JP2019055595A - Box manufacturing method and box manufacturing system - Google Patents

Abstract

To provide a box manufacturing method and a box manufacturing system which can reduce the rate of manufacturing defective products, improve manufacturing efficiency, and achieve cost reduction.SOLUTION: A box manufacturing method comprises: conveyance means 2 for conveying a sheet material 10; folding guide mechanisms 3, which are provided on both left and right sides along the conveyance means 2, for folding the sheet material 10 conveyed by the conveyance means 2 at predetermined positions; control means 4 for controlling the operation of the folding guide mechanisms 3; detection means 5 for detecting inclinations of left and right sheet end sides constituting joint parts 12 of a box body 11 formed of a sheet material, which has been folded by the folding guide mechanisms 3; and correction means 6 for correcting the shape of the box body formed by the folding guide mechanisms after the box body has been shaped. The control means 4 automatically adjusts the operation of at least one of the conveyance means 2 and the folding guide mechanisms by feedback control on the basis of the inclinations detected by the detection means 5.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a box making method and a box making system that fold a sheet material and join end portions together to form a flat box.

  Conventionally, this type of box making system includes a conveying unit that conveys a sheet material, a folding guide mechanism that folds the sheet material conveyed by the conveying unit at a predetermined position, and operations of the conveying unit and the folding guide mechanism. A system including control means for controlling is known (for example, see Patent Document 1). As shown in FIG. 2A, the sheet material is finally processed into a cylindrical box body in which the end portions are joined via the joining pieces 13 for gluing. The gaps s1 and s2 are maintained at positions before and after the conveying direction with the joining piece 13 interposed therebetween, between the opposite sides 14a and 15a, 14b and 15b, that is, between the flaps 14A and 15A, and 14B and 15B, respectively. Has been. The gaps s1 and s2 are necessary for assembling the box 11 three-dimensionally.

  As the conveyance means of the box making system, a left and right conveyance belt disposed inside the left and right folds of the sheet as in Patent Document 1 is generally used. The conveying belt is provided with a pair of upper and lower belts that sandwich the sheet material from above and below in a section until the both ends of the sheet are bent at 90 degrees. As a folding guide mechanism for folding the sheet material in accordance with the conveyance, folding bars for gradually bending and guiding the left and right ends of the sheet from the lower side to the inner side are arranged on the left and right, respectively. Also, the section from the state where both ends of the sheet are bent at 90 degrees to the state where the sheet is further folded at 180 degrees is omitted because the lower conveyor belt interferes with folding. A suction mechanism for adsorbing the upper surface of the sheet is provided. As the folding guide mechanism during this period, a folding belt is provided that gradually folds and guides the left and right ends of the sheet from the inner side toward the upper side.

  As described above, in the conventional box making system, a belt is frequently used as a conveying means or a bending guide mechanism. However, the running speed of the belt shifts from side to side due to a difference in the rotational speed of the motor or slip between the driving pulley and the belt. In addition, slippage between the sheet material and the belt is unavoidable due to the force applied to the sheet material due to the frictional resistance between the folding bar and the sheet material. Due to such shifts and slips in travel speed, the joint 12 when processed as a box as shown in FIG. 2B easily shifts. In the example shown in the figure, the creases are shifted from one side to the other for easy understanding. However, in most cases, the creases are shifted from each other, and the degree of the shift varies greatly from sheet to sheet. If the gaps s1, s2 between the flaps are too small or too large, various defective products such as being unable to be assembled into a three-dimensional box or greatly deformed.

  For this reason, various proposals have been made such as measuring the rotational speed of the belt motor to make it coincide with each other and adjusting the folding mechanism (see, for example, Patent Documents 1 to 3). However, since the thickness and the surface state of each sheet material are different, the joining portion is always displaced. In particular, with thick paper such as corrugated cardboard material, the folding position changes greatly in a discontinuous manner depending on the position of the corrugated corrugated paper, so that the folding position deviates greatly for each sheet material, and the variation becomes significant. Therefore, in the conventional box making system, the worker is to visually observe the state of the joint portion of the box body, which is the first trial processed, in particular, the gaps s1, s2, and based on past experience, only the respective parts are adjusted, After that, a square ring part for performing right angle correction of the box after processing is separately provided (for example, refer to Patent Document 4), and defective products that cannot be corrected still are excluded in a later inspection process (for example, , See Patent Document 5).

