JP2005081605A - Molding machine and molding method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve the problem that it is necessary to perform the aligning work of a clamp frame with respect to upper and lower molds by a worker using a molding means at every molding timing when a continuous resin sheet, on which patterns are printed at an almost constant interval, is continuously molded. <P>SOLUTION: The printing shift quantities (XPn and YPn) of a comparative pattern Pn with respect to a reference pattern P0 are detected at each time when the comparative pattern Pn is imaged by an imaging device 30 to be successively stored and, at the time of molding of the comparative pattern Pn, the acting positions of the upper and lower molds 51 and 53 set to a reference molding position in the reference pattern P0 are adjusted on the basis of the printing shift quantities (XPn and YPn) stored corresponding to the comparative pattern P becoming a molding object. By this constitution, the molding shift caused by printing shift is prevented to realize molding of high precision. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a molding apparatus and a molding method.

This type of forming apparatus is known in which a cut sheet on which a pattern is printed is held in a clamp frame, the clamp frame is disposed between the upper and lower molds of the molding means, and the upper and lower molds are aligned with respect to the pattern. . At this time, the operator visually aligns the pattern on the cut sheet with the upper and lower molds while moving the clamp frame manually or automatically, and prints the pattern by applying the upper and lower molds to the pattern. A molded product is molded at the position (see, for example, Patent Document 1).
JP 2002-361726 A

  When the above-described conventional molding apparatus is applied to a molding line and a continuous resin sheet with a pattern printed at a substantially constant interval is continuously molded, a clamp frame by an operator at a molding means at each molding timing Since the alignment work with respect to the upper and lower molds is required, the line has to be stopped. In addition, since the heating means for heating and softening the resin sheet is arranged in front of the molding means, when the molding line is stopped, the heating time in the heating means must be adjusted according to the operator's alignment work. Because it is not, it cannot be applied realistically.

  The present invention has been made in view of the above problems, and continuously aligns the upper and lower molds with respect to the pattern printed on the resin sheet, while continuously forming the continuous resin sheet on which the pattern is printed at substantially constant intervals. An object is to provide a molding apparatus and a molding method capable of molding.

  In order to achieve the above object, the invention according to claim 1 includes a conveying unit that conveys a continuous resin sheet on which a pattern is printed at a substantially constant interval while stopping the operation at the molding timing, and the molding timing. An image pickup unit that sequentially captures the pattern, and a print that sequentially stores the detected print deviation amount while detecting the print deviation amount with respect to a predetermined reference pattern of the same pattern every time the pattern is sequentially captured by the image pickup unit. When the resin sheet on which the pattern is imaged by the imaging means is carried in by the shift amount storage means, the heating means for heating and softening the carried resin sheet, and the upper and lower molds, the heating means When the heat-softened resin sheet is carried in, molding means for causing the upper and lower molds to act on the resin sheet at a predetermined molding position at the molding timing and molding the molded product at the pattern printing position. When the molding unit performs molding at the molding timing, the printing deviation amount stored in the storage unit corresponding to the pattern to be molded is acquired, and the reference pattern is handled based on the acquired printing deviation amount. A molding position correcting means for aligning the upper and lower molds from a reference molding position to the molding position is provided.

  In the invention according to claim 1 configured as described above, a continuous resin sheet on which a pattern is printed at a substantially constant interval by the conveying means is conveyed while stopping its operation at the molding timing of the molding means. . On the other hand, the imaging means sequentially images the pattern on the resin sheet every time it stops at the molding timing. The print deviation amount storage means sequentially stores the detected print deviation amount while detecting the print deviation amount with respect to a predetermined reference pattern of the same pattern every time the image pickup means sequentially captures the pattern. When the resin sheet on which the pattern is imaged by the imaging means is carried in, the heating means heats and softens the carried resin sheet. Here, the molding means has an upper and lower mold, and when the resin sheet heated and softened by the heating means is carried in, the upper and lower molds are made to act on the resin sheet at a predetermined molding position at the molding timing. Thus, the molded product is formed at the pattern printing position. At this time, the forming position correcting unit obtains a printing deviation amount corresponding to the pattern to be formed from the storing unit when the forming unit performs forming at the forming timing. Then, based on the acquired printing deviation amount, the upper and lower molds are aligned so that the pattern and the upper and lower molds coincide (formation position) from the reference molding position corresponding to the reference pattern.

  According to a second aspect of the present invention, in the molding apparatus according to the first aspect, the transport unit includes a transport amount adjusting unit capable of adjusting a transport amount when transporting the resin sheet, and the molding unit. Has upper and lower mold sheet width direction moving means capable of moving the upper and lower molds with respect to the width direction of the resin sheet, and the molding position correcting means is configured to adjust the conveyance amount adjusting means based on the acquired printing deviation amount. The above-mentioned alignment is performed by adjusting the transport amount and moving the upper and lower molds in the width direction of the resin sheet by the upper and lower mold sheet width direction moving means. In the invention according to claim 2 configured as described above, the conveyance unit is provided with a conveyance amount adjusting unit capable of adjusting the conveyance amount when the resin sheet is conveyed. Further, the molding means is provided with upper and lower mold sheet width direction moving means capable of moving the upper and lower molds relative to the width direction of the resin sheet. The molding position correcting unit causes the conveyance amount adjusting unit to adjust the conveyance amount based on the printing deviation amount acquired from the storage unit, and the upper and lower mold sheet width direction moving unit moves the upper and lower molds in the width direction of the resin sheet. Let As a result, the position where the upper and lower molds act on the resin sheet is aligned with the molding position that matches the printing position of the pattern to be molded.

