JP5871581B2 - Apparatus and method for separating molded articles - Google Patents

Description

  The present invention relates to a technique for separating a molded product from a molded product stack obtained by stacking molded products.

  The tray separating apparatus disclosed in Patent Document 1 includes a U-shaped arm (publication number 8) including a plurality of tray separation units (publication number 25), a U-shaped arm driving unit (publication number 18), and a push-up member (publication number). 11), and each tray stacked with the convex portion described as the inner outer end facing upward is separated upward from the tray group (publication reference 100). The tray separation unit is a synthetic resin rotation separation portion (publication reference number 27) in which an upper half-moon plate (publication number 28), a lower half-moon plate (publication number 29), and a connecting portion (publication number 30) are integrally formed. And an air cylinder (publication code 26) having an air cylinder rotation shaft (publication code 26a) integrated with the rotation separation unit.

At the initial stage when the air cylinder rotation shaft rotates to the first predetermined position, the upper half-moon claw portion (publication reference numeral 28a) of the upper half-moon plate abuts on the upper surface of the convex portion of the uppermost tray and moves upward on the uppermost tray. The lower half-moon claw portion (publication reference numeral 29a) of the lower half-moon plate is located outside the tray group and is located between the hook portion of the uppermost tray and the hook portion of the immediately lower tray.
When the air cylinder rotation shaft is rotated by a predetermined angle to the second predetermined position, the upper half-moon claw is in contact with the upper surface of the convex portion of the uppermost tray and prevents the upper tray from moving upward, and the lower half-moon claw The portion overlaps with the flange portion of the immediate lower tray in plan view and is between the flange portion of the uppermost tray and the flange portion of the immediately lower tray.
When separating the tray with the air cylinder rotating shaft rotated by a predetermined angle to the third predetermined position, the upper half-moon claw is located outside the tray group, and the lower half-moon claw overlaps with the bottom of the tray in the plan view. Located between the ridge of the tray and the ridge of the tray directly below. Thereby, the uppermost tray is separated upward, and the tray transport unit (publication code 3) transports the uppermost tray to an appropriate transport destination.
When the transport operation is finished, each tray separation unit is rotated back to the initial location by each air cylinder. When the number of trays in the tray group decreases, the push-up member pushes up the tray group.

JP 2007-314330 A

Since the tray has various shapes and sizes, it is necessary to change the shape and size of the upper and lower meniscus plates according to the shape of the tray. Moreover, it is necessary to change the space | interval of an upper half-moon board and a lower half-moon board according to the height of a tray. Therefore, it is necessary to prepare a tray separation unit in which the upper half-moon plate, the lower half-moon plate, and the connecting portion are integrally formed according to the type of tray, and to change the tray separation unit every time the type of tray to be used changes. is there.
Further, since the upper meniscus plate comes into contact with the upper surface of the convex portion of the tray, that is, the bottom of the tray, the bottom of the tray, which is easily noticeable in appearance, may be damaged.

In view of the above, the present invention does not require a separation unit that makes contact with the uppermost molded product of a molded product stack in which molded products having concave portions are stacked in a state where the convex portions corresponding to the concave portions are inserted into the concave portions of another molded product. Have the purpose of

The present invention is an apparatus for separating a molded product from a molded product stack in which a molded product having a concave portion is stacked in a state where a convex portion corresponding to the concave portion is inserted into a concave portion of another molded product ,
A liftable table for placing the molded product stack;
A latching portion that can be inserted at a first height into the gap between the molded products that constitute the molded product stack placed on the lifting table and can latch a molded product below the first height,
The second height where the molded product stack exists when the hook is inserted into the gap between the molded products constituting the molded product stack placed on the lifting table and the molded product is divided, a non-contact sensor elevating table placed on molded article stack it is detected whether or not exist in a non-contact,
From the state where the molded product stack placed on the lifting table is lowered from the height at which the second height exists , the detection signal of the non-contact sensor indicates the presence of the molded product stack. detecting the height of the lifting table when switched to a state representative of the presence, until the relative setting height from the height the detected raises the lifting table, forming the molded product stack molding And a separation control means for inserting the latching portion into the gap between the products.
Furthermore, the present invention is an apparatus for separating a molded product from a molded product stack in which a molded product having a concave portion is stacked in a state where a convex portion corresponding to the concave portion is inserted into a concave portion of another molded product,
A liftable table for placing the molded product stack;
A latching portion that can be inserted at a first height into the gap between the molded products that constitute the molded product stack placed on the lifting table and can latch a molded product below the first height,
In the second height where the molded product stack does not exist when the hook is inserted into the gap between the molded products constituting the molded product stack placed on the lifting table and the molded product is divided, A non-contact sensor for detecting in a non-contact manner whether or not there is a molded product stack placed on the lifting table;
From the state where the molded product stack placed on the lift table is raised from a height that does not exist at the second height, and the detection signal of the non-contact sensor indicates the absence of the molded product stack. Forming the molded product stack by detecting the height of the lift table when switched to a state representing the presence, and lowering the lift table to a relative set height based on the detected height And a separation control means for inserting the latching portion into the gap between the products.

Further, the present invention is a method of separating a molded product from a molded product stack in which a molded product having a concave portion is stacked in a state where a convex portion corresponding to the concave portion is inserted into a concave portion of another molded product ,
A liftable table for placing the molded product stack;
A latching portion that can be inserted at a first height into the gap between the molded products that constitute the molded product stack placed on the lifting table and can latch a molded product below the first height,
The second height where the molded product stack exists when the hook is inserted into the gap between the molded products constituting the molded product stack placed on the lifting table and the molded product is divided, using the non-contact sensor elevating moldings stack placed on the table for detecting whether it exists in a non-
From the state where the molded product stack placed on the lifting table is lowered from the height at which the second height exists , the detection signal of the non-contact sensor indicates the presence of the molded product stack. detecting the height of the lifting table when switched to a state representative of the presence, until the relative setting height from the height the detected raises the lifting table, forming the molded product stack molding It has the aspect which inserts the said latching | locking part in the clearance gap between goods.
Furthermore, the present invention is a method of separating a molded product from a molded product stack in which a molded product having a concave portion is stacked in a state where a convex portion corresponding to the concave portion is inserted into a concave portion of another molded product,
A liftable table for placing the molded product stack;
A latching portion that can be inserted at a first height into the gap between the molded products that constitute the molded product stack placed on the lifting table and can latch a molded product below the first height,
In the second height where the molded product stack does not exist when the hook is inserted into the gap between the molded products constituting the molded product stack placed on the lifting table and the molded product is divided, Using a non-contact sensor that detects non-contact whether or not there is a molded product stack placed on the lifting table,
From the state where the molded product stack placed on the lift table is raised from a height that does not exist at the second height, and the detection signal of the non-contact sensor indicates the absence of the molded product stack. Forming the molded product stack by detecting the height of the lift table when switched to a state representing the presence, and lowering the lift table to a relative set height based on the detected height It has the aspect which inserts the said latching | locking part in the clearance gap between goods.

  In other words, the lift table is moved up and down to a set height relative to the height of the lift table when the state of the detection signal of the non-contact sensor is switched when the lift table is moved up and down, and the molded product constituting the molded product stack A latching portion is inserted into the gap between them. This eliminates the need for a part that contacts the uppermost molded product of the molded product stack, and suppresses the attachment of scratches to the uppermost molded product.

Here, the first height and the second height may be the same or different.
The non-contact sensor includes a proximity switch such as a photoelectric sensor (photoelectric proximity switch), and may be a dielectric proximity switch or the like if the molded product is a metal, or a magnetic field proximity switch if the molded product is a magnetic material. Etc.
Raising and lowering the lifting table includes both lowering the lifting table and raising the lifting table.
The state of the detection signal of the non-contact sensor is switched at the second height from the state representing the presence of the molded product stack to the state representing the non-existence, from the state representing the non-existence of the molded product stack. It includes both switching to a state representing existence.
The relative set height may be the height at which the latching portion is inserted into the gap between the first molded product and the second molded product from the top of the molded product stack, or the Nth from the top of the molded product stack. It may be the height at which the latching portion is inserted into the gap between the molded product (N is an integer of 2 or more) and the (N + 1) th molded product.

