CROSS-REFERENCE TO RELATED APPLICATIONS
TECHNICAL FIELD
[0002] The present application relates to a film roll supply device to supply a film roll
to a bag-making and packaging machine.
BACKGROUND ART
[0004] When the film on the film roll is depleted in such bag-making and packaging machines,
it is necessary to replace the film roll. Conventionally, attaching a film roll to
a bag-making and packaging machine has been done using a manual method such as a method
in which a worker lifts the film roll and directly installs the film roll on a supporting
shaft of the bag-making and packaging machine, and a method, which is disclosed in
Patent Literature 1 (
Japanese Laid-open Patent Publication No. 2002-337817), in which the worker lifts the film roll to a predetermined height, loads the film
roll onto a cart, and then installs the film roll on the supporting shaft of the bag-making
and packaging machine by sliding the film roll on the cart horizontally.
SUMMARY OF THE INVENTION
[0005] However, in the case described above, it is necessary for the worker to stand near
the bag-making and packaging machine and perform work to switch out a film roll when
the film on the film roll is depleted. Such work not only imposes a burden on the
worker but also presents a risk of reducing work efficiency of the worker due to an
occurrence of standby time. Additionally, if the film on the film roll is depleted
at a time when the worker is performing other work, there is a risk of lengthening
a period of time until replacement of the film roll is completed and the bag-making
and packaging machine, which will have stopped due to lack of film, is restarted.
[0006] A goal of the claimed invention is to provide a film roll supply device that makes
it possible to improve replacement of a film roll in a bag-making and packaging machine.
[0007] A film roll supply device according to a first aspect of the claimed invention supplies
a film roll to a bag-making and packaging machine. The film roll supply device comprises
a receiver and a first driver. The receiver is configured to receive the film roll
to be supplied to the bag-making and packaging machine. The first driver is configured
to change an orientation of the receiver between a first orientation used when receiving
the film roll and a second orientation used when supplying the film roll to the bag-making
and packaging machine.
[0008] When work to replace a film roll using a film roll supply device is automated from
the standpoint of,
inter alia, reducing worker burden, improving work efficiency of the worker, and suppressing
downtime of the bag-making and packaging machine, there is a risk that an adverse
event such as scratching of a surface of a film on the film roll will occur during
transfer of the film roll to the receiver for supplying the film roll to the bag-making
and packaging machine.
[0009] However, because the film roll supply device according to the first aspect is configured
such that the orientation of the receiver to support the film roll to be supplied
to the bag-making and packaging machine is changed from the second orientation used
when supplying the film roll to the bag-making and packaging machine to the first
orientation used when receiving the film roll, the occurrence of adverse events such
as scratching of a surface of the film on the film roll is readily suppressed.
[0010] A film roll supply device according to a second aspect of the claimed invention is
the film roll supply device according to the first aspect, wherein the first driver
is configured to rotate the receiver about a rotation axis to change the orientation
of the receiver. The rotation axis extends in a direction same as an axial direction
of the film roll held by the receiver.
[0011] In the film roll supply device according to the second aspect, the orientation of
the receiver can be changed using a comparatively simple movement (rotary action).
[0012] A film roll supply device according to a third aspect of the claimed invention is
the film roll supply device according to the first or second aspect, further comprises
a preliminary placement section on which the film roll being transferred to the receiver
is preliminarily placed.
[0013] Because the film roll supply device according to the third aspect has the preliminary
placement section, it is possible to set the film roll on the preliminary placement
section in advance so that the film roll supply device can execute an action to replace
the film roll of the bag-making and packaging machine at a timing when replacement
of the film roll is required.
[0014] A film roll supply device according to a fourth aspect of the claimed invention is
the film roll supply device according to the third aspect, wherein the receiver is
configured to allow the film roll to move from the preliminary placement section to
the receiver when the receiver is in the first orientation, and restrict the film
roll from moving from the preliminary placement section to the receiver when the receiver
is in the second orientation.
[0015] In the film roll supply device according to the fourth aspect, because the film roll
is restricted from moving when the receiver is in the second orientation, it is possible
to suppress the occurrence of a phenomenon where the film roll moves from the preliminary
placement section to the receiver at an unintended timing.
[0016] A film roll supply device according to a fifth aspect of the claimed invention is
the film roll supply device according to the third or fourth aspect, wherein the preliminary
placement section is configured to support the film roll at a location higher than
the film roll transferred to the receiver in the first orientation.
[0017] In the film roll supply device according to the fifth aspect, because the preliminary
placement section supports the film roll higher than the film roll supported by the
receiver in the first orientation, the film roll can be moved to the receiver without
being lifted.
[0018] A film roll supply device according to a sixth aspect of the claimed invention is
the film roll supply device according to any of the third to fifth aspects, wherein
the receiver has a first surface. The preliminary placement section has a preliminary
placement surface on which the film roll is configured to be preliminarily placed.
When the film roll is transferred from the preliminary placement section to the receiver
in the first orientation, the film roll moves on the preliminary placement surface
and the first surface. When the film roll moves on the preliminary placement surface
and the first surface, the preliminary placement surface and the first surface are
parallel. Alternatively, when the film roll moves on the preliminary placement surface
and the first surface, the first surface is downwardly inclined from a proximal side
toward a distal side relative to the preliminary placement section.
[0019] In the film roll supply device according to the sixth aspect, due to the preliminary
placement surface and the first surface being disposed as described above, the film
roll can be smoothly moved from the preliminary placement surface to the first surface
of the receiver without being lifted.
[0020] A film roll supply device according to a seventh aspect of the claimed invention
is the film roll supply device according to the sixth aspect, wherein the receiver
has a second surface. When the receiver is in the first orientation, the second surface
is configured to restrict movement of the film roll that moves on the first surface
from the proximal side toward the distal side relative to the preliminary placement
section.
[0021] Because the film roll supply device according to the seventh aspect has the second
surface, it is possible to suppress the occurrence of adverse events, such as the
film roll that has moved onto the receiver falling from the receiver or failing to
be disposed at a desired position on the receiver.
[0022] A film roll supply device according to an eighth aspect of the claimed invention
is the film roll supply device according to the seventh aspect, wherein the receiver
includes a first plate-shaped member having the first surface, and a second plate-shaped
member having the second surface. When the first plate-shaped member and the second
plate-shaped member are viewed from a direction parallel to the first surface and
the second surface, the first surface and the second surface are disposed in a V shape.
[0023] In the film roll replacement device according to the eighth aspect, due to the first
surface and the second surface being disposed in a V shape, the position of the film
roll can be precisely positioned using the first surface of the first plate-shaped
member and the second surface of the second plate-shaped member.
[0024] Additionally, due to the first surface and the second surface being disposed in a
V shape, it is possible to control only a vertical-direction position of the receiver
when supplying the film roll to the bag-making and packaging machine, therefore making
it possible to control the position of the film roll during film roll supply using
a simple configuration.
[0025] A film roll supply device according to a ninth aspect of the claimed invention is
the film roll supply device according to the seventh or eighth aspect, wherein an
angle formed by the first surface and the second surface is within a range of 90°±30°.
[0026] In the film roll supply device according to the ninth aspect, due to the angle formed
by the first surface and the second surface being within the aforementioned angular
range, the position of the film roll can be precisely controlled using the first surface
and the second surface.
[0027] A film roll supply device according to a tenth aspect of the claimed invention is
the film roll supply device according to any of the seventh to ninth aspects, wherein
when the receiver is in the second orientation, the first surface and the second surface
support the film roll on the receiver from below.
[0028] In the film roll supply device according to the tenth aspect, the first surface and
the second surface can function as support surfaces for the film roll when the orientation
of the receiver is set to the second orientation.
[0029] Because the film roll supply device according to the claimed invention is configured
such that the orientation of the receiver to support a film roll to be supplied to
the bag-making and packaging machine is changed from the second orientation used when
supplying the film roll to the bag-making and packaging machine to the first orientation
used when receiving the film roll, the occurrence of adverse events such as scratching
of a surface of the film on the film roll is readily suppressed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030]
FIG. 1 is a schematic perspective view of a weighing and packaging system including
a bag-making and packaging machine to which a film roll is supplied by a film roll
replacement device according to one embodiment of a film roll supply device of the
claimed invention;
FIG. 2 is a schematic diagram of the bag-making and packaging machine of FIG. 1;
FIG. 3 is a schematic perspective view of a film supply section of the bag-making
and packaging machine of FIG. 1 and the film roll replacement device according to
one embodiment of the claimed invention, as seen from the left rear;
FIG. 4 is a schematic perspective view of the film supply section of the bag-making
and packaging machine of FIG. 1 and the film roll replacement device according to
one embodiment of the claimed invention, as seen from the right rear;
FIG. 5 is a schematic plan view of the film roll replacement device;
FIG. 6 is a schematic left-side view of the film roll replacement device;
FIG. 7 is a control block diagram of the bag-making and packaging machine and the
film roll replacement device;
FIG. 8 is a schematic right-side view of a right-side pushing member of the film roll
replacement device;
FIG. 9 is a schematic left-side view of a left-side pushing member of the film roll
replacement device;
FIG. 10A is a schematic plan view of part of the film roll replacement device and
illustrates an action of the film roll replacement device when a film roll is removed
from a supporting shaft of the bag-making and packaging machine;
FIG. 10B is a schematic plan view of part of the film roll replacement device and
illustrates the action of the film roll replacement device when the film roll is removed
from the supporting shaft of the bag-making and packaging machine;
FIG. 10C is a schematic plan view of part of the film roll replacement device and
illustrates the action of the film roll replacement device when the film roll is removed
from the supporting shaft of the bag-making and packaging machine;
FIG. 10D is a schematic plan view of part of the film roll replacement device and
illustrates the action of the film roll replacement device when the film roll is removed
from the supporting shaft of the bag-making and packaging machine;
FIG. 11 is a schematic left-side view illustrating the action of the film roll replacement
device when a winding core of a depleted film roll is retrieved from a supporting
shaft of the bag-making and packaging machine;
FIG. 12A is a schematic left-side view of part of the film roll replacement device
and illustrates movement of a film roll to the holding section and adjustment of a
height position of the holding section;
FIG. 12B is a schematic left-side view of part of the film roll replacement device
and illustrates the movement of the film roll to the holding section and the adjustment
of the height position of the holding section;
FIG. 12C is a schematic left-side view of part of the film roll replacement device
and illustrates the movement of the film roll to the holding section and the adjustment
of the height position of the holding section;
FIG. 12D is a schematic left-side view of part of the film roll replacement device
and illustrates the movement of the film roll to the holding section and the adjustment
of the height position of the holding section;
FIG. 12E is a schematic left-side view of part of the film roll replacement device
and illustrates the movement of the film roll to the holding section and the adjustment
of the height position of the holding section;
FIG. 13A is a schematic plan view of part of the film roll replacement device and
illustrates mounting of a film roll on a supporting shaft of the bag-making and packaging
machine by the film roll replacement device;
FIG. 13B is a schematic plan view of part of the film roll replacement device and
illustrates the mounting of the film roll on the supporting shaft of the bag-making
and packaging machine by the film roll replacement device;
FIG. 13C is a schematic plan view of part of the film roll replacement device and
illustrates the mounting of the film roll on the supporting shaft of the bag-making
and packaging machine by the film roll replacement device;
FIG. 13D is a schematic plan view of part of the film roll replacement device and
illustrates the mounting of the film roll on the supporting shaft of the bag-making
and packaging machine by the film roll replacement device;
FIG. 13E is a schematic plan view of part of the film roll replacement device and
illustrates the mounting of the film roll on the supporting shaft of the bag-making
and packaging machine by the film roll replacement device;
FIG. 14 is an enlarged view of the holding section of the film roll replacement device,
and is a drawing illustrating a method of measuring the height position up to the
center of the first film roll;
FIG. 15 is a control block diagram of the film roll replacement device of Modification
A; and
FIG. 16 is an enlarged view of the holding section of the film roll replacement device
of Modification B, and is a drawing illustrating a method of measuring the height
position up to the center of the first film roll.
FIG. 17A illustrates another example of a disposition of a first holding member and
a second holding member in the holding section of the film roll replacement device;
FIG. 17B illustrates yet another example of the disposition of the first holding member
and the second holding member in the holding section of the film roll replacement
device;
FIG. 18A illustrates an example of a disposition of a first holding surface of the
holding section and a conveyor surface of a conveyor of the film roll replacement
device;
FIG. 18B illustrates an example of the disposition of the first holding surface of
the holding section and the conveyor surface of the conveyor of the film roll replacement
device;
FIG. 19 illustrates another example of a first orientation of the holding section
in the film roll replacement device;
FIG. 20 illustrates another example of the disposition of the conveyor of the film
roll replacement device;
FIG. 21A is a schematic left-side view of the film roll replacement device according
to modification L, and depicts a state in which an orientation of the holding section
is a second orientation;
FIG. 21B is a schematic left-side view of the film roll replacement device according
to modification L, and depicts a state in which the orientation of the holding section
is a first orientation;
FIG. 22 is a schematic left-side view of the holding section of the film roll replacement
device according to modification M;
FIG. 23 is a schematic left-side view of another example of the holding section of
the film roll replacement device according to modification N; and
FIG. 24 is a schematic left-side view of yet another example of the holding section
of the film roll replacement device according to modification N.
DESCRIPTION OF EMBODIMENTS
[0031] A film roll replacement device 200 according to one embodiment of a film roll supply
device of the present disclosure shall now be described with reference to the drawings.
The following description is merely a specific example of the claimed invention, and
does not limit the technical scope of the claimed invention. It will be understood
that various changes in configuration and detail can be made without departing from
the spirit and scope of the invention as set forth in the claims.