  However, especially in the case of the above-mentioned cardboard, a paper with a large deviation cannot be corrected within the allowable range even in the square ring portion, resulting in a defective product. Defective products require a cumbersome operation such as cutting off and pulling out the band that has been once laminated and bound, causing a significant reduction in manufacturing efficiency and an increase in cost.

JP 2010-76150 A JP 2005-14411 A JP 2001-121624 A JP-A-9-165124 JP 2012-215468 A

  Therefore, in view of the above-described situation, the present invention intends to provide a box making method and a box making system that can reduce the incidence of defective products, improve production efficiency, and reduce costs. .

  In view of the present situation, the present inventor has intensively studied and inspected the state of the joint portion of the box body before being corrected at the square ring portion. With regard to the direction of inclination of the facing sheet material edge, it has been found that there is a tendency that the inclination in the same direction continues to some extent, and this inclination can be controlled by feeding back to the conveying means or folding guide mechanism In addition, if the tilt can be adjusted to some extent by left and right with Fordback control, it can be easily corrected to a non-defective product within the allowable range by further correction by the square ring part etc. even if the allowable range cannot be adjusted. The headline and the present invention were completed.

  That is, the present invention relates to a box making method in which sheet materials are folded and joined to form a flat box, and is provided on both left and right sides along the conveying means, and conveying means for conveying the sheet material. Joining of a folding guide mechanism for folding the conveyed sheet material at a predetermined position, control means for controlling the operation of the folding guide mechanism and the conveying means, and a box made of the sheet material folded by the folding guide mechanism Detecting means for detecting the inclination of the left and right sheet edges constituting the section, and the control means feeds back the operation of at least one of the bending guide mechanism and the conveying means based on the inclination detected by the detecting means. Provided is a box making method characterized by automatic adjustment by control.

  Here, the inclination is the inclination of the edge facing the gap between the left and right sheet edges excluding the bonding piece at the left and right sheet edge and the bonding area of the other sheet edge to which the bonding piece is bonded. Preferably there is.

  In addition, it is preferable that the inclination is an inclination angle of each edge with respect to the conveyance direction, or a relative inclination angle between the left and right sheet edges.

  Further, in the case where a correcting means for correcting the shape of the box formed by the bending guide mechanism is provided after the forming, the detecting means detects the inclination in the box before being corrected by the correcting means. Is preferred.

  Moreover, it is preferable that the said detection means detects the said inclination in the said box continuously after formation of the box by the said bending guide mechanism.

  The present invention also relates to a box making system that folds and joins sheet materials to form a flat box, and is provided on the left and right sides along the conveying means, conveying means for conveying the sheet material, A folding guide mechanism for folding the sheet material conveyed by the means at a predetermined position; a control means for controlling the operation of the folding guide mechanism and the conveying means; and a box body made of the sheet material folded by the folding guide mechanism. Detecting means for detecting the inclinations of the left and right sheet edges constituting the joint portion, and the control means operates at least one of the bending guide mechanism and the conveying means based on the inclination detected by the detecting means A box making system is also provided which is automatically adjusted by feedback control.

  Here, there is further provided correction means for correcting the shape of the box formed by the bending guide mechanism after forming, and the detection means detects the inclination in the box before being corrected by the correction means. preferable.

  Further, it is preferable that the detecting means detects the inclination in the box continuously after the formation of the box by the bending guide mechanism.

  Further, the detection means includes an imaging means for imaging at least the left and right sheet edges constituting the joint portion, and an arithmetic means for calculating the inclination of the sheet edge based on an image obtained by the imaging means. Those are preferred.

