Button badge making system

Abstract

In a button badge manufacturing system, even if the material runs out while button badges are being continuously manufactured, the system allows button badge manufacturing to continue without wasting the material from the button badges whose production was interrupted. [Solution] The button badge manufacturing system 300 comprises a printer 1, a crimping machine 100, and a controller 12. The crimping machine 100 has a first stocker 2a capable of holding multiple shell SEs, a first supply mechanism 2, and a first mold M1. When the controller 12 receives instructions to manufacture two or more button badges, it causes the first supply mechanism 2 to supply the first shell SE1 from the first stocker 2a to the first mold M1, and after the supply of the first shell SE1, it causes the printer to start printing the first backing sheet WF1, and after printing the first backing sheet WF1, it causes the printer 1 to supply the first backing sheet WF1 to the crimping machine 100, and if there is no second shell SE2 in the first stocker 2a, it stops printing the second backing sheet WF2.

Description

Technical Field

[0001] The present disclosure relates to a can badge manufacturing system for manufacturing can badges.

Background Art

[0002] In Patent Document 1, in a can badge manufacturing apparatus for manufacturing can badges, there is disclosed an apparatus including a printing unit that prints an image on a film, a covering means that covers a front cover with the film, and a can product assembling means that joins the front cover and the back cover covered with the film. The covering means and the can product assembling means crimp the material.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] An apparatus including a printer that prints an image on a sheet and a crimper that performs crimping has been devised. In this apparatus, the sheet on which the image is printed is supplied to the crimper, and the sheet, the front member, and the back member are crimped to complete the can badge. In this apparatus, printing of the image on the sheet and crimping can be executed in parallel. For example, when the previous sheet is being crimped with the front member and the back member in the crimper, an image can be printed on the next sheet in the printer. Thereby, before the previous can badge is completed, printing for the next can badge can be executed, so that the time required for continuously manufacturing a plurality of can badges is shortened.

[0005] In the above-described apparatus, the materials for the button badge, such as sheets, front and back components, and the colorants used to print images onto the sheets are consumed to complete the button badge. The user replenishes the apparatus with multiple quantities of each material in order to produce multiple button badges in succession. When producing multiple button badges in succession, if the button badge material or colorants run out, it becomes impossible to produce subsequent button badges. Therefore, the user needs to replenish the materials or colorants. When the user replenishes the materials or colorants, the printer and crimping machine are stopped. However, the stopping of the printer and crimping machine means that button badge production is interrupted. Some users, when the printer and crimping machine stop, remove the materials for the button badge being produced (for example, those consisting of a sheet and a front component, etc.) from the apparatus. After that, the user replenishes the materials or colorants. However, if the material for the partially manufactured button badge is removed from the above device, it results in the waste of the partially manufactured button badge material, and it becomes impossible to resume the production of button badges using the partially manufactured button badge material.

[0006] The purpose of this disclosure is to enable a button badge manufacturing system to continue producing button badges even if the material runs out while button badges are being continuously produced, without wasting the material of the button badges already being made. [Means for solving the problem]

[0007] (1) The button badge manufacturing system according to the present disclosure is a button badge manufacturing system comprising a printer, a crimping machine, and a controller, wherein the crimping machine has a first stocker capable of holding a plurality of shells, a first supply mechanism, and a first mold, and the controller, on the condition that it has received two or more button badge manufacturing instructions, causes the first supply mechanism to supply a first shell from the first stocker to the first mold, after the supply of the first shells, causes the printer to start printing a first backing sheet, after printing the first backing sheet, causes the printer to supply the first backing sheet to the crimping machine, causes the first supply mechanism to detect the presence or absence of a second shell in the first stocker, and executes or stops printing the second backing sheet depending on the presence or absence of the second shell.

[0008] If the printing of the backing card for the second button badge is initiated while the first button badge is being made, provided that the shell for the second button badge is available, the production of the second button badge can be completed earlier. If the shell for the second button badge is not available, the second button badge cannot be made, and printing the backing card for the second button badge would be a waste. With the above configuration, the printing of the backing card for the second button badge is stopped if the shell for the second button badge is not available, thus reducing the waste of backing card material.

[0009] (2) The controller may stop printing the second backing sheet if it detects that the second shell is absent.

[0010] (3) The crimping machine may have a transport mechanism and a crimping mechanism, and the controller may cause the transport mechanism to supply the printed first base sheet to the first mold, cause the printer to start printing the first medium, cause the printer to supply the first medium to the crimping machine after printing of the first medium is completed, stop the printer after supplying the first medium is completed, cause the transport mechanism to supply the first medium supplied from the printer to the first mold, and cause the crimping mechanism to crimp the first shell, the first base sheet and the first medium together to produce the first surface material.

