Patent Grant
10329111
The present invention relates to a system and a method for continuously delivering a sheet.
Conventionally, apparatuses are known for continuously delivering a sheet from an original material roll formed by winding the sheet.
When a remaining sheet amount of the original material roll becomes small in an apparatus of this type, for example, a joining operation of sheets such as that shown in
Specifically, in order to perform the joining operation, as shown in
As shown in
Next, as shown in
Accordingly, as shown in
As an apparatus for automatically performing the joining operation described above, for example, an apparatus described in Patent Literature 1 is known.
The apparatus described in Patent Literature 1 includes: a roll holding unit which holds a delivery-side original material roll and a standby-side original material roll; a joining unit which joins a sheet of the standby-side original material roll to a sheet of the delivery-side original material roll; and an XY mobile robot which retrieves an end section of the sheet of the standby-side original material roll and which guides the end section to a suction holding unit.
The joining unit includes a suction holding member configured to hold the end section of the sheet of the standby-side original material roll by suctioning the end section.
An adhesive tape is attached to the end section of the sheet held on the suction holding member, and the end section of the sheet is joined to an intermediate section of the sheet of the delivery-side original material roll by an adhesive force of the adhesive tape.
Patent Literature 1 does not clarify how the end section of the sheet held by the suction holding member is joined to the sheet of the delivery-side original material roll.
For example, the end section of the sheet held by the suction holding member is conceivably joined to the sheet of the delivery-side original material roll by moving the suction holding member toward the sheet of the delivery-side original material roll.
When the suction holding member moves in a direction approaching the standby-side original material roll during a movement of the suction holding member toward the sheet of the delivery-side original material roll, slack is created on a sheet between the suction holding member and the standby-side original material roll and a delivery speed of the sheet after a joining operation may change.
Therefore, the suction holding unit must be moved with respect to the delivery-side original material sheet so that slack is not created on the sheet between the suction holding member and the standby-side original material roll.
However, in this case, there is a risk that tension created on the sheet between the suction holding member and the standby-side original material roll changes a holding position of a tip section of the sheet with respect to the suction holding member, and the end section of the sheet can no longer be accurately joined to a sheet of the delivery-side original material roll.
Patent Literature 1: Japanese Unexamined Patent Publication No. H7-101602
An object of the present invention is to provide a sheet delivery system capable of preventing a holding position of a sheet with respect to a suction holding member from changing during a movement of the suction holding member, and a sheet delivery method using the sheet delivery system.
In order to solve the problem described above, the present invention provides a sheet delivery system for continuously delivering a sheet, the sheet delivery system including: a roll holding unit which holds a plurality of original material rolls, each formed by winding a sheet, in a state where delivery of the sheet is allowed; a joining unit which joins, to an intermediate section of a sheet being delivered from a delivery-side original material roll among the plurality of original material rolls held by the roll holding unit, an end section of a sheet of a standby-side original material roll that is a roll other than the delivery-side original material roll among the plurality of original material rolls held by the roll holding unit; an end section conveying apparatus which retrieves the end section of the sheet from the standby-side original material roll and which conveys the end section of the sheet to the joining unit; and a controller which controls an operation of the joining unit, wherein the joining unit includes: a suction holding member having a suction surface configured to suction the end section of the sheet of the standby-side original material roll conveyed by the end section conveying apparatus; a moving mechanism configured to move the suction surface of the suction holding member toward the intermediate section of the sheet of the delivery-side original material roll along a path set in advance so that tension is applied to a sheet between the standby-side original material roll and the suction holding member; and a regulating mechanism that is configured to switch between a regulated state in which a movement of the end section of the sheet with respect to the suction holding member due to the tension is regulated and an allowable state in which the movement of the end section of the sheet with respect to the suction holding member is allowed, and the controller switches the regulating mechanism to the regulated state during the movement of the suction surface toward the intermediate section of the sheet of the delivery-side original material roll.
In addition, the present invention provides a sheet delivery method using the sheet delivery system described above, the sheet delivery method including: a delivery step of delivering a sheet from the delivery-side original material roll; a conveying step of retrieving an end section of a sheet of the standby-side original material roll and conveying the end section of the sheet to the suction holding member of the joining unit using the end section conveying apparatus when a remaining sheet amount of the delivery-side original material roll falls below a remaining amount set in advance by the delivery step; and a joining step of joining the end section of the sheet of the standby-side original material roll to an intermediate section of the sheet of the delivery-side original material roll by moving the suction surface of the suction holding member toward the intermediate section of the sheet of the delivery-side original material roll using the moving mechanism while regulating a movement of the end section of the sheet with respect to the suction holding member using the regulating mechanism.
According to the present invention, a holding position of a sheet with respect to a suction holding member can be prevented from changing during a movement of the suction holding member.
Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. It is to be understood that the following embodiments are merely examples embodying the present invention and are not intended to limit the technical scope of the present invention.
