1. Field of the Invention
The present invention relates to a sheet package producing system. More particularly, the present invention relates to a sheet package producing system for producing a sheet package having a stack of sheets at a low cost and in a manner with compatibility to various sheet types.
2. Description Related to the Prior Art
X-ray films, printing sheets or other products of a sheet shape are shipped in a form of a sheet package by stacking those in a plurality. For example, continuous photosensitive material to be the X-ray film is prepared in a roll form, and cut into sheets of a regular length. The sheets are stacked in a plurality. A protective cover is loaded with the sheets to form a covered sheet stack. The protective cover is used for preventing the X-ray film from being bent or folded, and from being scratched. The covered sheet stacked is wrapped in a light-shielding packaging bag, and is enclosed tightly. The packaging bag is inserted in an outer box, and is shipped.
A producing system for the sheet package of the X-ray film include a slitting device, a cutting/stacking device, a bag packaging machine, a box forming device, a box packaging machine and a cardboard caser. The slitting device slits web of photosensitive material with a great width into continuous sheets with a width of a sheet size. The cutting/stacking device cuts the continuous sheets into the sheets, and stacks the sheets in the predetermined number. The bag packaging machine closes a bag by sealing in a pillow shape or sealing three edges. The box forming device produces the outer box for containing the X-ray film. The box packaging machine inserts the X-ray film into the outer box. The cardboard caser inserts the outer box with the X-ray film into a cardboard box.
The bag packaging machine, which is disposed downstream in the producing system for the sheet package, operates for one time while the cutting/stacking device creates a predetermined number of the sheets by cutting. It is necessary to change over the bag packaging machine rapidly specifically for production at the sheet size being different, or in a multi-type manner. Therefore, recently used types of the bag packaging machine have had a gradual tendency of enlargement in the size, raise in complexity, and raise in performance. There is a suggestion in JP-A 5-051021 to install a plurality of the cutting/stacking device in an upstream station. Paths of the sheets from the cutting/stacking device are joined up as a single path at the bag packaging machine.
The number of the sheet size of the X-ray film is small. It is general that the producing system is structured in a specialized manner for a predetermined size of the sheet size. In the producing system for the X-ray film, the protective cover is pre-bent at a target end portion to be folded. The sheets are stacked on the protective cover after the pre-bending. Then the protective cover is folded before forming the sheet package.
In the producing system including the cutting/stacking device in the plurality, the ability of processing of the bag packaging machine is considered as minimum ability. If a difference occurs between the ability and that required in view of profits, it requires a remarkably large space for installation, and also expenses for investment. Furthermore, the facilities with the producing system are hard to maintain in a stable state. This is the case typically because the personnel having high skill in monitoring and handling the producing system cannot be easily employed.
For multi-type production, frequent changes are inevitable in the bag packaging machine about the sheet size and the type. It is likely that the sheet size or the type is different between the bag packaging machine and the cutting/stacking device operating at the same time. The X-ray film different in the sheet size or the type at the time of processing in the bag packaging machine is stored in a temporary manner. This results in precise administration of addresses of the X-ray film in the reservoir, precision in planning the production with judgement in priority of plural processes, precision in the administration of the production in relation to instructions, monitoring of achievements and the like, and complexity in systemizing the administration of information. To reserve the X-ray film requires sufficient spaces, which is likely to be inconsistent to rapidity in shipment of the X-ray film.
The producing system specialized for the X-ray film has low compatibility with the producing system for products other than the X-ray film. If a new product of the X-ray film is developed, the producing system cannot be applied in the initially specialized structure. A problem arises in a short period of using the same facilities of the producing system.
In view of the foregoing problems, an object of the present invention is to provide a sheet package producing system for producing a sheet package having a stack of sheets at a low cost and in a manner with compatibility to various sheet types.
