JP2020027323A - Quality control system and quality control method - Google Patents

Abstract

To provide a quality control system etc., capable of identifying information on a product being defective during production and easily finding a problem thereof.SOLUTION: A quality control system 1 is provided in a bag making machine 2 that processes a barrel material etc., which is a web-like film, while conveying it to produce bags. The quality control system 1 comprises a quality data generation part 303 which associates production information, based upon data obtained by a sensor 10 provided for a bag making machine 2 and related to production of bags, with control numbers of the bags to generate quality data. The production information includes information on bonding processing on the barrel material etc., which is performed in the production of the bags, information on conveyance of the barrel material etc., and information on shapes of the bags.SELECTED DRAWING: Figure 8

Description

  The present invention relates to a quality management system and a quality management method.

  In a bag making machine, web-like films are stacked one on top of the other and conveyed, these films are laminated at a predetermined position, processed into a bag shape, and finally the film is cut to produce a bag.

  In a conventional bag making machine, as a measure for preventing the occurrence of a defect, an approach of performing a defect determination from process data or the like obtained from a sensor has been performed. These data are stored in a computer or the like and are also used for identifying defective products.

  For example, Patent Document 1 describes a quality control system of a processing machine in a post-processing field of printing in which a trouble occurrence time in a processing machine can be specified using production history information. The range of products that are expected to be affected can be narrowed down.

JP 2004-178388 A

  However, conventional bag making machines and the processing machine of Patent Document 1 do not link individual products with information at the time of production, and when a defect is found by visual inspection of products after production, However, when a customer points out a defective product after shipment, it was not possible to identify information at the time of production of the product and to identify which process had a problem.

  Also, for quality control, it is important to obtain appropriate information that affects the quality of the product, but there is no fixed information on what information should be obtained. also to identify the information, it often can not be found anywhere on whether there has been a problem since there is no difference in its value when it is not the case at the time of failure.

  The present invention has been made in view of the above problems, and has as its object to provide a quality management system or the like that can identify information at the time of production of a defective product and easily find the problem.

  A first invention for solving the above-described problem is a quality control system in a manufacturing apparatus that manufactures a product by processing the workpiece while transporting the workpiece, provided in the manufacturing apparatus. Based on the data obtained by the sensor, the production information relating to the production of the product, has a quality data creation unit that creates quality data in association with the identification information of the product, the production information, when the production of the product A quality control system includes a process for bonding the workpiece to be performed, a process for transporting the workpiece, and a process for the shape of the product.

  According to the present invention, it is possible to create and accumulate product-specific quality data in which individual products are linked to production information at the time of production. As a result, production information can be easily specified from a single product after production, and the production state of the product can be analyzed, the cause of occurrence of a defect can be specified, and the occurrence of a defect can be prevented. In addition, by using the information on the bonding process, transport, and the shape of the product as described above as the production information, it is possible to obtain appropriate production information for quality control, which greatly affects the quality of the product. It is possible to easily specify the cause of the failure that could not be easily specified conventionally.

It is desirable to have a failure determination unit that determines the failure of a product using the production information.
As a result, it is possible to determine the defect of the product and prevent the outflow of the defective product.

It is also desirable to have a quality data recording unit for recording the quality data, and a tendency judgment unit for judging pass / fail of the tendency of the production information using the quality data.
By performing a trend analysis of production information based on the accumulated quality data, it is possible to prevent the occurrence of defective products.

It is preferable that a data display unit is provided for displaying the production information corresponding to the identification information of the product when the identification information of the product is input.
As a result, the corresponding production information can be confirmed from the product identification information, and the cause of the product failure can be easily specified.

It is preferable that the manufacturing device prints identification information of the product on the product. Further, it is preferable that the quality management system of the present invention further includes an identification information acquisition unit that acquires the identification information read by a reading device provided in the manufacturing apparatus.
By printing the identification information of the product, it is possible to easily trace the cause of the defective product from the quality data using the identification information printed on the defective product, which is preferable in terms of traceability. As the quality data, the printed identification information can be read from the reading device and easily associated with the production information of the product.

  A second invention is a quality control method in a manufacturing apparatus for producing a product by processing the workpiece while transporting the workpiece, wherein the quality data creating unit includes a sensor provided in the manufacturing apparatus. Based on the data obtained in, the step of creating quality data by linking the production information on the production of the product with the identification information of the product, wherein the production information is processed during the production of the product A quality control method includes a method for bonding an object, a method for conveying the workpiece, and a method for a shape of the product.

  According to the present invention, it is possible to provide a quality management system or the like that can identify information at the time of production of a product in which a defect has occurred and can easily find the problem.

The figure which shows the outline of the quality management system 1. Example of bag 5. The figure which shows the outline of the bag making machine 2. The figure explaining conveyance of body material 51 and bottom material 52. The figure explaining the processing of the bag 5. The figure which shows the heat seal unit 20. FIG. 2 is a diagram illustrating a hardware configuration of a computer 4. FIG. 2 is a diagram showing a functional configuration of the quality management system 1. An example of an installation location of the sensor 10. An example of the sensor 10. The figure which shows the relationship between the data obtained by the sensor 10, and production information. 4 shows an example of data acquisition timing by the sensor 10. 9 is a flowchart showing processing of the control device 3 and the computer 4; The figure explaining quality data. The figure explaining the trend analysis of production information. 4 is an example of a display screen of the display unit 44. The figure which shows the outline of the paper container manufacturing apparatus 9.