Furthermore, the invention according to claim 3 is the molding apparatus according to claim 1, wherein the transport means includes a transport amount adjusting means capable of adjusting a transport amount when transporting the resin sheet, and a range of the molding means. A resin sheet moving means capable of moving the resin sheet conveyed to the width direction of the resin sheet, and the molding position correcting means is configured to adjust the conveyance amount adjusting means based on the acquired printing deviation amount. While adjusting the said conveyance amount, it is set as the structure which performs the said position by making the said resin sheet moving means move the said resin sheet to the width direction.
In the invention according to claim 3 configured as described above, the conveyance amount adjusting means capable of adjusting the conveyance amount when the resin sheet is conveyed to the conveyance means, and the resin sheet conveyed to the range of the molding means are the resin sheet. And a resin sheet moving means movable in the width direction. The molding position correction unit causes the conveyance amount adjustment unit to adjust the conveyance amount based on the print deviation amount acquired from the storage unit, and causes the resin sheet moving unit to move the resin sheet in the width direction. As a result, the position where the upper and lower molds act on the resin sheet is aligned with the molding position that matches the printing position of the pattern to be molded.

Further, the invention according to claim 4 is the molding apparatus according to claim 1, wherein the molding means includes upper and lower mold sheet width direction moving means capable of moving the upper and lower molds with respect to the width direction of the resin sheet. And an upper and lower mold sheet lengthwise moving means capable of moving the upper and lower molds with respect to the length direction of the resin sheet, and the molding position correcting means is arranged based on the acquired printing deviation amount. The upper and lower molds are moved in the width direction of the resin sheet by the width direction moving means, and the alignment is performed by moving the upper and lower molds in the length direction of the resin sheet by the upper and lower mold sheet length direction moving means. is there.
In the invention according to claim 4 configured as described above, the upper and lower mold sheet width direction moving means capable of moving the upper and lower molds relative to the width direction of the resin sheet as the molding means, and the upper and lower molds in the length direction of the resin sheet. And a vertical sheet lengthwise moving means that is movable with respect to. The molding position correcting means moves the upper and lower molds in the width direction of the resin sheet by the upper and lower mold sheet width direction moving means and moves the upper and lower mold sheet length direction moving means by the upper and lower mold sheet length direction moving means based on the printing deviation amount acquired from the storage means. The mold is moved in the length direction of the resin sheet. As a result, the position where the upper and lower molds act on the resin sheet is aligned with the molding position that matches the printing position of the pattern to be molded.

Further, the invention according to claim 5 is the molding apparatus according to claim 1, wherein the conveying means is capable of moving the resin sheet conveyed to the range of the molding means with respect to the width direction of the resin sheet. The molding means has upper and lower mold sheet length direction moving means capable of moving the upper and lower molds with respect to the length direction of the resin sheet, and the molding position correcting means has the acquisition position. The resin sheet moving means moves the resin sheet in the width direction based on the printed deviation amount, and the upper and lower mold sheet length direction moving means moves the upper and lower molds in the length direction of the resin sheet. The configuration is such that alignment is performed.
In the invention concerning Claim 5 comprised as mentioned above, the resin sheet moving means which can move the resin sheet conveyed by the conveyance means to the range of the shaping | molding means with respect to the width direction of the resin sheet is provided. Further, the molding means is provided with upper and lower mold sheet length direction moving means capable of moving the upper and lower molds with respect to the length direction of the resin sheet. Then, the molding position correcting means moves the resin sheet in the width direction to the resin sheet moving means based on the printing deviation amount acquired from the storage means, and the upper and lower molds are moved to the upper and lower mold sheet length direction moving means. Move in the length direction. As a result, the position where the upper and lower molds act on the resin sheet is aligned with the molding position that matches the printing position of the pattern to be molded.

Furthermore, the invention according to claim 6 is the molding apparatus according to any one of claims 1 to 5, wherein the imaging unit is configured to display a substantially printed portion on which the pattern is printed when imaging the pattern. It is set as the structure which has the resin sheet support means supported with respect to a substantially resin sheet conveyance surface.
In the invention according to claim 6 configured as described above, the imaging means is provided with a resin sheet supporting means. And when imaging a pattern, this resin sheet support means supports the substantially printing site | part with which the same pattern was printed with respect to the substantially resin sheet conveyance surface.

Furthermore, the invention according to claim 7 is the molding apparatus according to claim 6, wherein the imaging unit is disposed on the resin sheet side opposite to the imaging side and emits irradiation light to the resin sheet. The resin sheet irradiating means for irradiating and the irradiation light dispersing means disposed between the resin sheet irradiating means and the resin sheet for dispersing the irradiation light with respect to the resin sheet.
In the invention according to claim 7 configured as described above, the imaging means is provided with a resin sheet irradiation means and an irradiation light dispersion means. The resin sheet irradiation means is disposed on the resin sheet side opposite to the imaging side, and irradiates the resin sheet with irradiation light. The irradiation light dispersion means is disposed between the resin sheet irradiation means and the resin sheet, and disperses the irradiation light from the resin sheet irradiation means with respect to the resin sheet.