<First Embodiment>
Referring to
Specifically, the sheet delivery system 1 includes: a sheet delivery apparatus 2 which holds original material rolls R1 and R2, each formed by winding the sheet W and which continuously delivers the sheet W of the original material rolls R1 and R2; an operation robot (an end section conveying apparatus) 3 which, when a remaining amount of the sheet W of one original material roll (for example, the original material roll R1) becomes small in the sheet delivery apparatus 2, retrieves the sheet W of the other original material roll (for example, the original material roll R2) and conveys the sheet W to a joining unit 8 of the sheet delivery apparatus 2; and a controller 70 (refer to
The sheet delivery apparatus 2 includes: a roll holding unit 5 which holds the original material rolls R1 and R2 in a state where delivery of the sheet W is allowed; a guiding unit 6 which guides the sheets of the original material rolls R1 and R2 held by the roll holding unit 5 along a path set in advance; end section retrieving units 7A and 7B which respectively retrieves the sheets of the original material rolls R1 and R2 held by the roll holding unit 5; a joining unit 8 which joins the sheet of the original material roll R1 and the sheet of the original material roll R2 to each other; tape affixing units 9A and 9B which respectively affix a tape T (refer to
The supporting member 4 includes: a bottom plate 10 arranged parallel to an installation surface; four supporting columns 11 erected on the bottom plate 10; and a supporting plate 12 fixed to a side surface of the supporting columns 11.
The four supporting columns 11 are arranged in a single row.
The supporting plate 12 includes 18 supporting plate pieces 12a, and an attachment surface for attaching the configuration described above is formed by main surfaces of the supporting plate pieces 12a. Specifically, the 18 supporting plate pieces 12a are detachably attached to two supporting columns 11 adjacent to each other so as to span the two supporting columns 11. In addition, six supporting plate pieces 12a aligned in a height direction of the supporting columns 11 are attached to two supporting columns 11 adjacent to each other. Furthermore, the 18 supporting plate pieces 12a are fixed to the supporting columns 11 so that main surfaces of the 18 supporting plate pieces 12a are arranged on a same plane.
In the following description, a direction in which the four supporting columns 11 are lined up is assumed to be an X direction, a direction perpendicular to the main surfaces of the supporting plate pieces 12a is assumed to be a Y direction, and the height direction of the supporting columns 11 is assumed to be a Z direction.
Moreover, each of the supporting plate pieces 12a holds the components of the sheet delivery apparatus 2 so that a part of the components can be readily replaced.
For example, an uppermost supporting plate piece 12a provided in a rightmost column in
The roll holding unit 5 includes: a first roll holding unit 5A which holds the original material roll R1; and a second roll holding unit 5B which holds the original material roll R2. Moreover, since both roll holding units 5A and 5B have configurations symmetrical in the X direction, only the second roll holding unit 5B will be described and a description of the first roll holding unit 5A will be omitted.
The second roll holding unit 5B includes: a holding shaft 14 which supports the original material roll R2 in a state where the holding shaft 14 penetrates a center of the original material roll R2; a roll driving motor 15 which rotationally drives the holding shaft 14; and a remaining sheet amount detector 16 configured to detect a remaining amount of the sheet W of the original material roll R2.
The holding shaft 14 penetrates the supporting plate 12 in the Y direction and is further fixed to the supporting plate 12 in a state where the holding shaft 14 is rotatable around an axis along the Y direction with respect to the supporting plate 12.
The roll driving motor 15 corresponds to an original material roll driving unit which rotationally drives the original material rolls R1 and R2 around central axes thereof. Specifically, the roll driving motor 15 is attached to an end section of the holding shaft 14 on an opposite side to an end section which supports the original material roll R2.
The remaining sheet amount detector 16 is attached to the supporting plate 12 at a position separated from the original material roll R2 that is supported by the holding shaft 14. In addition, the remaining sheet amount detector 16 includes a sensor configured to detect a distance from the remaining sheet amount detector 16 to an outer peripheral surface of the original material roll R2. The controller 70 to be described later calculates radius of the original material rolls R1 and R2 or, in other words, a remaining sheet amount based on a result of detection by the remaining sheet amount detector 16 and a position of the holding shaft 14.
The guiding unit 6 includes: a plurality of support rollers 6a to 6g which support the sheet W delivered from the original material rolls R1 and R2 along a prescribed path; and a sheet storage mechanism 6h configured to temporarily store a prescribed amount of the sheet W delivered from the original material rolls R1 and R2.
Among the support rollers 6a to 6g, the support rollers 6c to 6g are commonly used for the sheets W of both original material rolls R1 and R2. On the other hand, the support roller 6a is used to guide the sheet W of the first original material roll R1 to the joining unit 8 to be described later. In addition, the support roller 6b is used to guide the sheet W of the second original material roll R2 to the joining unit 8.
The sheet storage mechanism 6h includes: an upper roller group 6A constituted by a plurality of rollers; a lower roller group 6B constituted by a plurality of rollers; and a moving mechanism (not shown) configured to move the roller groups 6A and 6B so that the roller groups 6A and 6B relatively approach each other or separate from each other. By providing the sheet W between the upper roller group 6A and the lower roller group 6B in a state where the upper roller group 6A and the lower roller group 6B are separated from each other and bringing the upper roller group 6A and the lower roller group 6B close to each other in this state, the sheet W can be delivered to downstream sides of both roller groups 6A and 6B in a state where rotations of the original material rolls R1 and R2 are stopped. Due to the sheet storage mechanism 6h, a joining operation of the sheet W to be described later can be performed in a state where rotations of both original material rolls R1 and R2 are stopped.