[0032] In the following description, expressions such as parallel, perpendicular, horizontal,
vertical, orthogonal, identical, etc., may be used. Meanings of these expressions
are not limited to strictly parallel, perpendicular, horizontal, vertical, orthogonal,
identical, etc., may also be substantially parallel, perpendicular, horizontal, vertical,
orthogonal, identical, etc.
[0033] For the sake of convenience, expressions such as "front (front surface)," "rear (back
surface)," "up," "down," "left," and "right" may be used to indicate directions in
the following description. Unless otherwise specified, these directional expressions
represent the directions of the arrows added to the drawings.
(1) Bag-making and packaging machine and weighing and packaging system
[0034] First, a bag-making and packaging machine 3, to which the film roll replacement device
200 supplies a film roll, and a weighing and packaging system 1 including the bag-making
and packaging machine 3, shall now be described with reference to FIGS. 1, 2, and
7. FIG. 1 is a schematic perspective view of the weighing and packaging system 1.
FIG. 2 is a schematic diagram of the bag-making and packaging machine 3. A control
block diagram of the bag-making and packaging machine 3 is shown in the lower part
of FIG. 7.
[0035] The weighing and packaging system 1 mainly has a combination weighing machine 2 and
the bag-making and packaging machine 3 (see FIG. 1).
(1-1) Combination weighing machine
[0036] The combination weighing machine 2 mainly has a plurality of weighing hoppers 2a
as in FIG. 1. The combination weighing machine 2 uses the plurality of weighing hoppers
2a to weigh articles P (e.g., potato chips) of a predetermined weight, and supplies
the articles to the bag-making and packaging machine 3 positioned thereunder. Specifically,
the combination weighing machine 2 conveys and supplies articles P supplied from a
supply conveyor (not shown in the figure) or the like to the plurality of weighing
hoppers 2a using a conveying means (not shown in the figure). The combination weighing
machine 2 measures the weight of the articles P supplied to each of the weighing hoppers
2a using a weighing means (not shown in the figure). The combination weighing machine
2 selects a combination of weighing hoppers 2a so that the total value of weight of
the articles P in the selected weighing hoppers 2a will fall within a predetermined
weight range. The combination weighing machine 2 supplies articles P of a predetermined
weight to the bag-making and packaging machine 3 by downwardly discharging the articles
P in weighing hoppers 2a selected in a combination.
(1-2) Bag-making and packaging machine
[0037] The bag-making and packaging machine 3 receives the supply of articles P from the
combination weighing machine 2, forms a bag B from a sheet-shaped film F, and manufactures
a bag B containing the articles P therein, as shown in FIG. 2. The bag-making and
packaging machine 3 mainly includes a bag-making and packaging section 3a, a film
supply section 100, and a packaging machine controller 4, as shown in FIGS. 1, 2,
and 7.
[0038] The film supply section 100 holds a film roll R1 around which the sheet-shaped film
F is wound, and supplies the film F paying out from the film roll R1 to the bag-making
and packaging section 3a. The bag-making and packaging section 3a receives the supply
of articles P from the combination weighing machine 2 and forms the sheet-shaped film
F supplied from the film supply section 100 to manufacture bags B containing the articles
P. The packaging machine controller 4 controls actions of various components of the
bag-making and packaging machine 3.
(1-2-1) Bag-making and packaging section
[0039] The bag-making and packaging section 3a mainly includes a forming mechanism 10, a
film-conveying device 20, a vertical seal mechanism 30, and a lateral seal mechanism
40, as shown in FIG. 2.
[0040] The forming mechanism 10 mainly includes a tube 12 and a former 14, as shown in FIG.
2. The tube 12 is a cylindrical member that is open at upper and lower ends. Articles
supplied by the combination weighing machine 2 are dropped into the opening at the
upper end of the tube 12 (see FIG. 2). The former 14 is positioned so as to surround
the tube 12. The former 14 forms the sheet-shaped film F conveyed by the film supply
section 100 into a tube shape, and forms a tubular film Ft having overlapping ends
in a direction orthogonal to the conveying direction of the film F.
[0041] The film-conveying device 20 conveys the film F supplied from the film supply section
100. Specifically, the film-conveying device 20 uses suction to hold the tubular film
Ft via a pair of belts (not shown in the figure) having a suction function, and conveys
the belts downward to convey the tubular film Ft and the sheet-shaped film Ft on the
upstream side.
[0042] The vertical seal mechanism 30 seals the tubular film Ft along the vertical direction.
The vertical seal mechanism 30 is positioned in front of the tube 12 as in FIG. 2.
The overlapping portion of the film F of the tubular film Ft is sandwiched between
the vertical seal mechanism 30 and the tube 12, and in this state, the overlapping
portion of the film F is heat sealed by a heater (not shown in the figure) of the
vertical seal mechanism 30.
[0043] With the articles P having been dropped to a bottom part of the tubular film Ft,
the lateral seal mechanism 40 sandwiches the tubular film Ft between a pair of sealing
jaws 42 having heaters installed therein, heat-seals the tubular film Ft along a direction
orthogonal to the conveying direction, and manufactures a bag B containing the articles
P. A cutter (not shown in the figure) is built into one of the pair of sealing jaws
42 to seal the tubular film Ft. When laterally sealing the tubular film Ft, the lateral
seal mechanism 40 uses the cutter to cut the tubular film Ft at a heightwise center
position of the portion laterally sealed by the sealing jaws 42, and separating the
bag containing the articles P from the following tubular film Ft.
(1-2-2) Film supply section
[0044] The film supply section 100 is provided behind and adjacent to the bag-making and
packaging section 3a as in FIG. 1, and supplies the sheet-shaped film F to the forming
mechanism 10 of the bag-making and packaging section 3a. The film supply section 100
mainly includes a holding mechanism 110, a support frame 120, a frame shaft 130, a
joining mechanism 160, a cutting mechanism 162, a plurality of rollers 170, and a
tension-adjusting mechanism 180.
[0045] The holding mechanism 110 includes a pair of supporting parts 112 and a support-shaft-driving
unit 116. Each of the pair of supporting parts 112 holds a film roll R1 in which a
film F is wound around a hollow winding core WC. The film supply section 100 supplies
the bag-making and packaging section 3a with film F paying out from the film rolls
R1 held by the supporting parts 112.
[0046] Due to the holding mechanism 110 having a plurality (e.g., two in this case) of supporting
parts 112, the holding mechanism 110 can simultaneously hold a replacement film roll
R1 in addition to the film roll R1 supplying film F to the bag-making and packaging
section 3a (the film roll R1 in use). Therefore, when the film F of the film roll
R1 in use has been used up, manufacture of bags B can be restarted in a short period
of time by using the film F of the replacement film roll R1.
[0047] The supporting parts 112 shall now be described in detail. The supporting parts 112
each have a supporting shaft 114 extending in a left-right direction. Film rolls R1
are mounted on the supporting shafts 114, and the mounted film rolls R1 are supported.
Specifically, the film rolls R1 are mounted on the supporting shafts 114 by inserting
the supporting shafts 114 through the winding cores WC of the film rolls R1. Air chucks
(not shown in the figure) or other fixing mechanisms are provided to the supporting
shafts 114. The film rolls R1 are fixed to the supporting shafts 114 by driving the
fixing mechanisms in a state in which the supporting shafts 114 have been inserted
through the hollow winding cores WC of the film rolls R1. The support-shaft-driving
unit 116 of the film supply section 100 may, for example, be a motor provided for
both of the supporting shafts 114, and the support-shaft-driving unit 116 causes the
supporting shafts 114 to rotate so that the film rolls R1 mounted on the supporting
shafts 114 are caused to rotate.
[0048] The support frame 120 is an arm-shaped member that supports the pair of supporting
parts 112. The support frame 120 is mounted at the center thereof on the frame shaft
130. The supporting parts 112 are mounted at both ends of the arm-form support frame
120 such that the frame shaft 130 is disposed between the supporting parts 112.
[0049] When the frame shaft 130 is caused to rotate by a motor or another frame-driving
unit 132, the support frame 120 rotates together with the frame shaft 130, and the
supporting shafts 114 of the pair of supporting parts 112 rotate about a center axis
of the frame shaft 130. Due to the support frame 120 rotating about the center axis
of the frame shaft 130, the supporting shafts 114 of the pair of supporting parts
112 are moved to respective film roll a replacement position, a film supply position,
or other positions. The film roll replacement position is a position at which film
roll R1 is supplied by the film roll replacement device 200 to the supporting shafts
114. The film supply position is a position at which the film F is paying out from
the film rolls R1 supported by the supporting shafts 114 to the bag-making and packaging
section 3a.
[0050] A leading end (the end opposite the side fixed to the winding core WC) of the film
F of the replacement film roll R1 mounted on one of the pair of supporting shafts
114 is set in a predetermined position. When the film F of the film roll R1 in use
(the film roll R1 mounted on the other supporting shaft 114) is used up (when the
remaining amount of the film F becomes equal to or less than a predetermined amount),
the joining mechanism 160 controlled by the packaging machine controller 4 joins a
vicinity of a trailing end (an end fixed to the winding core WC) of the film F of
the film roll R1 in use (in other words, the depleted film roll R1) and a vicinity
of the leading end of the film F of the replacement film roll R1. In addition, the
cutting mechanism 162 controlled by the packaging machine controller 4 cuts the film
F of the depleted film roll R1 on the side toward the depleted film roll R1 from the
location where the film is joined to the film F of the replacement film roll R1. As
a step of splicing the film F and a step of cutting the film F of the depleted film
roll R1 are automatically performed, the burden on the worker when a film roll R1
has been used up can be reduced in the bag-making and packaging machine 3.
[0051] The film F paying out from the film roll R1 supported on the supporting shaft 114
located in the film supply position is guided by a plurality of rollers 170 located
along a predetermined film-conveying path of the film supply section 100, and conveyed
to the forming mechanism 10 of the bag-making and packaging section 3a.
[0052] The film-conveying path of the film supply section 100 is provided with a tension-adjusting
mechanism 180 that adjusts the magnitude of tension applied to the conveyed film F.
[0053] The tension-adjusting mechanism 180 mainly has three fixed rollers 182, a movable
roller mechanism 184, a shaft 184a, an air cylinder 187, and an encoder 188 (see FIGS.
2 and 7). The movable roller mechanism 184 includes two movable rollers 185 and a
pair of arms 186 that support the movable rollers 185 (see FIG. 2). The pair of arms
186 are located to the left and right of the movable rollers 185 so that the movable
rollers 185, extending in the left-right direction, are held between the arms 186,
and the arms 186 support ends of the movable rollers 185. The pair of arms 186 are
rotatably supported by the shaft 184a extending in the left-right direction. A tip
of a rod (not shown in the figure) entering and exiting a cylinder (not shown in the
figure) of the air cylinder 187 is linked to an arm (not shown in the figure) extending
in a radial direction from the shaft 184a. Driving the air cylinder 187 generates
a force that causes the shaft 184a to rotate.
[0054] The fixed rollers 182 are fixed to a frame (not shown in the figure) and do not change
positions. The movable rollers 185 change positions in accordance with the movement
of the arms 186 between which the movable rollers 185 are mounted. The fixed rollers
182 and the movable rollers 185 are located in the film-conveying path via which the
film F paying out from the film rolls R1 supported by the supporting shafts 114 of
the supporting parts 112 moves toward the forming mechanism 10 of the bag-making and
packaging section 3a. The film F is wound on the fixed rollers 182 and the movable
rollers 185, which guide the film F being conveyed along the film-conveying path.
The movable rollers 185 move in accordance with the force exerted on the movable rollers
185 by the film F wound on the movable rollers 185.
[0055] One end of the shaft 184a is mounted to the encoder 188, which is for detecting a
rotation angle of the shaft 184a. The encoder 188 senses the movements of the movable
rollers 185. Detection results of the encoder 188 are used in,
inter alia, control of the positions of the movable rollers 185 by the packaging machine controller
4.
(1-2-3) Packaging machine controller
[0056] The packaging machine controller 4 is a device that controls the actions of the components
of the bag-making and packaging machine 3. The packaging machine controller 4 has,
for example, a CPU, storage devices such as a main storage device and an auxiliary
storage device, an input/output device, and various electric circuits and electronic
circuits. In the packaging machine controller 4, the CPU reads and executes programs
stored in memory, whereby the actions of the components of the bag-making and packaging
section 3a and the film supply section 100 are controlled.
[0057] Specifically, the packaging machine controller 4 is electrically connected to the
film-conveying device 20, the vertical seal mechanism 30, and the lateral seal mechanism
40 of the bag-making and packaging section 3a as shown in FIG. 7, and the packaging
machine controller 4 controls the actions of these components. The packaging machine
controller 4 is also electrically connected to the support-shaft-driving unit 116,
the frame-driving unit 132, the joining mechanism 160, the cutting mechanism 162,
and the air cylinder 187 of the film supply section 100, and the packaging machine
controller 4 controls the actions of these components. In addition, the packaging
machine controller 4 is electrically connected to the encoder 188 and a scanner 190
of the film supply section 100, and the packaging machine controller 4 receives signals
transmitted by these instruments. The scanner 190 is a device that reads codes such
as bar codes and matrix-type two-dimensional codes added to the film rolls R1.
[0058] During normal operation in which the bag-making and packaging section 3a manufactures
bags B, the packaging machine controller 4 controls actions of the support-shaft-driving
unit 116, the air cylinder 187, the film-conveying device 20, the vertical seal mechanism
30, and the lateral seal mechanism 40 in the following manner.
[0059] The packaging machine controller 4 controls the film-conveying device 20 so that
the sheet-shaped film F paying out from the film rolls R1 is conveyed at a predetermined
speed using the support-shaft-driving unit 116. The packaging machine controller 4
controls driving/stopping of the support-shaft-driving unit 116 and the speed at which
the film rolls R1 are caused to rotate by the support-shaft-driving unit 116, based
on the conveyed state of the film F and the sensing results of the encoder 188. In
addition, the packaging machine controller 4 controls the air cylinder 187 so that
the movable rollers 185 exert a constant force on the film F being conveyed. Furthermore,
the packaging machine controller 4 controls actions of the vertical seal mechanism
30 and the lateral seal mechanism 40 so that the vertical seal mechanism 30 vertically
seals the tubular film Ft at a predetermined timing and the lateral seal mechanism
40 laterally seals the tubular film Ft at a predetermined timing.