[0011] (4) The crimping machine has a second stocker capable of holding multiple back parts, a second supply mechanism, and a second mold. The controller may, after the production of the first front material is completed, or in parallel with the production of the first front material, cause the second supply mechanism to supply the first back parts from the second stocker to the second mold. After the production of the first front material is completed and the first back parts have been supplied, cause the crimping mechanism to crimp the first front material and the first back parts together to produce the first button badge. After the production of the first button badge is completed, the controller may stop the operation of the crimping machine.

[0012] (5) The crimping machine may have a transport mechanism and a crimping mechanism, and the controller may cause the transport mechanism to supply the first base sheet to the first mold, cause the printer to start printing the first medium, cause the printer to supply the first medium to the crimping machine after printing the first medium is completed, cause the transport mechanism to supply the first medium supplied from the printer to the first mold, and cause the crimping mechanism to crimp the first shell, the first base sheet and the first medium together to produce the first surface material.

[0013] (6) The controller may, on the condition that it has detected that there is no colorant in the printing of the first medium, instruct the printer to stop printing the second backing sheet.

[0014] (7) The crimping machine has a second stocker capable of holding a plurality of back parts, a second supply mechanism, and a second mold, and the controller may, after the production of the first front material is completed, or in parallel with the production of the first front material, cause the second supply mechanism to supply the first back parts from the second stocker to the second mold, and after the production of the first front material is completed and after the supply of the first back parts, cause the crimping mechanism to crimp the first front material and the first back parts together to produce the first button badge.

[0015] (8) The printer has a first tray capable of holding multiple sheets of paper, and the controller may, after the completion of printing on the first medium, cause the printer to detect whether or not there is a second sheet of paper in the first tray, and if it detects that there is no second sheet of paper, stop printing on the second sheet of paper.

[0016] (9) The printer has a first tray capable of holding multiple backing sheets, and the controller may, after the completion of printing on the first medium, cause the printer to detect whether or not there is a second backing sheet in the first tray, and if it detects that there is a second backing sheet, cause the printer to start printing on the second backing sheet, and after the completion of manufacturing the first button badge, cause the first supply mechanism to supply the second shell from the first stocker to the first mold, and after the supply of the second shell is complete, cause the printer to supply the second backing sheet to the crimping machine.

[0017] (10) The printer has a second tray capable of holding multiple media, and after the printing of the second backing sheet is completed, the controller may cause the printer to detect whether or not there is a second media in the second tray, and if it detects that the second media is present, it may start printing the second media.

[0018] (11) The printer has a second tray capable of holding multiple media, and the controller may, after the printing of the second backing sheet is completed, cause the printer to detect whether or not there is a second media in the second tray, and if it detects that there is no second media, stop printing of the second media.

[0019] (12) After the production of the first can badge is completed, the controller causes the second supply mechanism to detect the presence or absence of the second back part in the second stocker, causes the first supply mechanism to supply the second shell from the first stocker to the first mold, causes the printer to supply the second base paper and the second medium to the first mold, causes the caulking mechanism to caulk the second shell, the second base paper, and the second medium to produce a second front material, and may stop the operation of the caulking machine after the production of the second front material on the condition that it is detected that the second back part is absent.

[0020] (13) After the production of the first can badge is completed, the controller causes the second supply mechanism to detect the presence or absence of the second back part in the second stocker, causes the first supply mechanism to supply the second shell from the first stocker to the first mold, causes the printer to supply the second base paper and the second medium to the first mold, causes the caulking mechanism to caulk the second shell, the second base paper, and the second medium to produce a second front material, causes the second back part to be supplied from the second stocker to the second mold, and may produce a second can badge by caulking the second front material and the second back part after the production of the second front material on the condition that it is detected that the second back part is present.

Advantages of the Invention

[0021] According to the present disclosure, even when the material runs out while the can badges are being continuously produced, the production of the can badges can continue without wasting the materials during the production process.

Brief Description of the Drawings

[0022] [Figure 1] FIG. 1 is an external perspective view of a can badge production system 300. [Figure 2] FIG. 2 is an external perspective view of the can badge production system 300 with the exterior body 101 removed. [Figure 3] FIG. 3 is a top view of the can badge production system 300 with the exterior body 101 removed. [Figure 4] FIG. 4 is a block diagram of the first control unit 11 of the seaming machine 100. [Figure 5] FIG. 5 is a cross-sectional view showing the configuration of the can badge 200. [Figure 6] FIG. 6(A) is a top view of the medium PF, and FIG. 6(B) is a top view of the mount WF. [Figure 7] FIG. 7 is a schematic diagram showing the main configuration of the printer 1. [Figure 8] FIG. 8 is a block diagram showing the main configuration of the second control unit 50 of the printer 1. [Figure 9] FIG. 9 is a block diagram showing the main configuration of the controller 12. [Figure 10] FIG. 10 is a cross-sectional perspective view showing the configuration of the first supply mechanism 2. [Figure 11] FIG. 11 is a timing chart showing the operation of the can badge manufacturing system 300. [Figure 12] FIG. 12 is a timing chart showing the operation of the can badge manufacturing system 300 following FIG. 11. [Figure 13] FIG. 13 is a timing chart showing the operation of the can badge manufacturing system 300 following FIG. 12. [Figure 14] FIG. 14 is a timing chart showing the operation of the can badge manufacturing system 300 following FIG. 13. [Figure 15] FIG. 15 is a sequence diagram explaining the operation of the can badge manufacturing system 300 when the material of the can badge 200 runs out. [Figure 16] FIG. 16 is a sequence diagram explaining the operation of the can badge manufacturing system 300 following FIG. 15.