The first and second end section retrieving units 7A and 7B are attached to the supporting plate 12 at a position which is above both holding shafts 14 of the roll holding unit 5 and which is between both holding shafts 14 in the X direction. Moreover, since the first and second end section retrieving units 7A and 7B have configurations symmetrical in the X direction, only the second end section retrieving unit 7B will be described and a description of the first end section retrieving unit 7A will be omitted.
Referring to
The rotary shaft 17 penetrates the supporting plate 12 in the Y direction and is further fixed to the supporting plate 12 in a state where the rotary shaft 17 is rotatable around an axis along the Y direction with respect to the supporting plate 12. A rotational angle of the rotary shaft 17 is detected by the rotational angle detector 25 attached to a base end section of the rotary shaft 17.
The arms 18a and 18b correspond to rotary supporting members which are rotatable with respect to the roll holding unit 5 (the supporting plate 12) around the rotary shaft 17 being parallel to a central axis (the holding shaft 14) of the original material roll R2 so that a distance between the supporting shaft 19, to be described later, and the central axis of the original material roll R2 is adjustable.
Specifically, the arms 18a and 18b rotate around an axis of the rotary shaft 17 in accordance with extension/contraction operations of the rotary cylinder 22. A base end section (a head-side end section) of the rotary cylinder 22 is attached by a shaft 22b to the supporting plate 12 in a state where the base end section is rotatable with respect to the supporting plate 12 around an axis along the Y direction. On the other hand, a distal end section (a rod-side end section) of the rotary cylinder 22 is attached by a shaft 22a to intermediate sections of both arms 18a and 18b in a state where the distal end section is rotatable with respect to both arms 18a and 18b around an axis along the Y direction. The rotary valve 24 is configured to control supply of air to the rotary cylinder 22 and discharge of air from the rotary cylinder 22.
The supporting shaft 19 is a hollow shaft which internally includes a suction chamber 19a. A distal end section of the supporting shaft 19 includes a bottom wall for closing the suction chamber 19a. On the other hand, a base end section of the supporting shaft 19 is connected to a suction source (not shown) via the suction valve 26. Therefore, by opening the suction valve 26, air inside the suction chamber 19a is sucked out by the suction source.
In addition, as shown in
As described above, the plurality of suction rollers 21 are attached to the supporting shaft 19 in a state where the suction rollers 21 are rotatable around the axis of the supporting shaft 19 and are arranged separated from each other in a direction (Y direction) which is parallel to the axis. In addition, the suction rollers 21 are configured to come into rolling contact with the outer peripheral surface of the original material roll R2 in accordance with the original material roll R2 being rotationally driven, and include an outer peripheral surface configured to suction an end section of the sheet W in order to separate the end section of the sheet W from the original material roll R2.
The end section detector 27 is configured to detect a position of the end section of the sheet W of the original material roll R2 having been separated by the suction roller 21. Specifically, as shown in
The controller 70, to be described later, stops rotational driving of the original material roll R2 when the end section of the sheet W of the original material roll R2 is detected by the end section detector 27 and, in this state, the end section of the sheet W is grasped by a hand 60 of the operation robot 3. In other words, a position of the end section of the sheet W having been suctioned by the suction roller 21 and detected by the end section detector 27 corresponds to a sheet retrieval position for retrieving the sheet W from the original material roll R2. A sheet retrieval position is similarly set on the original material roll R2 or, in other words, the first end section retrieving unit 7A.
Referring to
Referring to
The joining mechanisms 28A and 28B are attached to the supporting plate 12 in a state where the joining mechanisms 28A and 28B are rotatable around the shaft 28a between a delivery position (a position of the joining mechanism 28A shown in
The rotary cylinders 29A and 29B include: a cylinder main body attached to the supporting plate 12 in a state where the cylinder main body is rotatable around a shaft 29a extending in the Y direction; and a rod attached to the joining mechanisms 28A and 28B (opposing plates 31a and 31b to be described later) in a state where the rod is rotatable around a shaft 29b extending in the Y direction. The joining mechanisms 28A and 28B rotate to the mounting position as the rod contracts with respect to the cylinder main body of the rotary cylinders 29A and 29B, and rotate to the delivery position as the rod extends from the cylinder main body of the rotary cylinders 29A and 29B.
The rotary valves 30A and 30B control extension/contraction operations of the rotary cylinders 29A and 29B by controlling supply of air to the rotary cylinders 29A and 29B and discharge of air from the rotary cylinders 29A and 29B.
Moreover, since the joining mechanisms 28A and 28B have configurations symmetrical in the X direction, the configuration of the joining mechanism 28B will be mainly described.
The joining mechanism 28B includes: opposing plates 31a and 31b which oppose each other in the Y direction; and a holding roller 32, a suction holding member 33, a pressing member 34, a cutting blade 35, a pressing blade 36, a push-in cylinder 37, a cutting cylinder 38, and a sheet pressing cylinder 39 provided between the opposing plates 31a and 31b.