As described above, it is not always necessary to limit the method of forming the printed portion of the pattern on the resin sheet on which the pattern is printed, and it can be easily understood that the method functions as the method.
For this reason, the invention according to claim 8 is a molding method for molding the printed portion of the pattern on the resin sheet on which the pattern is printed, and forms a continuous resin sheet on which the pattern is printed at substantially constant intervals. A conveyance process for conveying while stopping the operation at the timing, an imaging process for sequentially capturing the pattern at the molding timing, and printing for a predetermined reference pattern of the same pattern every time the pattern is sequentially captured in the imaging process A printing deviation amount storing step for sequentially storing the printing deviation amount while detecting the deviation amount, and when the resin sheet having the pattern captured in the imaging step is carried in, the resin sheet carried in is heated and softened. When the resin sheet having a heating process and an upper and lower mold and heated and softened in the heating process is carried in, the upper and lower molds act on the resin sheet at a predetermined molding position at the molding timing. When the molding process forms the molded product at the printing position of the pattern, and the molding process performs molding at the molding timing, the printing deviation amount stored in the storing process corresponding to the pattern to be molded is acquired. And a molding position correcting step for aligning the upper and lower molds with respect to the molding position from the reference molding position corresponding to the reference pattern based on the acquired printing deviation amount.
That is, it is not necessarily limited to a substantial molding apparatus, and there is no difference in being effective as a molding method.

As described above, according to the present invention, when forming a pattern to be formed based on the amount of printing deviation with respect to the reference pattern that defines the reference forming position of the pattern to be formed, which is detected by imaging with an imaging unit, By correcting the working position of the upper and lower molds to the molding position that matches the printing position of the same pattern from the reference molding position, it is possible to prevent molding deviation due to printing deviation on the resin sheet on which the continuous pattern is printed. Can be provided.
Moreover, according to the invention concerning Claim 2, by adjusting the conveyance amount of the resin sheet and the whole molding means in the resin sheet width direction, the pattern to be molded can be aligned with the molding position where the upper and lower molds act. it can.

Further, according to the invention of claim 3, the pattern of the molding object is aligned with the molding position where the upper and lower molds act by adjusting the transport amount of the resin sheet and the resin sheet in the molding area in the resin sheet width direction. can do.
Furthermore, according to the invention concerning Claim 4, the pattern of a shaping | molding object can be aligned with the shaping | molding position where an up-and-down type | mold acts by moving and adjusting the whole shaping | molding means to the resin sheet width direction and length direction. .
Furthermore, according to the invention concerning Claim 5, while moving and adjusting the resin sheet of a molding area in the resin sheet width direction, the pattern of the molding object is moved up and down by moving and adjusting the entire molding means in the resin sheet length direction. It can be aligned with the molding position where the mold acts.

Furthermore, according to the invention concerning Claim 6, tension can be given to an imaging surface about the resin sheet in which the drawdown has generate | occur | produced, and the imaging state of a pattern can be improved.
Furthermore, according to the invention concerning Claim 7, an imaging environment can be improved.
Further, according to the invention according to claim 8, on the basis of the printing deviation amount with respect to the reference pattern that defines the reference forming position of the pattern to be formed, which is detected by image pickup by the image pickup means, the formation of the pattern to be formed is performed. In this case, by appropriately correcting the operation position where the upper and lower molds act from the reference molding position to the molding position that matches the printing position of the same pattern, the resin sheet on which the continuous pattern is printed is prevented from being misaligned due to printing misalignment. It is possible to provide a molding method that can be used.

Here, embodiments of the present invention will be described in the following order.
(1) Configuration of thermoforming apparatus:
(2) Configuration of imaging device:
(3) Processing content of printing deviation amount detection processing:
(4) Processing content of molding position correction processing:
(5) Summary:

(1) Configuration of thermoforming apparatus:
FIG. 1 is a configuration diagram showing a configuration of a thermoforming apparatus including a molding apparatus according to the present invention.
In the figure, a thermoforming device 10 includes a resin sheet supply device 20, an imaging device 30, a heating device 40, a molding device 50, a trimming device 60, a knockout device 70, a scrap winding device 80, and a molding. The product conveyor apparatus 90 is comprised. The resin sheet supply apparatus 20 has a roll formed by winding a continuous resin sheet S on which a pattern is printed at a substantially constant interval, and the roll-shaped resin sheet S is fed out by a resin sheet conveying apparatus (not shown). Then, the resin sheet S is supplied to the subsequent devices 30 to 80.