MODE FOR CARRYING OUT THE INVENTION

[0023] Hereinafter, the can badge manufacturing system 300 according to the embodiments of the present disclosure will be described in detail. It should be noted that the following embodiments are merely examples of the present disclosure, and it is needless to say that the embodiments can be appropriately changed without departing from the gist of the present disclosure.

[0024] [Outline configuration of the button badge manufacturing system 300] In Figures 1 to 3, the vertical direction is defined based on the state in which the button badge manufacturing system 300 is installed for use. The front-to-back direction is defined with the side where the transport mechanism 3 is provided as the front. The left-to-right direction is defined when viewing the button badge manufacturing system 300 from the front. The ordinal numbers assigned to the materials of the button badge 200—the medium PF, the backing WF, the shell SE, and the back part BE—correspond to the order in which the button badges 200 are completed. For example, the materials of the first completed button badge 200 are denoted as first medium PF1, first backing WF1, first shell SE1, first surface material FM1, and first back part BE1. The materials of the second completed button badge 200 are second medium PF2, second backing WF2, second shell SE2, second surface material FM2, and second back part BE2. The ordinal numbers assigned to the button badge 200 itself are similar. In other words, the first completed button badge 200 is labeled as "First Button Badge 200," and the second completed button badge 200 is labeled as "Second Button Badge 200." When printer 1 stops printing, it means that it is waiting to print. Printing includes the medium PF and backing paper WF passing through printer 1 without ink being ejected.

[0025] As shown in Figures 1 to 5, the button badge manufacturing system 300 comprises a printer 1, a crimping machine 100, a controller 12, and an outer casing 101. The printer 1 supplies the medium PF and backing paper WF as the material for the button badge 200 to the crimping machine 100. The crimping machine 100 manufactures the button badge 200. The controller 12 monitors and controls the operation of the printer 1 and the crimping machine 100. The outer casing provides the appearance of the button badge manufacturing system 300 and ensures user safety.

[0026] [Overview of the 200-piece can badge set] As shown in Figure 5, the button badge 200 has a front material FM and a back part BE. The front material FM has, in order from the front side, a medium PF, a backing WF, and a shell SE. The edges of the medium PF and backing WF of the button badge 200 are folded to the back side of the shell SE, sandwiched between the shell SE and the back part BE, and crimped. As will be described later, in order to remove the button badge 200 by magnetic attraction, a magnetic material such as tin-plated steel sheet is used as the material for at least one of the shell SE and the back part BE.

[0027] [Media PF] The medium PF is a transparent film of L-size (89mm x 127mm). One side of the medium PF is the printing surface. The printing surface has an ink-receiving layer, and a mirror image (inverted image) of the predetermined image is printed on it. By facing the printed surface towards the back of the button badge 200, the normal image of the predetermined image is displayed on the front of the button badge 200. Note that the medium PF may be a size other than L-size. The medium PF may also be a translucent film.

[0028] As shown in Figure 6(A), the medium PF has a medium residual portion PFa, a medium connected portion PFb, a medium connecting portion PFc, and a medium linear weak portion PFd. One short side of the medium PF is called the medium edge portion PFe1. The medium residual portion PFa is an ear portion for the transport mechanism 3 to transport the medium PF from the printer 1 to the first mold M1. The medium connected portion PFb has a predetermined image printed on it. The medium connected portion PFb is surrounded by the medium residual portion PFa. The medium connected portion PFb has a contour shape corresponding to the shell SE and is larger in diameter than the shell SE. The medium connected portion PFb is predominantly located on the medium edge portion PFe1 side. The medium connecting portion PFc is the boundary portion between the medium residual portion PFa and the medium connected portion PFb. The medium linear weak portion PFd is a straight line portion that connects the medium edge portion PFe1 and the medium connecting portion PFc by the shortest distance. The media connection portion PFc and the media linear weak portion PFd are weaker and more prone to breakage than the media residual portion PFa and the media connected portion PFb. The media connection portion PFc and the media linear weak portion PFd may be, for example, a recess or the like that is thinner than the media residual portion PFa and the media connected portion PFb. The thickness of the media connection portion PFc and the media linear weak portion PFd may be the same as the thickness of the media residual portion PFa and the media connected portion PFb, and partially cut perforations may be formed in the media connection portion PFc and the media linear weak portion PFd, respectively. Hereinafter, the media connected portion PFb may be abbreviated as media PF.

