of the second industrial robot 30 in the zone-B to the upper roll chuck means of the two-stage roll transfer placement table 92.
Thus, the two-stage roll transfer placement table 92 includes a lower side-surface opening portion, through which the unprocessed plate-making roll 20 is transported from the robotic arm 18 of the first industrial robot 16 in the zone-A, and an upper side-surface opening portion, through which the plate-making roll 20 is transported from the robotic arm 32 of the second industrial robot 30 in the zone-B.
Reference symbol 14 represents a shutter, and the developing apparatus 42 is arranged in the zone-B across the shutter. Reference symbol 94 represents a mounting table for the second industrial robot 30 in the zone-B.
In the turnable range P of the robotic arm 32 of the second industrial robot 30 in the zone-B, a second ultrasonic cleaning apparatus 36B is mounted on the chromium plating apparatus 48, thereby constituting a two-stage processing apparatus 78. The unprocessed plate-making roll 20 is transported for processing from the robotic arm 32 of the second industrial robot 30 in the zone-B to each of the chromium plating apparatus 48 on the lower stage and the second ultrasonic cleaning apparatus 36B on the upper stage.
It is preferred that, in the two-stage processing apparatus, a processing apparatus which is relatively large in amount of a solution to be used be arranged on the lower stage, and a processing apparatus which is relatively small in amount of a solution to be used be arranged on the upper stage.
For example, it is preferred that the two-stage processing apparatus includes the copper plating apparatus arranged on the lower stage, and the degreasing apparatus arranged on the upper stage.
For example, it is preferred that the two-stage processing apparatus includes the etching apparatus arranged on the lower stage, and the resist removal apparatus arranged on the upper stage.
For example, it is preferred that the two-stage processing apparatus includes the chromium plating apparatus arranged on the lower stage, and the ultrasonic cleaning apparatus arranged on the upper stage.
In
The chromium plating apparatus 48 arranged on the lower stage of the two-stage processing apparatus 78 includes a roll loading and unloading opening portion 82 in a top surface of the chromium plating apparatus 48 so that the robotic arm 32 is allowed to enter through the top surface of the apparatus.
The second ultrasonic cleaning apparatus 36B arranged on the upper stage of the two-stage processing apparatus 78 includes a roll loading and unloading opening portion 84 in a side surface facing the second industrial robot 30 so that the robotic arm 32 is allowed to enter through the side surface of the apparatus.
Further, shutter members are provided to the roll loading and unloading opening portions 82 and 84, respectively, and are automatically opened when the robotic arm 32 transports the unprocessed plate-making roll 20. When the roll chuck members 80a to 80d chuck the unprocessed plate-making roll and the robotic arm 32 exits from the two-stage processing apparatus 78 to the outside, the shutter members are closed to prevent the entrance of dust, dirt, and the like.
With this configuration, various processing apparatus can be arranged in the handling area of the industrial robot, and hence there is an advantage in that the space for those processing apparatus is approximately halved as compared to the conventional fully automatic plate-making system described in, for example, Patent Documents 1 to 3. Further, there is an advantage in that the power consumption is approximately halved as compared to the conventional fully automatic plate-making system described in, for example, Patent Document 1.
10: fully automatic gravure plate-making processing system, 12, 13: wall, 14: shutter, 16: first industrial robot, 18, 32: robotic arm, 20: unprocessed plate-making roll, 21: paper polishing apparatus, 22a, 22b: roll stock apparatus, 24: photosensitive film coating apparatus, 26: laser exposure apparatus, 28a, 28b: control panel for industrial robot, 30: second industrial robot, 34: grinding wheel polishing apparatus, 36, 36A, 36B: ultrasonic cleaning apparatus, 38: degreasing apparatus, 40: copper plating apparatus, 42: developing apparatus, 44: etching apparatus, 46: resist removal apparatus, 48: chromium plating apparatus, 50: roll transfer placement table, 52: main control panel, 56: wall, 58, 60: door, 62: computer, 64: processed plate-making roll, 70: ultrasonic cleaning apparatus with drying function, 72, 74: chuck means, 78: two-stage processing apparatus, 80a to 80d: roll chuck member, 82, 84: roll loading and unloading opening portion, 92: two-stage roll transfer placement table, 94: mounting table, A, B, C: processing room, P, Q: turnable range.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2010-223936 | Oct 2010 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2011/071962 | 9/27/2011 | WO | 00 | 3/4/2013 |