In order to achieve the above and other objects and advantages of this invention, a sheet package producing system for producing a sheet package having a predetermined number of sheets is provided. A cutting/stacking device forms the sheets by cutting continuous sheet at a regular length, and for stacking the sheets in the predetermined number. A covered sheet stack producing device inserts the stacked sheets into a protective cover, to obtain a covered sheet stack. A packaging device packages the covered sheet stack to obtain the sheet package. The cutting/stacking device, the covered sheet stack producing device and the packaging device are connected in series with one another.
The cutting/stacking device, the covered sheet stack producing device and the packaging device are balanced in line capacity balance relative to one another.
The protective cover includes transversely extending plural bending lines for defining first, second and third portions, the first portion being positioned on an end face of the stacked sheets, the second and third portions being positioned on upper and lower faces of the stacked sheets. The covered sheet stack producing device includes a first handling module for placing either one of the second portion and the stacked sheets on an upper surface of a remaining one thereof. A folding module folds the protective cover along the plural bending lines, and squeezes the stacked sheets between the second and third portions, to obtain the covered sheet stack.
The cutting/stacking device includes a supply module for feeding the continuous sheet. A cutter module cuts the continuous sheet to obtain the sheets. A stacker module stacks the sheets in the predetermined number.
The first handling module places the protective cover on the stacked sheets. Furthermore, a second handling module is robotic, turns over a sheet orientation of the stacked sheets to locate the protective cover under the stacked sheets, and then sets the protective cover and the stacked sheets to the folding module. The folding module folds the protective cover by moving upward the third portion.
The cutting/stacking device further includes a synchronizing unit for synchronizing the supply module, the cutter module and the stacker module with one another.
The supply module, the cutter module and the stacker module include respectively drive power sources. The synchronizing unit electrically synchronizes the drive power sources.
In another preferred embodiment, the supply module, the cutter module and the stacker module include respectively first, second and third mechanisms being rotatable or movable. The cutting/stacking device includes a drive power source for actuating one of the first, second and third mechanisms. The synchronizing unit includes a transmission coupling for mechanically transmitting force of driving of the one mechanism to remaining ones of the first, second and third mechanisms.
The one mechanism is the second mechanism.
The covered sheet stack producing device further includes a pre-bending module, actuated earlier than the folding module, for bending the protective cover temporarily by forcibly depressing the third portion. The first handling module sets the protective cover on the pre-bending module, and then places the protective cover on the stacked sheets.
The second handling module includes a sheet chuck for capturing the stacked sheets. A moving robot arm moves the sheet chuck. A rotating mechanism is secured to the sheet chuck or the moving robot arm, for rotating the sheet chuck to turn over the sheet orientation.
The first handling module includes a cover suction pad for sucking the protective cover. A cover moving robot arm moves the cover suction pad.
The packaging device includes a bag packaging machine for packaging the covered sheet stack in a packaging bag. A box packaging machine packages the covered sheet stack in an outer box after packaging in the packaging bag, to obtain the sheet package.
The bag packaging machine includes a stack feeding module for feeding the covered sheet stack. A bag-forming/inserting module wraps the covered sheet stack with bag material. A package finishing module folds a margin flap of the bag material wrapping the covered sheet stack, to enclose the covered sheet stack in the packaging bag.
The box packaging machine includes a box forming module, being robotic, for forming the outer box by bending a plate material or sheet material. A box inserting module inserts the covered sheet stack into the outer box after packaging in the packaging bag.
The cutting/stacking device further includes a decurler module for eliminating or reducing a curling tendency of the continuous sheet.
Each of the cutting/stacking device, the covered sheet stack producing device and the packaging device includes plural modules. A pallet is disposed in each of the plural modules, having a size predetermined in consideration of a maximum size of the sheets, for supporting the continuous sheet, the sheets, the protective cover, the covered sheet stack or the sheet package.
In an alternative structure, the protective cover includes a transversely extending bending line for defining first and second portions, the bending line being adapted to folding, to oppose the first and second portions to one another. The covered sheet stack producing device includes a first handling module, being robotic, for placing either one of the first portion and the stacked sheets on an upper surface of a remaining one thereof. A folding module folds the protective cover along the bending line, and squeezes the stacked sheets between the first and second portions, to obtain the covered sheet stack.