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

(1. Quality control system 1)
FIG. 1 is a diagram schematically showing a quality management system 1 according to an embodiment of the present invention. The quality management system 1 performs quality control of bags produced by the bag making machine 2, and includes a control device 3, a computer 4, an image inspection device 6, an alarm device 8, and the like.

  The bag making machine 2 is a soft packaging bag making machine, and is a manufacturing apparatus for processing a web-like film or the like to produce a bag.

  FIG. 2 shows an example of a bag 5 which is a product produced by the bag making machine 2. FIG. 2A is a view of the surface of the bag 5, and FIGS. 2B and 2C are views in the thickness direction of the bag 5 along lines AA and BB in FIG. 2A, respectively. It shows a cross section.

  The bag 5 has, for example, a body member 51, a bottom member 52, a punch hole 53, a side seal portion 54, a bottom seal portion 55, a notch portion 56, and the like, and a management number 57 for each bag 5 is printed at a predetermined position. .

  The body member 51 is a base material of the bag 5, and the bottom member 52 is disposed between the front and back body members 51 at the bottom of the bag 5. In the present embodiment, a resin film is used as the body member 51 and the bottom member 52, and the bag 5 is produced by laminating and finally cutting a web-like film.

  The side seal portion 54 is formed by bonding the front and back body members 51 and 51 on both sides of the bag 5, and the bottom seal portion 55 is formed by bonding the front and back body member 51 and the bottom member 52 at the bottom of the bag 5. It is formed.

  The punch hole 53 is formed at the intersection of the side seal part 54 and the bottom seal part 55. The notch portion 56 is a cut formed in the side seal portion 54. The management number 57 is identification information for identifying each bag 5.

  As shown in FIG. 3, the bag making machine 2 includes a paper feed unit 21, a transport unit 22, a processing unit 23, a discharge unit 24, a printing device 25, a reading device 26, and the like.

  The paper feeding section 21 is formed by winding a body material 51 or a bottom material 52 (workpiece), which is a web-like film, around a reel. Supply.

  The transport section 22 transports the body material 51 and the bottom material 52 and sends them out to the processing section 23. In the processing unit 23, the body member 51 and the bottom member 52 are conveyed with tension, and in the conveyance unit 22, an appropriate tension is applied to the body member 51 and the bottom member 52 by dancer rollers described later. In the present embodiment, it is assumed that the body member 51 and the bottom member 52 are intermittently conveyed, and the conveyance of a certain distance and the temporary stop of the conveyance are repeated.

  FIG. 4A is a top view of the state of conveyance of the body member 51 and the bottom member 52 (hereinafter, referred to as the body member 51 and the like), and FIG. 4B is a line CC of FIG. FIG.

  As shown in FIG. 4, in the present embodiment, the body material 51 and the like are transported in the longitudinal direction with the narrow bottom material 52 sandwiched between the two front and back body materials 51. An arrow a in FIG. 4A indicates the direction of transport of the trunk material 51 and the like. The bottom member 52 is disposed at the center in the width direction of the body member 51. The width direction of the body member 51 is a direction orthogonal to the longitudinal direction of the body member 51 in a plane. In this embodiment, it is assumed that a picture (not shown) is printed on the front and back body members 51 in advance.

  The processing unit 23 produces the bag 5 by performing processing such as bonding, punching, and cutting while transporting the body material 51 and the like.

  The processing part 23 has a punch part 231, a bottom heat seal part 232, a side heat seal part 234, a notch processing part 236, a body material cut part 237, and the like.

  As shown in FIG. 5A, the punch portion 231 forms a punch hole 53 penetrating through the body member 51 and the like at a predetermined position, and a general industrial punch or the like can be used.

  The bottom heat seal portion 232 and the side heat seal portion 234 perform bonding by heat sealing at portions corresponding to the bottom seal portion 55 and the side seal portion 54 of the bag 5 shown in FIG. The bottom seal portion 55 and the side seal portion 54 after the heat sealing are cooled by a cooling mechanism (not shown) of the bottom heat seal portion 232 and the side heat seal portion 234, respectively.

  In the bottom heat seal portion 232 and the side heat seal portion 234, heat is applied to the body member 51 and the like using the heat seal unit 20 illustrated in FIG. 6, and the body member 51 and the like are bonded by heat welding to be processed into a bag shape. .

  The heat seal unit 20 has an upper unit 20a and a lower unit 20b.

  The upper unit 20a includes a heater 201, a hot plate 202, and the like, and can move up and down. The heater 201 heats the hot plate 202. The hot plate 202 heats the body member 51 and the like and thermally welds it. For example, a metal plate can be used.