[0060] Details of the control performed by the packaging machine controller 4 when the film
roll replacement device 200 supplies a film roll R1 to the bag-making and packaging
machine 3 shall now be described together with a description of the film roll replacement
device 200.
(2) Film roll supply device
(2-1) Overall summary
[0061] A summary of the film roll replacement device 200 according to one embodiment of
the claimed invention shall now be described with reference to FIGS. 3 to 9.
[0062] FIG. 3 is a schematic perspective view of the film supply section 100 of the bag-making
and packaging machine 3 and the film roll replacement device 200 as seen from the
left rear. FIG. 4 is a schematic perspective view of the film supply section 100 of
the bag-making and packaging machine 3 and the film roll replacement device 200 as
seen from the right rear. FIG. 5 is a schematic plan view of the film roll replacement
device 200. FIG. 6 is a schematic left-side view of the film roll replacement device
200. A control block diagram of the film roll replacement device 200 is shown in the
upper part of FIG. 7. FIG. 8 is a schematic right-side view of a right-side pushing
member 240 of the film roll replacement device 200. FIG. 9 is a schematic left-side
view of a left-side pushing member 250 of the film roll replacement device 200.
[0063] The film roll replacement device 200 supplies film rolls R1 to the bag-making and
packaging machine 3. For the sake of clarity in the description below, a film roll
R1 supplied by the film roll replacement device 200 to the bag-making and packaging
machine 3 may be referred to as a first film roll R1a.
[0064] In the present disclosure, the film roll replacement device 200 removes a depleted
film roll R1 or a partially used film roll R1 from a supporting shaft 114 of the bag-making
and packaging machine 3. The term "depleted film roll R1" means a film roll R1 in
which the film F wound around the winding core WC has been used up (the remaining
amount of the film F has become equal to or less than a predetermined amount). The
term "partially used film roll R1" means a film roll R1 that is no longer used in
the bag-making and packaging machine 3 at least temporarily even though the film F
has not been used up. For the sake of clarity in explanation below, a film roll R1
removed from the supporting shaft 114 of the bag-making and packaging machine 3 may
be referred to as a second film roll R1b.
[0065] The film roll replacement device 200 may be a device that has only the function of
supplying film rolls R1 to the bag-making and packaging machine 3. In this case, the
second film roll R1b may be manually removed from the supporting shaft 114 by a worker.
[0066] The film roll replacement device 200 is placed, for example, on the right side of
the film supply section 100 of the bag-making and packaging machine 3, as in FIGS.
3 and 4. The placement of the film roll replacement device 200 depicted in FIGS. 3
and 4 is merely one example, and may be changed as appropriate in accordance with
the specifications of the bag-making and packaging machine 3 and the film roll replacement
device 200.
[0067] The film roll replacement device 200 has a conveyor 210, a gate 220, a holding section
230, a right-side pushing member 240, a left-side pushing member 250, a stopper 260,
a winding-core-retrieving mechanism 270, and a first member 280, as shown in FIGS.
5 and 6. In addition, the film roll replacement device 200 has a gate-driving unit
222, a first driving unit 235, a second driving unit 236, a third driving unit 237,
a right-side pushing-member-driving unit 242, a left-side pushing-member-driving unit
252, a stopper-driving unit 262, a first-member-driving unit 282, an encoder 284,
a distance sensor 286, and a controller 290 as shown in FIG.7. The driving units 222,
235, 236, 237, 242, 252, 262, 282 are motors, air cylinders, and other machines for
actuating objects to be driven. The types of machines to use for the driving units
222, 235, 236, 237, 242, 252, 262, 282 may be selected as appropriate.
[0068] Details of the various components of the film roll replacement device 200 are described
below.
(2-2) Details
(2-2-1) Conveyor
[0069] The conveyor 210 forwardly conveys the first film roll R1a, which is to be supplied
to the bag-making and packaging machine 3, to the holding section 230. A worker may
supply the first film roll R1a to the conveyor 210, or an automatic guided vehicle
(AGV) for conveying the film roll R1a may supply the first film roll R1a to the conveyor
210.
[0070] In the present embodiment, the conveyor 210 is a belt conveyor that drives a conveyor
belt by a motor (not shown in the figure) to convey the film rolls R1. However, the
type of conveyor 210 is not limited to a belt conveyor; the conveyor 210 may be a
roller conveyor that does not have a drive source. Even in this case, for example,
if an end portion of the conveyor 210 on the holding section 230 side is lower than
an end portion of the conveyor 210 on the side opposite to the holding section 230,
the film rolls R1 can be conveyed to the holding section 230 even without a person
moving the film rolls R1.
[0071] The conveyor 210 may be omitted from the film roll replacement device 200. If there
is no conveyor 210, the AGV may directly convey and supply the first film roll R1a
to the holding section 230. Alternatively, a worker may directly supply the first
film roll R1a to the holding section 230.
(2-2-2) Gate
[0072] The gate 220 is placed in front of the conveyor 210 and to the rear of the holding
section 230 as shown in FIG. 5. In other words, the gate 220 is placed between the
conveyor 210 and the holding section 230 in a plan view as shown in FIG. 5.
[0073] The gate 220 is a member that restricts the movement of the first film roll R1a on
the conveyor 210, and prevents the first film roll R1a from moving to the holding
section 230 at unintended timings. The gate 220 is driven by the gate-driving unit
222 to move between a position (restricting position) of restricting the movement
of the first film roll R1a toward the holding section 230 and a position (non-restricting
position) of not restricting the movement of the first film roll R1a toward the holding
section 230.
[0074] Matters such as the timing at which the gate-driving unit 222 moves the gate 220
shall now be described hereinafter.
(2-2-3) Holding section
[0075] The holding section 230 is one example of a receiver to receive the first film roll
R1a to be supplied to the bag-making and packaging machine 3.
[0076] The holding section 230 is, at least temporarily, placed adjacent to a supporting
shaft 114 supporting a film roll R1 in the bag-making and packaging machine 3, as
shown in FIG. 5. Specifically, the holding section 230 is placed in a position adjacent
to the previously described supporting shaft 114 caused to move to the film roll replacement
device.
[0077] The holding section 230 holds the first film roll R1a supplied to the bag-making
and packaging machine 3. The holding section 230 also holds the second film roll R1b
removed from the supporting shaft 114.
[0078] The holding section 230 has a first end portion 231a placed, in the left-right direction,
on a far side of the supporting shaft 114 placed in the film roll replacement position,
and a second end portion 231b placed on the side opposite to the first end portion
231a, on a side near the supporting shaft 114 placed in the film roll replacement
position, as shown in FIG. 5. The holding section 230 holds the first film roll R1a
supplied by the conveyor 210 and the second film roll R1b removed from the supporting
shaft 114 between the first end portion 231a and the second end portion 231b, in an
orientation such that the winding core WC extends in the left-right direction.
[0079] The holding section 230 has a first holding member 232 and a second holding member
234 as shown in FIGS. 5 and 6. The first holding member 232 and the second holding
member 234 are arranged side by side in the front-rear direction. Specifically, the
first holding member 232 is located behind the second holding member 234 (on the conveyor
210 side) as shown in FIGS. 5 and 6. The first holding member 232 and the second holding
member 234 are flat members. However, the first holding member 232 and the second
holding member 234 are not limited to being flat as long as the holding section 230
can function as described below. The first holding member 232 has a first holding
surface 232a that supports the first film roll R1a, and the second holding member
234 has a second holding surface 234a that supports the first film roll R1a.
The first holding member 232 and second holding member 234 having flat-plate-shape
are arranged so as to form a V shape in a right-side view, as in FIG. 6. In other
words, the first holding member 232 and the second holding member 234 are arranged
such that, in a right-side view and a left-side view, the first holding surface 232a
and the second holding surface 234a form a V shape. In other words, the first holding
member 232 and the second holding member 234 are arranged such that in a view along
the axial directions of the supporting shafts 114 of the bag-making and packaging
machine 3, the first holding surface 232a and the second holding surface 234a form
a V shape. In other words, when the first holding member 232 and the second holding
member 234 are viewed from a direction parallel to the first holding surface 232a
and the second holding surface 234a, the first holding surface 232a and the second
holding surface 234a are disposed in a V shape. In particular, a line perpendicular
to the first holding surface 232a and a line perpendicular to the second holding surface
234a are orthogonal in this embodiment. However, the angle formed by a normal to the
first holding surface 232a and a normal to the first holding surface 232a (i.e., an
angle formed by the first holding surface 232a and the first holding surface 232a)
may be different than 90°. For example, the angle formed by the first holding surface
232a and the first holding surface 232a may be less than 90°, as shown in FIG. 17A,
or may be greater than 90°, as shown in FIG. 17B. An angle α formed by the first holding
surface 232a and the second holding surface 234a (see FIGS. 17A and 17B) is preferably
within a range of 90°±30°.
[0080] The first holding member 232 and the second holding member 234 arranged so as to
form a V shape are spaced apart such that a gap 230a is formed between the first holding
member 232 and the second holding member 234 in the trough of the V shape. In other
words, the gap 230a is formed in a lower part of the holding section 230. A front-rear-directional
width of the gap 230a is greater than an outer diameter of the winding cores WC of
the film rolls R1. The gap 230a in the holding section 230 is used to allow passage
of the winding core WC of the second film roll R1b, particularly the depleted film
roll R1, which has been removed from the supporting shaft 114 and moved to the holding
section 230, and to drop and discharge the winding core WC of the depleted film roll
R1 into the winding-core-retrieving mechanism 270.
[0081] The holding section 230 is driven by the first driving unit 235, the second driving
unit 236, and the third driving unit 237.
[0082] The first driving unit 235 rotates the holding section 230 about a rotation axis
O that extends in a left-right direction, which is one example of a first direction,
and is disposed at a predetermined position (see FIG. 14). For example, in a left-side
view, the first driving unit 235 causes the holding section 230 to rotate about an
intersection point X between a straight line imagined as an extension of the first
holding surface 232a and a straight line imagined as an extension of the second holding
surface 234a (see FIG. 14). Specifically, the first driving unit 235 rotates the holding
section 230 about the rotation axis O, thereby changing an orientation of the holding
section 230 between a first orientation and a second orientation (see FIG. 14). The
first orientation is used when receiving the first film roll R1a. The second orientation
is used when supplying the first film roll R1a to the bag-making and packaging machine
3. The first film roll R1a is supported in an orientation such that an axial direction
of the first film roll R1a matches the left-right direction (first direction identical
to a direction in which the rotation axis O extends) both when the holding section
230 is in the first orientation and when the holding section 230 is in the second
orientation. When the holding section 230 is in the first orientation, the perpendicular
line of the first holding surface 232a extends vertically and the perpendicular line
of the second holding surface 234a extends horizontally. The first orientation of
the holding section 230 shown here is merely one example. The orientation of the holding
section 230 when inclined slightly such that the first holding surface 232a lowers
from the rear toward the front may be the first orientation of the holding section
230. When the holding section 230 is in the second orientation, the line perpendicular
to the first holding surface 232a is tilted 45° in relation to a horizontal plane,
and the line perpendicular to the second holding surface 234a is also tilted 45° in
relation to a horizontal plane. When the holding section 230 in the second orientation
is viewed from the left, the first holding surface 232a is inclined 45° in relation
to a vertical plane, and the second holding surface 234a is inclined 45° in relation
to a vertical plane. In other words, when the holding section 230 in the second orientation
is viewed from the left, the first holding surface 232a and the second holding surface
234a are arranged symmetrically with respect to a vertical plane V spreading in the
up-down direction and the left-right direction (see FIG. 6). When the holding section
230 in the second orientation is viewed from the left, the first holding surface 232a
and the second holding surface 234a form an upward-opening V shape. When the holding
section 230 is in the second orientation, the first holding surface 232a and the second
holding surface 234a support the film roll R1 on the holding section 230 from below.
[0083] The second driving unit 236 moves the holding section 230 in the up-down direction.
[0084] The third driving unit 237 moves the holding section 230 in the left-right direction.
In other words, the third driving unit 237 moves the holding section 230 in the second
orientation to the left so as to approach the supporting shaft 114 located in the
film roll replacement position, and to the right so as to move away from the supporting
shaft 114 located in the film roll replacement position.
[0085] The third driving unit 237 of the present embodiment moves the holding section 230,
the right-side pushing member 240, and the left-side pushing member 250 simultaneously
to the left and right. In other words, the third driving unit 237 moves the holding
section 230 integrally with the right-side pushing member 240 and the left-side pushing
member 250 to the left and right.
[0086] Further details regarding,
inter alia, the timing at which the first driving unit 235, the second driving unit 236, and
the third driving unit 237 move the holding section 230 and the transfer of the first
film roll R1a from the conveyor 210 to the holding section 230 are described below.
(2-2-4) Right-side pushing member
[0087] The right-side pushing member 240 is a member placed adjacent to the first end portion
231a of the holding section 230, as shown in FIG. 5. The right-side pushing member
240 is a member that pushes a right end surface of the first film roll R1a held by
the holding section 230.
[0088] The right-side pushing member 240 is driven in the up-down direction by the right-side
pushing-member-driving unit 242. By driving the right-side pushing member 240 in the
up-down direction, the right-side pushing-member-driving unit 242 moves the right-side
pushing member 240 to a position (referred to as a contact position) where said member
can come into contact with an end surface of the first film roll R1a. In addition,
by driving the right-side pushing member 240 in the up-down direction, the right-side
pushing-member-driving unit 242 moves the right-side pushing member 240 to a position
(referred to as a non-contact position) where said member does not come into contact
with the film rolls R1 mounted on the supporting shafts 114 of the bag-making and
packaging machine 3.