  Here, the resin sheet conveying device includes a pulley fixed on a sprocket at the front end portion in the traveling direction of the clamp chain, spanning an endless clamp chain on sprockets appropriately disposed on both sides of a machine frame (not shown). The output shaft side of the servo motor device provided with the encoder is connected by a timing belt. And the resin sheet conveying apparatus rotatably supports the resin sheet S on the machine frame. The resin sheet S is provided so as to be intermittently fed by the resin sheet conveying device by a predetermined length of one shot at a time while the side edge is held by the clamp chain. It has been. The imaging device 30 is a device that images the pattern on the resin sheet S fed out from the resin sheet supply device 20, and the resin sheet S having a predetermined length is fed into the molding device 50 for each shot by the resin sheet conveying device. The pattern of the resin sheet S carried into the imaging device 30 is imaged.

  The heating device 40 includes an upper heater 41 and a lower heater 42, and when the resin sheet S having a predetermined length for each shot is fed into the molding device 50 by the resin sheet conveying device, the heating device 40 is provided with the heating device 40. On the other hand, the upper and lower surfaces of the resin sheet S carried in are heated by the upper and lower heaters 41 and 42, and the resin sheet S is heated and softened. The molding apparatus 50 has a male upper mold 51 on the upper side and a female lower mold 53 on the lower side, and the upper and lower molds 51 and 53 have a mold shape corresponding to the pattern printed on the resin sheet S. ing. Therefore, by causing the upper and lower molds 51 and 53 to act on the resin sheet S, a molded product corresponding to the pattern is formed. Here, an upper die cylinder 52 is connected to the upper die 51, and a lower die cylinder 54 is connected to the lower die 53. The upper mold 51 is driven up and down with the expansion and contraction operation of the upper mold cylinder 52, and the lower mold 53 is driven up and down with the expansion and contraction operation of the lower mold cylinder 54. The molding apparatus 50 molds the molded product into the resin sheet S by extending the upper mold cylinder 52 and extending the lower mold cylinder and substantially bringing the upper and lower molds 51 and 53 into contact with each other at the time of molding.

  The resin sheet S on which the molded product is molded is carried into the trimming device 60 in response to intermittent feeding for each shot to the molding device 50 by the resin sheet device. The trimming device 60 includes an upper blade die 61, a lower blade die 62, and a blade die driving device 63. During the trimming, the upper blade die 61 is driven downward along with the driving operation of the blade die driving device 63. The lower blade mold 62 is driven upward. And the upper blade type | mold 61 and the lower blade type | mold 62 substantially contact | abut, and a molded product is trimmed from the resin sheet S. FIG. At this time, the trimming apparatus 60 performs trimming while leaving several connection points. Therefore, the molded product is connected to the resin sheet S through this connection point. Thus, the resin sheet S to which the molded product is connected at several connection points is carried into the knockout device 70 by the resin sheet conveying device. The knockout device 70 includes an extruding portion 71 having a convex portion that drives up and down with respect to the resin sheet S directed downward, and a molded product support portion 72 that similarly drives up and down with respect to the resin sheet S.

  The molded product support 72 is formed in a concave shape, and the molded product can be accommodated in the concave shape. Then, the knockout device 70 drives the extruding portion 71 downward to insert the convex portion of the extruded portion 71 into the concave portion of the molded product of the resin sheet S carried in, and pushes the molded product downward. The molded product is removed from the resin sheet S. At this time, the removed molded product is accommodated in the concave shape while supporting the molded product to be pushed out by driving the molded product support portion 72 upward. The molded product accommodated in the concave shape of the molded product support portion 72 is placed on the molded product conveyor device 90, and sequentially sent out backward by the conveyor, and the molded product is collected. On the other hand, the resin sheet S from which the molded product has been removed by the knockout device 70 is taken up by the scrap take-up device 80.

  In the present embodiment, as described above, the resin sheet S on which patterns are printed at substantially constant intervals is formed. If the interval between the patterns is constant, the resin sheet S is fed into the molding device 50 based on the interval, and the upper and lower molds 51 and 53 are made to act on the pattern, so that a molded product corresponding to the pattern can be obtained. It becomes possible to mold. On the other hand, if there is a printing misalignment in the pattern and the resin sheet S having a predetermined length is fed to the molding apparatus 50, the position of the pattern and the upper and lower molds 51 and 53 is shifted due to the misprinting. The molded product cannot be molded.

  Therefore, in the present embodiment, the molding apparatus 50 is provided with a molding apparatus moving table 55. The molding apparatus moving table 55 mounts the entire molding apparatus 50 that holds the upper mold cylinder 52 and the lower mold cylinder 54. The entire molding apparatus 50 is placed in the X direction (the length direction of the resin sheet S) and the Y direction. It can be moved in the width direction of the resin sheet S. At this time, the movement is performed by ball screw shafts arranged in the X and Y directions (not shown). Then, a servo motor including an encoder is connected to the ball screw shaft, and the servo motor is rotated based on a command from the servo motor controller, and the molding apparatus 50 is moved in the length direction and the width direction of the resin sheet S. Moreover, about the resin sheet conveying apparatus in this embodiment, while being able to adjust conveyance length with the servomotor apparatus mentioned above, a clamp chain is made independent about the resin sheet conveying apparatus of the molding area where the shaping | molding apparatus 50 is arrange | positioned. Deploy. Here, the clamp chain in the molding area is placed on a clamp chain moving table that is movable in the width direction of the resin sheet S (not shown). Then, the clamp chain in the molding area can be moved in the width direction of the resin sheet S by the clamp chain moving table.