Furthermore, the present invention is a method of separating a molded product from a molded product stack in which a molded product having a concave portion is stacked in a state where a convex portion corresponding to the concave portion is inserted into a concave portion of another molded product ,
A liftable table for placing the molded product stack;
A latching portion that can be inserted at a first height into the gap between the molded products that constitute the molded product stack placed on the lifting table and can latch a molded product below the first height,
The second height where the molded product stack exists when the hook is inserted into the gap between the molded products constituting the molded product stack placed on the lifting table and the molded product is divided, using a non-contact sensor elevating moldings stack placed on the table for detecting whether exist in a non-contact,
From the state where the molded product stack placed on the lifting table is lowered from the height at which the second height exists , the detection signal of the non-contact sensor indicates the presence of the molded product stack. The height of the elevating table when the state is switched to a state representing the presence is detected, and the gap between the molded products at a predetermined position from the top of the molded product stack is determined based on the detected height. The lift table is raised until it is set, and the latching portion is inserted into the gap between the molded products.
Furthermore, the present invention is a method of separating a molded product from a molded product stack in which a molded product having a concave portion is stacked in a state where a convex portion corresponding to the concave portion is inserted into a concave portion of another molded product,
A liftable table for placing the molded product stack;
A latching portion that can be inserted at a first height into the gap between the molded products that constitute the molded product stack placed on the lifting table and can latch a molded product below the first height,
In the second height where the molded product stack does not exist when the hook is inserted into the gap between the molded products constituting the molded product stack placed on the lifting table and the molded product is divided, Using a non-contact sensor that detects non-contact whether or not there is a molded product stack placed on the lifting table,
From the state where the molded product stack placed on the lift table is raised from a height that does not exist at the second height, and the detection signal of the non-contact sensor indicates the absence of the molded product stack. The height of the elevating table when the state is switched to a state representing the presence is detected, and the gap between the molded products at a predetermined position from the top of the molded product stack is determined based on the detected height. The lifting / lowering table is lowered until the hook is inserted into the gap between the molded products.

  That is, the gap between the molded products at a predetermined position from the top of the molded product stack is set to the first height with reference to the height of the lifted table when the lift table is moved up and down and the state of the detection signal of the non-contact sensor is switched. The raising / lowering table is moved up and down until it becomes, and the latching portion is inserted into the gap between the molded products constituting the molded product stack. This eliminates the need for a part that contacts the uppermost molded product of the molded product stack, and suppresses the attachment of scratches to the uppermost molded product.

  Here, the gap between the molded products at a predetermined position from the top of the molded product stack may be a gap between the first molded product and the second molded product from the top of the molded product stack, or the top of the molded product stack. To the Nth (N is an integer of 2 or more) molded product and the N + 1th molded product.

  It should be noted that the conveying device, the molded product take-out device, the trimming device, the molding take-out device, etc., including the device for separating the molded product described above, the conveying method including the method for separating the molded product, the molded product take-out method, the trimming method, the molding. Inventions such as a method of taking out also have the above-described actions and effects.

According to the inventions according to claim 1, claim 2, claim 4, claim 5, claim 6 and claim 7, a convex part corresponding to the concave part is a concave part of another molded part. It is possible to eliminate the need for a separation unit that comes into contact with the uppermost molded product of the molded product stack that is stacked in the state of being inserted into the product.
In the invention according to claim 3, it is possible to easily separate the uppermost molded article, divided could be easier to take out the best molded article, since the insertion position of the engaging portion with respect to the molded article stack is changed by the input, the molded article It is possible to reduce the switching work when the height changes .

The front view which illustrates the outline of the molded article manufacturing system 1. FIG. The top view which illustrates the outline of the molded article manufacturing system 1. FIG. FIG. 4 is a vertical cross-sectional view illustrating the molding apparatus 20 when the molding die 23 is at a separation position L11. FIG. 3 is a vertical cross-sectional view illustrating the molding apparatus 20 when the molding die 23 is in the proximity position L13. FIG. 3 is a plan view illustrating a sheet conveying apparatus 10. FIG. 5 is a vertical sectional view illustrating the trimming device 40 when the mold 43 is at the separation position L22. (A) is a vertical sectional view illustrating the suction boxes 50 and 80, (b) is a bottom view illustrating the suction boxes 50 and 80, and (c) is a view of each of the molded products P1 to P9 common to the positions L1 to L4. The top view which illustrates arrangement | positioning. (A) is a principal part vertical sectional view which illustrates conveyors 61 and 64 typically, (b) is a top view which illustrates the upper surface 61a, 63a, and 64a side of conveyors 61, 63, and 64. The left view which illustrates the molded article replenishment apparatus 70 and the molded article sorting apparatus 5 on the supply position L3. The top view which illustrates the supply position L3 and the molded article sorting apparatus 5. FIG. FIG. 4A is a front view illustrating a molded product sorting device 5, and FIG. 4B is a perspective view illustrating a main part of the molded product sorting device 5. (A) is a front view illustrating a main part of the molded product sorting apparatus 5, and (b) is a front view illustrating the hooking portion 220 in an exploded manner. (A) And (b) is a top view which decomposes | disassembles and illustrates the gap | interval insertion member 221 and the opening insertion member 225. The block diagram which illustrates the outline of the electric circuit structure of the molded article manufacturing system 1. FIG. The block diagram which illustrates the outline of the electric circuit structure of the molded article replenishment apparatus. (A) And (b) is a figure which illustrates typically various composition of molded article stack ST1. The flowchart which illustrates an initialization process. The flowchart which illustrates a supplement goods carrying-in process. The flowchart which illustrates a division process. (A)-(d) is a front view which illustrates typically operation | movement of the molded article sorting apparatus 5. FIG. (A)-(d) is a front view which shows typically operation | movement of the molded article sorting apparatus which concerns on a modification. (A)-(d) is a front view which shows typically operation | movement of the molded article sorting apparatus which concerns on a modification.

  Embodiments of the present invention will be described below. Of course, the embodiments described below are merely illustrative of the present invention.

(1) Outline of the device for separating molded products:
First, the outline | summary of the molded article sorting apparatus which concerns on one Embodiment of this invention with reference to FIGS. 1-20 suitably is demonstrated.
The molded product manufacturing system 1 shown in FIGS. 1 and 2 includes a molded product sorting apparatus 5 that separates the molded product PR3 from the molded product stack ST1 in which the molded products PR3 are stacked. In FIGS. 1 and 2, the sheet conveyance direction D1 and the conveyance direction D2 of the molded product PR1 are directions from left to right. In FIG. 2, the width direction D4 is a horizontal direction orthogonal to the conveyance direction D2 of a molded product. As shown in FIGS. 9 and 12, the molded product sorting apparatus 5 includes an elevating table 210, a latching unit 220, a non-contact sensor 230, and a separation control unit 240.

  The lifting table 210 is a table that can be lifted and lowered for placing the molded product stack ST1. The latching portion 220 is inserted at a first height H1 into the gap CL1 between the molded products PR3 constituting the molded product stack ST1 placed on the lifting table 210, and is lower than the first height H1. The molded product PR3 can be hooked. The non-contact sensor 230 detects in a non-contact manner whether or not the molded product stack ST1 placed on the lifting table 210 exists at the second height H2. As shown in FIG. 20 and the like, the separation control means 240 is set relative to the height H3 of the lifting table 210 when the lifting table 210 is lifted and the state of the detection signal of the non-contact sensor 230 is switched. The lifting table 210 is moved up and down to a height H6, and the latching portion 220 is inserted into the gap CL1 between the molded products PR3 constituting the molded product stack ST1.

  That is, the lifting table 210 is moved up and down to a relative set height H6 based on the height H3 of the lifting table 210 when the state of the detection signal of the non-contact sensor 230 is switched by moving up and down. The latching portion 220 is inserted into the gap CL1 between the molded products PR3 constituting the product stack ST1. This eliminates the need for a part that contacts the uppermost molded product of the molded product stack ST1, and suppresses the attachment of scratches to the uppermost molded product.

  Further, when the latching portion 220 has the upper surface 223 that is obliquely lowered toward the molded product stack ST1 placed on the lifting table 210, the uppermost molded product can be easily separated.

  Further, when the latching portion 220 has a vertical surface 227 that intersects the upper surface 223 and has a positioning portion 226 that determines the horizontal position of the molded product PR3 above the first height H1, the divided uppermost molded product can be obtained. It can be made easy to take out.

  Further, the separation control means 240 has a height input means 242 for receiving an input for determining a relative set height H6, and lifts the lifting table 210 to a relative set height H6 determined by the received input. The latching portion 220 may be inserted into the gap CL1 between the molded products PR3 constituting the molded product stack ST1. In this aspect, since the insertion position of the latching portion 220 with respect to the molded product stack ST1 is changed by input, switching work when the height of the molded product PR3 is changed can be reduced.

(2) Explanation of molded product manufacturing system:
The molded product manufacturing system 1 shown in FIGS. 1 and 2 includes each part represented by SE1 to SE13, and forms a predetermined number of molded products PR1 for each shot from a moldable sheet SH1 and requires a supplementary molded product PR3. The predetermined number of molded products PR1 are transported in an aligned state and stacked at the stacking position L4, and a set number of molded product stacks ST1 are taken out. The shot means a unit for handling the molded product PR1 at a time. In the case of the molded product manufacturing system 1, the number of unseparated molded products SH2a formed from the sheet SH1 for each shot, the number of molded products PR1 formed from the molded sheet SH2 for each shot, and the suction box for each shot The number of molded products PR1 conveyed at 50 and 80 is the same. In FIG. 2 and the like, the number of molded articles handled in one shot is 9 in total, 3 in the transport direction D1, D2 and 3 in the width direction D4.
The molded product manufacturing system 1 includes a molded product take-out device 4 that conveys a plurality of molded products PR1 arranged at the supply position L3 in an aligned state and stacks them at the stacking position L4. The trimming extraction device 3 includes a sheet conveying device 10, a trimming device 40, and a molded product extraction device 4. The forming / extracting device 2 includes a sheet conveying device 10, a forming device 20, a trimming device 40, and a molded product extracting device 4.