[0089] Furthermore, the right-side pushing member 240 is driven in the left-right direction
by the third driving unit 237. In particular, while the right-side pushing member
240 being in the contact position, the third driving unit 237 moves the right-side
pushing member 240 to the left so that the right end surface of the first film roll
R1a held by the holding section 230 is pushed by the right-side pushing member 240,
and the first film roll R1a is moved leftward toward the supporting shaft 114 located
in the film roll replacement position.
[0090] There are no particular limitations as to the shape of the right-side pushing member
240; said member has a substantially rectangular shape in a right-side view as in
FIG. 8. In an upper part of the right-side pushing member 240 there is preferably
formed a recess 240a that conforms to a shape of an outer diameter of the supporting
shafts 114 of the bag-making and packaging machine 3. There are no particular limitations
as to the shape; the recess 240a is, for example, U-shaped or V-shaped. For example,
if the recess 240a is U-shaped, the recess 240a is substantial rectangular and a lower
end part thereof is formed in a semicircular shape in a right-side view. Moreover,
if the recess 240a is U-shaped, the recess 240a may be a semicircular recess in a
right-side view as shown in FIG. 8. In the present disclosure, a semicircular recess
240a is formed in an upper part of the right-side pushing member 240. Preferably,
a diameter A of the semicircle of the recess 240a is greater than a diameter D1 of
the supporting shaft 114 on which the first film roll R1a is mounted, and is less
than a diameter D2 of an outer circumference of the winding core WC of the first film
roll R1a.
[0091] Reasoning for providing a recess 240a of these dimensions in the upper part of the
right-side pushing member 240 shall now be described.
[0092] Normally in the first film roll R1a, an end surface of the winding core WC of the
first film roll R1a is located farther to the outside in an axial direction of the
winding core WC than the film F wound around the winding core WC. Should a recess
240a of the above mentioned dimensions be formed in the upper part of the right-side
pushing member 240, the right-side pushing member 240 driven by the third driving
unit 237 is able to push only the winding core WC of the first film roll R1a if the
right-side pushing-member-driving unit 242 moves the right-side pushing member 240
in the up-down direction such that a bottom part of the recess 240a in the right-side
pushing member 240 comes to be located in a vicinity below a lowest point of the supporting
shaft 114 on which the first film roll R1a is to be mounted.
[0093] Should the film F be wound comparatively loosely around the winding core WC of the
first film roll R1a, and the right-side pushing member 240 pushes only the portion
of the F at the end surface of the first film roll R1a, there is a risk that part
of the film F will be misaligned in the left-right direction and the film supply section
100 will not be able to convey the film F to an appropriate position in the bag-making
and packaging section 3a. By contrast, if the right-side pushing member 240 pushes
only the end surface of the winding core WC, the left-right-directional misalignment
of part of the film F wound around the first film roll R1a can be suppressed even
if the right-side pushing member 240 pushes the end surface of the first film roll
R1a.
[0094] Even in cases in which the right-side pushing member 240 pushes the portion of the
film F at the end surface of the first film roll R1a in addition to the end surface
of the winding core WC, the left-right-directional misalignment of the film F in the
first film roll R1a is suppressed by pushing at least the end surface of the winding
core WC.
[0095] The shape of the right-side pushing member 240 is not limited to the U shape described
here. For example, the right-side pushing member 240 may have a shape other than a
U shape that can at least push the right end surface of the winding core WC without
coming into contact with the supporting shaft 114.
[0096] If there are no disadvantages in particular, the right-side pushing member 240 may
push only the portion of the film F on the right end surface of the first film roll
R1a.
[0097] The manner in which the right-side pushing-member-driving unit 242 and the third
driving unit 237 move the right-side pushing member 240 shall now be described hereinafter.
(2-2-5) Left-side pushing member
[0098] The left-side pushing member 250 is a member located adjacent to the second end portion
231b of the holding section 230 as shown in FIG. 5. The left-side pushing member 250
is a member that pushes the right end surface of the first film roll R1a mounted on
a supporting shaft 114 of the bag-making and packaging machine 3. In addition, the
left-side pushing member 250 is a member that pushes a left end surface of the second
film roll R1b removed from a supporting shaft 114 of the bag-making and packaging
machine 3.
[0099] The left-side pushing member 250 is driven in the up-down direction by the left-side
pushing-member-driving unit 252. By driving the left-side pushing member 250 in the
up-down direction, the left-side pushing-member-driving unit 252 moves the left-side
pushing member 250 to a position (referred to as a contact position) where said member
can come into contact with the end surface of the first film roll R1a and the end
surface of the second film roll R1b. In addition, by driving the left-side pushing
member 250 in the up-down direction, the left-side pushing-member-driving unit 252
moves the left-side pushing member 250 to a position (referred to as a non-contact
position) where said member does not come into contact with the film rolls R1 mounted
on the supporting shafts 114 of the bag-making and packaging machine 3.
[0100] Furthermore, the left-side pushing member 250 is driven in the left-right direction
by the third driving unit 237.
[0101] With the left-side pushing member 250 in the contact position and the left-side pushing
member 250 located on the right side of the first film roll R1a, the third driving
unit 237 moves the left-side pushing member 250 to the left. At this time, the left-side
pushing member 250 pushes the right end surface of the first film roll R1a in which
the supporting shaft 114 is inserted into part of a hollow part of the winding core
WC, and moves the first film roll R1a leftward to a predetermined position on the
supporting shaft 114.
[0102] In addition, with the left-side pushing member 250 in the contact position and the
left-side pushing member 250 located on the left side of the second film roll R1b,
the third driving unit 237 moves the left-side pushing member 250 to the right. At
this time, the left-side pushing member 250 pushes the left end surface of the second
film roll R1b in which the supporting shaft 114 is supported, and moves the second
film roll R1b to the holding section 230.
[0103] There are no particular limitations as to the shape of the left-side pushing member
250; said member is substantially rectangular in a left-side view as in FIG. 9. In
an upper part of the left-side pushing member 250 is formed a recess 250a having the
same shape as the recess 240a of the right-side pushing member 240. Because the shape
of the recess 250a is the same as the shape of the recess 240a, details of the shape
of the recess 250a shall not be described. Due to the recess 250a being formed in
the upper part of the left-side pushing member 250, the left-side pushing member 250
can push the winding core WC of the first film roll R1a and the winding core WC of
the second film roll R1b.
[0104] The shape of the left-side pushing member 250 is not limited to a U shape. For example,
the left-side pushing member 250 may have a shape other than a U shape that can at
least push the right end surface of the winding core WC of the first film roll R1a
or the left end surface of the winding core WC of the second film roll R1b without
coming into contact with the supporting shaft 114.
[0105] If there are no disadvantages in particular, the left-side pushing member 250 may
push only the portion of the film F on the right end surface of the first film roll
R1a.
[0106] There are some cases in which almost no film F remains on the second film roll R1b
when the second film roll R1b is removed from the supporting shaft 114. Therefore,
the left-side pushing member 250 preferably pushes at least the left end surface of
the winding core WC when the second film roll R1b is removed from the supporting shaft
114.
[0107] The manner in which the left-side pushing-member-driving unit 252 and the third driving
unit 237 move the left-side pushing member 250 shall now be described hereinafter.
(2-2-6) Stopper
[0108] The stopper 260 is a member for closing the gap 230a in the holding section 230 in
the second orientation (see FIG. 6) and preventing the second film roll R1b removed
from the supporting shaft 114 from falling from the gap 230a into the winding-core-retrieving
mechanism 270 below.
[0109] The stopper 260 is driven by the stopper-driving unit 262 to move between a closed
position at which the gap 230a is closed and an open position at which the gap 230a
is not closed. When the stopper 260 is placed in the closed position, the stopper
260 prevents the winding core WC of the second film roll R1b from falling into the
winding-core-retrieving mechanism 270. When the stopper 260 is placed in the open
position, the stopper 260 allows the winding core WC of the second film roll R1b to
fall into the winding-core-retrieving mechanism 270.
[0110] The timings at which the stopper-driving unit 262 moves the stopper 260 shall now
be described hereinafter.
(2-2-7) Winding-core-retrieving mechanism
[0111] The winding-core-retrieving mechanism 270 is a mechanism that retrieves the second
film roll R1b removed from the supporting shaft 114 and fallen from the gap 230a in
the holding section 230 in the second orientation. Particularly, the winding-core-retrieving
mechanism 270 is a mechanism for retrieving the winding core WC of a depleted film
roll R1 serving as the second film roll R1b falling from the gap 230a in the holding
section 230 in the second orientation.
[0112] The second film roll R1b fallen from the gap 230a in the holding section 230 slides
down an inclined surface 272 of the winding-core-retrieving mechanism 270 and is retrieved
in a retrieval area 274 directly below the conveyor 210 (see FIG. 6). The manner of
retrieving the second film roll R1b fallen from the gap 230a in the holding section
230 may be designed as appropriate.
(2-2-8) First member and encoder
[0113] The first member 280 and the encoder 284 are components used to measure a diameter
of the first film roll R1a supplied to the bag-making and packaging machine 3.
[0114] The first member 280 is located above the conveyor 210.
[0115] The first member 280 is located in a predetermined first position (standby position)
when not being used to measure the diameter of the first film roll R1a. The first
position is a position at which the first member 280 does not come into contact with
the first film roll R1a conveyed along the conveyor 210, even if the first member
280 had been present in the first position. When the first member 280 is used to measure
the diameter of the first film roll R1a, the first-member-driving unit 282 downwardly
moves the first member 280 to a second position where contact is made with an outer
peripheral surface (upper end) of the first film roll R1a carried on the conveyor
210.
[0116] The first-member-driving unit 282 in this embodiment is a motor to which the encoder
284 is attached. The encoder 284 measures an amount of rotational displacement of
the motor when the first-member-driving unit 282 moves the first member 280 from the
first position to the second position, and transmits to the controller 290 (described
hereinafter) a signal corresponding to the measured amount of rotational displacement.
[0117] The controller 290, serving as a first measuring unit, calculates a distance the
first member 280 moves from the first position to the second position based on the
signal of the encoder 284. Furthermore, the controller 290 measures the diameter of
the first film roll R1a on the conveyor 210 based on the calculated distance that
the first member 280 moves.
(2-2-9) Distance sensor
[0118] The distance sensor 286 is a sensor that contactlessly measures a distance from a
predetermined reference position to the outer peripheral surface of the film roll
R1. For example, the distance sensor 286 is located directly below the gap 230a in
the holding section 230. There are no limitations as to the type of the distance sensor
286; for example, the distance sensor 286 is a laser distance sensor. The distance
sensor 286 can measure a distance from a reference position where the distance sensor
286 is located to the outer peripheral surface of the film roll R1 carried on the
holding section 230, or to the outer peripheral surface of the film roll R1 mounted
on the supporting shaft 114.
[0119] The application of the distance sensor 286 shall now be described hereinafter.
(2-2-10) Controller
[0120] The controller 290 is a device that controls the actions of the components of the
film roll replacement device 200. The controller 290 has, for example, a CPU, storage
devices such as a main storage device and an auxiliary storage device, an input/output
device, and various electric circuits and electronic circuits.
[0121] The controller 290 is electrically connected to the conveyor 210, the gate-driving
unit 222, the first driving unit 235, the second driving unit 236, the third driving
unit 237, the right-side pushing-member-driving unit 242, the left-side pushing-member-driving
unit 252, the stopper-driving unit 262, the first-member-driving unit 282, and the
encoder 284, as shown in FIG. 7. The controller 290 controls actions of the conveyor
210, the gate-driving unit 222, the first driving unit 235, the second driving unit
236, the third driving unit 237, the right-side pushing-member-driving unit 242, the
left-side pushing-member-driving unit 252, the stopper-driving unit 262, and the first-member-driving
unit 282. In addition, the controller 290 receives signals output by the encoder 284
and the distance sensor 286. In addition, the controller 290 is communicably connected
to the packaging machine controller 4 of the bag-making and packaging machine 3.
[0122] The controller 290 controls the actions of the components of the film roll replacement
device 200 and causes the film roll replacement device 200 to execute actions such
as the following due to the CPU executing programs stored in the storage devices.
[0123] The controller 290 removes a film roll R1 (the second film roll R1b) that has been
used or has experienced interrupted use from the supporting shaft 114. The controller
290 also moves the holding section 230 to align a height position of a center of a
replacement film roll R1 (the first film roll R1a) held by the holding section 230
and a height position of a center of the supporting shaft 114 on which the first film
roll R1a is to be mounted. The controller 290 also moves the holding section 230 to
the left to move the first film roll R1a held by the holding section 230 to a supporting
part 112 of the bag-making and packaging machine 3 (to the supporting shaft 114 of
the supporting part 112).
[0124] Below is a description, made with reference to FIGS. 10 to 13, of the manner in which
the film roll replacement device 200 removes the second film roll R1b from the supporting
shaft 114 and mounts the replacement first film roll R1a on the supporting shaft 114.
FIGS. 10A to 10E are schematic plan views of part of the film roll replacement device
200, and are intended to illustrate the actions of the film roll replacement device
200 when the second film roll R1b is removed from the supporting shaft 114 of the
bag-making and packaging machine 3. FIG. 11 is a schematic left-side view for illustrating
the actions of the film roll replacement device 200 when the second film roll R1b
is removed from the supporting shaft 114 of the bag-making and packaging machine 3.
FIGS. 12A to 12E are schematic left-side views of part of the film roll replacement
device 200 and are intended to illustrate movement of the first film roll R1a to the
holding section 230 and adjustment of a height position of the holding section 230.