The above objects and advantages of the present invention will become more apparent from the following detailed description when read in connection with the accompanying drawings, in which:
In
Web 8 with a great width as uncut material of X-ray film is fed in the slitting device 2. Slitting blades 9 of the slitting device 2 slit the web 8 at a width of each X-ray film as product. A continuous sheet 10 is obtained. A spool 12 is set in a continuous sheet container 11, and winds the continuous sheet 10 in a roll form. After this, the continuous sheet container 11 is removed from the slitting device 2 and set into the cutting/stacking device 3.
The cutting/stacking device 3 is constituted by various modules which are a supply module 14, a decurler module or uncurler module 15, a cutter module 16 and a stacker module 17. The supply module 14 is provided with the continuous sheet container 11 containing the continuous sheet 10. There is a regular tension control mechanism which applies predetermined tension to the continuous sheet 10. The continuous sheet 10 is drawn from the continuous sheet container 11 in a state with the tension. The supply module 14 includes a splicing unit for connecting a rear end of the continuous sheet 10 with a front end of a new continuous sheet when the remainder of the continuous sheet 10 decreases and comes near to the minimum.
A heating roller 19 and a cooler are included in the decurler module 15. The heating roller 19 is heated at a temperature lower than that which would influence the quality of the X-ray film. The heating roller 19 contacts the continuous sheet 10 kept curved, to uncurl the continuous sheet 10. After the heating roller 19 operates, the cooler cools the continuous sheet 10 and keeps the uncurled state of the continuous sheet 10. A dancer roller 20 is disposed upstream from the heating roller 19, and absorbs small changes in the tension of the continuous sheet 10.
The cutter module 16 includes a suction drum 22 and a rotary oscillation cutter 23. The suction drum 22 operates for feeding the continuous sheet 10 at a regular rate. The rotary oscillation cutter 23 is actuated in synchronism with the suction drum 22 electrically and mechanically. The continuous sheet 10 is cut by the rotary oscillation cutter 23 at a regular length, to be sheets 25 or X-ray films. See
The stacker module 17 includes stackers 27 and 28 and a sorting gate. The stackers 27 and 28 receive the sheets 25 from the cutter module 16, and reserve the sheets 25 in a stacked state. The sorting gate guides the sheets 25 to an appropriate one of the stackers 27 and 28. In
The supply module 14, the decurler module 15, the cutter module 16 and the stacker module 17 has a pallet or base plate having a common size determined in consideration of the expected maximum size of an X-ray film. Each of the modules can be added, removed or exchanged easily by retention with bolts.
In
Control units are associated with respectively the supply, decurler, cutter and stacker modules 14–17 in a separate manner. A main control unit for administrating the whole of the producing system is provided. The separate control units are connected to the main control unit, and receive signals for a start and stop of operation, and command of speed. For other items of the control, the separate control units operate per each of workpieces. Note that the supply, decurler, cutter and stacker modules 14–17 may be synchronized by other constructions than the flexible couplings 92 and the drive main shafts 114–117. In
The covered sheet stack producing device 4 is constituted by a sheet handling module 30, a cover handling module 31, a pre-bending module 33 and a folding module 34. The sheet handling module 30 captures a stack of the sheets 25 from the stacker module 17 in the cutting/stacking device 3. A protective cover 32 is handled by the cover handling module 31. The pre-bending module 33 pre-bends the protective cover 32 before folding in the final step. The folding module 34 folds the protective cover 32 loaded with the sheets 25.
In
Grooves 27e and 27f are formed in the quadrilateral pallet 27a of the stacker 27. The sheet handling module 30 inserts the chuck plates 45c and 45d into the grooves 27e and 27f. Then the chuck plates 45a and 45b are moved down toward the chuck plates 45c and 45d, to squeeze the sheets 25. The joints of the sheet moving robot arm 36 are actuated, to pick up the sheets 25 from the stacker 27.