  For example, the sheet supply unit SE1 unwinds the roll SH0 around which the sheet SH1 is wound, and conveys the continuously connected continuous sheet SH1 in a predetermined sheet conveying direction D1 toward a predetermined forming position L1. This operation is performed intermittently under the control of the control panel 100 (control unit SE13).

As the sheet SH1, a moldable sheet such as a resin sheet such as a thermoplastic resin sheet, a thermoplastic sheet other than a resin exhibiting thermoplasticity, or paper can be used. The resin sheet may be a resin sheet made of only a resin such as a thermoplastic resin, a sheet made of a material in which an additive such as a filler is added to the resin, a single layer sheet, or a laminated sheet laminated with different materials. Good. The material of the sheet SH1 is polyethylene (Polyethylene), polypropylene (Polypropylene), polystyrene (Polystyrene), poly (vinyl chloride), ABS resin (Acrylonitrile-butadiene-styrene resin), polyethylene terephthalate (Poly (ethylene). terephthalate)), polycarbonate, Polyamide, Acrylic resin, combinations thereof, and the like. Further, the sheet SH1 may be in the form of a sheet or film, and may be wound into a roll or cut to a predetermined length. The thickness of the sheet can be various thicknesses such as about 1 to 2 mm and about 0.25 to 1 mm, and can be a thick sheet of about 3 mm or more, or a film of about 0.25 mm or less. .
The molded product PR1 formed from the sheet SH1 includes a container such as a food container, a component such as an inner box or an operation panel of a home appliance, and the like.

  The heating unit SE2 has a heater SE2a, and radiates and heats the sheet SH1 being conveyed to a temperature at which the sheet SH1 is softened without melting. In the heating unit SE2 shown in FIG. 1, heaters SE2a are arranged on the upper side and the lower side of the sheet SH1, but either one can be omitted. The sheet SH1 may be heated by contact heating with a hot plate, heating with hot air, heating with a burner, or the like.

  The sheet conveying apparatus 10 illustrated in FIG. 5 includes holding and conveying mechanisms 11 and 11 that hold the edges SH1c and SH1c of the sheets SH1 to SH3 and convey the sheets SH1 to SH3 in the sheet conveying direction D1. Each holding and conveying mechanism 11 drives the endless chain 12 provided with a plurality of holding mechanisms for holding the edge portion SH1c of the sheet by a servo motor 14 so as to circulate. The holding of the sheet edge may be performed by clamping the sheet edge or by holding the sheet edge with a piercing member. The sheet transport apparatus may be divided into a plurality of sheets in the sheet transport direction D1. The sheets SH <b> 1 to SH <b> 3 connected in the sheet conveyance direction D <b> 1 are intermittently conveyed according to the control of the control panel 100.

  The forming device 20 of the forming unit SE3 illustrated in FIGS. 3 and 4 is provided below the table 21 that can be raised and lowered on the upper surface SH1a side of the sheet SH1, the table 22 that can be raised and lowered on the lower surface SH1b side of the sheet SH1, and the upper table 21. The molding die 23, the clamp 24 provided on the lower table 22, and the differential pressure supply mechanism 25 for supplying the differential pressure to the molding surface 23a from the differential pressure supply hole 23b are provided. Each mold 23 and each clamp 24 are arranged at the molding position L1 in accordance with the alignment state (see FIG. 7C) of the respective molded products PR1 placed at the supply position L3. Each mold 23 is a female mold that is recessed upward, but may be a male mold that is convex downward or a mold that is uneven. Further, the mold may be disposed on the lower side and the clamp may be disposed on the upper side. The tables 21 and 22 are moved closer to and away from each other in a vertical direction between a set separation position and a proximity position by a molding table drive mechanism (not shown). As a result, the mold 23 moves up and down between the separation position L11 shown in FIG. 3 and the proximity position L13 shown in FIG. 4, and the clamp 24 is located between the separation position L12 shown in FIG. 3 and the proximity position L14 shown in FIG. Go up and down.

When the sheet SH1 in the heat-softened state for one shot is carried into the forming position L1 with the forming die 23 and the clamp 24 separated from each other as shown in FIG. 3, the forming apparatus 20 forms as shown in FIG. The mold 23 and the clamp 24 are brought close to each other, and a negative pressure is applied to the differential pressure supply hole 23b by the differential pressure supply mechanism 25 to bring the sheet SH1 into close contact with the molding surface 23a. In this manner, the sheet SH1 can be formed for each shot using each forming die 23. When the forming apparatus 20 separates the forming mold 23 and the clamp 24, the forming sheet SH2 as shown in FIG. 6 is unloaded from the forming position L1 while being connected to the sheet SH1, and is loaded into the trimming position L2. At this time, the sheet SH1 of the next shot is carried into the forming position L1. In this way, the forming apparatus 20 intermittently vacuum forms the sheet SH1 according to the control of the control panel 100.
In addition to the above-described vacuum forming, the sheet SH1 may be formed by differential pressure forming such as pressure forming or pressure forming, press forming, forming other than thermo forming, and the like. The compressed air vacuum forming is a differential pressure forming using both compressed air and vacuum. Thermoforming includes differential pressure molding and press molding. The molded product PR1 includes a differential pressure molded product such as a vacuum molded product, a compressed air molded product, and a compressed air vacuum molded product, a press molded product, and the like.

  The trimming device 40 of the trimming unit SE4 illustrated in FIG. 6 includes a table 41 that can be raised and lowered on the upper surface SH1a side of the molded sheet SH2, a table 42 that can be raised and lowered on the lower surface SH1b side of the molded sheet SH2, and a table 42 on the lower side. A die 43 and a cutting blade 44 provided, and a receiving member 45 provided under the upper table 41 are provided. Each die 43 and each cutting blade 44 are arranged at the trimming position L2 in accordance with the alignment state (see FIG. 7C) of the molded products PR1 placed at the supply position L3. Each die 43 is convex upward, but may be concave downward or uneven. Further, the cutting blade may be arranged on the upper side and the receiving member may be arranged on the lower side, or the mold may be arranged on the upper side. Each cutting blade 44 can be a Thomson blade, for example, and has a cutting edge facing the receiving member 45 around each die 43. The tables 41 and 42 are moved closer to and away from each other in a vertical direction between a set separation position and a proximity position by a trimming table drive mechanism (not shown). As a result, the mold 43 and the cutting blade 44 are moved up and down between the separation position L22 and the proximity position L24, and the receiving member 45 is moved up and down between the separation position L21 and the proximity position L23.

  As shown in FIG. 6, the trimming device 40 brings the mold 43 and the receiving member 45 close to each other when the molding sheet SH2 for one shot is carried into the trimming position L2 with the mold 43 and the receiving member 45 being separated from each other. Then, the molded sheet SH2 is placed (arranged) on each mold 43, and the molded sheet SH2 that is in contact with the receiving member 45 around the molded product SH2a is cut by the cutting blade 44. In this way, the molding sheet SH2 arranged in each die 43 can be trimmed by one shot so that each molding PR1 is arranged in each die 43. When the trimming device 40 separates the mold 43 and the receiving member 45, as shown in FIGS. 1 and 5, the scrap sheet SH3 is unloaded from the trimming position L2 while being connected to the formed sheet SH2, and is loaded into the scrap collecting unit SE5. Then, the suction box 50 enters between the mold 43 and the receiving member 45, and each molded product PR1 is unloaded from the mold 43 and carried into the molded product release portion SE6. At this time, the molding sheet SH2 of the next shot is carried into the trimming position L2. In this way, the trimming device 40 intermittently trims the molded sheet SH2 according to the control of the control panel 100.

The molded product PR1 shown in FIGS. 1 and 7 is an inverted container, and extends outwardly from the convex portion PR1a corresponding to the concave portion for storing food and other articles, and the peripheral portion of the convex portion PR1a. The flange portion PR1b is formed. The convex part PR1a of the molded product PR1 in the inverted state is slightly smaller toward the upper side, and can be inserted into a concave part for storing articles of the molded product PR1 adjacent thereto. The flange part PR1b of the molded product PR1 in an inverted state is disposed at the lowest position of the molded product PR1. Of course, the molded product may be an upright container or an article other than the container.
The trimming device is a device that presses the cutting blade against the receiving member and cuts the formed sheet, a device that punches the formed sheet with the cutting blade around the mold, and the upper blade and the lower blade that are in sliding contact with each other. Devices for punching out, etc. are included. Therefore, the die sheet or the like may be used for trimming the molded sheet SH2.

  The scrap collection unit SE5 transports and collects the scrap sheet SH3 around the molded product PR1 in the sheet conveyance direction D1 in a state where the scrap sheet SH3 is connected to the molded sheet SH2. This operation is intermittently performed under the control of the control panel 100.