[0029] [WF cardboard backing] The backing card WF is a white film of L size. However, the backing card WF may be a size other than L size. The size of the backing card WF may differ from the size of the media PF. The backing card WF may be a color other than white. The image may be printed on the backing card WF instead of the media PF, or the image may be printed on both the media PF and the backing card WF. The button badge 200 does not require a backing card WF. If the backing card WF is omitted and the front side of the shell SE has a metallic sheen, the front side of the button badge 200 can be given a metallic sheen.

[0030] As shown in Figure 6(B), the backing sheet WF has a backing sheet remaining portion WFa, a backing sheet connected portion WFb, a backing sheet connecting portion WFc, and a backing sheet linear weak portion WFd. One short side of the backing sheet WF is referred to as the backing sheet edge portion WFe1. The backing sheet remaining portion WFa is an ear portion for the transport mechanism 3 to transport the backing sheet WF from the printer 1 to the first mold M1. The backing sheet connected portion WFb is surrounded by the backing sheet remaining portion WFa. The backing sheet connected portion WFb has a contour shape corresponding to the shell SE and is larger in diameter than the shell SE. The backing sheet connected portion WFb is predominantly located on the backing sheet edge portion WFe1 side. The backing sheet connecting portion WFc is the boundary portion between the backing sheet remaining portion WFa and the backing sheet connected portion WFb. The linear weak portion WFd of the backing paper is a straight section that connects the backing paper edge WFe1 and the backing paper connecting portion WFc at the shortest distance. The backing paper connecting portion WFc and the linear weak portion WFd are weaker and more prone to breakage than the backing paper remaining portion WFa and the backing paper connected portion WFb. The backing paper connecting portion WFc and the linear weak portion WFd may be, for example, a recess or the like that is thinner than the backing paper remaining portion WFa and the backing paper connected portion WFb. The thickness of the backing paper connecting portion WFc and the linear weak portion WFd is the same as the thickness of the backing paper remaining portion WFa and the backing paper connected portion WFb, and perforations that are partially cut may be formed on the backing paper connecting portion WFc and the backing paper linear weak portion WFd, respectively. Hereinafter, the backing paper connected portion WFb may be abbreviated as backing paper WF.

[0031] [Printer 1] Printer 1 is an inkjet printer. Printer 1 may have a serial head or a line head ejection head that ejects ink as a colorant. As shown in Figures 7 and 8, Printer 1 includes a first tray 20A, a second tray 20B, a first feeding unit 21A, a second feeding unit 21B, a transport roller unit 28, a recording unit 29, an ejection roller unit 32, a platen 40, a second control unit 50, a tray sensor 57, and a remaining ink sensor 58.

[0032] [Tray 1, 20A; Tray 2, 20B] The first tray 20A and the second tray 20B are detachably mounted on the printer 1. The first tray 20A can hold multiple backing sheets (WF). The second tray 20B can hold multiple media (PF).

[0033] [First feeding section 21A, second feeding section 21B] The first feeding unit 21A comprises a shaft 22A, a feeding arm 23A, and a feeding roller 24A. The shaft 22A is supported by the frame of the printer 1. The feeding arm 23A is rotatably supported on the shaft 22A. The feeding arm 23A is biased downward by its own weight or by an elastic force such as a spring. The feeding roller 24A is rotatably supported at the rotating end of the feeding arm 23A. The feeding roller 24A is rotationally driven by a transport motor 55 and feeds the cardboard base WF held on the first tray 20A to the transport path 25. Similarly, the second feeding unit 21B comprises a feeding roller 24B, a feeding arm 23B, and a shaft 22B, and feeds the media PF supported on the second tray 20B to the transport path 25.

[0034] [Transport path 25] The transport path 25 starts from the rear ends of the first tray 20A and the second tray 20B, extends from bottom to top on the rear side of the printer 1, makes a U-turn, passes through the recording unit 29, and reaches the receiving opening 3a of the transport mechanism 3. Part of the transport path 25 is formed by an outer guide member 26 and an inner guide member 27 that are facing each other at a predetermined interval. Within the transport path 25, the backing paper WF and media PF are transported in the transport direction indicated by the dashed arrow in Figure 7.

[0035] [Conveyor roller section 28] The transport roller section 28 is positioned on the upstream side of the recording section 29 in the transport direction. The transport roller section 28 includes a transport roller 30 and a pinch roller 31. The pinch roller 31 presses against the transport roller 30. When the transport roller 30 is rotationally driven by the transport motor 55, the pinch roller 31 moves along with it. The backing paper WF and media PF are held between the transport roller 30 and the pinch roller 31 and transported.

[0036] [Discharge roller section 32] The discharge roller section 32 is located downstream of the recording section 29 in the transport direction. The discharge roller section 32 includes a discharge roller 33 and a spur 34. The spur 34 presses against the discharge roller 33. When the discharge roller 33 is rotationally driven by the transport motor 55, the spur 34 moves along with it. The backing paper WF and media PF are held between the discharge roller 33 and the spur 34 and transported.