  The lower unit 20b includes a heater 203, a rubber plate 204, and the like. The heater 203 heats the body member 51 and the like. The rubber plate 204 is for sandwiching the body member 51 and the like between the hot plate 202 of the upper unit 20a.

  The heat seal unit 20 lowers the upper unit 20a as shown by the arrow in FIG. 6A when the transfer of the body material 51 and the like is temporarily stopped, and heats the upper unit 20a as shown in FIG. The body member 51 and the like are sandwiched between the plate 202 and the rubber plate 204 of the lower unit 20b, and the body member 51 and the like are heated and thermally welded to be bonded. When the bonding is completed, the upper unit 20a is raised as shown by the arrow in FIG. 6C, and the conveyance of the body 51 and the like is resumed as shown in FIG. Send out.

  FIG. 6 shows an example of the side heat seal portion 234, and the side seal portion 54 is formed by thermal welding between the body members 51 on the front and back sides. With respect to the bottom heat seal portion 232, the heat seal unit 20 operates in the same manner, so that the front and back body members 51 and the bottom member 52 are thermally welded to form the bottom seal portion 55.

  As shown in FIG. 5C, the notch processing portion 236 forms a cut in the body 51 at a position corresponding to the notch portion 56 of the bag 5, and a cutter or the like is used.

  The body material cutting portion 237 cuts the body material 51 and the like at a cutting line b1 in the longitudinal direction of the body material 51 and a cutting line b2 in the width direction of the body material 51 shown in FIG. Is separated into individual bags 5 (see FIG. 2A), and a cutter or the like can be used.

  Returning to the description of FIG. The discharge unit 24 discharges each bag 5 produced by the processing unit 23, and uses a belt conveyor or the like. In this embodiment, non-defective products are ejected and defective products are rejected in accordance with the result of the defective judgment of the bag 5.

  The printing device 25 prints the management number 57 of the bag 5, and an ink jet printer, a laser marker, or the like can be used. The management number 57 is identification information for identifying each of the bags 5, and a plurality of numbers and characters arranged as shown in FIG. 2A are used. In the example of FIG. 2A, the management number 57 itself is printed on the bag 5. However, the management number 57 may be printed as a code such as a barcode or a two-dimensional code.

  The reading device 26 reads the management number 57 of the bag 5. As the reading device 26, a camera, a code reader, or the like can be used. In the present embodiment, the printing device 25 and the reading device 26 are disposed in front of the punch unit 231, and the printing of the management number 57 by the printing device 25 and the reading of the management number 57 by the reading device 26 are performed before punching. The positions of the printing device 25 and the reading device 26 are not particularly limited.

  Returning to the description of FIG. The control device 3 controls the operation of the bag making machine 2. In this embodiment, the control device 3 creates quality data from production information based on data (measurement data and image data described later) obtained by sensors of the bag making machine 2. The failure determination of the bag 5 is executed. The sensors, production information, and quality data will be described later. As the control device 3, for example, a PLC (programmable logic controller) is used, but it is not limited to this. It is also possible to use a computer as shown in FIG.

  The computer 4 records quality data and the like, determines the tendency of production information, and the like.

  FIG. 7 is a diagram illustrating a hardware configuration of the computer 4. The computer 4 includes, for example, a control unit 41, a storage unit 42, an input unit 43, a display unit 44, a communication control unit 45, and the like connected by a bus. However, without being limited to this, various configurations can be appropriately adopted.

  The control unit 41 includes a CPU, a ROM, a RAM, and the like. The CPU calls a program related to the processing of the computer 4 stored in the storage unit 42, the storage medium such as the ROM, and executes the program in the work area on the RAM. The ROM is a non-volatile memory, and permanently stores programs such as a boot program and BIOS, data, and the like. The RAM is a volatile memory, and temporarily stores programs and data loaded from the storage unit 42, the ROM, and the like, and includes a work area used by the control unit 41 to perform various processes.

  The storage unit 42 is a hard disk drive, a solid state drive, a flash memory, or the like, and stores a program executed by the control unit 41, data necessary for executing the program, an OS, and the like. These programs and data are read and executed by the control unit 41 as needed.

The input unit 43 is a keyboard, a mouse, or the like, and performs various setting inputs to the computer 4.
The display unit 44 is, for example, a liquid crystal display or the like.
The communication control unit 45 is a communication interface that mediates communication via a network or the like, and communicates with the control device 3, the image inspection device 6, and the like.

  The image inspection device 6 analyzes image data of the body 51 and the like obtained by the sensor of the bag making machine 2 and transmits the analysis data to the control device 3. Further, the image inspection device 6 transmits image data of the body material 51 and the like to the computer 4. As the image inspection device 6, the computer described in FIG. 7 can be used. The analysis data will be described later.

  The warning device 8 issues a visual or audible warning in accordance with the result of the defect determination in the control device 3 or the result of the tendency determination in the computer 4. As the alarm device 8, for example, a general signal light, a speaker, or the like can be used.

  FIG. 8 is a diagram showing a functional configuration of the quality management system 1. As shown in FIG. 8, the quality management system 1 includes a data acquisition unit 301, an identification information acquisition unit 302, a quality data creation unit 303, a failure determination unit 304, a quality data recording unit 401, a tendency determination unit 402, and an image data recording unit. 403, a data display unit 404, and the like.