When the pattern printed on the resin sheet S sent to the molding apparatus 50 and the positions of the upper and lower molds 51 and 53 are shifted by configuring the molding apparatus 50 and the resin sheet conveying apparatus in this way, the following method is used. It is possible to align the operation positions of the upper and lower molds 51 and 53 with respect to the pattern.
a. After the resin sheet S is conveyed to the molding device 50, the conveyance amount of the resin sheet S is adjusted based on the printing deviation amount in the X direction, and the entire molding device 50 is adjusted to Y based on the printing deviation amount in the Y direction. Move in the direction.
b. The entire molding apparatus 50 is moved in the X direction based on the printing deviation amount in the X direction, and the entire molding apparatus 50 is moved in the Y direction based on the printing deviation amount in the Y direction.

c. After the resin sheet S is conveyed to the molding apparatus 50, the conveyance amount of the resin sheet S is adjusted based on the printing deviation amount in the X direction, and the clamping chain in the molding area is adjusted based on the printing deviation amount in the Y direction. Move in the Y direction.
d. The entire molding apparatus 50 is moved in the X direction based on the printing deviation amount in the X direction, and the clamp chain in the molding area is moved in the Y direction based on the printing deviation amount in the Y direction. Here, the printing misalignment amounts in the X direction and the Y direction are detected based on the pattern imaged by the imaging device 30 and a predetermined reference pattern. Next, the configuration of the imaging apparatus 30 and the detected printing deviation amount will be described.

(2) Configuration of imaging device:
FIG. 2 is a configuration diagram illustrating the configuration of the imaging device 30.
In the figure, an image pickup device 30 picks up a CCD camera support column 31 erected substantially perpendicularly to the resin sheet S and images the pattern of the resin sheet S attached to the upper part of the CCD camera support column 31 from above. The CCD camera 31a, the light 32a that illuminates the resin sheet S from the lower surface with respect to the image of the CCD camera 31a, the light storage box 32 that stores the light 32a, the light of the light 32a that is disposed inside the light storage box 32 A reflection plate 32b that reflects the light upward, a milky white glass plate 33 that is disposed above the light receiving box 32 and that disperses the light 32a, and an imaging device 30 that is disposed above the milky white glass plate 33. The transparent acrylic plate 34 on which the resin sheet S carried in is placed, and the resin sheet S is not caught on the carry-in side surface of the transparent acrylic plate 34. To way, bent downwards in carrying end, and a resin sheet introduction member 35 for introducing the loading of the resin sheet S. In this configuration, the pattern on the resin sheet S carried into the imaging device 30 is imaged. Here, in the present embodiment, a configuration is adopted in which the upper surface of the transparent acrylic plate 34 is aligned with the transport surface of the resin sheet S. However, the transparent acrylic plate 34 is arranged slightly above the transport surface of the resin sheet S. May be. Thereby, it becomes possible to image the pattern while extending the central portion that hangs downward due to the flexibility of the resin sheet S.

  Next, the configuration of the resin sheet S to be imaged will be described. FIG. 3 is a configuration diagram showing the configuration of the resin sheet S. In the figure, the resin sheet S is printed with patterns P0, P1, P2, P3,. Here, the pattern P0 is a pattern printed on the tip of the resin sheet S, and the pattern P1 is imaged when the pattern P0 is imaged by the imaging device 30 and sequentially conveyed and carried into the molding device 50. 30. Here, in the present embodiment, the pattern P0 is set as a reference pattern, and an image obtained by capturing the reference pattern P0 is set as a reference image. Further, the pattern Pn (n = 1, 2, 3...) Is set as a comparison pattern Pn with respect to the reference pattern P0, and an image obtained by capturing the comparison pattern Pn is set as a comparison image.

  Then, the printing deviation amount of the comparison pattern Pn with respect to the reference pattern P0 is detected based on the image position of the comparison image with respect to the image position of the reference image. FIG. 4 is a schematic diagram schematically showing how a printing deviation amount is generated. In the figure, the reference image when the reference pattern P0 is imaged is stored as data. Then, every time the comparative pattern Pn is sequentially captured, the image positions of the reference image and the comparative image are compared, and the printing misalignment amount X in the X direction (the length direction of the resin sheet S) and the Y direction (the resin sheet S) are compared. The amount of printing deviation Y in the width direction) is detected. For each detection, the printing deviation amount (XPn, YPn) is stored, and when the corresponding comparison pattern Pn is sent to the molding apparatus 50, the stored printing deviation amount (XPn, YPn) is acquired and acquired. Based on the printing deviation amount (XPn, YPn), the operation positions of the upper and lower molds 51, 53 are aligned by the above-described methods.

(3) Processing content of printing deviation amount detection processing:
Next, the processing content of the printing deviation amount detection processing executed by the controller (not shown) is shown in the flowchart of FIG.
In the figure, when a roll-shaped resin sheet S is first mounted on the resin sheet supply device 20, the tip portion of the resin sheet S is mounted on the imaging device 30. When the front end of the resin sheet S is attached to the imaging device 30, the reference pattern P0 printed on the front end of the resin sheet S is imaged (step S105). Then, the image data of the reference pattern P0 is stored in the memory as a reference image (step S110). Next, the reference pattern P0 is transported to the molding device 50 based on a predetermined length (step S115), and trial molding is performed by causing the upper and lower molds 51 and 53 to act on the transported reference pattern P0. (Step S120).