[0037] [Sensor 35, 3rd Sensor] The third sensor 35 is positioned on the upstream side of the transport roller section 28 in the transport direction. The third sensor 35 comprises a support shaft 36 positioned outside the transport path 25, an arm section 37 that rotates around the support shaft 36, a light-shielding section 38 extending to the opposite side of the arm section 37 across the support shaft 36, and an optical sensor 39. The optical sensor 39 is a so-called photointerrupter and has a light-emitting section and a light-receiving section. The light-emitting section is, for example, a light-emitting diode, and the light-receiving section is, for example, a photodiode. The light-emitting section irradiates light onto the light-receiving section. The light-receiving section outputs a signal corresponding to the amount of light received. The output signal of the light-receiving section may be a voltage signal whose voltage changes according to the amount of light received, or it may be another signal. The arm portion 37 is pushed down and rotated as the backing board WF and media PF pass through the transport path 25. The light-shielding portion 38 rotates together with the arm portion 37, moving forward and backward in the optical path of the light emitted by the light-emitting portion of the optical sensor 39, thereby changing the amount of light received by the light-receiving portion. Hereinafter, the output signal of the light-receiving portion of the optical sensor 39 will be referred to as the detection signal of the third sensor 35.

[0038] [Record Section 29] The recording unit 29 is located between the transport roller unit 28 and the discharge roller unit 32, which are oriented toward transport. The recording unit 29 also faces the platen 40 from above. The recording unit 29 comprises a carriage 41 and a recording head 42. The carriage 41 is supported by guide rails 43 and 44. The guide rails 43 and 44 extend in the left-right direction and are spaced apart from each other in the front-rear direction. The carriage 41 moves back and forth along the guide rails 43 and 44. The recording head 42 is mounted on the carriage 41. Multiple nozzles 45 are formed on the underside of the recording head 42. The recording head 42 ejects minute ink droplets from the nozzles 45. As the carriage 41 moves, the recording head 42 ejects ink droplets onto the medium PF on the platen 40, thereby printing an image onto the medium PF.

[0039] [Platen 40] The platen 40 is located between the transport roller section 28, which is oriented towards transport, and the discharge roller section 32. The platen 40 faces the recording section 29 from below and supports the base paper WF and media PF, which are transported by the transport roller section 28, from below.

[0040] [Tray Sensor 57] The tray sensor 57 outputs a signal corresponding to the mounting status of the first tray 20A and the second tray 20B, respectively. The mounting status refers to whether the first tray 20A is in a state where the backing paper WF can be fed, and whether the second tray 20B is in a state where the media PF can be fed. The tray sensor 57 may be a mechanical sensor or an optical sensor, for example.

[0041] [Battery level sensor 58] The ink level sensor 58 detects whether the ink level in each ink cartridge—yellow (Y), magenta (M), cyan (C), and black (K)—is above a predetermined height. The printer 1 detects that there is ink if the ink level in the ink cartridge is above the predetermined height, and detects that there is no ink if the ink level is below the predetermined height. The ink level sensor 58 may be a mechanical sensor or an optical sensor, for example.

[0042] [Second Control Unit 50] The second control unit 50 comprises a second arithmetic unit 51, a second storage unit 52, a second interface 53, and an ASIC (Application Specific Integrated Circuit) 54. The second arithmetic unit 51 is, for example, a CPU (Central Processing Unit) or an FPGA (Field Programmable Gate Array). The second storage unit 52 is, for example, a ROM (Read Only Memory), RAM (Random Access Memory), EEPROM (Electrically Erasable Programmable ROM), flash ROM, or HDD (Hard Disk Drive). The second interface 53 may be a wired interface such as USB (Universal Serial Bus) or a wireless interface such as Bluetooth (registered trademark). The second storage unit 52 stores the program and parameters. The second arithmetic unit 51 executes the program according to the parameters. The second interface 53 connects the second control unit 50 and the controller 12 to perform signal input and output. The ASIC 54 performs input and output processing for the second control unit 50. The ASIC135 is connected to the transport motor 55, the carriage motor 56, the recording head 42, the third sensor 35, the tray sensor 57, and the remaining amount sensor 58. When the ASIC54 receives a drive signal for the transport motor 55 from the second calculation unit 51, it inputs a drive current to the transport motor 55 corresponding to the drive signal. Similarly, when the ASIC54 receives a drive signal for the carriage motor 56 from the second calculation unit 51, it inputs a drive current to the carriage motor 56 corresponding to the drive signal. When the transport motor 55 is rotated according to the drive current, the first feeding unit 21A, the second feeding unit 21B, the transport roller unit 28, the discharge roller unit 32, and the carriage 41 are driven. When the carriage motor 56 is rotated according to the drive current, the carriage 41 is driven.