  According to the present invention as described above, there is provided detection means for detecting the inclination of the left and right sheet edges constituting the joint portion of the box folded by the bending guide mechanism, and based on the inclination detected by the detection means. Since the control means automatically adjusts the operation of at least one of the bending guide mechanism and the conveying means by feedback control, it can be controlled so that the deviation of the inclination of the sheet edge is eliminated, so that defective products can be reduced. Even if it is not possible to adjust to the acceptable range of acceptable products, it can be processed into a state that can be corrected to acceptable products within the acceptable range by further correction at the square ring etc., improving production efficiency and reducing cost can do.

BRIEF DESCRIPTION OF THE DRAWINGS Schematic explanatory drawing which shows the whole structure of the box making system which concerns on typical embodiment of this invention. Explanatory drawing which shows the box body boxed.

  Next, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

  As shown in FIG. 1, the box making system 1 according to the present invention is a processing system that folds and joins a sheet material 10 to form a flat box body 11, a conveying means 2 that conveys the sheet material 10, A bending guide mechanism 3 provided on the left and right sides along the conveying means 2 for folding the sheet material 10 conveyed by the conveying means 2 at a predetermined position, and a control means 4 for controlling the operation of the bending guide mechanism 3; The detecting means 5 for detecting the inclination of the left and right sheet edges constituting the joint portion 12 of the box 11 made of the sheet material folded by the folding guide mechanism 3 and the shape of the box formed by the folding guide mechanism. And a correcting means 6 for correcting after formation.

  Based on the inclination detected by the detection means 5, the control means 4 automatically adjusts the operation of at least one of the transport means 2 and the bending guide mechanism 3 by feedback control. The correction means 6 is not essential. In the following embodiments, an example in which a corrugated cardboard sheet that has been pre-printed and formed with a line (fold), a flap groove, and a joining piece (glue piece) is processed into a flat corrugated cardboard case will be described. However, the sheet material is not limited to a corrugated cardboard sheet, and various sheet materials can be used.

  As the conveying means 2, a conveying means used in a conventionally known box making system can be widely adopted. In this example, a pair of upper and lower conveying belts 20 and 21 are provided inside the left and right folds, respectively. A sheet material is sandwiched between the upper and lower conveyor belts 20 and 21 and conveyed. The lower conveying belt 21 is provided only as a section until the left and right sides of the sheet are folded at 90 degrees, and in the subsequent sections, a suction mechanism for adsorbing and conveying the upper surface of the sheet to the lower surface of the upper conveying belt 20 is provided instead. It has been. Specifically, the upper conveying belt 20 is provided with a suction hole, and a suction device 22 is provided on the upper side of the belt for sucking air through the hole and adsorbing the sheet material on the lower surface side. It has been.

  As for the bending guide mechanism 3, a bending guide mechanism used in a conventionally known box making system can be widely used. In this example, the folding bars 30 are provided on the left and right sides of the section until the left and right sides of the sheet are bent at 90 degrees. Guide members 31 for guiding the valley side (inner side) of the fold of the sheet material are similarly provided on the left and right. Further, in the section after the sheet is bent at 90 degrees, a folding belt 32 that further folds and guides the left and right ends of the sheet from the inner side to the upper side according to the conveyance is disposed, and the folds of the sheet material are arranged. A pressing roller 33 is provided to press from the outer side which is the mountain side toward the inner side.

  The control means 4 rotates the drive motor (not shown) that drives the conveyor belts 20 and 21, adjusts the left and right positions of the guide member 31, rotates the drive motor (not shown) that drives the folding belt 32, and rotates the folding belt. A computer including a calculation device and a storage device that controls the position adjustment operation, the left and right position adjustment operation of the pressing roller 33, and is connected to the calculation means 51 of the detection means 5 that is also configured by a computer. .

  The detecting means 5 is provided at a position for detecting the inclination of the box 11 before being corrected by the correcting means 6. Although the box 11 after the correction may be detected, since the inclination is changed by the correction, it is preferable before the correction. Specifically, the detection unit 5 measures the inclination of the sheet edge sides 14a and 15a (14b and 15b) based on at least the imaging unit 50 that images the joint 12 of the box 11 and the image obtained by the imaging unit 50. It comprises calculation means 51 for calculating. The imaging means 50 is installed at least below in order to take an image of the joint 12 on the lower surface side of the box 11 at the position where the box 11 is discharged from the transport means 2.