  When trial molding is performed, the molded product is taken out and checked for molding deviation. Here, if a molding deviation occurs, it can be seen that there is a printing deviation of the reference pattern P0 with respect to the operation position of the upper and lower molds 51 and 53. Therefore, by moving and adjusting the positions of the upper and lower molds 51 and 53 so as to eliminate this printing misalignment, the operating position of the upper and lower molds 51 and 53 is set to a reference molding position that matches the reference pattern P0 (step S125). . Thus, when the reference molding position is set, continuous operation is started (step S130). At this time, in a state where the reference pattern P0 is carried into the molding apparatus 50, the pattern P1 is carried into the imaging apparatus 30. Therefore, 1 is substituted for n in order to initialize the comparison pattern Pn to be imaged by the imaging device 30 (step S135).

  Then, the image capturing apparatus 30 captures the comparative pattern Pn (step S140), detects the print misalignment amount (XPn, YPn) (step S145), and print misalignment amount storage data table TBL as shown in FIG. Are sequentially stored (step S150). The processes from step S140 to step S150 are performed until the operation is completed (steps S155 and S160). Thereby, each printing deviation amount (XPn, YPn) can be stored in the printing deviation amount storage data table TBL for the comparative pattern Pn.

(4) Processing content of molding position correction processing:
FIG. 7 is a flowchart showing the processing contents of the molding position correction processing executed when molding is performed by the molding apparatus 50.
In the figure, when a resin sheet S having a predetermined length is carried into the molding apparatus 50 by the resin sheet conveying apparatus (step S205), the pattern numbers (patterns P0, P1, P2,...) To be molded are displayed. Determination is made (step S210). When the number of the pattern to be formed is determined, the printing deviation amount storage data table TBL is searched based on the number of the pattern, and the corresponding printing deviation amount (XPn, YPn) is read (step S215). Next, the upper and lower molds 51 and 53 are adjusted by performing an upper and lower mold working position adjustment process for adjusting the working positions of the upper and lower molds 51 and 53 with respect to the resin sheet S based on the read printing deviation amounts (XPn, YPn). Positioning with respect to the pattern Pn is performed (step S220). This vertical action position adjustment process will be described later. Then, using the adjusted operation position as the molding position, the upper and lower molds 51 and 53 are allowed to act on the resin sheet S to mold a molded product corresponding to the pattern Pn (step S225).

FIG. 8 is a flowchart showing the processing contents of the vertical die action position adjustment process executed in step S220 of the molding position correction process described above. Here, the method a. The case where is adopted will be described.
In the figure, first, the read printing deviation amount XPn in the X direction (the length direction of the resin sheet S) is analyzed, and the deviation amount from the reference molding position (X direction) is detected (step S305). Here, the feed amount of the resin sheet S is calculated based on the deviation amount from the reference molding position. That is, based on this deviation amount, it is determined whether the resin sheet S sent to the molding apparatus 50 by a predetermined length is further sent in the + direction (feed direction) or in the − direction (return direction), and The feed amount is calculated. Based on this feed amount, the transport amount of the resin sheet transport device is controlled to adjust so as to eliminate the printing misalignment in the X direction (step S310).

  Next, the printing deviation amount YPn in the read Y direction (width direction of the resin sheet S) is analyzed, and the deviation amount from the reference molding position (Y direction) is detected (step S315). Here, the movement adjustment amount with respect to the width direction of the resin sheet S of the molding apparatus 50 is calculated based on the deviation amount from the reference molding position. That is, based on this deviation amount, it is determined whether the molding apparatus 50 is moved in the + direction (width-back side direction) or the-direction (width-side side direction), and the movement adjustment amount is calculated. . Then, the molding apparatus moving table 55 is controlled based on the movement adjustment amount to move the clamp chain in the Y direction, and the printing misalignment in the Y direction is eliminated (step S320).

FIG. 9 is a flowchart showing the processing contents of the vertical die action position adjustment process executed in step S220 of the molding position correction process described above. Here, the method b. The case where is adopted will be described.
In the figure, first, the read printing deviation amount XPn in the X direction (the length direction of the resin sheet S) is analyzed, and the deviation amount from the reference molding position (X direction) is detected (step S405). Here, the movement adjustment amount with respect to the length direction of the resin sheet S of the molding apparatus 50 is calculated based on the deviation amount from the reference molding position. That is, based on this deviation amount, it is determined whether to move in the + direction (feed direction of the resin sheet S) or in the − direction (return direction of the resin sheet S), and the movement adjustment amount is calculated. . Then, based on this movement adjustment amount, the molding apparatus movement table 55 is controlled to eliminate the printing misalignment in the X direction (step S410).