[0043] The second control unit 50 rotates the transport motor 55 to start feeding the backing paper WF to the first feeding unit 21A, and if the detection signal of the third sensor 35 does not change within a predetermined time, it detects that there is no backing paper WF. If the detection signal of the third sensor 35 changes within the same predetermined time, it detects that there is a backing paper WF. The second control unit 50 rotates the transport motor 55 to start feeding the medium PF to the second feeding unit 21B, and if the detection signal of the third sensor 35 does not change within a predetermined time, it detects that there is no medium PF. If the detection signal of the third sensor 35 changes within the same predetermined time, it detects that there is a medium PF. The second control unit 50's second calculation unit 51 ejects ink from the nozzle 45 of the recording head 42 according to the image data. In this embodiment, no ink is ejected onto the backing paper WF. The second control unit 50 detects the mounting status of the first tray 20A and the second tray 20B from the output signal of the tray sensor 57.

[0044] [Crimping machine 100] The crimping machine 100 produces button badges 200 using the backing paper WF and media PF supplied by the printer 1 as materials. As shown in Figures 2 to 4, the crimping machine 100 comprises a first supply mechanism 2, a transport mechanism 3, a peeling mechanism 4, a rotating mechanism 5, a crimping mechanism 6, a second supply mechanism 7, a removal mechanism 8, a collection box 9, a button badge holder 10, and a first control unit 11.

[0045] [First supply mechanism 2] As shown in Figure 10, the first supply mechanism 2 comprises a first stocker 2a, a first supply slope 2b, a first supply slider 2c, and a first sensor 2d. The first stocker 2a is a vertically elongated cylindrical member capable of holding multiple shells SE. The inside of the horizontal cross-section of the first stocker 2a is shaped to conform to the outer shape of the shells SE. The first stocker 2a may be replaced to match the outer shape of the shells SE. As shown in Figure 2, the shells SE are stacked vertically within the first stocker 2a. Of the shells SE within the first stocker 2a, the lowest shell SE is placed on the first supply slope 2b.

[0046] The first supply slope 2b has a guide surface that guides the shell SE and the first supply slider 2c toward the first mold M1. A gap is provided between the guide surface of the first supply slope 2b and the lower end of the first stocker 2a, allowing exactly one shell SE to pass through. The first supply slider 2c is a flat plate member and moves back and forth on the guide surface of the first supply slope 2b by a rack and pinion mechanism (not shown). The first supply slider 2c slides the lowest shell SE among the shell SE in the first stocker 2a on the guide surface of the first supply slope 2b and transports it to the first mold M1. In this way, the shell SE is supplied to the first mold M1. As described later, with the shell SE supplied to the first mold M1, the transport mechanism 3 sequentially transports the base paper WF and the medium PF onto the first mold M1.

[0047] The first sensor 2d has an arm portion 2d1, a spring 2d3, and a contact 2d4. The arm portion 2d1 is pivotally supported on an axis 2d2. The spring 2d3 biases the rotating end of the arm portion 2d1 upward. When the tip of the arm portion 2d1 is pushed downward by the load of the shell SE in the first stocker 2a, the contact 2d4 opens. When there is no shell SE in the first stocker 2a, the rotating end of the arm portion 2d1 advances into the first stocker 2a, and the contact 2d4 becomes conductive. As a result, the first supply mechanism detects the presence or absence of a shell SE in the first stocker and outputs a signal according to the detection result.

[0048] [Conveying mechanism 3] The transport mechanism 3 is positioned on the front of the button badge manufacturing system 300, covering the discharge port from the printer 1 through which the backing paper WF and media PF are discharged. The transport mechanism 3 includes a receiving port 3a, a fourth sensor 3b, a transport motor (not shown), and a group of transport rollers (not shown). The receiving port 3a guides the backing paper WF and media PF discharged by the printer 1 to the fourth sensor 3b. The fourth sensor 3b detects the backing paper WF and media PF discharged by the printer 1. The transport motor rotates the group of transport rollers. The group of transport rollers transports the backing paper WF and media PF from the receiving port 3a to the first mold M1.

[0049] The transport mechanism 3 transports the backing paper WF and media PF from the printer 1 to the first mold M1. At this time, the backing paper WF is transported in the first transport direction Dc1 with the backing paper edge WFe1 as the leading edge, and the media PF is transported in the first transport direction Dc1 with the media edge PFe1 as the leading edge. The transport mechanism 3 also transports the remaining backing paper WFa and the remaining media PFa from the first mold M1 to the recovery box 9. At this time, the backing paper WF is transported in the second transport direction Dc2 with the backing paper edge WFe2 as the leading edge, and the media PF is transported in the second transport direction Dc2 with the media edge PFe2 as the leading edge.