  The suction box 50 illustrated in FIGS. 7A and 7B can simultaneously hold the trimmed molded products PR1 placed on the plurality of molds 43 in the aligned state as shown in FIG. 7C. And releasable from the hold. The suction box 50 has a substantially box shape having an internal space 51 connected to the differential pressure supply unit 53, and a number of suction holes 52 smaller than the molded product PR1 are formed on the lower surface 50a in order to apply negative pressure to the outside. ing. Further, the suction box 50 can horizontally reciprocate along the molded product conveyance direction D2 between the trimming position L2 and the molded product release unit SE6. The suction box 50 enters the trimming position L2 when the cutting blade 44 and the receiving member 45 of the trimming device 40 are separated from each other and applies a negative pressure to the suction hole 52 to suck the molded product PR1 to the lower surface 50a. It moves to release part SE6, stops the action of negative pressure, and releases molded product PR1 from lower surface 50a. The molded product PR1 may be released by supplying pressurized air from the suction hole 52. These operations are intermittently performed under the control of the control panel 100.

  The molded product release section SE6 releases (places) each molded product PR1 conveyed in the aligned state as shown in FIG. 7C from the lower surface 50a of the suction box on the molded product delivery conveyor 61. The molded product delivery conveyor 61 illustrated in FIGS. 8A and 8B simultaneously places the molded products PR1 in the aligned state as shown in FIG. 7C and sends them out in the molded product conveyance direction D2. The molded product delivery conveyor 61 is a vacuum conveyor having an internal space 65 connected to a differential pressure supply unit 67. In order to apply negative pressure to the outside, a large number of suction holes 66 smaller than the molded product PR1 are formed in the endless belt. Has been. Further, the molded product delivery conveyor 61 includes an elevating mechanism 68 for changing the height of the upper surface 61a. The molded product delivery conveyor 61 maintains the aligned state by moving upward when the suction box 50 that has attracted each molded product PR1 to the lower surface 50a in the aligned state has moved to the molded product release section SE6. Is placed on the upper surface 61a and lowered to its original height, and then each molded product PR1 is sent to the downstream molded product delivery conveyor 62 in an aligned state. This operation is intermittently performed under the control of the control panel 100.

  The inspection unit SE7 is provided with a detection device 33 for inspecting each molded product PR1 moving on the molded product delivery conveyor 62. The detection device 33 includes a sensor that detects whether or not a molded product exists at positions P1 to P9 shown in FIG. 7C, and an optical sensor that detects whether or not the molded product is within a set size range. A color meter for detecting whether the molded product is within the set color range, a weight sensor for detecting whether the molded product is within the set weight range, a metal detector for detecting metal as a foreign object, Etc. can be used. The molded product delivery conveyor 62 simultaneously places (places) the molded products PR1 in the aligned state as shown in FIG. 7C and sends them out in the molded product conveyance direction D2. The molded product delivery conveyor 62 sends each molded product PR1 to the downstream molded product delivery conveyor 63 in an aligned state in accordance with the operation of the upstream molded product delivery conveyor 61. This operation is intermittently performed under the control of the control panel 100.

  The standby unit SE8 is provided with a molded product delivery conveyor 63 that places (places) the molded products PR1 on the upper surface 63a at the same time in an aligned state as shown in FIG. 7C and sends them in the molded product conveyance direction D2. . In standby unit SE8, non-standard molded products (defective products) may be removed as necessary. This operation may be performed by a device that discharges non-standard products using a suction head or the like, or may be performed manually. The molded product delivery conveyor 63 sends the molded products PR1 to the downstream end conveyor 64 in an aligned state in accordance with the operation of the upstream molded product delivery conveyor 62. This operation is intermittently performed under the control of the control panel 100.

  FIG. 9 illustrates the molded product replenishing device 70 provided on the terminal conveyor 64 (supply position L3) in the molded product replenishing section SE9. The end conveyor 64 places (places) the molded products PR1 before the replenishment process in the aligned state as shown in FIG. As shown in FIGS. 8A and 8B, the end conveyor 64 is a vacuum conveyor having an internal space 65 connected to the differential pressure supply unit 67. In order to apply negative pressure to the outside, the molded product PR1 is used. Many suction holes 66 smaller than the endless belt are formed. Moreover, the terminal conveyor 64 is provided with the raising / lowering mechanism 68 for changing the height of the upper surface 64a. When the suction box 80 is moved to the supply position L3 after the replenishment process, the final conveyor 64 is moved upward to maintain the aligned state so that each molded product PR1 is sucked to the lower surface 80a of the suction box 80, and the original conveyor 64 is restored. The molded product PR1 is lowered to the height and is carried in an aligned state from the upstream molded product delivery conveyor 63. This operation is intermittently performed under the control of the control panel 100.

  The molded product replenishing device 70 includes an arm 71, a suction head 72, and a control unit 73. The molded product replenishing device 70 performs a process of replenishing the replenished molded product PR3 placed (arranged) on the lifting table 210 to the replenishment position L6 on the terminal conveyor 64. The arm 71 moves the suction head 72 up and down, left and right and back and forth according to a command from the control unit 73. The suction head 72 is connected to a differential pressure supply unit (not shown) and applies a negative pressure to the outside in accordance with a command from the control unit 73 to suck the replenishment molded product PR3 or stop the negative pressure operation. The molded product PR3 is released. The control unit 73 drives the arm 71 and the suction head 72 according to the control of the control panel 100 (control unit SE13).

  As shown in FIGS. 9 and 10, when the horizontal direction orthogonal to the conveyance direction D2 of the plurality of molded products PR1 by the suction box 80 is the width direction D4, the replenishment product is supplied from the supply position L3 to one outer side D4a in the width direction D4. A molded product sorting device 5 of the supply unit SE12 is provided. Note that a molded product sorting device may also be provided from the supply position L3 to the other outer side D4b in the width direction D4. In accordance with a command from the control panel 100, the molded product replenishing device 70 moves the replenished molded product PR3 placed on the lifting table 210 to the replenishment position L6.

  The suction box 80 that conveys the molded product PR1 from above the terminal conveyor 64 can simultaneously hold the molded products PR1 after replenishment processing placed on the terminal conveyor 64 in an aligned state as shown in FIG. 7C. At the same time, it can be released from the holding. As shown in FIGS. 7A and 7B, the suction box 80 has a substantially box shape having an internal space (51) connected to the differential pressure supply unit (53), and applies negative pressure to the outside. Therefore, many suction holes (52) smaller than the molded product PR1 are formed in the lower surface 80a. Further, the suction box 80 can be reciprocated horizontally between the supply position L3 and the stacking position L4 along the molded product conveyance direction D2. The suction box 80 enters the supply position L3 after the replenishment process, applies negative pressure to the suction hole (52) to suck the molded product PR1 to the lower surface 80a, moves to the stacking position L4 of the stacking section SE10, and is negative. The action of pressure is stopped and the molded product PR1 is released from the lower surface 80a. The molded product PR1 may be released by supplying compressed air from the suction hole (52).

  The stacking part SE10 releases the molded products PR1 after the replenishment process conveyed in the aligned state as shown in FIG. 7C from the lower surface 80a of the suction box, on the stack delivery conveyor 91 (stacking position L4). Stack on. The stack delivery conveyor 91 simultaneously places a molded product stack ST1 in which a set number of molded products PR1 are stacked in an aligned state as shown in FIG. 7C, and sends them out in the molded product transport direction D2. The stack delivery conveyor 91 is provided with an elevating mechanism for changing the height of the upper surface, and is raised when the suction box 80 that sucks the molded products PR1 in an aligned state on the lower surface 80a has moved onto the stacking position L4. The molded product PR1 is stacked while maintaining the aligned state by the above, and when the set number of molded products PR1 are stacked, the molded product stack ST1 is lowered to its original height, and then the molded product stack ST1 is aligned and the downstream stack takeout conveyor. To 92. This operation is intermittently performed under the control of the control panel 100.

  The take-out unit SE11 is provided with a stack take-out conveyor 92 that places (places) the molded product stack ST1 delivered from the stack delivery conveyor 91 and further conveys it in the product delivery direction D2. The stack take-out conveyor 92 operates in accordance with the operation of the upstream stack delivery conveyor 91 according to the control of the control panel 100. Most of the molded product stack ST1 on the stack take-out conveyor 92 is boxed by an operator in the vicinity, and a part thereof is transferred onto a supply table 274 described later.

9 to 12 includes a lifting / lowering table 210, a latching section 220, a non-contact sensor 230, a separation control unit 240, and a supplement supply apparatus 270.
As shown in FIG. 11B and the like, the lifting table 210 is formed with contact portion insertion holes 212 that vertically pass the contact portions 282 of the positioning pusher 280, and the upper surface is a mounting surface of the molded product stack ST1. 211.

  As shown in FIGS. 11A and 12A, the latching portions 220 and 220 are provided at positions sandwiching the molded product stack ST <b> 1 placed on the lifting table 210. One latching part 220 is attached to the upper end part of the contact part 272 via the cylinder support member 268 and the advance / retreat drive part 260. The other latching portion 220 is attached to the upper end portion of the contact portion 282 of the positioning pusher 280 via the cylinder support member 269 and the advance / retreat drive portion 260. As illustrated in FIG. 12B and FIGS. 13A and 13B, each latching portion 220 includes a gap insertion member 221 and an opening insertion member 225.