The holding roller 32 is attached to the opposing plates 31a and 31b in a state where the holding roller 32 is rotatable around a rotary shaft 32a extending in the Y direction between both opposing plates 31a and 31b. In addition, the holding roller 32 is for supporting the sheet W between the support roller 6b and the support roller 6c (the holding roller 32 of the joining mechanism 28A holds the sheet W between the support roller 6a and the support roller 6c). Specifically, in the joining mechanism 28B having rotated to the mounting position, an upper end of the holding roller 32 of the joining mechanism 28B is arranged at an approximately same height position as a lower end of the support roller 6b, and the sheet W guided to the holding roller 32 from the support roller 6b is arranged approximately horizontally. On the other hand, in the joining mechanism 28A having rotated to the delivery position, the holding roller 32 of the joining mechanism 28A is arranged above the support roller 6a. Accordingly, the sheet W is guided upward from the support roller 6a toward the holding roller 32 and guided downward from the holding roller 32 toward the support roller 6c.
Referring to
In this case, the suction holding member 33 is provided between the shaft 28a and the holding roller 32. In addition, the suction holding member 33 is attached to the opposing plates 31a and 31b so that the suction surface 33d is arranged approximately parallel to a YZ plane (refer to
Furthermore, as indicated by a solid line and a chain double-dashed line in
The pressing member 34 includes a pressing surface 34b which presses a tip section of the sheet W between the pressing member 34 and a pressed surface 33e of the suction holding member 33. In this case, the pressed surface 33e is a side surface of the suction holding member 33 extending from an edge of the suction surface 33d in an opposite direction to a direction to which the suction surface 33d faces.
Specifically, the pressing member 34 is attached to the opposing plates 31a and 31b so as to be rotatable with respect to the opposing plates 31a and 31b around the shaft 28a between a restricted position (a position indicated by the solid line in
In other words, the opposing plates 31a and 31b, the shafts 39a and 39b, the sheet pressing cylinder 39, and the sheet pressing valve 42 correspond to a pressing driving mechanism which drives the pressing member 34 so that the pressing surface 34b approaches and retreats from the pressed surface 33e. In addition, the pressing driving mechanism corresponds to a regulating mechanism that is configured to switch between a regulated state (a restricted position) in which a movement of the end section of the sheet W with respect to the suction holding member 33 due to the tension is regulated and an allowable state in which the movement of the end section of the sheet W with respect to the suction holding member 33 is allowed. In this case, as shown in
The cutting blade 35 and the pressing blade 36 are for cutting the sheet W provided between the suction holding member 33 and the holding roller 32. Specifically, as indicated by a solid line and a chain double-dashed line in
Referring to
The tape affixing unit 9B includes: a fixed frame 44 which is fixed to the supporting plate 12; a moving frame 45 which is attached to the fixed frame 44 so as to be movable in the Y direction; a driving mechanism 66 which drives the moving frame 45; and a tape attaching mechanism (an adhesive attaching mechanism) 46 which is attached to the moving frame 45.
Referring to
The moving frame 45 is attached to the fixed frame 44 so as to be movable between a position (a position shown in
Specifically, the moving frame 45 includes: a base plate 45a; side plates 45b and 45c erected on both end sections in the X direction of the base plate 45a; a supporting plate 45d extending downwardly from one end section in the X direction of the base plate 45a; a slider 45e which is fixed to surfaces of the side plates 45b and 45c facing respectively opposite sides; and a slide rail 45f which engages with the slider 45e. The slider 45e engages the slide rail 45f so as to be slidable in the Y direction, and the slide rail 45f engages the rail 44d so as to be slidable in the Y direction.
The driving mechanism 66 includes: a ball screw 66a attached to the fixed frame 44 in a state where the ball screw 66a is rotatable around an axis along the Y direction; a nut 66b which is screwed by the ball screw 66a and which is fixed to the moving frame 45 (the base plate 45a); and a moving motor 66c which rotationally drives the ball screw 66a. As the ball screw 66a is rotated by the moving motor 66c, the nut 66b and the moving frame 45 being fixed to the nut 66b move in the Y direction.
The tape attaching mechanism 46 is for attaching the tape T to the end section of the sheet W suctioned by the suction surface 33d of the joining mechanism 28B.
In addition, the tape attaching mechanism 46 is attached to the supporting plate 45d of the moving frame 45. Therefore, due to driving by the moving motor 66c, the tape attaching mechanism 46 is configured to move between a tape attaching position (a position shown in
Specifically, the tape attaching mechanism 46 includes: a delivery roller 46a which holds a roll formed by winding the tape T is wound in a state where delivery of the tape T is allowed; a winding roller 46b which takes up a release paper of the tape T; a cutting blade 46c which cuts only an adhesive layer of the tape T; a pushing tool 46d which presses the adhesive layer of the tape T against the sheet W; a pushing tool cylinder 46e which drives the pushing tool 46d in the Z direction; a winding motor 46f which rotationally drives the winding roller 46b; and a pushing tool valve 46g which controls driving of the pushing tool cylinder 46e.