[0050] [Peeling mechanism 4] The peeling mechanism 4 comprises a peeling arm 4a and a peeling head 4b. The peeling arm 4a rotates about a pivot axis (not shown). The peeling head 4b is located at the tip of the peeling arm 4a. The rotation of the peeling arm 4a causes the peeling head 4b to reciprocate between a standby position and a pressing and fixing position. In the pressing and fixing position, the peeling head 4b presses against the backing paper WF on the first mold M1, pressing and fixing the backing paper connection portion WFb. With the peeling head 4b pressing and fixing the backing paper connection portion WFb on the first mold M1, the transport mechanism 3 transports the remaining backing paper portion WFa to the collection box 9, causing the backing paper connecting portion WFc and the backing paper linear weak portion WFd to break, and the backing paper connection portion WFb is peeled off from the remaining backing paper portion WFa. After the remaining portion of the backing paper WFa is collected in the collection box 9, the peeling arm 4a rotates and the peeling head 4b moves to the standby position. Then, when the transport mechanism 3 supplies the medium PF onto the first mold M1, the medium connection portion PFb is similarly peeled off from the remaining portion of the medium PFa.

[0051] [Rotation mechanism 5] The rotating mechanism 5 comprises a rotating support table 5a, a first mold M1, and a second mold M2. The rotating support table 5a rotates around a rotation axis 5b with the vertical direction as its axial direction. The first mold M1 and the second mold M2 are supported on the upper surface of the rotating support table 5a. The rotation of the rotating support table 5a causes the first mold M1 and the second mold M2 to reciprocate between a material supply position and a crimping position P2 for crimping the surface material FM and the can badge 200. Hereinafter, the material supply position will be referred to as the supply position P1. The first mold M1 and the second mold M2 face each other across the rotation axis. Therefore, when the first mold M1 is in the supply position P1, the second mold M2 is in the crimping position P2. Conversely, when the first mold M1 is in the crimping position P2, the second mold M2 is in the supply position P1.

[0052] [Crimping mechanism 6] The crimping mechanism 6 comprises a lifting device 6a, an upper die M0, and a crimping motor 62. The crimping mechanism 6 rotates the crimping motor 62 to raise and lower the upper die M0 on the lifting device 6a at the crimping position P2, pressing it against and separating it from the first die M1 and the second die M2. The rotating mechanism 5 moves the first die M1 from the supply position P1 to the crimping position P2. The crimping mechanism 6 lowers the upper die M0 and presses it against the first die M1, crimping the shell SE, the backing paper WF, and the medium PF together to produce the surface material FM. While holding the surface material FM, the crimping mechanism 6 raises the upper die M0. The rotating mechanism 5 moves the second die M2 from the supply position P1 to the crimping position P2. The crimping mechanism 6, while holding the front material FM, lowers the upper die M0 and presses it against the second die M2, crimping the front material FM and the back part BE together to produce the button badge 200. When the crimping mechanism 6 raises the upper die M0, the rotating mechanism 5 moves the second die M2 to the supply position P1 with the button badge 200 placed on it.

[0053] [Second supply mechanism 7] The second supply mechanism 7 comprises a second stocker 7a, a second supply slope 7b, a second supply slider 7c, and a second sensor 7d. The second stocker 7a is a vertically elongated cylindrical member capable of holding multiple back parts BE. The inside of the horizontal cross-section of the second stocker 7a is shaped to conform to the outer shape of the back parts BE. The second stocker 7a may be replaced to match the outer shape of the back parts BE. The back parts BE are stacked vertically within the second stocker 7a. Of the back parts BE within the second stocker 7a, the bottom back part BE is placed on the second supply slope 7b.

[0054] The second supply slope 7b has a second supply guide surface that guides the back parts BE and the second supply slider 7c toward the second mold M2. A gap is provided between the guide surface of the second supply slope 7b and the lower end of the second stocker 7a, allowing exactly one back part BE to pass through. The second supply slider 7c is a flat plate member and moves back and forth on the guide surface of the second supply slope 7b by a rack and pinion mechanism (not shown). The second supply slider 7c slides the lowest back part BE among the back parts BE in the second stocker 7a on the second supply guide surface of the second supply slope 7b and transports it to the second mold M2. In this way, back parts BE are supplied to the second mold M2.

[0055] The second sensor 7d has the same configuration as the first sensor 2d of the first supply mechanism 2. The second sensor 7d detects the presence or absence of back part BE in the second stocker 7a and outputs a signal according to the detection result.

[0056] [Removal mechanism 8] The retrieval mechanism 8 comprises a retrieval arm 8a, a retrieval head 8b, and a seat portion 8c. The retrieval arm 8a rotates about a pivot axis (not shown). The retrieval head 8b is a magnetic member. The retrieval head 8b is provided at the tip of the retrieval arm 8a. The rotation of the retrieval arm 8a causes the retrieval head 8b to reciprocate between a retrieval position and a retrieval position. The seat portion 8c is provided at the retrieval position. The seat portion 8c has an upper surface and a groove. The upper surface of the seat portion 8c is an inclined surface that slopes downward toward the can badge holder 10. The groove portion of the seat portion 8c has an opening shape that can accommodate only the tip portion of the retrieval arm 8a, including the retrieval head 8b. The groove portion has a depth such that the retrieval head 8b housed in the groove cannot magnetically attract the can badge 200 on the seat portion 8c.