In
The protective cover 32 consists of a sufficiently thick plate with rigidity, such as a cardboard. In
In
In
The folding module 34 includes a quadrilateral pallet 62, guide ridges 63 and a folding arm 64. The quadrilateral pallet 62 supports the sheets 25 and the protective cover 32 placed thereon. The guide ridges 63 regulate three edges of the sheets 25 and the protective cover 32 on the quadrilateral pallet 62. The folding arm 64 folds the protective cover 32 to squeeze the sheets 25. The folding arm 64 includes an arm portion 65 and a folding pad 66. The arm portion 65 has substantially a channel shape, and has one end rod supported on a lateral wall of the quadrilateral pallet 62 in a rotatable manner. The folding pad 66 is a suction pad secured to a remaining end rod of the arm portion 65. The arm portion 65 is rotatable between a first position of the phantom line and a second position of the solid line. When the arm portion 65 rotates from the first position to the second position, the folding pad 66 pushes the protective cover 32 and folds the same to wrap the sheets 25.
A covered sheet stack 67 is created by inserting the sheets 25 in the protective cover 32. In
The pre-bending module 33 and the folding module 34 have the pallet or base plate having a common size determined in consideration of the expected maximum size of an X-ray film. Each of the modules can be added, removed or exchanged easily by retention with bolts. In the general-purpose robots in the sheet handling module 30 and the cover handling module 31, the sheet chuck 44 and the cover suction pads 55 can be exchanged for each of types of the products. Thus, various types and sizes of the products can be produced.
Control units are separately associated with respectively the modules included in the covered sheet stack producing device 4. However, the general-purpose robots in the sheet handling module 30 and the cover handling module 31 are controlled in a harmonized manner. The main control unit for the producing system is provided. The separate control units of the modules in the covered sheet stack producing device 4 are connected to the main control unit, and receive signals for a start and stop of operation, and command of speed.
The bag packaging machine 5 includes a stack feeding module 71, a bag-forming/inserting module 72 and a package finishing module 73. The stack feeding module 71 feeds the covered sheet stack 67 from the covered sheet stack producing device 4 toward a downstream side. The bag-forming/inserting module 72 packages the covered sheet stack 67 according to the pillow packaging. The stack feeding module 71 consists of a conveyor belt, and sends the covered sheet stack 67 to the bag-forming/inserting module 72. Note that the stack feeding module 71, instead of the conveyor belt, may include a chain having plural feeding claws.
In
The package finishing module 73 includes a flap folding mechanism of a general-purpose type. A corner of a rear flap 76a of the packaging bag 76 is grasped by a robot hand which is disposed in the package finishing module 73 and secured to a robot being movable straight. The robot hand applies tension to the rear flap 76a in two directions, and folds it without creating wrinkles. A front flap 76b of the packaging bag 76 is also folded. The rear and front flaps 76a and 76b are retained by a retention mechanism contacting an upper surface of the packaging bag 76. Finally, a sticker 78 is attached to the rear and front flaps 76a and 76b to secure those to the packaging bag 76.
The stack feeding, bag-forming/inserting, and package finishing modules 71–73 have a pallet or base plate having a common size determined in consideration of the expected maximum size of an X-ray film. Each of the modules can be added, removed or exchanged easily by retention with bolts. Control units are associated with respectively the stack feeding, bag-forming/inserting, and package finishing modules 71–73 in the bag packaging machine 5 in a separate manner. The separate control units are connected to the main control unit, and receive signals for a start and stop of operation, and command of speed.
The box packaging machine 6 includes a box forming module 96, a box inserting module 80 and a cardboard caser. The box forming module 96 consists of a general-purpose robot similar to that of the cover handling module 31 described above. See
The box inserting module 80 inserts a guide plate into the outer box 82, to place the packaging bag 76 having the covered sheet stack 67 into the outer box 82. Then a lid of the outer box 82 is closed. A sticker 86 is attached to the outer box 82 by the box inserting module 80. In the box inserting module 80, information such as a lot number is printed to the outer box 82. An image processor inspects the outer box 82 for appearance to check the attached state of the sticker 86, the printed state and the like.