When attaching the adhesive layer of the tape T to the sheet W, in a process of moving the tape attaching mechanism 46 from the retreated position to the tape attaching position, the winding motor 46f is driven to drive the pushing tool cylinder 46e and the tape T is pressed against the side of the sheet W with the pushing tool 46d. Accordingly, a partial range of the adhesive layer (in the drawing, the adhesive layer is also denoted by reference character T for the sake of convenience) of the tape T having been cut by the cutting blade 46c is attached onto the sheet W.
Referring to
Specifically, the operation robot 3 includes: a robot main body 47 which conveys the end section of the sheet W; and a moving mechanism 48 which supports the robot main body 47 so as to be movable in the X direction.
The robot main body 47 includes: a movable body 54 which is movably supported by the moving mechanism 48; and a multi-jointed arm 55 provided on the movable body 54.
The multi-jointed arm 55 includes: a turning section 56 attached to the movable body 54 in a state where the turning section 56 is turnable around a turning axis J1 along the Z axis direction; a first arm 57 attached to the turning section 56 in a state where the first arm 57 is swingable around a first horizontal direction axis J2; a second arm 58 attached to the first arm 57 in a state where the second arm 58 is swingable around a second horizontal direction axis J3; a third arm 59 attached to the second arm 58 in a state where the third arm 59 is rotatable around a third horizontal direction axis J4; and a hand 60 attached to the third arm 59 in a state where the hand 60 is swingable around an axis J5 that is perpendicular to the third axis J4.
In addition, the multi-jointed arm 55 includes: a first motor 61 which turnably drives the turning section 56 with respect to the movable body 54; a second motor 62 which drives the first arm 57 with respect to the turning section 56; a third motor 63 which drives the second arm 58 with respect to the first arm 57; a fourth motor 64 which rotationally drives the third arm 59 with respect to the second arm 58; and a fifth motor 65 which drives the hand 60 with respect to the third arm 59.
Referring to
The grasping actuators 60b include: an actuator main body (reference symbol omitted); and a pair of driving units 60g and 60h which protrude from the actuator main body. The pair of driving units 60g and 60h approach each other as air is supplied to the actuator main body and separate from each other as air is discharged from the actuator main body. The grasping valve 60c is configured to control supply of air to the grasping actuators 60b and discharge of air from the grasping actuators 60b.
The grasping unit 60d is attached to the driving unit 60g. On the other hand, the grasping unit 60e is attached to the driving unit 60h.
As shown in
In other words, in the multi jointed arm 55, the turning section 56, the arms 57 to 59, and the motors 61 to 65 correspond to a supporting mechanism which supports the hand 60 in a state where the hand 60 is movable within a movement range set in advance.
On the other hand, the moving mechanism 48 shown in
Specifically, as shown in
On the other hand, the movable body 54 of the robot main body 47 includes: a movable body main body 54a provided on the main body unit 49; a slider 54b which is fixed to a lower surface of the movable body main body 54a and which engages the rail 53 in a state where the slider 54b is slidable in the X direction; and a fixed section 54e which is fixed to a part of the belt 51 positioned between both pulleys 50a and 50b.
When the pulley 50a is rotated by the moving motor 52, in accordance with a movement of the part of the belt 51 positioned between both pulleys 50a and 50b, the fixed section 54c which is fixed thereto moves in the X direction. As a result, the slider 54b slides relative to the rail 53 and, accordingly, the movable body main body 54a fixed to the slider 54b and the robot main body 47 supported by the movable body main body 54a move in the X direction.
In addition, the main body unit 49 of the moving mechanism 48 includes: a standby position detector 49a (refer to
Moreover, a portion of the operation robot 3 other than the hand 60 corresponds to a holding unit driving mechanism which drives the hand 60.
Referring to
Specifically, the controller 70 includes: a holding control unit 71 which controls driving of the roll holding units 5A and 5B; a retrieval control unit 72 which controls driving of the end section retrieving units 7A and 7B; an affixing control unit 73 which controls driving of the tape affixing units 9A and 9B; a joining control unit 74 which controls driving of the joining unit 8; and a robot control unit 75 which controls driving of the operation robot 3.
The holding control unit 71 starts driving of the roll driving motor 15 when the remaining sheet amount detector 16 detects that a remaining roll amount of the delivery-side original material roll R1 is smaller than a remaining amount set in advance. On the other hand, the holding control unit 71 stops the roll driving motor 15 when the end section detector 27 detects an end section of the standby-side original material roll R2 on the suction roller 21.
The retrieval control unit 72 controls driving of the rotary valve 24 so that the suction roller 21 comes into contact with the original material rolls R1 and R2 based on results of detections by the remaining sheet amount detector 16 and the rotational angle detector 25.
When a position of the suction roller 21 is changed in accordance with a remaining amount of the sheet W of the original material rolls R1 and R2 in this manner, a retrieval position of the sheet W by the operation robot 3 changes in accordance with the change.
Therefore, as shown in
Specifically, the retrieval control unit 72 calculates a movement distance D1 based on an angular difference θ1 between a reference position and a current position of the arms 18a and 18b and the radius of rotation R. In addition, the retrieval control unit 72 calculates an amount of variation ΔX in the X direction and an amount of variation ΔZ in the Z direction based on an angular difference θ2 with respect to the X direction of a movement direction of the arms 18a and 18b from the reference position to the current position and the movement distance D1.