  As such a detection means 5, for example, a quality inspection apparatus described in JP2013-68544A or a determination apparatus disclosed in JP9-22464A can be used. In this example, the configuration of the quality inspection apparatus is adopted, and the shape accuracy of the box 11, the print quality of the surface, and the presence or absence of foreign matter are determined simultaneously with the inclination of the sheet end sides 14 a and 15 a (14 b and 15 b) of the joint portion 12. inspect. That is, an imaging unit (not shown) that images the upper surface of the box 11 immediately after being discharged from the conveying unit 2 is also provided, and both the upper and lower sides of the box 11 are imaged to perform the above-described various inspections simultaneously. . However, as for the lower surface side, in addition to imaging at such a location, it is possible in the middle of the conveying means 2, specifically, in the middle of being adsorbed and conveyed by the upper conveying belt.

  For feedback control, it is possible to accurately perform control without time lag by reflecting the inclination immediately after being folded and joined to the box 11, and the deviation from the transport direction can also be accurately calculated. However, it is also possible to take an image after the boxes 11 are once stacked and taken out. In this case, the relative inclination of the left and right sheet edge sides can be detected, and feedback control can be performed based on the relative inclination.

  The image pickup means 50 is an area sensor camera in which CCD image pickup devices are arranged in the vertical and horizontal directions. The number and arrangement of the cameras are not particularly limited as long as each region can be imaged, and the entire lower surface may be imaged by one camera. In particular, since the area of the lower surface having the joint is highly likely to be displaced from each other when folded, it is possible to improve the efficiency of misalignment arithmetic processing and the like by imaging the two areas sandwiching the joint with different cameras. Is preferable. It is also preferable to provide a line sensor camera in which CCD image sensors are arranged in a horizontal row on both sides. The imaging means on the upper surface side can be similarly applied.

  The calculating means 51 calculates the inclination of the end sides 14a, 15a (14b, 15b). Specifically, the edges 14a and 15a (14b and 15b) are detected from the density change of the captured image obtained from the imaging unit 50, and the inclination angle with respect to the transport direction is calculated. The edge detection may be performed after first detecting the corners of the flaps 14A, 15A (14B, 15B). The inclination may be a relative inclination angle between the left and right sheet edge sides 14a and 15a. In this example, the interval between the gaps s1 and s2 is also calculated. This interval may be the length of a line segment that connects the central portions of the end sides, or may be the length between corners, for example. Further, the area of the gap or the average length calculated from the area may be used.

  It is also a preferred embodiment that the information on the inclination angle of the sheet edge side and the interval between the gaps s1, s2 is displayed on a separately provided display device so that the operator can check the situation. In this case, it is also preferable to display not only the numerical values but also the captured images of the gaps s1 and s2 and the graphs of the left and right inclination angles together with the past several sheets. As a result, it is possible for the operator to separately adjust each part other than the operation of automatically performing feedback control by the control means 4.

  When the information on the inclination and the interval is transmitted to the control unit 4, based on this information, the control unit 4 performs feedback control for adjusting the operations of the transport unit 2 and the bending guide mechanism 3. Specifically, the information on the inclination and the interval is stored in the storage device, and the operation state of the conveying means 2 and the bending guide mechanism 3 stored in the storage device in advance, that is, the rotation of the driving motors of the conveying belts 20 and 21 is stored. Information on the speed, the left and right positions of the guide member 31 (such as the angular position of the stepping motor), the rotational speed of the drive motor of the folding belt 32, the position of the folding belt 32, the left and right positions of the pressing roller 33, and the inclination and interval From the above information, each part is set so that the interval is within a normal range, and the left / right inclination is parallel to the smaller angle with the other angle so that the angle with respect to the transport direction is zero. Adjust and control the operation.

  More specifically, in this example, feedback control is performed mainly on the operations of the conveyor belts 20 and 21 and the operation of the folding belt 32 based on the information on the inclination. In order to eliminate the difference when the inclinations of the left and right sheet edges are different, control is mainly performed to adjust the operation of the folding belt 32 (rotational speed and position of the motor). In order to make it coincide with the conveyance direction, feedback control for adjusting the operation (rotational speed of the motor) of the conveyance belts 20 and 21 is performed. Ford back control is performed to adjust mainly the left and right positions of the guide member 31 and the left and right positions of the pressing roller 33 based on the interval information. For these feedback controls, known feedback control methods such as PID control and PI control can be widely applied.