The gap insertion member 221 is attached to the piston tip portion 265 of the advance / retreat drive unit 260 with a screw 266 so that the upper side is substantially vertical, and the lower side has an inclined part 222 having an upper surface 223 that is obliquely lowered toward the molded product stack ST1. Has been. The tip end portion 222a of the inclined portion 222 extends in a claw shape at a plurality of locations. The inclined portion 222 is formed with a plurality of openings 224 through which the positioning portion 226 of the opening insertion member 225 passes vertically.
Of course, the gap insertion member 221 can have various shapes having an upper surface that is inclined obliquely toward the molded product stack ST1 at a portion inserted into the gap CL1 between the molded products.

The opening insertion member 225 is attached to the piston tip 265 with a screw 267 via the gap insertion member 221 with the upper side facing substantially vertical, the middle part is inclined downward toward the molded product stack ST1, and the lower side is the uppermost molded product. The positioning unit 226 determines the horizontal position of PR11. The uppermost molded product PR11 is the uppermost molded product PR3 of the molded product stack ST1, and is the molded product PR3 above the first height H1 into which the tip end portion 222a is inserted. The distal end portion 226 a of the positioning portion 226 extends in a claw shape at a plurality of locations corresponding to each opening 224 and is inserted into each opening 224. The positioning portion 226 has a vertical surface 227 that intersects the upper surface 223 of the inclined portion, and determines the horizontal position of the uppermost molded product PR11.
Of course, the opening insertion member 225 can have various shapes having a vertical plane intersecting the upper surface 223 of the inclined portion.

  The non-contact sensor 230 shown in FIG. 12A or the like is a photoelectric sensor including a projector 232 and a light receiver 234 arranged at a second height H2 sandwiching the molded product stack ST1. The second height H2 is set to a height at which the lower molded product stack ST1 exists from the molded product PR3 that is latched by the latching portion 220 at the first height H1. FIG. 11A shows an example in which the projector 232 is attached to the cylinder support member 268 and the light receiver 234 is attached to the cylinder support member 269. Of course, the projector 232 and the light receiver 234 can be provided at various positions, for example, by reversing the positions of the projector 232 and the light receiver 234. As the projector 232, a laser diode (LD), a light emitting diode (LED), or the like can be used, and the horizontal optical axis toward the light receiver 234 is set to the second height H2. The light receiver 234 can use a phototransistor, a photodiode, a position detection photodiode (PSD), or the like, and outputs a detection signal in a different state depending on whether or not the light from the projector 232 is detected. When the molded product stack ST1 placed on the lifting table 210 is present at the second height H2, the light from the projector 232 is blocked, so the light receiver 234 generates a detection signal in the light blocking state. When the molded product stack ST1 does not exist at the second height H2, the light from the light projector 232 enters the light receiver 234, and the light receiver 234 generates a detection signal of the light receiving state. In this way, the non-contact sensor 230 detects in a non-contact manner whether or not the molded product stack ST1 exists at the second height H2.

  The separation control unit 240 includes an elevation table driving unit 250 and an advance / retreat driving unit 260. As shown in FIG. 20B, the height of the lift table 210 when the lift table 210 is moved up and down and the state of the detection signal of the non-contact sensor 230 is changed to H3. For convenience, the distance from the floor to the upper surface (mounting surface 211) of the lifting table 210 is defined as a height H3. As shown in FIG. 20 (c), the separation control means 240 raises and lowers the lifting table 210 to a relative set height H6 with reference to the height H3, as shown in FIGS. 12 (a) and 20 (d). Thus, the latching part 220 is inserted into the gap CL1 between the molded products PR3 constituting the molded product stack ST1.

A lifting table driving unit 250 shown in FIG. 11A and the like includes a guide 252 for moving the lifting table 210 in a predetermined direction, a servo motor 254 that drives the lifting table 210 to move up and down while controlling the height of the lifting table 210, Is provided.
The forward / backward drive unit 260 shown in FIG. 12 includes a piston 264 with a hooking portion 220 attached to a tip end portion 265, and a cylinder 262 that drives the piston 264 forward / backward. As the cylinder 262, an air cylinder, an electric cylinder, or the like can be used. As shown in FIG. 11A, one cylinder 262 is attached to a cylinder support member 268. The cylinder support member 268 is attached to the upper end portion of the contact portion 272. The other cylinder 262 is attached to a cylinder support member 269. The cylinder support member 269 is attached to the upper end portion of the contact portion 282 of the positioning pusher 280. When the piston 264 is advanced by the cylinder 262, the latching portion 220 is advanced to a predetermined advance position L34, and when the piston 264 is retracted by the cylinder 262, the latching portion 220 is retracted to a predetermined retracted position L33.

The replenishment carry-in device 270 includes a supply base 274, contact portions 271 and 272, and pushers 273 and 280.
The supply table 274 shown in FIGS. 9 and 10 is a table on which the molded product stack ST <b> 1 to be carried into the lift table 210 is placed, and is installed on the outer side D <b> 4 a in the width direction from the lift table 210. The contact portion 271 is provided on the outer side D4b in the width direction of the lifting table 210. The contact portion 272 is provided on the opposite side of the molded product conveyance direction D2 from the lifting table 210 so as to be substantially orthogonal to the contact portion 271. The supply pusher 273 is arranged on the outer side D4a in the width direction of the supply table 274, and pushes the molded product stack ST1 carried in the supply table 274 to the outer side D4b on the other side in the width direction D4 to abut against the abutting portion 271 to move up and down. Place on the table 210. The positioning pusher 280 presses the molded product stack ST1 replenished on the lifting table 210 in a direction opposite to the molded product transport direction D2 and abuts against the contact portion 272 to position in the horizontal direction.

  The control unit SE13 is provided with a control panel 100 that controls the operation of the entire molded product manufacturing system. The control panel 100 is connected to the molded product replenishing device 70, the molded product sorting device 5 and the like, and performs a process of separating the molded product PR3 from the molded product stack ST1 placed on the lifting table 210.

  FIG. 14 shows an electric circuit configuration of a molded product manufacturing system centering on the control panel 100. The control panel 100 includes a central control circuit 101 that controls the operation of the entire control panel, a sheet conveyance control unit 111 that controls the operation of the sheet conveyance apparatus 10, a heater control unit 112 that controls the operation of the heater SE2a, and a mechanism of the molding apparatus 20. A molding control unit 113 that controls the operation of the molding mechanism 20a that constitutes the unit, a trimming control unit 114 that controls the operation of the trimming mechanism 40a that constitutes the mechanism unit of the trimming device 40, and a suction box control that controls the operation of the suction box 50 Section 115, conveyor control section 116 that controls the operation of conveyors 61 to 64, suction box control section 117 that controls the operation of suction box 80, conveyor control section 118 that controls the operation of conveyors 91 and 92, and operation of detection device 33 Detection control unit 119 for controlling the operation and replenishment of the molded product for controlling the operation of the molded product replenishing device 70 Control unit 120, non-contact sensor control unit 121 that controls the operation of the non-contact sensor 230, pusher control unit 122 that controls the operation of the supply pusher 273, pusher control unit 123 that controls the operation of the positioning pusher 280, and lift table drive The elevator table control unit 124 for controlling the unit 250, the latching unit advance / retreat control unit 125 for controlling the advance / retreat drive unit 260, the information output unit 131, the operation unit 132, and the like are provided.

The central control circuit 101 is a circuit in which a CPU (Central Processing Unit) 102, a ROM (Read Only Memory) 103, a RAM (Random Access Memory) 104, a timer circuit 105, a nonvolatile memory 106, and the like are connected to an internal bus. It is said that. The CPU 101 controls each part of the molded article manufacturing system 1 while using the RAM 104 as a work area based on a control program recorded in the ROM 103 or the nonvolatile memory 106.
The information output unit 131 includes, for example, a display, an audio output device, and a printer, and outputs various types of information indicating the contents of various settings received from the user and the operating status of the molded product manufacturing system 1 by display or the like. The operation unit 132 includes, for example, a plurality of buttons and receives operation input from the user.

  FIG. 15 illustrates an outline of the electric circuit configuration of the molded article replenishing device 70. The control unit 73 of the molded product replenishing device 70 includes an arm drive control unit 73 a that controls the operation of the arm 71, a suction head control unit 73 b that controls the operation of the suction head 72, and an external input / output I for connecting the control panel 100. / F73c, etc. The control unit 73 may be configured with a CPU, a ROM, a RAM, and the like.

FIG. 16 (a) schematically illustrates various configurations of a molded product stack ST1 in which the supplementary molded products PR3 are stacked. Each molded product PR3 has a convex part PR1a and a flange part PR1b, and the convex part PR1a of the lower molded product PR3 is in the concave part for storing articles in the upper molded product PR3 with the convex part PR1a facing upward. Has been inserted. Here, the height of each molded product PR3 is H4 (H4> 0), the pitch between the vertically adjacent molded products PR3, that is, the pitch of the flange portion PR1b is H5 (H5> 0), and the lifting table 210 is moved up and down. The relative set height for raising and lowering the lifting table 210 with reference to the height H3 of the lifting table 210 when the state of the detection signal of the non-contact sensor 230 is changed is H6. When the first height H1 and the second height H2 are the same, the set height H6 is higher than the height H4 of the molded product, and the pitch H5 of the flange portion is added to the height H4 of the molded product. It is made smaller than H4 + H5. When H6-H4 is a predetermined height α, 0 <α <H5.
The first molded product from the top of the molded product stack ST1 is referred to as the top molded product PR11, and the second molded product from the top of the molded product stack ST1 is referred to as the direct molded product PR12.