  The data acquisition unit 301 is for the control device 3 to acquire the measurement data obtained by the sensor 10 and the analysis data obtained by the image inspection device 6 from the sensor 10 and the image inspection device 6.

  The identification information acquisition unit 302 is for the control device 3 to acquire the management number 57 of the bag 5 read by the reading device 26 from the reading device 26.

  In the quality data creation unit 303, the control device 3 creates quality data by linking the production information with the management number 57.

  The defect determination unit 304 is for the control device 3 to determine the defect of the bag 5 using the production information of the quality data.

  The quality data recording unit 401 is for the computer 4 to record the quality data in the storage unit 42.

  The tendency determining unit 402 is for the computer 4 to determine whether the tendency (time transition) of the production information is good or bad using the quality data.

  The image data recording unit 403 is for the computer 4 to receive image data of the body material 51 and the like from the image inspection device 6 and record the image data in the storage unit 42.

  The data display unit 404 displays the production information corresponding to the management number 57 on the display unit 44 in response to the input of the management number 57 of the bag 5 by the computer 4.

(2. Sensor 10 and production information)
In the present embodiment, sensors 10 for obtaining data serving as a source of production information regarding the production of bags 5 are attached to various parts of the bag making machine 2. FIG. 9 is an example of a location where the sensors 10 (10a to 10e) are installed in the bag making machine 2.

  The sensor 10 is broadly divided into a sensor for obtaining data which is a source of production information on the shape of the bag 5, a sensor for obtaining data which is a source of production information on bonding processing of the body 51, and the like. There is one for obtaining data which is a source of production information on transportation such as 51.

(2-1. A sensor for obtaining data that is a source of production information on the shape of the bag 5; sensor 10a)
The sensors 10a (10a-1 to 10a-3) are arranged on the transport path of the body 51 and the like, and photograph the body 51 and the like being transported as shown in FIG. For example, a camera is used as the sensor 10a, and image data obtained by photographing the body member 51 and the like is transmitted to the image inspection device 6. The image inspection device 6 obtains analysis data on the shape of the bag 5 by analyzing the image data, and transmits the analysis data to the control device 3.

  The sensor 10a-1 is disposed, for example, at the subsequent stage of the punch unit 231, and captures an image of the body 51 and the like (see FIG. 5A) immediately after the punch holes 53 are made. The image inspection device 6 analyzes the image data to determine the position of the punched hole 53 and transmits the position to the control device 3 as analysis data. If the punched holes 53 are not formed at appropriate positions, the holes may be broken at the time of drilling or the contents may flow out due to a shift in the processing position.

  The sensor 10a-2 is disposed, for example, at a stage subsequent to the side heat seal unit 234, and photographs the body member 51 and the like after heat sealing (see FIG. 5B). The image inspection apparatus 6 analyzes the image data to determine the position of the side seal portion 54 and the bottom seal portion 55 (hereinafter, the side seal portion 54 and the bottom seal portion 55 may be referred to as a seal portion), and obtains the analysis data. To the control device 3. If the position of the seal portion is not appropriate, the filling of the bag 5 due to insufficient capacity may be caused.

  The sensor 10a-3 is disposed, for example, at the subsequent stage of the body material cutting section 237, and is configured to cut the individual bags 5 (see FIG. 2A) after cutting along the cutting lines b1 and b2 shown in FIG. 5D. Shoot. The image inspection device 6 analyzes the image data to determine the cut position of the body member 51 and the position of the notch portion 56, and transmits the data to the control device 3 as analysis data. These positions can be obtained as relative positions with respect to a reference point (a specific picture or the like) of the body member 51. If the positions are not appropriate, poor appearance or poor function will result.

  FIG. 11A summarizes the above, and analyzes data obtained by analyzing the image data obtained by the sensor 10 a with the image inspection device 6 (the position of the punch hole, the position of the seal portion, the cut of the body 51). The position and the position of the notch 56) are sent to the control device 3 and used as production information on the overall shape of the bag 5.

(2-2. Sensors for Obtaining Data on Which Production Information on Bonding of Body Material 51 and the Like is Obtained; Sensors 10b, 10c, and 10d)
As shown in FIG. 6, the sensors 10b, 10c, and 10d are provided in the heat seal unit 20 of the bottom heat seal unit 232 and the side heat seal unit 234.

  The sensor 10b is a sensor for measuring the height of the upper unit 20a, and for example, a distance sensor for measuring a distance from the sensor 10b to the upper unit 20a is used.

  The sensor 10b continuously measures the height of the upper unit 20a when sealing is performed at predetermined time intervals, and transmits the measurement data to the control device 3. The control device 3 obtains the sealing time and the sealing pressure from the height value received from the sensor 10b and its time transition, and uses it as production information.