  Although detection of the interval between the gaps s1 and s2 is not essential, in this example, information on the interval is detected and used for feedback control. It is also used to judge defective products. It is also preferable that this interval information is not used for feedback control but only for defective product determination. This is because, in particular, when the interval is large, it is often possible to return to the normal range by correction by the correction means 6 without adjustment control. As for the inclination information, information having an inclination that is too large and is larger than a predetermined inclination that will not return to the allowable range even by correction may be a defective product.

  The straightening means 6 is composed of a square ring portion that performs right-angle straightening that has been widely used conventionally. Of course, other correction means may be configured.

  Although the embodiments of the present invention have been described above, the present invention is not limited to these embodiments, and can of course be implemented in various forms without departing from the gist of the present invention.

DESCRIPTION OF SYMBOLS 1 Box making system 2 Conveying means 3 Bending guide mechanism 4 Control means 5 Detection means 6 Correction means 10 Sheet material 11 Box body 12 Joint part 13 Joining piece 14A, 14B, 15A, 15B Flap 14a, 14b, 15a, 15b End 20 Conveying belt 21 Conveying belt 22 Suction device 30 Folding bar 31 Guide member 32 Folding belt 33 Pressing roller 50 Imaging means 51 Computing means s1, s2 Gap

Claims (10)

In a box making method of folding and joining sheet materials to form a flat box,
Conveying means for conveying the sheet material;
A folding guide mechanism that is provided on both the left and right sides along the conveying means and folds the sheet material conveyed by the conveying means at a predetermined position;
Control means for controlling operations of the bending guide mechanism and the conveying means;
Detecting means for detecting the inclination of the left and right sheet edges constituting the joint portion of the box made of the sheet material folded by the bending guide mechanism;
The box making method, wherein the control means automatically adjusts the operation of at least one of the bending guide mechanism and the conveying means by feedback control based on the inclination detected by the detection means.   The inclination is an inclination of the edge facing a gap between left and right sheet edges excluding a bonding piece at one of the left and right sheet ends and a bonding region of the other sheet edge to which the bonding piece is bonded. The box making method according to 1.   The box making method according to claim 1 or 2, wherein the inclination is an inclination angle of each edge with respect to a conveyance direction.   The box making method according to claim 1 or 2, wherein the inclination is a relative inclination angle between the left and right sheet edges.   2. When the correction means for correcting the shape of the box formed by the bending guide mechanism is provided after forming, the detection means detects the inclination in the box before being corrected by the correction means. The box making method of any one of -4.   The box making method according to any one of claims 1 to 5, wherein the detection means detects the inclination of the box continuously after the box is formed by the bending guide mechanism. A box making system that folds and joins sheet materials to form a flat box,
Conveying means for conveying the sheet material;
A folding guide mechanism that is provided on both the left and right sides along the conveying means and folds the sheet material conveyed by the conveying means at a predetermined position;
Control means for controlling operations of the bending guide mechanism and the conveying means;
Detecting means for detecting the inclination of the left and right sheet edges constituting the joint portion of the box made of the sheet material folded by the folding guide mechanism;
A box making system, wherein the control means automatically adjusts the operation of at least one of the bending guide mechanism and the conveying means by feedback control based on the inclination detected by the detection means. Further comprising a correcting means for correcting the shape of the box formed by the bending guide mechanism after forming,
The box making system according to claim 7, wherein the detecting means detects the inclination of the box before being corrected by the correcting means.   The box making system according to claim 7 or 8, wherein the detection means detects the inclination of the box continuously after the formation of the box by the bending guide mechanism.   The detection means includes: imaging means for imaging at least left and right sheet edge sides constituting the joint portion; and calculation means for calculating the inclination of the sheet edge side based on an image obtained by the imaging means. The box making system of any one of 7-9.

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