(3) Operation, operation, and effect of molded product manufacturing system having molded product sorting device:
In the molded product manufacturing system 1, the control panel 100 controls the parts SE1 to SE12 shown in FIGS. 1 and 2 to form the molded product PR1 in an aligned state from the sheet SH1, and replenish these molded products PR1 with the molded product. After the replenishment process, the molded product PR1 is stacked at the stacking position L4 in an aligned state, and when the set number is stacked, the molded product stack ST1 is taken out.

  That is, the sheet SH1 wound around the roll SH0 is unwound by the sheet supply unit SE1, and is softened by being heated by the heating unit SE2 when it is a thermoplastic sheet. The heat-softened formable sheet SH1 is carried into the forming unit SE3 by shot unit by the sheet conveying device 10 and is formed to form unseparated formed products SH2a. The formed sheet SH <b> 2 to be formed is carried into the trimming unit SE <b> 4 for each shot and trimmed to form a molded product PR <b> 1 on each die 43. The molded product PR1 arranged in each mold 43 is held in the suction box 50 for each shot, and placed in an aligned state on the molded product delivery conveyor 61 of the molded product release unit SE6, and passes through the conveyors 62 and 63. Then, it is conveyed onto the terminal conveyor 64 of the molded product replenishing section SE9. The molded product PR3 on the lifting table 210 is replenished to the replenishment position L6 on the terminal conveyor 64 by the molded product replenishing device 70. The plurality of molded products PR1 on the terminal conveyor 64 after the replenishment process are held in the suction box 80 for each shot and stacked on the stack delivery conveyor 91 of the stacking unit SE10.

  The control panel 100 counts the molded products PR1 stacked at the stacking position L4. When the number of stacks reaches the set number, the control panel 100 lowers the stack delivery conveyor 91 to the height of the stack takeout conveyor 92, and the stack delivery conveyor 91. The upper molded product stack ST1 is taken out onto the stack takeout conveyor 92 of the takeout part SE11. A part of these molded product stacks ST1 is moved by the operator onto the supply table 274 of the replenishment product supply unit SE12 and placed on the lifting table 210.

  The control panel 100 performs a process of separating the molded product PR3 from the molded product stack ST1 according to the flowcharts illustrated in FIGS. When the power is turned on, the control panel 100 performs the processes shown in FIGS. The control panel 100 that performs the processes of FIGS. 17 to 19 constitutes the separation control means 240 together with the lifting table drive unit 250, the advance / retreat drive unit 260, and the replenishment carry-in device 270. The control panel 100 that performs the process of step S102 (hereinafter, “step” is omitted) in FIG. 17 constitutes a height input unit 242 that receives an input for determining a relative set height H6. Hereinafter, the operation, action, and effect of the molded product manufacturing system 1 having the molded product sorting apparatus 5 will be described.

The initial setting process shown in FIG. 17 is performed when an operation for starting production of the molded product PR1 is received by the operation unit 132.
When the process is started, the control panel 100 receives an operation input of the height H4 of the molded product by the operation unit 132 (S102). For example, a setting screen having an operation input field for the height of the molded product is displayed on the information output unit 131, and a numerical value input (for example, in mm) in the operation input field is received by a button of the operation unit 132 or the like. The input of the product height H4 can be received. In the initial setting process, the above-mentioned predetermined height α is set to a relative set height H6 (H6> 0) by adding the height H4 of the molded product. Therefore, the height H4 and the set height H6 of the molded product have a one-to-one correspondence, and the input in S102 is an input for determining the relative set height H6.

  In S104, the advancing / retreating drive units 260, 260 are driven to retract the latching units 220, 220 to the retracted position L33 shown in FIG. In S106, when there is no replenishment molded product PR3 on the lift table 210, the replenishment product loading process shown in FIG. 18 is performed. For example, whether or not the molded product PR3 is present on the lifting table 210 is determined by raising the lifting table 210 to a predetermined upper limit position slightly lower than the second height H2 and inputting a detection signal of the non-contact sensor 230. However, it can be performed by determining whether or not the detection signal is in a light shielding state.

  Assuming that the replenishment product loading process shown in FIG. 18 is performed, it is assumed that the pushers 273 and 280 are retracted and the molded product stack ST1 is placed on the supply table 274. When the replenishment product loading process is started, the control panel 100 controls the lifting table driving unit 250 to a predetermined loading position where the upper surface of the supply table 274 and the upper surface are combined to lower the lifting table 210 (S202). In S204, the supply pusher 273 is advanced so that the molded product stack ST1 on the supply base 274 abuts against the contact portion 271 on the outer side D4b in the width direction and is placed on the lifting table 210, and then the supply pusher 273 is moved. Evacuate. In S206, the positioning pusher 280 is advanced to the advance position L31 as shown in FIG. 11A, and the molded product stack ST1 is abutted against the contact portion 272 to position in the horizontal direction.

  In S208, the lifting table driving unit 250 is controlled to lift the lifting table 210. In S210, it is determined whether or not the detection signal of the non-contact sensor 230 is in a light shielding state. The light shielding state occurs when the uppermost molded product PR11 of the molded product stack ST1 on the lift table 210 reaches the second height H2. When in the light-shielded state, the control panel 100 controls the lift table driving unit 250 to stop the lift table 210 from rising (S212), and ends the replenishment carry-in process.

  In S108 of FIG. 17, the lift table driving unit 250 is controlled to lower the lift table 210. The lowering of the lifting table 210 starts from the height at which the molded product stack ST1 exists at the second height H2. In S110, it is determined whether or not the detection signal of the non-contact sensor 230 is switched from the light shielding state to the light receiving state. As shown in FIG. 20B, when the uppermost part of the molded product stack ST1 reaches the second height H2, the detection signal of the non-contact sensor 230 is switched from the light shielding state to the light receiving state, and the condition is satisfied. At this time, the control panel 100 acquires information on the height H3 of the lifting table 210 from the servo motor 254, and holds it in the RAM 104 (S112).

  In S114, the target height is obtained by adding the relative set height H6 = H4 + α shown in FIG. 16A to the detected height H3 of the lifting table. In S116, as shown in FIG. 20 (c), the lift table 210 is controlled by controlling the lift table drive unit 250 up to a relative set height H6 based on the detected height H3, that is, the target height H3 + H6. To raise. Thereafter, the control panel 100 controls the advancing / retreating drive units 260, 260 to advance the latching units 220, 220 to the advance position L34, and as shown in FIG. 20 (d), the uppermost molded product PR11 and the directly below molded product PR12. And, specifically, the inclined portions 222 and 222 are inserted into the clearance CL1 between the flange portions PR1b (S118), and the initial setting process is terminated. At this time, the uppermost molded product PR11 is slightly lifted along the upper surfaces 223 and 223 of the inclined portions 222 and 222 and separated from the directly molded product PR12, and the vertical surfaces 227 and 227 intersecting the upper surfaces 223 and 223 of the inclined portions are formed. The horizontal positions are substantially determined by the positioning portions 226 and 226 that are provided. In FIG. 20A, the uppermost molded product PR10 before being taken out by the molded product replenishing device 70 is indicated by a broken line.

The sorting process shown in FIG. 19 is performed after the initial setting process. This operation may be performed when an operation for confirming the start of manufacture is received by the operation unit 132. Hereinafter, the sorting process will be described with reference to FIG.
When the process is started, the control panel 100 determines whether or not the uppermost molded product PR10 constituting the molded product stack ST1 has been carried out by the molded product replenishing device 70 (S302). For example, the condition is satisfied when a signal representing carry-out of the uppermost molded product PR10 shown in FIG. When the uppermost molded product PR10 is carried out, the control panel 100 drives the advance / retreat drive units 260, 260 to retract the latching units 220, 220 from the advanced position L34 to the retracted position L33 shown in FIG. S304). In S306, similarly to S106, when there is no replenishment molded product PR3 on the lift table 210, the replenishment product loading process shown in FIG. 18 is performed.

  In S308, the lifting table driving unit 250 is controlled to lower the lifting table 210. The lowering of the lifting table 210 starts from the height at which the molded product stack ST1 exists at the second height H2. In S310, it is determined whether or not the detection signal of the non-contact sensor 230 is switched from the light shielding state to the light receiving state. The light shielding state is a state representing the presence of the molded product stack ST1 at the second height H2, and the light receiving state is a state representing the absence of the molded product stack ST1 at the second height H2. When the molded product stack ST1 exists at the second height H2, the light shielding state continues, and the process of S310 is repeated. As shown in FIG. 20B, when the uppermost part of the molded product stack ST1 reaches the second height H2, the detection signal of the non-contact sensor 230 is switched from the light shielding state to the light receiving state, and the condition is satisfied. At this time, the control panel 100 acquires information on the height H3 of the lifting table 210 from the servo motor 254, and stores it in the RAM 104 (S312). In this manner, the control panel 100 detects the height H3 of the lifting table 210 when the detection signal of the non-contact sensor 230 is switched from the light shielding state to the light receiving state.