  Next, the printing deviation amount YPn in the read Y direction (width direction of the resin sheet S) is analyzed, and the deviation amount from the reference molding position (Y direction) is detected (step S415). Here, the movement adjustment amount with respect to the width direction of the resin sheet S of the molding apparatus 50 is calculated based on the deviation amount from the reference molding position. That is, based on this deviation amount, it is determined whether the molding apparatus 50 is moved in the + direction (width-back side direction) or the-direction (width-side side direction), and the movement adjustment amount is calculated. . Then, based on this movement adjustment amount, the forming apparatus movement table 55 is controlled to eliminate the printing misalignment in the Y direction (step S420).

FIG. 10 is a flowchart showing the processing contents of the vertical die action position adjustment process executed in step S220 of the molding position correction process described above. Here, the method c. The case where is adopted will be described.
In the figure, first, the read printing deviation amount XPn in the X direction (the length direction of the resin sheet S) is analyzed, and the deviation amount from the reference molding position (X direction) is detected (step S505). Here, the feed amount of the resin sheet S is calculated based on the deviation amount from the reference molding position. That is, based on this deviation amount, it is determined whether the resin sheet S sent to the molding apparatus 50 by a predetermined length is further sent in the + direction (feed direction) or in the − direction (return direction), and The feed amount is calculated. Based on this feed amount, the transport amount of the resin sheet transport device is controlled to adjust so as to eliminate the printing misalignment in the X direction (step S510).

  Next, the printing deviation amount YPn in the read Y direction (width direction of the resin sheet S) is analyzed, and the deviation amount from the reference molding position (Y direction) is detected (step S515). Here, the movement adjustment amount with respect to the width direction of the resin sheet S is calculated based on the deviation amount from the reference molding position. That is, based on this deviation amount, it is determined whether the resin sheet S is moved in the + direction (width-back side direction) or the-direction (width-side side direction), and the movement adjustment amount is calculated. . Then, by controlling the clamp chain moving table described above based on the movement adjustment amount and moving the clamp chain in the Y direction, the printing misalignment in the Y direction is eliminated (step S520).

FIG. 11 is a flowchart showing the processing contents of the upper and lower mold action position adjustment processing executed in step S220 of the molding position correction processing described above. Here, the method d. The case where is adopted will be described.
In the figure, first, the read printing deviation amount XPn in the X direction (length direction of the resin sheet S) is analyzed, and the deviation amount from the reference molding position (X direction) is detected (step S605). Here, the movement adjustment amount with respect to the length direction of the resin sheet S of the molding apparatus 50 is calculated based on the deviation amount from the reference molding position. That is, based on this deviation amount, it is determined whether to move in the + direction (feed direction of the resin sheet S) or in the − direction (return direction of the resin sheet S), and the movement adjustment amount is calculated. . Then, based on this movement adjustment amount, the molding apparatus movement table 55 is controlled to eliminate the printing misalignment in the X direction (step S610).

  Next, the printing deviation amount YPn in the read Y direction (width direction of the resin sheet S) is analyzed, and the deviation amount from the reference molding position (Y direction) is detected (step S615). Here, the movement adjustment amount with respect to the width direction of the resin sheet S is calculated based on the deviation amount from the reference molding position. That is, based on this deviation amount, it is determined whether the resin sheet S is moved in the + direction (width-back side direction) or the-direction (width-side side direction), and the movement adjustment amount is calculated. . Based on this movement adjustment amount, the above-described clamp chain movement table is controlled to eliminate printing misalignment in the Y direction (step S620).

(5) Summary:
As described above, each time the comparative pattern Pn is imaged by the imaging device 30, the printing deviation amount (XPn, YPn) of the comparative pattern Pn with respect to the reference pattern P0 is detected and sequentially stored, and at the time of forming the comparative pattern Pn. The working position of the upper and lower molds 51 and 53 set as the reference molding position in the reference pattern P0 is adjusted based on the printing misalignment amount (XPn, YPn) stored corresponding to the comparison pattern Pn to be molded. Therefore, molding deviation due to printing deviation can be prevented, and high-precision molding can be realized.

It is the block diagram which showed the structure of the thermoforming apparatus. It is the block diagram which showed the structure of the imaging device. It is the block diagram which showed the structure of the resin sheet. It is the schematic diagram which showed typically the generation | occurrence | production aspect of the printing deviation | shift amount. It is the flowchart which showed the processing content of printing misalignment amount detection processing. It is the block diagram which showed the structure of the printing misalignment amount storage data table. It is the flowchart which showed the processing content of the shaping | molding position correction process. It is the flowchart which showed the processing content of the vertical type | mold action position adjustment process. It is the flowchart which showed the processing content of the vertical type | mold action position adjustment process. It is the flowchart which showed the processing content of the vertical type | mold action position adjustment process. It is the flowchart which showed the processing content of the vertical type | mold action position adjustment process.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Thermoforming apparatus 20 ... Resin sheet supply apparatus 30 ... Imaging device 31 ... CCD support column 31a ... CCD camera 32 ... Light storage box 32a ... Light 32b ... Reflecting plate 33 ... Milky white glass plate 34 ... Transparent acrylic board 35 ... Resin sheet Introducing member 40 ... heating device 41 ... upper heater 42 ... lower heater 50 ... forming device 51 ... upper die 52 ... upper die cylinder 53 ... lower die 54 ... lower die cylinder 55 ... forming device moving table 60 ... trimming device 61 ... upper blade Mold 62 ... Lower blade mold 63 ... Blade mold drive device 70 ... Knockout device 71 ... Extrusion unit 72 ... Molded product support unit 80 ... Scrap winding device 90 ... Molded product conveyor device