FIGS. 13A to 13E are schematic plan views of part of the film roll replacement device
200 and are intended to illustrate the mounting of the first film roll R1a on the
supporting shaft 114 of the bag-making and packaging machine 3 by the film roll replacement
device 200.
(A) Removal of second film roll from supporting shaft of bag-making and packaging
machine
[0125] When a request to replace a film roll R1 is transmitted from the packaging machine
controller 4, the controller 290 first removes the film roll R1 (second film roll
R1b) from the supporting shaft 114 of the bag-making and packaging machine 3.
[0126] Though not an action of the film roll replacement device 200, the action of the bag-making
and packaging machine 3 when the packaging machine controller 4 transmits a request
to replace a film roll R1 shall first be described. Particularly, the action of the
bag-making and packaging machine 3 shall now be described regarding when the film
F is used up from the film roll R1 that had so far been used in the bag-making and
packaging machine 3.
[0127] The packaging machine controller 4 senses that the film F of the film roll R1 used
so far has been used up based on, for example, movement of the movable rollers 185
detected based on a signal output by the encoder 188. Upon sensing that the film F
of the film roll R1 has been used up, the packaging machine controller 4 controls
the joining mechanism 160 to join the vicinity of the trailing end of the film F of
the depleted film roll R1 and the vicinity of the leading end of the film F of the
replacement film roll R1. The packaging machine controller 4 also controls the cutting
mechanism 162 to cut the film F of the depleted film roll R1 at a predetermined position.
[0128] The packaging machine controller 4 then drives the frame-driving unit 132 to move
the supporting shaft 114 supporting the replaced film roll R1 (the film roll R1 to
be used for packaging from this point onward) to the film supply position and move
the supporting shaft 114 supporting the depleted film roll R1 to the film roll replacement
position.
[0129] At this time, if the frame-driving unit 132 happens to be driven without the film
F of the depleted film roll R1 having been cut, there is a risk of an adverse event
such as the film F becoming entangled in the rollers 170 of the bag-making and packaging
machine 3.
[0130] Before driving the frame-driving unit 132, the packaging machine controller 4 preferably
controls the support-shaft-driving unit 116 to cause the supporting shaft 114 supporting
the depleted film roll R1 to rotate in a direction of winding the film F. At this
time, if the film F of the depleted film roll R1 and the film F extending toward the
bag-making and packaging machine 3 remain connected, the movable rollers 185 are moved
upward. Therefore, the packaging machine controller 4 can sense based on the sensing
result from the encoder 188 that the depleted film roll R1 and the bag-making and
packaging section 3a are connected by the film F pulled out from the depleted film
roll R1. When the depleted film roll R1 and the bag-making and packaging section 3a
remain connected by the film F, the packaging machine controller 4 does not perform
control to drive the frame-driving unit 132, and, for example, causes the bag-making
and packaging machine 3 and the film roll replacement device 200 to stop due to an
error.
[0131] After having moved the supporting shaft 114 supporting the second film roll R1b to
the film roll replacement position and before transferring the second film roll R1b
to the holding section 230, the packaging machine controller 4 preferably controls
the action of the support-shaft-driving unit 116 to cause the supporting shaft 114
supporting the second film roll R1b to rotate and to wind the film F of the second
film roll R1b on the winding core WC. Due to this configuration, it is possible to
suppress adverse events such as when the film F remaining on the second film roll
R1b is entangled with the various components of the film roll replacement device 200,
and the winding core WC of the second film roll R1b to be discharged to the winding-core-retrieving
mechanism 270 is not discharged to the winding-core-retrieving mechanism 270.
[0132] An amount of winding of the film F of the second film roll R1b (an amount of rotation
of the supporting shaft 114 on which the second film roll R1b is mounted) is preferably
determined based on a film roll diameter of the second film roll R1b so that the film
F does not hang down from the second film roll R1b.
[0133] To realize this objective, for example, the film roll replacement device 200 moves
the holding section 230 to be directly below the supporting shaft 114 placed in the
film supply position before the packaging machine controller 4 actuates the support-shaft-driving
unit 116 in order to wind the film F. The film roll replacement device 200 then causes
the distance sensor 286 to measure the distance from the distance sensor 286 to the
outer peripheral surface (lowest part) of the second film roll R1b. The controller
290 of the film roll replacement device 200 then measures (calculates) the film roll
diameter of the second film roll R1b based on a value measured by the distance sensor
286 and a positional relationship between the distance sensor 286 and the supporting
shaft 114 disposed in the film supply position stored in advance in a storage device.
The controller 290 then transmits the measured film roll diameter of the second film
roll R1b to the packaging machine controller 4. The packaging machine controller 4
determines the winding amount of the film F of the second film roll R1b (the rotation
amount of the supporting shaft 114) based on the received film roll diameter of the
second film roll R1b so that the film F does not hang down from the second film roll
R1b.
[0134] In this embodiment, the controller 290 of the film roll replacement device 200 measures
the film roll diameter of the second film roll R1b, but as an alternative, the packaging
machine controller 4 may measure (calculate) the film roll diameter of the second
film roll R1b based on the value measured by the distance sensor 286. In this embodiment,
the value measured by the distance sensor 286 is used to measure the film roll diameter
of the second film roll R1b, but this feature is not provided by way of limitation;
for example, the film roll diameter of the second film roll R1b may be measured based
on a value measured by a distance sensor (not shown in the figure) provided to the
bag-making and packaging machine 3.
[0135] The packaging machine controller 4, for example, transmits a request to replace a
film roll R1 to the controller 290 of the film roll replacement device 200 immediately
before the action of winding the film F onto the winding core WC of the second film
roll R1b. The timing at which the packaging machine controller 4 transmits the request
to replace a film roll R1 to the controller 290 may be determined as appropriate unless
there is no contradiction. For example, if the film roll diameter of the second film
roll R1b is not measured using the value measured by the distance sensor 286 when
the film F is wound onto the winding core WC of the second film roll R1b, the timing
at which the packaging machine controller 4 transmits a request to replace a film
roll R1 to the controller 290 may occur after the action of winding the film F onto
the winding core WC of the second film roll R1b.
[0136] Now, description of the removal of the second film roll R1b from the supporting shaft
114 disposed in the film roll replacement position performed by the film roll replacement
device 200 is made, with reference to FIGS. 10A to 10D and FIG. 11. The following
description is merely one example of the action of removing the second film roll R1b
performed by the film roll replacement device 200, and may be changed as appropriate.
[0137] It is presumed in the description below that at the point in time depicted in FIG.
10A, there is no film roll R1 on the holding section 230, the holding section 230
is disposed in a position adjacent to the front of the gate 220, and the right-side
pushing member 240 and the left-side pushing member 250 are disposed in the non-contact
position previously described. Also at the point in time depicted in FIG. 10A, the
gap 230a in the holding section 230 is closed by the stopper 260.
[0138] When the controller 290 receives a request to replace the film roll R1 from the packaging
machine controller 4, the controller 290 controls the action of the third driving
unit 237 to move the holding section 230 from the position depicted in FIG. 10A, which
is adjacent to the gate 220, leftward to a position directly below the supporting
shaft 114 disposed in the film roll replacement position of FIG. 10B. At this time,
the controller 290 controls the second driving unit 236 to move the holding section
230 to the lowest position in the vertical movable range so that the holding section
230 does not come into contact with the supporting shaft 114 or the second film roll
R1b mounted on the supporting shaft 114.
[0139] When the holding section 230 is located directly below the supporting shaft 114 as
in FIG. 10B, the distance sensor 286 measures the distance from the distance sensor
286 to the outer peripheral surface (the lowest part) of the second film roll R1b.
[0140] Preferably, the packaging machine controller 4, based on the value measured by the
distance sensor 286, causes the supporting shaft 114 supporting the second film roll
R1b to rotate to wind the film F of the second film roll R1b onto the winding core
WC before the second film roll R1b is transferred to the holding section 230, as previously
described. The packaging machine controller 4 then causes the fixing mechanism to
cease fixing the supporting shaft 114 and the second film roll R1b together.
[0141] Based on the positional relationship between the distance sensor 286 and the holding
section 230 stored in advance in a storage device, and the distance from the distance
sensor 286 to the outer peripheral surface of the second film roll R1b, the controller
290 measures the distance in the up-down direction between the holding section 230
(a predetermined representative location on the holding section 230) and the outer
peripheral surface of the second film roll R1b supported by the supporting shaft 114.
[0142] Next, the controller 290 controls the second driving unit 236 and adjusts the height
position of the holding section 230 based on the distance in the up-down direction
between the holding section 230 and the outer peripheral surface of the second film
roll R1b supported by the supporting shaft 114. Specifically, the controller 290 controls
the second driving unit 236 and moves the holding section 230 near to the second film
roll R1b.
[0143] The controller 290 also controls the action of the left-side pushing-member-driving
unit 252 and raises the left-side pushing member 250 to a position (the previously-described
contact position) where the left-side pushing member 250 does not come into contact
with the supporting shaft 114 and the left-side pushing member 250 comes into contact
with the winding core WC of the second film roll R1b.
[0144] Next, the controller 290 controls the action of the third driving unit 237 and moves
the holding section 230 rightward from the position depicted in FIG. 10B to the position
in FIG. 10C (the position where the holding section 230 is located at the point in
time of FIG. 10A). Through this process, the second film roll R1b is pushed and moved
by the left-side pushing member 250 onto the holding section 230 as is depicted in
FIG. 10C.
[0145] Upon moving the holding section 230 to the position depicted in FIG. 10C, the controller
290 controls the action of the left-side pushing-member-driving unit 252 and moves
the left-side pushing member 250 to the previously-described non-contact position.
[0146] Next, the controller 290 causes the stopper 260 to be moved to the open position
by the stopper-driving unit 262. As a result, the second film roll R1b (the winding
core WC of the second film roll R1b) falls from the gap 230a in the holding section
230. The detection result from the distance sensor 286 can be used to determine whether
or not the second film roll R1b has fallen safely.
[0147] In this embodiment, it is assumed that the second film roll R1b is the depleted film
roll R1, but it is acceptable if the controller 290 does not cause the stopper-driving
unit 262 to drive the stopper when the second film roll R1b is a film roll R1 with
film F still remaining (a film roll R1 of which use has been interrupted in the bag-making
and packaging machine 3). For example, in this case, the controller 290 may, using
an output device (a display, a speaker, or the like) (not shown in the figure), issue
a notification that the film roll R1 with remaining film F is present in the holding
section 230. Based on this notification, a worker takes out the film roll R1 with
remaining film present in the holding section 230.
[0148] When the controller 290 has caused the stopper 260 to be moved by the stopper-driving
unit 262 to the open position, the second film roll R1b, after falling from the gap
230a in the holding section 230, slides down the inclined surface 272 of the winding-core-retrieving
mechanism 270 to be retrieved in the retrieval area 274 located directly below the
conveyor 210, as shown in FIG. 11.
(B) Mounting of first film roll on supporting shaft of bag-making and packaging machine
[0149] When removal of the second film roll R1b from the supporting shaft 114 of the bag-making
and packaging machine 3 is complete, the controller 290 supplies the first film roll
R1a to the bag-making and packaging machine 3 and mounts the first film roll R1a on
the supporting shaft 114.
[0150] The movement of the first film roll R1a to the holding section 230 and the adjustment
of the height position of the holding section 230 shall first be described with reference
to FIGS. 12A to 12E. The mounting of the first film roll R1a onto the supporting shaft
114 of the bag-making and packaging machine 3, performed by the film roll replacement
device 200, shall then be described with reference to FIGS. 13A to 13E.
(B-1) Movement of first film roll to holding section and adjustment of height position
of holding section
[0151] It is presumed in the description below that at the point in time depicted in FIG.
12A, a film roll R1 is not present on the holding section 230, and the holding section
230, which is in the second orientation previously described, is located in a position
(initial position) adjacent to the front of the gate 220. In addition, at the point
in time depicted in FIG. 12A, the gate 220 is in a position where the first film roll
R1a is restricted from moving toward the holding section 230, and the first film roll
R1a is being carried on the conveyor 210 in a position adjacent to the gate 220. A
configuration is preferably adopted such that when the holding section 230 is in the
second orientation, the first film roll R1a is restricted from moving from the conveyor
210 to the holding section 230 by the first holding member 232 so that the first film
roll R1a cannot move onto the holding section 230 (see FIG. 12A). Adopting this configuration
makes it possible to suppress the situation where the first film roll R1a moves from
the conveyor 210 to the holding section 230 at an unintended timing even when the
gate 220 is omitted. The first member 280 is located in the above-described first
position where the first member 280 is apart from the first film roll R1a and above
the first film roll R1a.
[0152] In this state, the controller 290 causes the first-member-driving unit 282 to move
the first member 280 to a second position where contact is made with the outer peripheral
surface (upper end) of the first film roll R1a carried on the conveyor 210 (see FIG.
12B).
[0153] When the first-member-driving unit 282 has moved the first member 280 from the first
position to the second position, the controller 290 receives a signal, sent by the
encoder 284, corresponding to an amount of rotational displacement of a motor (the
first-member-driving unit 282). The controller 290 calculates the distance the first
member 280 moves from the first position to the second position based on the signal
of the encoder 284. Furthermore, the controller 290, serving as a first measuring
unit, measures (calculates) the diameter of the first film roll R1a on the conveyor
210 based on the calculated movement distance of the first member 280. For example,
a distance from the first position to a conveying surface (the surface on which the
first film roll R1a is carried) of the conveyor 210 is stored in advance in a storage
device of the controller 290. The controller 290 calculates the diameter of the first
film roll R1a by subtracting the distance the first member 280 moves from the first
position to the second position, from the distance from the first position to the
conveying surface of the conveyor 210.
[0154] Next, the controller 290 causes the first-member-driving unit 282 to move the first
member 280 to the first position where contact is not made with the outer peripheral
surface of the first film roll R1a.