  That is, during the operation of the heat seal unit 20 described with reference to FIGS. 6A to 6D, the height of the upper unit 20a decreases during the lowering of the upper unit 20a (see FIG. 6A), During sealing (see FIG. 6B), the value is relatively stable at a low value, and increases while the upper unit 20a is ascending (see FIG. 6C). The sealing time can be obtained from the time transition of the height of the upper unit 20a as a time during which the height of the upper unit 20a is a low value and the fluctuation is within a certain range.

  Since the sealing pressure is correlated with the height when the upper unit 20a is at the lowest position, that is, the height of the upper unit 20a during sealing, the height can be used as the sealing pressure. The height can be obtained as an average value or a minimum value of the height of the upper unit 20a during the above-mentioned sealing time from the time transition of the height of the upper unit 20a measured by the sensor 10b. The sealing time and the sealing pressure affect the sealing strength, and if these values are not appropriate values, the leakage of the contents due to insufficient sealing strength is caused.

  The sensor 10c is a thermocouple that measures the heating temperature of the body member 51 and the like, and the sensor 10d is a radiation thermometer that measures the temperature of the seal immediately after sealing (before cooling). These temperatures are correlated with the temperatures generated in the body member 51 and the like during sealing, and if not appropriate values, there is a possibility that the contents may flow out due to insufficient sealing strength.

  The sensor 10c is attached to the hot plate 202 as shown in FIG. 6, and continuously measures the surface temperature of the hot plate 202 at the time of sealing as a heating temperature of the body member 51 or the like at predetermined time intervals. The measurement data of the sensor 10c is transmitted to the control device 3, and the control device 3 uses the measurement data of the sensor 10c during the sealing time as production information.

  The sensor 10d is provided on the transport path of the body 51 and the like, and measures the surface temperature of the seal portion of the body 51 sent from the heat seal unit 20 in a non-contact manner as shown in FIG. Data measured by the sensor 10d is transmitted to the control device 3 and used as production information.

  FIG. 11B summarizes the above, and the measurement data (the height of the upper unit, the heating temperature) obtained by the sensors 10b and 10c is sent to the control device 3, and from the measurement data, the bonding process is performed. As the production information, the sealing time, the sealing pressure, and the heating temperature during the sealing time are obtained. Further, the measurement data (temperature of the seal portion) obtained by the sensor 10d is sent to the control device 3, and is similarly used as production information on the bonding process.

(2-3. Sensors for Obtaining Data on Which Production Information is Conveyed Regarding Transportation of Body Material 51 and the Like; Sensors 10e, 10f, 10g, and 10h)
The sensor 10e is a pressure sensor provided in the transport unit 22, and measures the air pressure of the air cylinder 222 used for controlling the position of the dancer roller 221 as shown in FIG. Data measured by the sensor 10e is transmitted to the control device 3 and used as production information. The air pressure is directly linked to the control of the feed amount of the body 51 and the like, and the control of the feed amount of the body 51 and the like cannot be performed well unless the air pressure is in an appropriate range.

  The sensor 10f is disposed on the transport path of the body 51 and the like, like the sensor 10a of FIG. 10A, and photographs a specific pattern (not shown) of the body 51 while the body 51 and the like are temporarily stopped. The image inspection device 6 analyzes the image data, obtains a deviation of the pattern from the reference position as a deviation of the feed amount of the body member 51 and the like, and transmits the deviation to the control device 3 as analysis data. If this shift amount is large, it leads to a shift in the processing position in the processing unit 23. In the present embodiment, the sensor 10f is arranged at a stage preceding the bottom heat seal portion 232, but is not limited to this.

  The sensors 10g are also arranged on the transport path of the body 51 and the like, and a pair of sensors 10g are provided so as to sandwich the body 51 and the like as shown in FIG. These sensors 10g capture the same plane position of the front and back body members 51, respectively. The image inspection device 6 detects the pattern of the front and back body members 51 from the image data, obtains the positional deviation amount of the front and back body members 51 based on the positions of the patterns, and transmits the displacement to the control device 3 as analysis data. If this shift amount is large, it leads to poor appearance due to the shift of the picture on the front and back. In the present embodiment, the sensor 10g is disposed downstream of the side heat seal portion 234 in the transport path of the body material 51 and the like, but is not limited thereto.

  The sensor 10h is also disposed on the transport path of the body 51 and the like, and captures an image of the body 51 and the like, similarly to the sensor 10a of FIG. The image inspection device 6 obtains the position of the bottom member 52 from the image data, and transmits it to the control device 3 as analysis data. If the bottom material 52 is not at an appropriate position, the appearance and the function of the bag 5 may be poor. In the present embodiment, the sensor 10h is disposed at a stage preceding the bottom heat seal portion 232 in the transport path of the body material 51 and the like, but is not limited thereto.

  FIG. 11C summarizes the above, and the measurement data (air pressure) obtained by the sensor 10e is sent to the control device 3 and is used as production information on the conveyance of the body material 51 and the like. The analysis data (deviation in feed amount, displacement of the front and back body members 51, and position of the bottom member 52) obtained by analyzing the image data obtained by the sensors 10f, 10g, and 10h by the image inspection device 6 are controlled. It is sent to the device 3 and is used as production information on the conveyance of the body material 51 and the like.