Claims (8)

A conveying means for conveying a continuous resin sheet on which a pattern is printed at a substantially constant interval while stopping operation at a molding timing;
Imaging means for sequentially imaging the pattern at the molding timing;
Printing deviation amount storage means for sequentially storing the detected printing deviation amount while detecting the printing deviation amount with respect to a predetermined reference pattern of the same pattern each time a pattern is sequentially imaged by the imaging means;
When the resin sheet imaged with the pattern is carried in by the imaging means, heating means for heating and softening the carried resin sheet;
When the resin sheet having the upper and lower molds and heated and softened by the heating means is carried in, the upper and lower molds act on the resin sheet at a predetermined molding position at the molding timing, and the pattern printing is performed. Molding means for molding a molded product at a position;
When the molding unit performs molding at the molding timing, the printing deviation amount stored in the storage unit corresponding to the pattern to be molded is acquired, and a reference corresponding to the reference pattern is obtained based on the acquired printing deviation amount. A molding apparatus comprising: a molding position correcting unit that aligns the upper and lower molds with respect to the molding position from the molding position.   The conveying means has a conveying amount adjusting means capable of adjusting a conveying amount when conveying the resin sheet, and the molding means is an upper and lower mold sheet capable of moving the upper and lower molds in the width direction of the resin sheet. A width direction moving unit, and the forming position correcting unit causes the conveyance amount adjusting unit to adjust the conveyance amount based on the acquired printing deviation amount, and the upper and lower mold sheet width direction moving unit includes the upper and lower molds. The molding apparatus according to claim 1, wherein the alignment is performed by moving the resin sheet in a width direction of the resin sheet.   The conveyance means includes a conveyance amount adjustment means capable of adjusting a conveyance amount when conveying the resin sheet, and a resin sheet capable of moving the resin sheet conveyed to the range of the molding means in the width direction of the resin sheet. The molding position correction unit causes the conveyance amount adjustment unit to adjust the conveyance amount based on the acquired printing deviation amount, and causes the resin sheet movement unit to move the resin sheet in the width direction. The molding apparatus according to claim 1, wherein the positioning is performed by moving the molding apparatus.   The molding means includes an upper and lower mold sheet width direction moving means capable of moving the upper and lower molds with respect to the width direction of the resin sheet, and an upper and lower mold sheet capable of moving the upper and lower molds with respect to the length direction of the resin sheet. And the molding position correction means moves the upper and lower molds in the width direction of the resin sheet by the upper and lower mold sheet width direction moving means based on the acquired printing deviation amount, and 2. The molding apparatus according to claim 1, wherein the positioning is performed by moving the upper and lower molds in the length direction of the resin sheet by the mold sheet length direction moving means.   The conveying means includes a resin sheet moving means capable of moving the resin sheet conveyed to the range of the forming means with respect to the width direction of the resin sheet, and the forming means attaches the upper and lower molds to the resin sheet. It has an upper and lower mold sheet length direction moving means movable in the length direction, and the molding position correcting means moves the resin sheet in the width direction to the resin sheet moving means based on the acquired printing deviation amount. The molding apparatus according to claim 1, wherein the positioning is performed by moving the upper and lower molds in the length direction of the resin sheet by the upper and lower mold sheet length direction moving means.   The said imaging means has the resin sheet support means which supports the substantially printed site | part with which the said pattern was printed with respect to the substantially resin sheet conveyance surface, when imaging the said pattern. The molding apparatus according to any one of 5.   The imaging means is disposed on the resin sheet side opposite to the imaging side and irradiates the resin sheet with irradiation light, and between the resin sheet irradiation means and the resin sheet. The molding apparatus according to claim 6, further comprising: an irradiation light dispersion unit that is disposed and disperses the irradiation light with respect to the resin sheet. A molding method for molding a printed portion of a pattern on a resin sheet on which a pattern is printed,
A transporting step of transporting a continuous resin sheet on which a pattern is printed at a substantially constant interval while stopping the operation at the molding timing;
An imaging step of sequentially imaging the pattern at the molding timing;
A printing deviation amount storing step of sequentially storing the same amount of printing deviation while detecting the amount of printing deviation with respect to a predetermined reference pattern of the same pattern every time a pattern is imaged in the imaging step.
When the imaged resin sheet of the pattern is carried in the imaging step, a heating step for heating and softening the resin sheet carried in the same,
When the resin sheet having the upper and lower molds and heated and softened in the heating step is carried in, the upper and lower molds act on the resin sheet at the predetermined molding position at the molding timing, and the pattern printing is performed. Molding process for molding a molded product at a position;
When the molding process performs molding at the molding timing, the printing deviation amount stored in the storage process corresponding to the pattern to be molded is acquired, and the reference corresponding to the reference pattern is obtained based on the acquired printing deviation amount. And a molding position correcting step for aligning the upper and lower molds from the molding position to the molding position.

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