[0155] Next, the controller 290 controls the action of the first driving unit 235 to cause
the holding section 230 to rotate and change the orientation of the holding section
230 from the second orientation to the first orientation. The holding section 230
in the first orientation allows the first film roll R1a to move from the conveyor
210 to the holding section 230. Particularly, in the present embodiment, when the
holding section 230 is in the first orientation, the first holding surface 232a is
horizontal. The controller 290 controls the action of the first driving unit 235 to
cause the holding section 230 to rotate 45° counterclockwise in a left-side view,
and changes the orientation of the holding section 230 from the second orientation
to the first orientation (see FIG. 12C). For example, if the holding section 230 on
the first holding surface 232a slightly inclined so as to lower from rear to front
is defined as the holding section 230 in the first orientation, the angle at which
the controller 290 causes the holding section 230 to rotate may be determined, as
appropriate, to be a predetermined angle other than 45°.
[0156] The controller 290 also controls the action of the gate-driving unit 222 to move
the gate 220 to a position where the first film roll R1a is not restricted from moving
toward the holding section 230 (see FIG. 12C). The controller 290 also controls the
action of the conveyor 210 to move the first film roll R1a to the holding section
230 (see FIG. 12C).
[0157] A conveyor surface 210a of the conveyor 210 on which the first film roll R1a is placed
preferably supports the first film roll R1a at the same height as that of the first
film roll R1a transferred to the holding section 230 in the first orientation 230,
as shown in FIG. 18A. However, the conveyor surface 210a of the conveyor 210 may instead
support the first film roll R1a at a location higher than the height at which the
first film roll R1a is transferred to the holding section 230 in the first orientation,
as shown in FIG. 18B. Adopting this configuration makes it possible for the first
film roll R1a to be moved to the holding section 230 without being lifted on the conveyor
210.
[0158] In the present embodiment, when the first film roll R1a is transferred from the conveyor
210 to the holding section 230 in the first orientation, the first film roll R1a moves
on the conveyor surface 210a of the conveyor 210, which is one example of a preliminary
placement surface, and on the first holding surface 232a of the first holding member
232 of the holding section 230. In order to facilitate movement of the first film
roll R1a, the conveyor surface 210a and the first holding surface 232a are parallel
as shown in FIG. 18A when, for example, the first film roll R1a is moving on the conveyor
surface 210a and the first holding surface 232a. The first holding surface 232a more
preferably is downwardly inclined from a proximal side toward a distal side relative
to the conveyor 210, as shown in FIG. 19, when the first film roll R1a is moving on
the conveyor surface 210a and the first holding surface 232a. Adopting this configuration
makes it possible for the first film roll R1a on the conveyor 210 to be moved onto
the holding section 230 without being lifted.
[0159] Additionally, at least when the first film roll R1a moves on the conveyor surface
210a and the first holding surface 230a, the conveyor surface 210a may be configured
to be downwardly inclined toward the holding section 230 as shown in FIG. 20. Adopting
this configuration makes it possible for the first film roll R1a to be moved to the
holding section 230 even if the conveyor 210 is not operated or if the conveyor 210
does not have a drive source. The conveyor 210 may be attached to the film roll replacement
device 200 such that the conveyor surface 210a is downwardly inclined toward the holding
section 230. Alternatively, the conveyor 210 may have a driving unit (not shown) for
changing an inclination of the conveyor 210, and the controller 290 may change an
orientation of the conveyor 210 such that the conveyor surface 210a is downwardly
inclined toward the holding section 230 at a necessary timing.
[0160] When the holding section 230 is in the first orientation, the second holding surface
234a of the second holding member 234 of the holding section 230 restricts movement
of the first film roll R1a that moves on the first holding surface 232a from the proximal
side toward the distal side relative to the conveyor 210. Thus, due to the holding
section 230 having the second holding surface 234a to restrict movement of the first
film roll R1a that moves on the first holding surface 232a from the proximal side
toward the distal side relative to the conveyor 210, it is possible to suppress adverse
events, such as the first film roll R1a that has moved onto the holding section 230
falling from the holding section 230 or failing to be disposed at a desired position
on the holding section 230.
[0161] When the first film roll R1a has moved onto the holding section 230, the controller
290 then controls the action of the first driving unit 235 to cause the holding section
230 to rotate, and changes the orientation of the holding section 230 from the first
orientation to the second orientation. Particularly, in the present embodiment, because
the holding section 230 with the horizontal first holding surface 232a is the holding
section 230 in the first orientation, the controller 290 controls the action of the
first driving unit 235 to cause the holding section 230 to rotate 45° clockwise in
a left-side view, and changes the orientation of the holding section 230 from the
first orientation to the second orientation (see FIG. 12C). For example, if the holding
section 230 on the first holding surface 232a slightly inclined so as to lower from
rear to front is defined as the holding section 230 in the first orientation, the
angle at which the controller 290 causes the holding section 230 to rotate may be
determined, as appropriate, to be a predetermined angle other than 45°.
[0162] The controller 290 also controls the action of the gate-driving unit 222 to move
the gate 220 to a position where the first film roll R1a is restricted from moving
toward the holding section 230 (see FIG. 12D). The controller 290 also stops the action
of the conveyor 210.
[0163] Next, based on the measured diameter of the first film roll R1a, the controller 290
controls the action of the second driving unit 236 to move the holding section 230
to a position where the height position of the center of the first film roll R1a held
in the holding section 230 is aligned with the height of the center of the supporting
shaft 114 disposed in the film roll replacement position.
[0164] For example, specifically, the controller 290 changes the height position of the
holding section 230 in the following manner. The description shall be made with reference
to FIG. 14. FIG. 14 is an enlarged view of the holding section 230 of the film roll
replacement device 200, and is a drawing for describing a method of measuring the
height position to the center of the first film roll R1a.
[0165] It is presumed in the description below that the storage device of the controller
290 has stored therein information on the height position of the center of the supporting
shaft 114 disposed in the film roll replacement position (e.g., a height H1 from a
floor surface to the center of the supporting shaft 114). It is also presumed in the
description below that the controller 290 ascertains, for example, a height position
that is the current location of the intersection point X between a straight line imagined
as an extension of the first holding surface 232a and a straight line imagined as
an extension of the second holding surface 234a in a left-side view (e.g., a height
h1 from the floor surface to the intersection point X).
[0166] Under such conditions, the controller 290 calculates in the following manner the
height position of the center of the first film roll R1a currently held by the holding
section 230. Because the height h1 from the floor surface to the intersection point
X is known at present, the height from the floor surface to the center (represented
by symbol C) of the first film roll R1a can be determined when the value of h2 is
determined in FIG. 14. The controller 290 has calculated the diameter D of the first
film roll R1a as previously described. In addition, in a left-side view, an angle
θ formed between a straight line connecting the intersection point X and the center
C and a line perpendicular to the first holding surface 232a is determined according
to the design of the holding section 230 and is therefore known. Therefore, using
a trigonometric function, h2 can be calculated by the formula D/2cos
θ. The controller 290 calculates the height position of the center of the first film
roll R1a currently held by the holding section 230 by adding the value h1 and the
value h2 together. When the height position of the center of the first film roll R1a
currently held by the holding section 230 is calculated and the holding section 230
is moved upward by a distance of Δh = H1-(h1+h2), the height position of the center
of the first film roll R1a held by the holding section 230 will be aligned with the
height position of the center of the supporting shaft 114 disposed in the film roll
replacement position.
[0167] The controller 290 then controls the action of the second driving unit 236 to move
the holding section 230 upward by a distance of Δh from the position drawn in double-dash
lines to the position drawn in solid lines, as in FIG. 12E. As a result, the height
position of the center of the first film roll R1a held by the holding section 230
is aligned with the height position of the center of the supporting shaft 114 disposed
in the film roll replacement position. If the value of Δh is negative, the holding
section 230 is caused to move downward.
[0168] Due to the structure of the holding section 230, the center C of the first film roll
R1 held in the holding section 230 is disposed in the same position as the intersection
point X previously described in the front-rear direction. In other words, in a left-side
view, the center of the first film roll R1 held in the holding section 230 is disposed
on a straight line extending in the vertical direction through the intersection point
X. Therefore, if the film roll replacement device 200 is designed such that the front-rear-directional
position of the intersection point X does not change, there is no need, in the front-rear
direction, to adjust the position of the center of the first film roll R1a held in
the holding section 230 and the position of the center of the supporting shaft 114
disposed in the film roll replacement position.
[0169] The film roll replacement device 200 preferably has, for example, both an electric
cylinder and an air cylinder as the second driving unit 236. The reason therefor shall
now be described.
[0170] Even, for example, using only an electric cylinder as the second driving unit 236,
the film roll replacement device 200 can move the holding section 230 to a position
where the height position of the center of the first film roll R1a held by the holding
section 230 is aligned with the height of the center of the supporting shaft 114 disposed
in the film roll replacement position. However, since the first film roll R1a is a
heavy object, a large electric cylinder will be needed if the holding section 230
carrying the first film roll R1a is to be moved by an electric cylinder alone. Therefore,
the film roll replacement device 200 preferably uses an air cylinder in addition to
an electric cylinder.
[0171] As a specific control, for example, when moving the holding section 230, the controller
290 controls an electro-pneumatic regulator (not shown in the figure) to gradually
increase an internal pressure of the air cylinder. When a slight movement of the holding
section 230 (a movement of the first film roll R1a held in the holding section 230)
is sensed using the distance sensor 286 or the like, the controller 290 controls the
electric cylinder to bring the height position of the center of the first film roll
R1a held in the holding section 230 into alignment with the height of the center of
the supporting shaft 114 disposed in the film roll replacement position while pressure
generated by the electro-pneumatic regulator (not shown in the figure) is kept constant.
(B-2) Mounting of first film roll onto supporting shaft of bag-making and packaging
machine
[0172] The following is a description of how the first film roll R1a is mounted onto the
supporting shaft 114 by the film roll replacement device 200 after the height position
of the center of the first film roll R1a held by the holding section 230 and the height
position of the center of the supporting shaft 114 disposed in the film roll replacement
position have come into alignment.
[0173] It is presumed in the description below that at the point in time depicted in FIG.
13A, as seen in plan view, the holding section 230 is disposed in front of the gate
220 in an adjacent position (initial position), and the right-side pushing member
240 and the left-side pushing member 250 are disposed in the non-contact positions
previously described.
[0174] First, the controller 290 controls the action of the right-side pushing-member-driving
unit 242 to move the right-side pushing member 240 to a contact position where said
member can be in contact with the right end surface of the first film roll R1a, and
particularly a contact position where said member can at least be in contact with
the winding core WC of the first film roll R1a.
[0175] Next, the controller 290 controls the action of the third driving unit 237 to move
the holding section 230 from the initial position leftward toward the supporting shaft
114 disposed in the film roll replacement position in FIG. 13B on the left side, and
transfer the first film roll R1a held in the holding section 230 to the supporting
part 112. This step shall now be described in detail.
[0176] When the controller 290 controls the action of the third driving unit 237 to move
the holding section 230 leftward, the supporting shaft 114 is inserted into the hollow
part of the winding core WC of the first film roll R1a held by the holding section
230, and the first film roll R1a of the holding section 230 is transferred to the
supporting shaft 114. Particularly, when there is little difference between the outer
diameter of the supporting shaft 114 and a diameter of the hollow part of the winding
core WC, there are cases in which even if the holding section 230 is moved to the
left, the first film roll R1a will not move to the left beyond a certain point due
to friction between an inner surface of the hollow part of the winding core WC and
an outer surface of the supporting shaft 114. However, because the right-side pushing
member 240 is disposed adjacent to the first end portion 231a (right end portion)
of the holding section 230, when the first film roll R1a comes to be disposed to the
right of the first end portion 231a of the holding section 230, a right end surface
of the first film roll R1a is pushed by the right-side pushing member 240 driven by
the third driving unit 237, and the supporting shaft 114 is inserted deeper into the
hollow part of the winding core WC of the first film roll R1a (see FIG. 13B). In other
words, at this time, the controller 290 controls the action of the third driving unit
237 to cause the end surface of the first film roll R1a held by the holding section
230 to be pushed by the right-side pushing member 240 and the first film roll R1a
moves to the supporting shaft 114.
[0177] When the region over which the holding section 230 can move left is sufficiently
wide, the supporting shaft 114 can be sufficiently inserted into the hollow part of
the winding core WC of the first film roll R1a by the right-side pushing member 240
alone, and the first film roll R1a can be set at a predetermined position on the supporting
shaft 114.
[0178] Such a design makes it necessary to ensure sufficient area for the holding section
230 to move, presenting a possibility that the floor area required for installing
the bag-making and packaging machine 3 and the film roll replacement device 200 will
increase. Therefore, the film roll replacement device 200 is preferably designed as
follows.
[0179] When the second end portion 231b of the holding section 230 reaches the vicinity
of a supporting end of the supporting shaft 114, the controller 290 controls the action
of the second driving unit 236 to move the holding section 230 slightly downward,
and controls the action of the third driving unit 237 to move the holding section
230 rightward to the initial position.
[0180] The controller 290 then controls the action of the right-side pushing-member-driving
unit 242 to move the right-side pushing member 240 to the non-contact position. The
controller 290 also controls the action of the left-side pushing-member-driving unit
252 to move the left-side pushing member 250 to a contact position where said member
can be in contact with the right end surface of the first film roll R1a that has been
moved to the supporting shaft 114, and particularly a contact position where said
member can at least be in contact with the right end surface of the winding core WC
of the first film roll R1a.
[0181] Next, the controller 290 controls the action of the third driving unit 237 to move
the holding section 230 and the left-side pushing member 250 to the left to a predetermined
position (the position depicted in FIG. 13D). This predetermined position is determined
in advance according to factors such as the dimensions of the film rolls R1 to be
used. As a result of the controller 290 controlling the actions of the film roll replacement
device 200 in this manner, the first film roll R1a is positioned by the left-side
pushing member 250 to be disposed in an appropriate position on the supporting shaft
114.