Furthermore, the retrieval control unit 72 separates the sheet W from the original material rolls R1 and R2 using the suction roller 21 by opening the suction valve 26 at a timing set in advance.
The robot control unit 75 controls the moving motor 52 based on results of detections by the standby position detector 49a and the operating position detector 49b so that the robot main body 47 moves to the standby position in a situation where the sheet W is being delivered from one of the original material rolls R1 and R2 and that the robot main body 47 moves to the operating position in a situation where a joining operation of the sheet W is required.
In addition, the robot control unit 75 controls the first to fifth motors 61 to 65 so that the hand 60 moves toward a sheet retrieval position calculated by the retrieval control unit 72, and controls the grasping valve 60c so that the sheet W suctioned by the suction roller 21 is grasped by the hand 60 as shown in
Furthermore, as shown in
Moreover, as shown in
In this case, as shown in
The joining control unit 74 controls the rotary valves 30A and 30B so that, as shown in
In addition, after the tip section of the sheet W is bent along the pressed surface 33e by the hand 60 as shown in
Moreover, the joining control unit 74 controls the rotary valve 30B so that the joining mechanism 28B moves from the mounting position to the delivery position as shown in
In this state, as shown in
The affixing control unit 73 controls the moving motor 66c so that, in a state where the joining mechanism 28B is rotated to the mounting position as shown in
In addition, the affixing control unit 73 controls the winding motor 46f and the pushing tool valve 46g so that the adhesive layer of the tape T is attached to the sheet W by taking up the release paper of the tape T and pushing the pushing tool 46d toward the side of the sheet W during the movement of the tape attaching mechanism 46 to the tape attaching position.
Hereinafter, a process executed by the controller 70 will be described with reference to
The process by the controller 70 is started in a state where both joining mechanisms 28A and 28B are arranged at the delivery position as shown in
First, based on a result of detection by the remaining sheet amount detector 16, a determination is made on whether or not a remaining sheet amount of the delivery-side original material roll R1 is below a remaining amount set in advance (step S1).
When it is determined that the remaining sheet amount is below the remaining amount set in advance, as shown in
Next, both arms 18a and 18b are rotated so that the suction roller 21 approaches the standby-side original material roll R2 and, at the same time, suction by the suction roller 21 is started (step S3). Accordingly, the suction roller 21 enters a state where the suction roller 21 is capable of coming into rolling contact with the standby-side original material roll R2 in accordance with rotational driving of the standby-side original material roll R2.
In this case, the standby-side original material roll R2 is rotated counterclockwise in
Next, a determination is made on whether or not the end section of the sheet W suctioned by the suction roller 21 is detected by the end section detector 27 (step S5: detecting step).
When it is determined that the end section of the sheet W is not detected, driving of the standby-side original material roll R2 in step S4 is continued.
On the other hand, when it is determined that the end section of the sheet W is detected as shown in
Next, a position of the end section of the sheet W detected by the end section detector 27 is computed as shown in
In this state, as shown in
In other words, in steps S1 to S10, a conveying step is performed in which the end section of the sheet W of the standby-side original material roll R2 is retrieved using the operation robot 3 and the end section of the sheet W is conveyed to the suction holding member 33 when the remaining amount of the sheet W of the delivery-side original material roll R1 falls below the remaining amount set in advance.
By executing step S10, when the end section of the sheet W is suctioned by the suction surface 33d as shown in
Next, as shown in
In this state, the tip section of the sheet W is pressed between the pressing member 34 and the pressed surface 33e by rotating the pressing member 34 (step S14).
Subsequently, both arms 18a and 18b are rotated so that the suction roller 21 separates from the standby-side original material roll R2 (step S15) and, the standby-side original material roll R2 is rotated in reverse (clockwise in
In this state, the adhesive layer of the tape T is attached to the sheet W as shown in
Next, the pushing tool 46d is raised and the tape attaching mechanism 46 is retreated to the retreated position (step S19), and the joining mechanism 28B is rotated to the delivery position as shown in
In this state, rotation of the delivery-side original material roll R1 is stopped (step S21). In step S21, at the same time the rotation of the delivery-side original material roll R1 is stopped, the upper roller group 6A and the lower roller group 6B of the sheet storage mechanism 6h shown in
Subsequently, pressing of the sheet W by the pressing member 34 is released as shown in
In other words, in steps S12 to S23, a joining step is performed in which the end section of the sheet W of the standby-side original material roll R2 is joined to the intermediate section of the sheet W of the delivery-side original material roll R1 by moving the suction surface 33d of the suction holding member 33 toward the intermediate section of the sheet W of the delivery-side original material roll R1 while restricting movement of the end section of the sheet W with respect to the suction holding member 33.