(2-4. Timing of Data Acquisition of Sensor 10)
As described above, in the present embodiment, data (image data and measurement data) is obtained by the sensor 10 as shown in FIG. I have. Conveying such cylinder member 51 is performed for each distance corresponding to one bag 5 L (see FIG. 5 (d)), after obtaining the data for the portion of the bag 5 _n to be as shown in FIG. 12 (a) Then, as shown by an arrow a in FIG. 12B, the body material 51 and the like are conveyed by the above-described distance L, and data on the next bag 5n _{+ 1} is obtained as shown in FIG. FIG. 12 shows a sensor 10 a that obtains image data as an example of the sensor 10.

(3. Quality control method)
FIG. 13 is a flowchart illustrating the quality management method according to the present embodiment. S1 to S9 in FIG. 13 are processes executed by the control device 3, and S10 to S16 in FIG. 13 are processes executed by the control unit 41 of the computer 4.

  In this embodiment, while the bag making machine 2 is operating, the body material 51 and the like are intermittently transported as described above, and data is obtained by the sensor 10 during the temporary stop. As shown in FIG. 11, the sensors 10b, 10c, 10d, and 10e transmit their measurement data directly to the control device 3, and the control device 3 receives these measurement data from the sensors 10b, 10c, 10d, and 10e. Acquire (S1).

  On the other hand, image data obtained by photographing the body material 51 and the like by the sensors 10a, 10f, 10g, and 10h is sent to the image inspection device 6. The image inspection apparatus 6 analyzes the image data and analyzes the above-described analysis data (the position of the punched hole 53, the position of the seal portion, the cut position of the body 51 and the position of the notch 56, the displacement of the feed amount of the body 51, etc. The position shift of the front and back body members 51 and the position of the bottom member 52 are obtained and transmitted to the control device 3. The control device 3 receives and acquires these analysis data from the image inspection device 6 (S2).

  The reading device 26 reads the management number 57 printed by the printing device 25 and transmits the management number 57 to the control device 3. The control device 3 receives and acquires the management number 57 from the reading device 26 (S3).

  The control device 3 creates quality data by linking production information based on the measurement data received in S1 and the analysis data received in S2 with the management number 57 (S4).

  As described with reference to FIG. 11, the analysis data received from the image inspection device 6 is used as it is as production information, and the measurement data (the temperature of the seal portion and the air pressure) of the sensors 10d and 10e are also used directly as production information. As described above, for the measurement data of the sensors 10b and 10c, the control device 3 determines the sealing time, the sealing pressure, and the heating temperature during the sealing time from the measurement data, and uses these values as production information.

  FIG. 14A shows an example of the association between the production information and the management number 57. In the present embodiment, after the management number 57 of the bag 5 is read by the reading device 26, the transport required for the portion of the bag 5 to be transported by the sensor 10 to a position where data (the measurement data and the image data) is obtained. The number of times is set in advance for each sensor 10. In FIG. 14A, d1 is an example, and after the reading device 26 reads the management number 57 of the bag 5 and the body 51 or the like is transported d1 times, the portion of the bag 5 moves to the position of the sensor 10d. Then, the temperature of the seal portion is measured by the sensor 10d.

  Therefore, the management number 57 read by the reading device 26 when the body 51 or the like has been transported N times is linked to the temperature (production information) of the seal portion measured by the sensor 10d when the body 51 or the like has been transported N + d1 times. .

  The same applies to the case where the data of the bag 5 has already been obtained by the sensor 10 before the reading device 26 reads the management number 57 of the bag 5.

  For example, in this embodiment, before reading the control number 57 of the bag 5 by the reading device 26, at the time when the control number 57 is printed by the printing device 25, the air pressure is measured by the sensor 10e as production information on the portion of the bag 5 I do. In the present embodiment, the number of transports d2 required for the body 51 and the like to be transported from the printing device 25 to the reading device 26 is also set in advance, and the bag read by the reading device 26 when the body 51 and the like are transported N times. The management number 57 of No. 5 can be linked with the air pressure (production information) measured by the sensor 10e when the body material 51 or the like is transported Nd twice.

  In this way, as shown in FIG. 13B, the production information 100 of the bag 5 is linked to the management number 57 of the bag 5, and quality data is created. If necessary, information such as the production time, lot number, and product type of the bag 5 may also be acquired and linked to the management number 57.

  The control device 3 transmits the created quality data to the computer 4 (S5), and determines the failure of the bag 5 using the production information 100 of the quality data (S6).

  In the determination of S5, for example, a defect determination is performed based on whether or not the value a of a certain piece of production information 100 is within a predetermined range, or a combination (a, b) of a plurality of values a and b of the pieces of production information 100 is determined. Although it is possible to make a failure determination based on whether or not it is within a predetermined range, the determination method is not particularly limited. Criteria (such as the above-described predetermined range) used for the defect determination can be set from the computer 4.