  In S314, the target height is obtained by adding the relative set height H6 = H4 + α (see FIG. 16A) determined by the input received in S102 of FIG. 17 to the detected height H3 of the lifting table. In S316, as shown in FIG. 20C, the lift table 210 is controlled by controlling the lift table drive unit 250 to a relative set height H6 with respect to the detected height H3, that is, to a target height H3 + H6. To raise. This process is a process of moving the lifting table 210 up and down until the gap CL1 between the molded products PR11 and PR12 at a predetermined position from the top of the molded product stack ST1 is set to the first height H1.

  In S318, the advancing / retreating drive units 260, 260 are controlled to advance the latching units 220, 220 from the retracted position L33 to the advanced position L34, and as shown in FIG. 20 (d), the uppermost molded product PR11 and the direct molded product PR12. The inclined portions 222 and 222 are inserted into the clearance CL1, specifically, the clearance CL1 between the flange portions PR1b. At this time, the uppermost molded product PR11 is separated from the direct molded product PR12 by the flange portion PR1b contacting the upper surfaces 223 and 223 of the inclined portions 222 and 222 and being slightly lifted along the upper surfaces 223 and 223 of the inclined portions. Further, since the vertical surfaces 227 and 227 of the positioning portions 226 and 226 intersecting the upper surfaces 223 and 223 of the inclined portions are outside the flange portion PR1b of the uppermost molded product PR11, the horizontal position of the uppermost molded product PR11 is almost determined. .

When the molded product replenishing device 70 uses the suction head 72 to suck and lift the upper part (projection PR1a) of the uppermost molded product PR11, the tip portions 222a and 222a of the inclined portions inserted at the first height H1 are the first. The flange part PR1b of the direct molded product PR12 below the height H1 is hooked. Therefore, the direct molded product PR12 is prevented from being unloaded when the uppermost molded product PR11 is unloaded.
In addition, since the uppermost molded product PR11 is slightly lifted by the upper surfaces 223 and 223 of the inclined portions, the uppermost molded product is easily separated. Further, since the horizontal position of the uppermost molded product PR11 is substantially determined by the vertical surfaces 227 and 227 of the positioning portion, the separated uppermost molded product is easily taken out.

  In S320, it is determined whether or not to end the production of the molded product PR1. This determination can be, for example, a determination as to whether or not the number of molded product stacks ST1 taken out has reached a target number, or a determination as to whether or not an operation for finishing production has been accepted by the operation unit 132. When manufacturing is continued, the control panel 100 repeats the processes of S302 to S320. When the production is finished, the control panel 100 finishes the sorting process.

In the molded product manufacturing system 1, the lifting table 210 is moved up and down to a set height H6 relative to the height H3 of the lifting table 210 when the state of the detection signal of the non-contact sensor 230 is switched. 210 moves up and down, and the latching portion 220 is inserted into the gap CL1 between the molded products PR3 constituting the molded product stack ST1. This eliminates the need for a part such as a separation unit that contacts the upper surface of the convex portion of the molded product stack ST1, that is, the bottom of the molded product. Due to the absence of such parts, the adhesion of scratches to the bottom of the molded product, which is conspicuous in appearance, is suppressed.
Further, since the height of the lifting table 210 for separating the molded product PR3 from the molded product stack ST1 is determined according to the relative set height H6 and the switching of the detection state of the non-contact sensor 230, various heights can be obtained. The molded product can be separated from the molded product stack without parts such as a separation unit.
Furthermore, even if the interval between the molded products varies, the elevating table 210 moves up and down with the uppermost part of the molded product stack ST1 as a reference, so that the certainty of dividing the molded products is high.

(4) Modification:
Various modifications can be considered for the present invention.
The molded product sorting device can be applied to a molded product supply device that supplies a molded product to a laminating apparatus that laminates a film on the molded product, in addition to replenishing the molded product with the molded product take-out device.
The order of the steps of the above-described processing can be changed as appropriate. For example, in the initial setting process of FIG. 17, the process of S104 may be performed before S102.
When the servo motor 254 accepts a relative lift, the relative set height H6 may be directly commanded to the servo motor 254 in S116 and S316 without performing the processes of S114 and S314.
In addition to the sheet, the material forming the molded product applicable to the molded product sorting apparatus may be a molded material such as a lump, granule, or powder.

In addition to the suction boxes 50 and 80, the means for holding the upper part of each molded product and transporting the molded product may be a suction head or the like corresponding to the position of each molded product. Further, as a means for conveying the molded product, a means for conveying the molded product while holding the upper part of each molded product such as a suction box instead of the conveyors 61, 62, 63, 64 may be used. As means for conveying the molded product stack, means for conveying the molded product stack while holding the side surface of the molded product stack instead of the conveyors 91 and 92 may be used.
In addition to transmissive photoelectric proximity switches, non-contact sensors include reflector photoelectric proximity switches, reflective photoelectric proximity switches, ultrasonic proximity switches, capacitive proximity switches, dielectric proximity switches, and dielectric proximity switches. It may be a switch, a magnetic field proximity switch, or the like.

As shown in FIGS. 21 and 22, the first height H1 and the second height H2 may be different.
FIG. 21 schematically illustrates the operation of the molded product sorting apparatus in which H2 <H1. When the uppermost molded product PR10 shown in FIG. 21A is carried out by the molded product replenishing device 70, the control panel 100 drives the advance / retreat drive units 260 and 260 to retract the latching units 220 and 220 to the retracted position L33. Let Further, the lift table 210 is lowered by controlling the lift table drive unit 250, and the height of the lift table 210 when the detection signal of the non-contact sensor 230 is switched from the light shielding state to the light receiving state as shown in FIG. H3 is detected.

Thereafter, as shown in FIG. 21 (c), the lift table drive unit 250 is controlled to a relative set height H6 = H4 + β with respect to the detected height H3, that is, to the target height H3 + H6. Increase 210. β is H1−H2 + α. Thereby, the clearance CL1 between the molded products PR11 and PR12 at a predetermined position from the top of the molded product stack ST1 becomes the first height H1. Then, the advancing / retreating drive units 260 and 260 are controlled to advance the latching units 220 and 220 to the advance position L34, and as shown in FIG. 21 (d), the inclined parts 222 and 222 are formed in the gaps between the molded products PR11 and PR12. To insert.
Therefore, this modification can also eliminate the need for a separation unit that contacts the uppermost molded product of the molded product stack, and can suppress the attachment of scratches to the molded product.

Moreover, as shown in FIG. 22, it is good also considering the time when it switches from the state showing the non-existence of a molded article stack in the 2nd height to the state showing presence as detection height H3.
FIG. 22 schematically illustrates the operation of the molded product sorting apparatus in which the detection height H3 is when the detection signal of the non-contact sensor 230 is switched from the light receiving state to the light shielding state. When the uppermost molded product PR10 shown in FIG. 22A is carried out by the molded product replenishing device 70, the control panel 100 drives the advance / retreat drive units 260, 260 to retract the latching units 220, 220 to the retracted position L33. Let Further, the lift table 210 is raised by controlling the lift table drive unit 250, and the height of the lift table 210 when the detection signal of the non-contact sensor 230 switches from the light receiving state to the light shielding state as shown in FIG. H3 is detected.

Thereafter, as shown in FIG. 22 (c), the lifting table driving unit 250 is controlled to a relative set height H6 = H4 + β with respect to the detected height H3, that is, to a target height H3 + H6. Increase 210. In this example, H6 <0, and β = H1−H2 + α <0. Thereby, the clearance CL1 between the molded products PR11 and PR12 at a predetermined position from the top of the molded product stack ST1 becomes the first height H1. Then, the advancing / retreating drive units 260, 260 are controlled to advance the latching units 220, 220 to the advance position L34, and as shown in FIG. 22 (d), the inclined parts 222, 222 are formed in the gaps between the molded products PR11, PR12. To insert.
Therefore, this modification can also eliminate the need for a separation unit that contacts the uppermost molded product of the molded product stack, and can suppress the attachment of scratches to the molded product.

  The molded product sorting apparatus can also divide the molded products into N pieces (N is an integer of 2 or more) from the molded product stack. Here, a description will be given with reference to FIG. For example, when two molded products PR3 are divided from the molded product stack ST1, if the predetermined height α2 is set to H5 <α2 <2 × H5 and the relative set height is H62 = H4 + α2, the molded product stack ST1 The latching portion 220 is inserted into the gap between the second molded product PR12 and the third molded product PR13 from the top. The molded products PR11 and PR12 above the first height H1 are lifted by the upper surface 223 of the inclined portion, and the horizontal positions of the molded products PR11 and PR12 are substantially determined by the vertical surface 227 of the positioning portion. As a result, the molded product PR3 is separated from the molded product stack ST1 every two sheets, and is to be carried out. In addition, when dividing into three, if the predetermined height α3 is set to 2 × H5 <α3 <3 × H5 and the relative set height is set to H63 = H4 + α3, the latching portion is formed in the gap between the molded products PR13 and PR14. 220 is inserted. The same applies when dividing into four or more.