In this state, by causing the cutting blade 35 and the pressing blade 36 of the joining mechanism 28A to protrude to the side of the joining mechanism 28B as shown in
As a result, in accordance with tension applied to the sheet W, the sheet W is delivered from the standby-side original material roll R2 as shown in
As described above, during the movement of the suction surface 33d toward the intermediate section of the sheet W of the delivery-side original material roll R1, a movement of the end section of the sheet W with respect to the suction holding member 33 can be regulated by the regulating mechanism (the opposing plates 31a and 31b, the shafts 39a and 39b, the sheet pressing cylinder 39, the sheet pressing valve 42, and the pressing member 34) of the suction holding member 33.
Therefore, a holding position of the sheet W with respect to the suction holding member 33 can be prevented from changing during a movement of the suction holding member 33.
Furthermore, the first embodiment also achieves the following effects.
Since only a tip section of the sheet W is restrained in the regulated state, slack formed on the sheet W can be taken up using tension applied to the sheet W.
When slack is formed on an end section of the sheet W on the suction surface 33d, the slack formed on the sheet W can be smoothed by moving the hand 60 so as to rub the sheet W.
Since the tip section of the sheet W can be pressed between the pressing member 34 and the pressed surface 33e which extends in a direction opposite to a direction to which the suction surface 33d face, a movement of the sheet W can be regulated without the regulating mechanism (the pressing member 34) being an obstacle in a process of bringing the suction surface 33d close to the delivery-side original material roll R1.
In addition, such regulation of the movement of the sheet W can be automatically performed by the hand 60 and the pressing member 34.
The tape T can be attached to the end section of the sheet W suctioned by the suction surface 33d by moving the tape attaching mechanism 46 to the tape attaching position shown in
Accordingly, the tape T can be attached to the end section of the sheet W while avoiding interference with the suction holding member 33.
<Second Embodiment>
Although the first embodiment includes a single joining unit 8 for joining the sheet W of the original material roll R1 and the sheet W of the original material roll R2 to each other, the joining unit 8 may be provided in plurality.
Specifically, a sheet delivery system 1 according to the second embodiment shown in
On the other hand, the sheet delivery system 1 according to the second embodiment includes a single operation robot 3 configured to convey the end section of the sheet W from each of four sheet retrieval positions (end section retrieving units 7A and 7B) to both joining units 8.
Specifically, the operation robot 3 according to the second embodiment includes a moving mechanism 48 which supports a robot main body 47 between two operating positions (positions indicated by chain double-dashed lines in
Accordingly, joining operations at the two joining units 8 can be executed by one operation robot 3.
Moreover, while an example in which two joining units 8 are provided has been described, joining operations can be performed by one operation robot 3 even when a plurality of joining units 8 are provided.
In addition, the sheet delivery system 1 according to the second embodiment includes a roller driving motor (a suction roller driving unit) 76 which rotationally drives a suction roller 21. Therefore, a sheet holding position at which the sheet W is held by the hand 60 can always be kept constant.
For example, a case where a position of the suction roller 21 (the end section of the sheet W) indicated by the solid line in
However, rotating both arms 18a and 18b causes the suction roller 21 to rotate due to tension created on the sheet W and changes a position of the end section of the sheet W.
In consideration thereof, by rotating the suction roller 21 with the roller driving motor 76, the position of the end section of the sheet W can be returned to a position which can be detected by an end section detector 27 or, in other words, the sheet holding position.
Furthermore, while an example in which two original material rolls R1 and R2 are held with respect to one joining unit 8 has been described, a plurality of original material rolls may be held with respect to one joining unit 8.
The specific embodiment described above mainly includes an invention configured as described below.
Specifically, the present invention provides a sheet delivery system for continuously delivering a sheet, the sheet delivery system including: a roll holding unit which holds a plurality of original material rolls, each formed by winding a sheet, in a state where delivery of the sheet is allowed; a joining unit which joins, to an intermediate section of a sheet being delivered from a delivery-side original material roll among the plurality of original material rolls held by the roll holding unit, an end section of a sheet of a standby-side original material roll that is a roll other than the delivery-side original material roll among the plurality of original material rolls held by the roll holding unit; an end section conveying apparatus which retrieves the end section of the sheet from the standby-side original material roll and which conveys the end section of the sheet to the joining unit; and a controller which controls an operation of the joining unit, wherein the joining unit includes: a suction holding member having a suction surface configured to suction the end section of the sheet of the standby-side original material roll conveyed by the end section conveying apparatus; a moving mechanism configured to move the suction surface of the suction holding member toward the intermediate section of the sheet of the delivery-side original material roll along a path set in advance so that tension is applied to a sheet between the standby-side original material roll and the suction holding member; and a regulating mechanism that is configured to switch between a regulated state in which a movement of the end section of the sheet with respect to the suction holding member due to the tension is regulated and an allowable state in which the movement of the end section of the sheet with respect to the suction holding member is allowed, and the controller switches the regulating mechanism to the regulated state during the movement of the suction surface toward the intermediate section of the sheet of the delivery-side original material roll.
As described above, during the movement of the suction surface toward the intermediate section of a sheet of the delivery-side original material roll, a movement of an end section of a sheet with respect to the suction holding member can be regulated by the regulating mechanism of the suction holding member.
Therefore, according to the present invention, a holding position of a sheet with respect to the suction holding member can be prevented from changing during a movement of the suction holding member.