  If it is determined in S6 that there is no defect (S7; NO), the process is terminated as it is, but if it is determined that there is a defect (S7; YES), the control device 3 outputs a reject signal to the bag making machine 2 (S7). S8) The bag 5 having the defect is rejected by the discharge unit 24. The control device 3 outputs an alarm signal to the alarm device 8 (S9), and causes the alarm device 8 to generate a visual or audible alarm. This makes it possible to discharge defective products from the production line and prevent them from flowing out. Instead of rejecting the defective product, if the defective product is generated, the bag 5 can be discharged in a state where the two left and right bags are connected without cutting along the cutting line b1. It is also possible to select defective products visually.

  On the other hand, the computer 4 acquires image data of the body material 51 and the like captured by the sensors 10a, 10f, 10g, and 10h from the image inspection device 6 (S10), and records the image data in the storage unit 42 (S11).

  Further, when the computer 4 receives the quality data transmitted from the control device 3 in S5 (S12), the computer 4 records the quality data in the storage unit 42 (S13), and as shown in FIG. And accumulate quality data for each. The image data of each bag 5 recorded in S11 can be linked with the quality data of the bag 5.

  Subsequently, the computer 4 performs a trend analysis of the production information 100 from the accumulated quality data, and determines whether or not the trend (time transition) is good (S14). In S14, the computer 4 performs a trend analysis of each piece of production information 100, and determines whether a failure is likely to occur due to factors such as device deterioration. An example will be briefly described with reference to FIG. 15. For example, even if the deviation of the feed amount, which is the production information 100, does not exceed the threshold at the current time t, if the time transition is likely to exceed the threshold soon, It is determined that the tendency of the shift of the feed amount is not. The trend analysis of the production information 100 can use the SPC (statistical process control) method, the MT (maharano bis Taguchi) method, or the like. The result of the trend analysis of the production information 100 determines whether there is any problem in the transition. Failure can be prevented. Criteria such as a threshold used for the determination can be set from the computer 4.

  If it is determined in S14 that the tendency of the production information 100 is good (S15; YES), the process is terminated as it is (S15; NO). Is output (S16), and a visual or audible alarm is generated from the alarm device 8. This can alert the operator.

  The quality control in the bag making machine 2 is performed as described above, and the storage unit 42 of the computer 4 accumulates the production information 100 linked to the management number 57 of each bag 5.

  When a defect of the bag 5 is found by a visual inspection or the like, the operator inputs the management number 57 of the bag 5 to the computer 4. When the management number 57 is input, the computer 4 refers to the quality data in the storage unit 42, extracts the production information 100 corresponding to the management number 57, and displays it on the display unit 44 of the computer 4. FIG. 16 shows an example of the display screen.

  As described above, the production time, the lot number, the product type, and the like can be linked to the production information 100 in addition to the management number 57. By inputting the values of these items, the production information 100 corresponding to the relevant value is input. Can be extracted and displayed. Further, by designating the specific production information 100, it is possible to display a certain number of latest data on the production information 100 or the like. The display format of the production information 100 differs depending on the purpose of display, and is not particularly limited. For example, it can be displayed in the form of a table, a line graph, an area graph, a pie graph, or the like.

  As described above, in the present embodiment, it is possible to create and accumulate product-specific quality data in which the management number 57 of each bag 5 and the production information 100 at the time of production are linked. As a result, the production information 100 can be easily specified from the bag 5 after the production, and the production state of the bag 5 can be analyzed, the cause of the failure occurrence can be specified, and the failure occurrence can be prevented. In addition, as described above, by using the information on the bonding process of the body material 51 and the like, the conveyance, and the shape of the bag 5 as the production information 100, the quality of the bag 5 is greatly affected. 100 can be obtained, and it is possible to specify the cause of the failure which could not be easily specified conventionally.

  Further, in the present embodiment, it is possible to prevent the outflow of defective products by performing the defect determination of the bag 5 using the production information 100, and to analyze the tendency of the production information 100 based on the accumulated quality data, thereby performing the bag analysis. It is possible to prevent the occurrence of defective products.

  Further, in this embodiment, when the management number 57 of the bag 5 is input to the computer 4, the production information 100 corresponding to the management number 57 is displayed. The production information 100 to be checked can be confirmed, and the cause of the failure of the bag 5 can be easily specified.

  Further, in the present embodiment, by printing the management number 57 on the bag 5, it is possible to easily trace the cause of the defective product from the quality data using the control number 57 printed on the defective product, and in terms of traceability. preferable. As the quality data, the printed management number 57 can be read from the reading device 26 and easily associated with the production information 100 of the bag 5.

  However, the present invention is not limited to this. For example, the bag 5 is not limited to FIG. 2 and may have various shapes as needed. The production information 100 is not limited to the above, and data of temperature and humidity at the time of production of the bag 5 may be recorded.

  Instead of reading by the reading device 26, a management number 57 for printing by the printing device 25 can be directly transmitted to the control device 3, and the management number 57 can be linked to the production information 100. The device 26 can be omitted. Further, the management number 57 may be printed in advance on the body material 51 or the like in the previous process or the like. In this case, the production information obtained in the previous process can be linked as quality data.