[0182] In the state depicted in FIG. 13D, the left-side pushing member 250 and the supporting
shaft 114 are disposed in overlapping positions in the left-right direction. However,
because the recess 250a is formed as previously described in the left-side pushing
member 250, the supporting shaft 114 and the left-side pushing member 250 do not come
into contact even if the left-side pushing member 250 and the supporting shaft 114
are disposed in overlapping positions in the left-right direction.
[0183] The controller 290 then issues a notification to the packaging machine controller
4 that the supply of the first film roll R1a to the supporting shaft 114 has ended.
The controller 290 also controls the action of the third driving unit 237 to move
the holding section 230 to the initial position (the same position as that depicted
in FIG. 13A) at a predetermined timing (see FIG. 13E). The controller 290 controls
the action of the left-side pushing-member-driving unit 252 to move the left-side
pushing member 250 to the non-contact position described above (see FIG. 13E). Furthermore,
the controller 290 controls the action of the second driving unit 236 to move the
holding section 230 to the height position depicted in FIG. 12A at a predetermined
timing.
[0184] If the timing at which the controller 290 moves the holding section 230 to the initial
position and moves the left-side pushing member 250 to the non-contact position is
delayed until the timing at which the packaging machine controller 4 controls the
action of the fixing mechanism of the supporting shaft 114 to fix the first film roll
R1a and the supporting shaft 114 together, the left-side pushing member 250 can also
be given the function of restricting the position of the first film roll R1a.
[0185] Though this is not a detail pertaining to the actions of the film roll replacement
device 200, at the point in time when the supply of the first film roll R1a to the
supporting shaft 114 has ended and the first film roll R1a has been fixed to the supporting
shaft 114, the packaging machine controller 4 preferably causes the first film roll
R1a to rotate via the support-shaft-driving unit 116 and reads a bar code or matrix-type
two-dimensional code (not shown in the figure) on the film roll R1 via the scanner
190 disposed near the supporting shaft 114 disposed in the film roll replacement position.
The packaging machine controller 4 then preferably confirms whether or not the type
of film roll R1 specified by the bar code or matrix-type two-dimensional code read
by the scanner 190 matches the type of film roll R1 that should be mounted on the
supporting shaft 114. This feature would make it possible to check if the correct
film roll R1 has been supplied to the bag-making and packaging machine 3 even if the
film roll R1 is automatically supplied to the bag-making and packaging machine 3.
(3) Characteristics
(3-1)
[0186] The film roll replacement device 200 according to one embodiment of the film roll
supply device of the claimed invention supplies the first film roll R1a to the bag-making
and packaging machine 3. The film roll replacement device 200 is provided with: a
holding section 230, which is one example of the receiver; and a first driving unit
235, which is one example of the first driver. The holding section 230 receives the
first film roll R1a to be supplied to the bag-making and packaging machine 3. The
first driving unit 235 changes an orientation of the holding section 230 between a
first orientation used when receiving the first film roll R1a and a second orientation
used when supplying the first film roll R1a to the bag-making and packaging machine
3.
[0187] When work to replace a film roll R1 using a film roll replacement device is automated
from the standpoint of,
inter alia, reducing a worker burden, improving work efficiency of the worker, and suppressing
downtime of the bag-making and packaging machine 3, there is a risk that an adverse
event such as scratching of a surface of a film F on the film roll R1 will occur during
transfer of the film roll R1 to the holding section 230 for supplying the film roll
R1 to the bag-making and packaging machine 3.
[0188] However, because the film roll replacement device 200 is configured such that the
orientation of the holding section 230 to support the first film roll R1a to be supplied
to the bag-making and packaging machine 3 is changed from the second orientation used
when supplying the first film roll R1a to the bag-making and packaging machine 3 to
the first orientation used when receiving the first film roll R1a, the occurrence
of adverse events such as scratching of a surface of the film F on the first film
roll R1a is readily suppressed.
(3-2)
[0189] In the film roll replacement device 200, the first driving unit 235 rotates the holding
section 230 about a rotation axis O to change the orientation of the holding section
230. The rotation axis O extends in the direction same as an axial direction of the
first film roll R1a held by the holding section 230.
[0190] In the film roll replacement device 200, the orientation of the holding section 230
can be changed using a comparatively simple movement (rotary action).
(3-3)
[0191] The film roll replacement device 200 is provided with a conveyor 210 as a preliminary
placement section on which the first film roll R1a being transferred to the holding
section 230 is preliminarily placed. The conveyor 210 is one example of the preliminary
placement section, on which the first film roll R1a being transferred to the holding
section 230, serving as one example of the receiver, is preliminarily placed.
[0192] Because the film roll replacement device 200 has the conveyor 210, it is possible
to set the first film roll R1a on the conveyor 210 in advance so that the film roll
replacement device 200 can execute an action to replace the film roll R1 of the bag-making
and packaging machine 3 at a timing when replacement of the film roll is required.
[0193] In the embodiment described above, the film roll replacement device 200 is assumed
to have the preliminary placement section (conveyor 210 in the present embodiment).
However, even if the film roll replacement device 200 does not have the preliminary
placement section, changing the orientation of the holding section 230, by the first
driving unit 235, between the first orientation suited to receiving the first film
roll R1a and the second orientation used when supplying the first film roll R1a to
the bag-making and packaging machine 3, can facilitate to supply the first film roll
R1a to the holding section 230 with an AGV or the like.
(3-4)
[0194] In the film roll replacement device 200, the holding section 230 allows the first
film roll R1a to move from the conveyor 210 to the holding section 230 when the holding
section 230 is in the first orientation and restricts the first film roll R1a from
moving from the conveyor 210 to the holding section 230 when the holding section 230
is in the second orientation.
[0195] In the film roll replacement device 200, because the first film roll R1a is restricted
from moving when the holding section 230 is in the second orientation, it is possible
to suppress a phenomenon where the first film roll R1a moves from the conveyor 210
to the holding section 230 at an unintended timing.
[0196] Additionally, adopting this configuration makes it possible to suppress the occurrence
of the phenomenon where the first film roll R1a moves from the conveyor 210 to the
holding section 230 at an unintended timing even when installation of the gate 220
is omitted.
(3-5)
[0197] In the film roll replacement device 200, the conveyor 210 supports the first film
roll R1a at a location higher than the location at which the first film roll R1a is
transferred to the holding section 230 in the first orientation.
[0198] Because the film roll replacement device 200 is configured such that the conveyor
210 supports the first film roll R1a higher than the first film roll R1a supported
by the holding section 230 in the first orientation, the first film roll R1a can be
moved to the holding section 230 without being lifted.
(3-6)
[0199] In the film roll replacement device 200, the holding section 230 has the first holding
surface 232a serving as one example of the first surface. The conveyor 210 has the
conveyor surface 210a serving as one example of the preliminary placement surface
on which the first film roll R1a is preliminarily placed. When the first film roll
R1a is transferred from the conveyor 210 to the holding section 230 in the first orientation,
the first film roll R1a moves on the conveyor surface 210a and the first holding surface
232a. When the first film roll R1a moves on the conveyor surface 210a and the first
holding surface 232a, the conveyor surface 210a and the first holding surface 232a
are parallel. Alternatively, when the first film roll R1a moves on the conveyor surface
210a and the first holding surface 232a, the first holding surface 232a is downwardly
inclined from the proximal side toward the distal side relative to the conveyor 210.
[0200] In the film roll replacement device 200, due to the conveyor surface 210a and the
first holding surface 232a being disposed as described above, the first film roll
R1a can be smoothly moved from the conveyor surface 210a to the first holding surface
232a of the holding section 230 without being lifted.
[0201] In cases in which the conveyor surface 210a and the first holding surface 232a are
parallel and horizontal when the first film roll R1a moves on the conveyor surface
210a and the first holding surface 232a, the first holding surface 232a is preferably
disposed at a position at the height same as the conveyor surface 210a or lower than
the conveyor surface 210a at this timing. Additionally, in cases in which the first
holding surface 232a is downwardly oriented from the proximal side toward the distal
side relative to the conveyor surface 210a when the first film roll R1a moves on the
conveyor surface 210a and the first holding surface 232a, the end section of the conveyor
210 on the holding-section 230 side is preferably disposed at a position higher than
the end section of the first holding surface 232a on the proximal side relative to
the conveyor 210 at this timing.
(3-7)
[0202] In the film roll replacement device 200, the holding section 230 has a second holding
surface 234a serving as one example of the second surface. When the holding section
230 is in the first orientation, the second holding surface 234a restricts movement
of the first film roll R1a that moves on the first holding surface 232a from the proximal
side toward the distal side relative to the conveyor 210.
[0203] Because the film roll replacement device 200 has the second holding surface 234a,
it is possible to suppress the occurrence of adverse events, such as the first film
roll R1a that has moved onto the holding section 230 falling from the holding section
230 or failing to be disposed at a desired position on the holding section 230.
[0204] The holding section 230 may also have, separately from the second holding surface
234a for supporting the first film roll R1a, a member to restrict movement of the
first film roll R1a that moves on the first holding surface 232a from the proximal
side toward the distal side relative to the conveyor 210.
(3-8)
[0205] In the film roll replacement device 200, the holding section 230 includes a first
holding member 232 serving as one example of a first plate-shaped member having the
first holding surface 232a, and a second holding member 234 serving as one example
of a second plate-shaped member having the second holding surface 234a. When the first
holding member 232 and the second holding member 234 are viewed from a direction parallel
to the first holding surface 232a and the second holding surface 234a, the first holding
surface 232a and the second holding surface 234a are disposed in a V shape.
[0206] In particular, when the first holding member 232 and the second holding member 234
of the holding section 230 in the second orientation are viewed from a direction parallel
to the first holding surface 232a and the second holding surface 234a, the first holding
surface 232a and the second holding surface 234a are disposed in a V shape so as to
have line symmetry with respect to a vertical line.
[0207] In the film roll replacement device 200, due to the first holding surface 232a and
the second holding surface 234a being disposed in a V shape, the position of the first
film roll R1a can be precisely positioned using the first holding surface 232a of
the first holding member 232 and the second holding surface 234a of the second holding
member 234.
[0208] Additionally, due to the first holding surface 232a and the second holding surface
234a to support the film roll R1 from below being disposed in a V shape, a central
position of the film roll R1 supported by the holding surface 230,regardless of the
diameter of the film roll R1, is disposed at roughly the same position in the front-rear
direction on the holding section 230 in the second orientation. Therefore, the film
roll replacement device 200 may control only a vertical-direction position of the
holding section 230 when supplying the first film roll R1a to the bag-making and packaging
machine 3, provided that the front-rear-direction position of the rotation axis O
about which the holding section 230 is rotated is not changed. In other words, as
it is unnecessary to control the front-rear-direction position of the holding section
230 when the first holding surface 232a and the second holding surface 234a are disposed
in a V shape, it is possible to control the position of the first film roll R1a supplied
to the bag-making and packaging machine 3 using a simple configuration.
(3-9)
[0209] In the film roll replacement device 200, the angle formed by the first holding surface
232a and the second holding surface 234a is within the range of 90°±30°.
[0210] In the film roll replacement device 200, due to the angle formed by the first holding
surface 232a and the second holding surface 234a being within the aforementioned angular
range, the position of the first film roll R1a can be precisely positioned using the
first holding surface 232a and the second holding surface 234a.
(3-10)
[0211] In the film roll replacement device 200, when the holding section 230 is in the second
orientation, the first holding surface 232a and the second holding surface 234a support
the first film roll R1a on the holding section 230 from below.
[0212] In the film roll replacement device 200, the first holding surface 232a and the second
holding surface 234a can function as support surfaces for the first film roll R1a
when the orientation of the holding section 230 is set to the second orientation.
(4) Modifications
[0213] Modifications of the present embodiment are presented below. The modifications may
be combined as appropriate provided no contradictions occur therebetween.
(4-1) Modification A
[0214] In the above embodiment, the controller 290 measures the diameter D of the first
film roll R1a based on the signal output by the encoder 284 attached to a motor serving
as the first-member-driving unit 282.
[0215] However, a measurement method based on the signal output by the encoder 284 is not
provided by way of limitation to the method of measuring the diameter D of the first
film roll R1a.
[0216] For example, the film roll replacement device 200 may have a first sensor 285 instead
of the encoder 284 as shown in FIG. 15. In addition, the first-member-driving unit
282 may be an air cylinder or another driving mechanism other than a motor in this
case. The first sensor 285 is located, for example, directly below the first member
280 or directly above the first member 280. The first sensor 285 is a laser distance
sensor that contactlessly measures a first distance (a distance in the up-down direction
in this modification) from a first reference position (e.g., a position where the
first sensor 285 is installed) to the first member 280 in contact with the outer peripheral
surface of the first film roll R1a.
[0217] The controller 290, serving as a first measuring unit, measures (calculates) the
diameter D of the first film roll R1a based on the first distance measured by the
first sensor 285. For example, a distance between the first reference position and
the conveying surface of the conveyor 210 (the surface on which the first film roll
R1a is placed) is stored in advance in a storage device of the controller 290. The
controller 290 calculates the diameter D of the first film roll R1a from the first
distance and the distance from the first reference position to the conveying surface
of the conveyor 210.
(4-2) Modification B
[0218] In the above embodiment, the controller 290 serving as a first measuring unit measures
the diameter D of the first film roll R1a, and based on the diameter D of the first
film roll R1a, the controller 290 controls the action of the second driving unit 236
to move the holding section 230 to a position where the height position of the center
of the first film roll R1a held by the holding section 230 is aligned with the height
of the center of the support shaft 114 of the bag-making and packaging machine 3.