The regulating member can restrain an entire end section of a sheet with respect to the suction holding member. However, in this case, when slack is formed in an end section of the sheet on the suction surface, since a movement of the entire end section of the sheet is regulated by the restraint applied by the regulating member, the slack formed on the sheet cannot be taken up. When attaching an adhesive on the end section of the sheet, slack of the sheet hinders the attachment of the adhesive.
In consideration thereof, in the sheet delivery system described above, the regulating mechanism favorably restrains only a tip section of the sheet with respect to the suction holding member in the regulated state.
According to this aspect, since only the tip section of the sheet is restrained in the regulated state, slack formed on the sheet can be stretched using tension applied to the sheet.
In the sheet delivery system described above, favorably, the end section conveying apparatus includes a sheet holding unit which holds the end section of the sheet of the standby-side original material roll, and a holding unit driving mechanism which drives the sheet holding unit, and the controller controls the holding unit driving mechanism so that: the sheet holding unit places the end section of the sheet on the suction surface of the suction holding member; the sheet holding unit releases the hold on the end section of the sheet; and the sheet holding unit further rubs, along the suction surface, the end section of the sheet placed on the suction surface.
According to this aspect, when slack is formed on an end section of a sheet on the suction surface, the slack formed on the sheet can be smoothed by having the sheet holding unit move so as to rub the sheet.
While the regulation of a sheet by the regulating mechanism can be performed by, for example, sandwiching an end section of the sheet between the regulating mechanism and the suction surface, in this case, the regulating mechanism must be retreated during a process of bringing the suction surface close to the intermediate section of the sheet of the delivery-side original material roll.
In consideration thereof, favorably, in the sheet delivery system described above, the suction holding member includes a pressed surface which extends from an edge of the suction surface in a direction opposite to a direction to which the suction surface faces, the regulating mechanism includes: a pressing member having a pressing surface which sandwiches a tip section of the sheet between the pressing surface and the pressed surface; and a pressing driving mechanism which drives the pressing member so that the pressing surface approaches and retreats from the pressed surface, and the controller controls the holding unit driving mechanism so that: the sheet holding unit places the end section of the sheet on the suction surface so that the tip section of the sheet exceeds the edge of the suction surface and is arranged outside of the suction surface; the sheet holding unit releases the hold on the end section of the sheet; and the sheet holding unit further pushes the tip section of the sheet along the pressed surface so that the tip section of the sheet bends along the pressed surface, and the controller controls the pressing driving mechanism so that the tip section of the sheet pushed along the pressed surface becomes sandwiched between the pressed surface and the pressing surface.
According to this aspect, since a tip section of a sheet can be pressed between the pressing member and the pressed surface which extends in a direction opposite to a direction to which the suction surface faces, movement of the sheet can be regulated without the regulating mechanism (the pressing member) being an obstacle in a process of bringing the suction surface close to the delivery-side original material roll.
In addition, such regulation of the movement of a sheet can be automatically performed by the sheet holding unit and the pressing member.
Favorably, the sheet delivery system described above includes: an adhesive attaching mechanism which attaches, to the end section of the sheet suctioned by the suction surface, an adhesive for attaching the end section of the sheet of the standby-side original material roll to the intermediate section of the sheet of the delivery-side original material roll; and a movement supporting mechanism which supports the adhesive attaching mechanism so as to be movable between an adhesive attaching position at which the adhesive attaching mechanism opposes the suction surface in order to attach the adhesive to the end section of the sheet and a retreated position at which the adhesive attaching mechanism is retreated from a movement path of the suction holding member so as to allow a movement of the suction holding member.
According to this aspect, the adhesive can be attached to an end section of a sheet suctioned by the suction surface by moving the adhesive attaching mechanism to the adhesive attaching position, and the suction holding member can be moved by moving the adhesive attaching mechanism to the retreated position.
As a result, the adhesive can be attached to an end section of a sheet while avoiding interference with the suction holding member.
In addition, the present invention provides a sheet delivery method using the sheet delivery system described above, the sheet delivery method including: a delivery step of delivering a sheet from the delivery-side original material roll; a conveying step of retrieving an end section of a sheet of the standby-side original material roll and conveying the end section of the sheet to the suction holding member of the joining unit using the end section conveying apparatus when a remaining sheet amount of the delivery-side original material roll falls below a remaining amount set in advance by the delivery step; and a joining step of joining the end section of the sheet of the standby-side original material roll to an intermediate section of the sheet of the delivery-side original material roll by moving the suction surface of the suction holding member toward the intermediate section of the sheet of the delivery-side original material roll using the moving mechanism while regulating a movement of the end section of the sheet with respect to the suction holding member using the regulating mechanism.
According to the present invention, since movement of an end section of a sheet with respect to the suction holding member can be regulated by the regulating mechanism, a holding position of a sheet with respect to the suction holding member can be prevented from changing during a movement of the suction holding member.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014-134735 | Jun 2014 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2015/067595 | 6/18/2015 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2016/002532 | 1/7/2016 | WO | A |
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| Number | Date | Country | |
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| 20170137251 A1 | May 2017 | US |