  Further, the sensor 10 is not limited to the one described above. For example, an encoder may be used in place of the sensor 10f, and the deviation of the feed amount of the body member 51 or the like may be obtained using the encoder. However, since the feed amount detected by the encoder does not always coincide with the actual feed amount due to the tension of the body member 51 or the like, the sensor 10f ( Camera) is better.

  Further, in the present embodiment, the body material 51 and the like are intermittently conveyed, but the present invention is not limited to this. When the intermittent conveyance is not performed, the management number 57 of the bag 5 and the production information 100 can be linked by setting a conveyance time in advance instead of the number of times of conveyance.

  For example, instead of the number of times of conveyance d1 in FIG. 14A, after reading the management number 57 of the bag 5 with the reading device 26, the conveyance required for the portion of the bag 5 to be conveyed to the position where data is obtained by the sensor 10d. Predetermine the time. Then, the management number 57 of the bag 5 read by the reading device 26 at a certain time may be linked to the surface temperature of the seal portion measured by the sensor 10d when the above-described transport time has elapsed from that time.

  In addition, a separate sensor for detecting the control number 57 is provided in association with each sensor 10, and production information based on data obtained by each sensor 10 is linked to the control number 57 detected by the sensor associated with the sensor 10. You may.

  Further, in the present embodiment, an example of the bag making machine 2 has been described. However, the present invention is not limited to this, and can be applied to other manufacturing apparatuses, for example, a paper container manufacturing apparatus.

  The paper container manufacturing apparatus produces a paper container (product) by a sack sticking process or a frame sealer process while transporting a paper (workpiece) serving as a base material. And the shape of the paper container can be used.

  FIG. 17 is a view schematically showing the manufacturing apparatus 9 that executes the sack sticking process, and includes a paper feeding unit 91 that supplies paper, a processing unit 92 that processes paper, and a discharge unit 93 that discharges a paper container that has processed paper. ing. The processing unit 92 includes an application unit 921 that applies an adhesive to a bonded portion of the paper, a folding unit 922 that performs a folding process on the paper, and a pressure-conveying unit 923 that presses the paper and bonds the paper at the bonded portion. .

  In this case, for example, the deviation (meandering) of the sheet from the regular conveyance position is measured by a photoelectric sensor or the like as production information on the sheet conveyance state, and the amount of pressure applied by the pressure-contact conveyor unit 923 as production information on the sheet adhesion state. Is measured by a pressure sensor. Further, as production information relating to the shape of the paper container, a folding position of the paper is determined from image data obtained by the sensor, and the production information is linked with identification information to be printed on the paper container (paper) by a printing device (not shown). It is possible to create quality data. Such production information also leads to poor appearance of the paper container, insufficient bonding strength, and the like, and can be effectively used for quality control.

  As described above, the preferred embodiments of the present invention have been described with reference to the accompanying drawings, but the present invention is not limited to such examples. It will be apparent to those skilled in the art that various changes or modifications can be made within the scope of the technical idea disclosed in the present application, and these naturally belong to the technical scope of the present invention. I understand.

1: quality control system 2: bag making machine 3: control device 4: computer 5, bag 6: image inspection device 8, alarm device 9, paper container manufacturing device 10, sensors 21, 91: paper feed unit 22, transport unit 23 , 92: processing unit 24, 93: discharge unit 25: printing device 26: reading device 51: body material 52: bottom material 53: punch hole 54: side seal portion 55: bottom seal portion 56: notch portion 57: management number 301 : Data acquisition unit 302: identification information acquisition unit 303: quality data creation unit 304: defect determination unit 401: quality data recording unit 402: tendency determination unit 403: image data recording unit 404: data display unit

Claims (7)

A quality control system in a manufacturing apparatus that produces a product by processing the workpiece while transporting the workpiece,
Based on data obtained by a sensor provided in the manufacturing device, based on data obtained by the production of the product, having a quality data creating unit that creates quality data in association with the identification information of the product,
The production information,
A quality control system comprising: a process for bonding the workpiece performed during production of the product; a process for transporting the workpiece; and a process for the shape of the product.   The quality management system according to claim 1, further comprising a defect determination unit that determines a defect of a product using the production information. A quality data recording unit that records the quality data,
A tendency determining unit that determines whether the tendency of the production information is good or bad using the quality data;
The quality management system according to claim 1, wherein the quality management system comprises:   The quality control according to any one of claims 1 to 3, further comprising a data display unit that displays the production information corresponding to the identification information of the product when the identification information of the product is input. system.   The quality management system according to claim 1, wherein the manufacturing apparatus prints identification information of the product on the product.   6. The quality management system according to claim 5, further comprising an identification information acquisition unit configured to acquire the identification information read by a reading device provided in the manufacturing apparatus. A quality control method in a manufacturing apparatus for producing a product by processing the workpiece while transporting the workpiece,
A quality data creating unit, based on data obtained by a sensor provided in the manufacturing apparatus, has a step of creating quality data by linking production information on the production of the product with identification information of the product,
The production information,
A quality control method comprising: a process for bonding the workpiece performed during production of the product; a process for transporting the workpiece; and a process for the shape of the product.

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