[0219] However, the controller 290 may measure the height position of the first film roll
R1a held by the holding section 230 without measuring the diameter D of the first
film roll R1a, and the controller 290 may use this measurement result as a basis to
control the action of the second driving unit 236 to move the holding section 230
to a position where the height position of the center of the first film roll R1a held
by the holding section 230 is aligned with the height of the center of the support
shaft 114 of the bag-making and packing machine 3. A specific example shall now be
described with reference to FIG. 16. FIG. 16 is an enlarged view of the holding section
230 of the film roll replacement device 200, and is a drawing for describing the method
of measuring the height position up to the center of the first film roll R1a.
[0220] In Modification B, the film roll replacement device 200 does not have the first member
280, the first-member-driving unit 282, or the encoder 284. In Modification B, the
controller 290, serving as a second measuring unit, measures the height position of
the center of the first film roll R1a held by the holding section 230. The controller
290 uses, for example, the measurement result from the distance sensor 286 previously
described. In Modification B, the distance sensor 286 functions as a sensor that contactlessly
measures a second distance from a second reference position (the position of the distance
sensor 286) to the outer peripheral surface (the lowest part) of the first film roll
R1a held by the holding section 230.
[0221] In the storage device of the controller 290 are stored, for example, a height h1'
between the distance sensor 286 and the floor surface, and a height h2' between the
distance sensor 286 and the intersection point X between the straight line imagined
as an extension of the first holding surface 232a and the straight line imagined as
an extension of the second holding surface 234a (see FIG. 16). It can be seen from
the structure of the holding section 230 in the present modification that in a left-side
view, the center C of the first film roll R1a, the intersection point X, and a line
the intersection point Y, that is extended from the center C of the first film roll
R1a and that is perpendicular to the first holding surface 232a form a right isosceles
triangle. Therefore, if the distance sensor 286 is able to measure a second distance
(h2'+h3') from the position of the distance sensor 286 serving as the second reference
position to the outer peripheral surface (the lowest part) of the second film roll
R1b, the controller 290 can calculate the distance from the floor surface to the center
C of the first film roll R1a, using the formula h1'+h2'+Root(2)×h3'/(Root(2)-1). The
values of h1' and h2' are known, and the value of h3' can be calculated by subtracting
the known value h2' from the second distance measured by the distance sensor 286.
[0222] In this modification, a case is assumed in which the angle formed by the first holding
surface 232a and the second holding surface 234a is 90°, but the angle formed by the
first holding surface 232a and the second holding surface 234a need not be 90°. In
this case, the figure formed by connecting the center C of the first film roll R1a,
the intersection point X, and the intersection point Y would not be a right isosceles
triangle, but if the angle formed between the line segment joining the center C of
the first film roll R1a and the line segment joining the intersection point X and
the intersection point Y or the like is known, the height position of the first film
roll R1a held by the holding section 230 can be measured (calculated) using a trigonometric
function.
(4-3) Modification C
[0223] In the above embodiment, the first member 280 comes into contact with the outer peripheral
surface of the first film roll R1a from above, but this feature is not provided by
way of limitation. For example, the first member 280 may come into contact with the
outer peripheral surface of the first film roll R1a from a side (e.g., from the rear).
In this case as well, the controller 290 can measure the diameter D of the first film
roll R1a using the same method as in the above embodiment.
(4-4) Modification D
[0224] In the above embodiment, the holding section 230, the right-side pushing member 240,
and the left-side pushing member 250 are driven together by the third driving unit
237, but this feature is not provided by way of limitation. For example, the holding
section 230, the right-side pushing member 240, and the left-side pushing member 250
may be driven by respective separate driving units. In addition, for example, one
of the right-side pushing member 240 and the left-side pushing member 250 may together
with the holding section 230 be driven by the third driving unit 237, and the other
of the right-side pushing member 240 and the left-side pushing member 250 may be driven
by a driving unit separate from the third driving unit 237.
(4-5) Modification E
[0225] In the above embodiment, the film roll replacement device 200 is a stationary device.
However, the film roll replacement device 200 is not limited to being stationary,
and may be, for example, a self-propelled device having wheels or another movement
mechanism.
(4-6) Modification F
[0226] In the above embodiment, the controller 290 functions as a first measuring unit to
measure the diameter of the first film roll, and in Modification B, the controller
290 functions as a second measuring unit to measure the height position of the center
of the first film roll held by the holding section. However, this feature is not provided
by way of limitation; the first measuring unit or the second measuring unit may be
configured separate from the controller 290.
(4-7) Modification G
[0227] In the above embodiment, the controller 290 measures the diameter of the first film
roll R1a, and adjusts the height position of the center of the first film roll R1a
based on the measurement result. However, this feature is not provided by way of limitation;
the controller 290 may, for example, adjust the height position of the center of the
first film roll R1a based on a value of the diameter of the first film roll R1a input
from an input device (not shown in the figure).
(4-8) Modification H
[0228] The winding-core-retrieving mechanism 270 need not be provided to the film roll replacement
device 200. If the second film roll R1b is automatically removed from the second film
roll R1b and the first film roll R1a is automatically attached to the support shaft
114, the winding-core-retrieving mechanism 270 is preferably provided to the film
roll replacement device 200 in order to reduce the burden on the worker who takes
away the second film roll R1b from the holding section 230 (the winding core WC of
the depleted film roll R1).
(4-9) Modification I
[0229] If the winding-core-retrieving mechanism 270 is not provided and there is no need
for the winding core WC of the depleted film roll R1 to fall from the gap 230a of
the holding section 230, the holding section 230 may be a V-shaped member in which
the first holding member 232 and the second holding member 234 of the above embodiment
are integrated.
(4-10) Modification J
[0230] In the above embodiment, the holding section 230 is a V-shaped member, but the shape
of the holding section 230 is not limited to that of a V For example, the holding
section 230 may be a flat plate-shaped member in which a groove extending in the left-right
direction (a groove in which the film roll R1 will fit) is formed in the center in
the front-rear direction.
[0231] Where the holding section 230 is a flat plate-shaped member, for example, the holding
section 230 may, as the first orientation, take downwardly inclined orientation from
the proximal side toward the distal side relative to the conveyor 210 such that the
film roll R1 being supplied from the conveyor 210 readily moves, and may, as the second
orientation, take a horizontal orientation such that the film roll R1 fitted into
the groove does not roll out from the groove, although the holding section 230 is
not limited to this configuration.
[0232] In the case described above, the holding section 230 preferably has a member to restrict
movement of the first film roll R1a moving from the proximal side toward the distal
side relative to the conveyor 210, such that the film roll R1 being supplied from
the conveyor 210 does not roll and fall.
(4-11) Modification K
[0233] In the above embodiment, it is assumed that the diameters of the replacement film
rolls R1 (the first film roll R1a) are not uniform, but the film rolls R1 may all
have the same diameter. In this case, there is no need for the second driving unit
236 to perform positioning of the height position of the center of the first film
roll R1a held by the holding section 230 and the height position of the center of
the support shaft 114 of the bag-making and packaging machine 3.
(4-12) Modification L
[0234] In the embodiment described above, a case is illustrated in which the holding section
230 is rotated such that the position of the intersection point X of a straight line
imagined as an extension of the first holding surface 232a and a straight line imagined
as an extension of the second holding surface 234a (see FIG. 14) is used as the rotational
center of the rotation axis O. However, the position of the rotation axis of the holding
section 230 is not limited to the position illustrated in the embodiment described
above.
[0235] One example of a configuration in which the rotational center O1 of the holding section
230 is disposed at a position other than the intersection point X of a straight line
imagined as an extension of the first holding surface 232a and a straight line imagined
as an extension of the second holding surface 234a is illustrated in FIGS. 21A and
21B. FIG. 21A is a schematic left-side view of the film roll replacement device 200
according to modification L, and depicts a state in which the orientation of the holding
section 230 is a second orientation. FIG. 21B is a schematic left-side view of the
film roll replacement device 200 according to modification L, and depicts a state
in which the orientation of the holding section 230 is a first orientation.
[0236] The film roll replacement device 200 according to modification L is similar to the
film roll replacement device 200 according to the embodiment described above except
for the position of the rotation axis O1 of the holding section 230; therefore, the
configuration of the holding section 230, etc., other than the position of the rotation
axis O1 is not described here.
[0237] In the film roll replacement device 200 according to the embodiment described above,
when the holding section 230 takes the second orientation, the intersection point
X of a straight line imagined as an extension of the first holding surface 232a and
a straight line imagined as an extension of the second holding surface 234a is disposed
roughly directly below the center of the film roll R (center of the winding core WC)
held by the holding section 230 in the second orientation (see FIGS. 11 and 12D).
Additionally, in the embodiment described above, the gap 230a is provided in the holding
section 230 as described previously, and when the holding section 230 takes the second
orientation, the winding core WC of the used film roll R1 serving as the second film
roll R1b is caused to fall from the gap 230a. Therefore, when the holding section
230 takes the second orientation, the intersection point X of a straight line imagined
as an extension of the first holding surface 232a and a straight line imagined as
an extension of the second holding surface 234a is disposed at a position superposed
on the gap 230a in the front-rear direction (see FIG. 11).
[0238] Therefore, a configuration in which the holding section 230 is rotated around the
intersection point X when the orientation of the holding section 230 is changed to
the second orientation, and the winding core WC of the used film roll R1 falls from
the gap 230a, may cause problems such as a mechanism to rotate the holding section
230 hinders retrieval of the winding core WC or the configuration of the film roll
replacement device 200 becomes complicated.
[0239] Thus, in the film roll replacement device 200 according to modification L, the rotation
axis O1 is disposed at a position offset from directly below the center of the film
roll R1 (center of the winding core WC) held by the holding section 230 in the second
orientation in the front-rear direction, or more specifically a position offset from
directly below the gap 230a in the holding section 230 in the second orientation in
the front-rear direction (see FIGS. 21A and 21B). Even when the rotation axis O1 is
disposed at such a position, rotating the holding section 230 about the rotation axis
O1 makes it possible to change the orientation of the holding section 230 between
the first orientation (see FIG. 21B) and the second orientation (see FIG. 21A).
[0240] FIGS. 21A and 21B depict the rotation axis O1 at a position superposed on the first
holding member 232 in the front-rear direction, but the position of the rotation axis
O1 is not limited to the position depicted in FIGS. 21A and 21B. For example, the
position of the rotation axis O1 may be a position superposed on the second holding
member 234 in the front-rear direction or may be a position not superposed on either
the first holding member 232 or the second holding member 234 in the front-rear direction.
However, if the rotation axis O1 is disposed at a position spaced a large distance
from the first holding member 232 and the second holding member 234, the first holding
member 232 and the second holding member 234 will move a large distance when the orientation
of the holding section 230 is changed, and thus there is a risk that the film roll
replacement device 200 will increase in size.
[0241] As yet another example, the rotation axis O1 may be disposed at a location directly
below the gap 230a in the holding section 230 in the second orientation in the front-rear
direction, other than the intersection point X of a straight line imagined as an extension
of the first holding surface 232a and a straight line imagined as an extension of
the second holding surface 234a.
(4-13) Modification M
[0242] In the embodiment described above, the holding section 230 is configured such that
the plate-shaped first holding member 232 and the plate-shaped second holding member
234 are combined, and the first holding surface 232a and the second holding surface
234a are disposed in a V shape. However, the holding section having such a V shape
may be realized using other structures.
[0243] For example, the holding section 230' may be configured such that a plurality of
rollers 238 extending in the left-right direction are lined up to form a plurality
of V shapes in a side view, as shown in FIG. 22 (FIG. 22 is a left-side view). In
such cases, the holding section 230' holds the film roll R1 using a holding surface
of a first roller group 232' including a plurality of rollers 238 (i.e., a virtual
plane 232a' linking parts of the rollers 238 in the first roller group 232' supporting
the film roll R) that is disposed on the rearward side, and a holding surface of a
second roller group 234' including a plurality of rollers 238 (i.e., a virtual plane
234a' linking parts of the rollers 238 in the second roller group 234' supporting
the film roll R) that is disposed on the frontward side.
(4-14) Modification N
[0244] In the embodiment described above, the holding section 230 is formed by combining
the plate-shaped first holding member 232 and the plate-shaped second holding member
234. However, the holding section 230 may be realized using another structure.
[0245] For example, the holding section 230" may have a structure in which two shafts 239
extending in the left-right direction are lined up in the front-rear direction, as
shown in FIG. 23. When configured in this manner, the holding section 230" holds the
film roll R1 fitted between the two shafts. In this case, the holding section 230"
may have a configuration for adjusting a front-rear-direction gap between the shafts
such that the film roll R1 can be suitably held even when the diameter of the film
roll R1 changes.
[0246] Additionally, for example, the holding section 230" may be a roller conveyor in which
a plurality of rollers 239a extending in the left-right direction are lined up in
the front-rear direction, as shown in FIG. 24. In this configuration, a movement-restricting
member 239b to restrict the film roll R1 from moving forward is preferably provided
to the frontward side of the roller conveyor. When configured in this manner, the
holding section 230" holds the film roll R1 carried on the roller conveyor serving
as the holding section 230".
[0247] The claimed invention is useful as a film roll supply device that makes it possible
to improve replacement of a film roll in a bag-making and packaging machine.
REFERENCE SIGNS LIST
[0248]
- 3
- Bag-making and packaging machine
- 200
- Film roll replacement device (film roll supply device)
- 210
- Preliminary placement section
- 210a
- Conveyor surface (preliminary placement surface)
- 230
- Holding section (receiver)
- 232
- First holding member
- 232a
- First holding surface (first surface)
- 234
- Second holding member
- 234a
- Second holding surface (second surface)
- 235
- First driving unit (first driver)
- O
- Rotation axis
- R1a
- First film roll (film roll)
CITATION LIST
PATENT LITERATURE