In addition, the shaping | molding extraction apparatus which is not provided with the heating apparatus, the trimming extraction apparatus which is not provided with the shaping | molding apparatus, the molded article extraction apparatus which is not provided with the trimming apparatus, the conveying apparatus which is not provided with the stacking part, The method corresponding to these apparatuses , Etc. can also obtain the basic actions and effects described above.
Of course, even the invention consisting only of the constituent elements according to the independent claims can obtain the basic actions and effects described above.

As described above, according to the present invention, it is possible to provide a technique or the like that eliminates the need for the separation unit that contacts the uppermost molded product of the molded product stack according to various aspects.
Of course, the configurations disclosed in the above-described embodiments and modifications are mutually replaced, the combinations are changed, the known technology, and the configurations disclosed in the above-described embodiments and modifications are mutually. It is possible to implement a configuration in which replacement or combination is changed. The present invention includes these configurations and the like.

DESCRIPTION OF SYMBOLS 1 ... Molded article manufacturing system, 2 ... Mold extraction apparatus, 3 ... Trimming extraction apparatus,
4 ... molded product take-out device, 5 ... molded product sorting device,
61, 62, 63 ... molded article delivery conveyor, 64 ... terminal conveyor,
70 ... Molded product replenishing device, 71 ... Arm, 72 ... Suction head, 73 ... Control unit,
91 ... Stack delivery conveyor, 92 ... Stack removal conveyor,
100 ... Control panel,
210 ... Lifting table, 211 ... Placement surface, 212 ... Contact part insertion hole,
220 ... Hanging part,
221 ... Gap insertion member, 222 ... Inclined part, 222a ... Tip part,
223 ... upper surface, 224 ... opening,
225 ... opening insertion member, 226 ... positioning part, 226a ... tip part,
227 ... vertical plane,
230 ... non-contact sensor, 232 ... projector, 234 ... light receiver,
240 ... separation control means, 242 ... height input means,
250 ... Lifting table drive unit, 252 ... Guide, 254 ... Servo motor,
260 ... advance / retreat drive part, 262 ... cylinder, 264 ... piston, 265 ... tip part,
266, 267 ... screws, 268, 269 ... cylinder support members,
270 ... Replenishment carry-in device,
271, 272 ... abutting part, 273 ... pusher for supply, 274 ... supply stand,
280 ... positioning pusher, 282 ... contact portion,
CL1 ... Gap between molded products,
H1 ... first height, H2 ... second height, H3 ... height of lifting table,
H4: height of the molded product, H5: pitch of the flange portion, H6: relative set height,
L6 ... replenishment position,
L31 ... advance position, L33 ... retracted position, L34 ... advance position,
PR1 ... molded product, PR1a ... convex part, PR1b ... flange part,
PR3: Replenished molded product, PR11: Top molded product, PR12: Directly molded product.

Claims (7)

A device that separates a molded product from a molded product stack in which a molded product having a concave portion is stacked in a state where a convex portion corresponding to the concave portion is inserted into a concave portion of another molded product ,
A liftable table for placing the molded product stack;
A latching portion that can be inserted at a first height into the gap between the molded products that constitute the molded product stack placed on the lifting table and can latch a molded product below the first height,
The second height where the molded product stack exists when the hook is inserted into the gap between the molded products constituting the molded product stack placed on the lifting table and the molded product is divided, a non-contact sensor elevating table placed on molded article stack it is detected whether or not exist in a non-contact,
From the state where the molded product stack placed on the lifting table is lowered from the height at which the second height exists , the detection signal of the non-contact sensor indicates the presence of the molded product stack. detecting the height of the lifting table when switched to a state representative of the presence, until the relative setting height from the height the detected raises the lifting table, forming the molded product stack molding An apparatus comprising: separation control means for inserting the latching portion into a gap between products.   A device that separates a molded product from a molded product stack in which a molded product having a concave portion is stacked in a state where a convex portion corresponding to the concave portion is inserted into a concave portion of another molded product,
  A liftable table for placing the molded product stack;
  A latching portion that can be inserted at a first height into the gap between the molded products that constitute the molded product stack placed on the lifting table and can latch a molded product below the first height,
  In the second height where the molded product stack does not exist when the hook is inserted into the gap between the molded products constituting the molded product stack placed on the lifting table and the molded product is divided, A non-contact sensor for detecting in a non-contact manner whether or not there is a molded product stack placed on the lifting table;
  From the state where the molded product stack placed on the lift table is raised from a height that does not exist at the second height, and the detection signal of the non-contact sensor indicates the absence of the molded product stack. Forming the molded product stack by detecting the height of the lift table when switched to a state representing the presence, and lowering the lift table to a relative set height based on the detected height An apparatus comprising: separation control means for inserting the latching portion into a gap between products. The latching portion has an inclined portion having an upper surface obliquely lowered toward a molded product stack placed on the lifting table, a vertical surface intersecting the upper surface, and an upper side than the first height. With a positioning part that determines the horizontal position of the molded product,
The separation control means has a height input means for receiving an input for determining the relative set height, and lifts the lift table to a relative set height determined by the received input to The apparatus according to claim 1, wherein the hooking portion is inserted into a gap between the molded products constituting the slab . A method of separating a molded product from a molded product stack obtained by stacking a molded product having a concave portion with a convex portion corresponding to the concave portion inserted into a concave portion of another molded product ,
A liftable table for placing the molded product stack;
A latching portion that can be inserted at a first height into the gap between the molded products that constitute the molded product stack placed on the lifting table and can latch a molded product below the first height,
The second height where the molded product stack exists when the hook is inserted into the gap between the molded products constituting the molded product stack placed on the lifting table and the molded product is divided, using a non-contact sensor elevating moldings stack placed on the table for detecting whether exist in a non-contact,
From the state where the molded product stack placed on the lifting table is lowered from the height at which the second height exists , the detection signal of the non-contact sensor indicates the presence of the molded product stack. detecting the height of the lifting table when switched to a state representative of the presence, until the relative setting height from the height the detected raises the lifting table, forming the molded product stack molding A method comprising inserting the latching portion into a gap between products.   A method of separating a molded product from a molded product stack obtained by stacking a molded product having a concave portion with a convex portion corresponding to the concave portion inserted into a concave portion of another molded product,
  A liftable table for placing the molded product stack;
  A latching portion that can be inserted at a first height into the gap between the molded products that constitute the molded product stack placed on the lifting table and can latch a molded product below the first height,
  In the second height where the molded product stack does not exist when the hook is inserted into the gap between the molded products constituting the molded product stack placed on the lifting table and the molded product is divided, Using a non-contact sensor that detects non-contact whether or not there is a molded product stack placed on the lifting table,
  From the state where the molded product stack placed on the lift table is raised from a height that does not exist at the second height, and the detection signal of the non-contact sensor indicates the absence of the molded product stack. Forming the molded product stack by detecting the height of the lift table when switched to a state representing the presence, and lowering the lift table to a relative set height based on the detected height A method comprising inserting the latching portion into a gap between products. A method of separating a molded product from a molded product stack obtained by stacking a molded product having a concave portion with a convex portion corresponding to the concave portion inserted into a concave portion of another molded product ,
A liftable table for placing the molded product stack;
A latching portion that can be inserted at a first height into the gap between the molded products that constitute the molded product stack placed on the lifting table and can latch a molded product below the first height,
The second height where the molded product stack exists when the hook is inserted into the gap between the molded products constituting the molded product stack placed on the lifting table and the molded product is divided, using a non-contact sensor elevating moldings stack placed on the table for detecting whether exist in a non-contact,
From the state where the molded product stack placed on the lifting table is lowered from the height at which the second height exists , the detection signal of the non-contact sensor indicates the presence of the molded product stack. The height of the elevating table when the state is switched to a state representing the presence is detected, and the gap between the molded products at a predetermined position from the top of the molded product stack is determined based on the detected height. The raising and lowering table is raised until it is set, and the latching portion is inserted into the gap between the molded products.   A method of separating a molded product from a molded product stack obtained by stacking a molded product having a concave portion with a convex portion corresponding to the concave portion inserted into a concave portion of another molded product,
  A liftable table for placing the molded product stack;
  A latching portion that can be inserted at a first height into the gap between the molded products that constitute the molded product stack placed on the lifting table and can latch a molded product below the first height,
  In the second height where the molded product stack does not exist when the hook is inserted into the gap between the molded products constituting the molded product stack placed on the lifting table and the molded product is divided, Using a non-contact sensor that detects non-contact whether or not there is a molded product stack placed on the lifting table,
  From the state where the molded product stack placed on the lift table is raised from a height that does not exist at the second height, and the detection signal of the non-contact sensor indicates the absence of the molded product stack. The height of the elevating table when the state is switched to a state representing the presence is detected, and the gap between the molded products at a predetermined position from the top of the molded product stack is determined based on the detected height. The raising and lowering table is lowered until it is set, and the latching portion is inserted into the gap between the molded products.

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