The cardboard caser consists of a multi-joint robot of a general-purpose type to handle the outer box 82, and inserts five outer boxes 82 to a single outer packaging cardboard box.
The box forming module 96, the box inserting module 80 and the cardboard caser have a pallet or base plate having a common size determined in consideration of the expected maximum size of an X-ray film. Each of the modules can be added, removed or exchanged easily by retention with bolts. Control units are associated with respectively the box forming module 96, the box inserting module 80 and the cardboard caser in a separate manner. The separate control units are connected to the main control unit, and receive signals for a start and stop of operation, and command of speed.
The operation of the above embodiment is described now. In
The continuous sheet container 11 containing the continuous sheet 10 is removed from the slitting device 2 and set into the cutting/stacking device 3. Then the continuous sheet 10 is drawn from the continuous sheet container 11 in a state with tension applied by the regular tension control mechanism. The continuous sheet 10 is unwound, and uncurled by operation of the heating roller 19 of the decurler module 15 and the cooler.
The continuous sheet 10 after being uncurled is fed by the suction drum 22 in the cutter module 16 at a regular rate, and cut by the rotary oscillation cutter 23 synchronized with the suction drum 22. Thus, the sheets 25 in
In
At the same time as the sheets 25 are produced and stacked, the protective cover 32 is pre-bent. In
In
In
In the folding module 34, the arm portion 65 rotates from the position of the phantom line to the position of the solid line. The folding pad 66 pushes the protective cover 32 to fold the pre-bent end portion tightly to the surface of the sheets 25. The covered sheet stack 67 is obtained as combination of the protective cover 32 and the sheets 25. In
In the bag packaging machine 5 provided with the covered sheet stack 67 by the covered sheet stack producing device 4, the stack feeding module 71 feeds the covered sheet stack 67 toward the bag-forming/inserting module 72. In
In the package finishing module 73, a robot hand grasps a corner of the rear flap 76a of the packaging bag 76. The robot hand applies tension to the rear flap 76a in two directions, while the flap folding mechanism of a general-purpose type folds it without creating wrinkles. Also, the front flap 76b of the packaging bag 76 is folded. The retention mechanism contacts the upper surface of the packaging bag 76 and keeps the rear and front flaps 76a and 76b closed. Then the sticker 78 is attached to secure the rear and front flaps 76a and 76b to the packaging bag 76.
In the box packaging machine 6, the box forming module 96 having the general-purpose robot bends the blank sheet 83. See
The box inserting module 80 inserts the guide plate into the outer box 82, and loads it with the packaging bag 76 containing the covered sheet stack 67. Then the lid of the outer box 82 is closed. The sticker 86 is attached. In the box inserting module 80, the lot number and the like are printed to the outer box 82. The image processor is used to inspect the attached state of the sticker, the printed state and the like.
The outer box 82 containing the packaging bag 76 is handled by the cardboard caser, and inserted in an outer packaging cardboard box, which is provided with five outer boxes 82.
In the X-ray film producing system, the slitting device 2, the cutting/stacking device 3, the covered sheet stack producing device 4, the bag packaging machine 5 and the box packaging machine 6 are connected in series, and are balanced in relation to the line capacity balance. Accordingly, it is unnecessary to keep a space for reservation of the material. No complicated administration of materials is required. Any of the modules included in the system has a pallet or base plate having a common size determined in consideration of the expected maximum size of an X-ray film. Each of the modules can be added, removed or exchanged easily according to an amount of production.
In the above embodiment, the sheet package producing system is used in the manufacture of X-ray films. However, sheets to be packaged according to the invention may be photo films, heat sensitive film, photosensitive heat developable films, PPC paper sheets, and any other suitable material of a shape of a film, sheet or plate.
Although the present invention has been fully described by way of the preferred embodiments thereof with reference to the accompanying drawings, various changes and modifications will be apparent to those having skill in this field. Therefore, unless otherwise these changes and modifications depart from the scope of the present invention, they should be construed as included therein.
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