[0057] At the extraction position, the extraction head 8b approaches the second mold M2 at the supply position P1 and magnetically attracts the button badge 200 placed on the second mold M2. While magnetically attracting the button badge 200, the extraction head 8b moves to the retrieval position as the extraction arm 8a rotates. At the retrieval position, the tip portion of the extraction arm 8a, including the extraction head 8b, is housed in the groove of the seat portion 8c. The button badge 200 comes into contact with the upper surface of the seat portion 8c and cannot enter the groove, so it detaches from the extraction head 8b. Released from the magnetic attraction of the extraction head 8b, the button badge 200 slides down the upper surface of the seat portion 8c and falls into the button badge holder 10 for retrieval.

[0058] [First control unit 11] As shown in Figure 4, the first control unit 11 includes a first calculation unit 111, a first storage unit 112, a first interface 113, a first drive circuit 114, a second drive circuit 115, a third drive circuit 116, a fourth drive circuit 117, a fifth drive circuit 118, a sixth drive circuit 119, and a seventh drive circuit 120. The first internal bus 110 connects the first calculation unit 111, the first storage unit 112, the first interface 113, the first drive circuit 114, the second drive circuit 115, the third drive circuit 116, the fourth drive circuit 117, the fifth drive circuit 118, the sixth drive circuit 119, and the seventh drive circuit 120. The first drive circuit 114 is connected to the first supply mechanism 2. The second drive circuit 115 is connected to the transport mechanism 3. The third drive circuit 116 is connected to the peeling mechanism 4. The fourth drive circuit 117 is connected to the rotating mechanism 5. The fifth drive circuit 118 is connected to the crimping mechanism 6. The sixth drive circuit 119 is connected to the second supply mechanism 7. The seventh drive circuit 120 is connected to the extraction mechanism 8.

[0059] The first arithmetic unit 111 is, for example, a CPU or FPGA. The first storage unit 112 is, for example, a ROM, RAM, flash ROM, HDD, etc. The first interface 113 may be a wired interface such as USB, or a wireless interface such as Bluetooth®. The first storage unit 112 stores firmware and parameters. The parameters include output values ​​and drive amounts for operating the button badge manufacturing system 300. The first arithmetic unit 111 controls each part of the button badge manufacturing system 300 according to the parameters by executing the firmware. The first interface 113 connects the first control unit 11 and the controller 12 to input and output signals. The controller 12 may be, for example, a personal computer or a mobile terminal such as a smartphone.

[0060] [Controller 12] Controller 12 is equipped with an application program for operating the button badge manufacturing system 300. Controller 12 may be, for example, a personal computer or a mobile device such as a tablet or smartphone. As shown in Figure 9, Controller 12 comprises a third arithmetic unit 91, a third storage unit 92, and a third interface 93. The third internal bus 90 connects the third arithmetic unit 91, the third storage unit 92, and the third interface 93. The third arithmetic unit 91 is a CPU. The third storage unit 92 may be, for example, ROM, RAM, flash ROM, HDD, SSD (Solid State Drive), etc. The third interface 93 connects Controller 12 to the printer 1 and the crimping machine 100 and performs signal input and output. The third interface 93 may be a wired interface such as USB or a wireless interface such as Bluetooth®. The third storage unit 92 stores the operating system, the application program, and setting parameters. When the controller 12 receives a command from the user of the button badge manufacturing system 300 to manufacture a button badge 200 by executing an application program, it monitors and controls the operation of the printer 1 and the crimping machine 100 to manufacture the button badge 200.

[0061] [Operation of the Button Badge Manufacturing System 300] The button badge manufacturing system 300 operates as shown in the timing charts in Figures 11 to 14 when all the materials for the button badges 200 are available. Having all the materials for the button badges 200 means that when a user instructs the button badge manufacturing system 300 to produce two or more button badges 200, all the materials constituting the button badges 200 are available in the number of button badges 200 to be produced. In the timing charts in Figures 11 to 14, the top row indicates which JOB the operation pertains to. The first JOB is the JOB for producing the first button badge 200, and the second JOB is the JOB for producing the second button badge 200. The second row from the top shows the operation of the controller 12. The third to sixth rows show the operation of the printer 1. The seventh to sixteenth rows represent the operation of the crimping machine 100. Of these rows, the seventh row shows the process name of the operation performed by the crimping machine 100. The 8th to 16th rows describe the names of the various parts of the crimping machine 100, including the transport mechanism 3, the transport mechanism 3 as a peeling mechanism, the transport mechanism 3 as a discharge mechanism, the first supply mechanism 2 for supplying the shell, the second supply mechanism 7 for supplying the back part BE, the peeling mechanism 4, the rotating mechanism 5, the crimping mechanism 6, and the removal mechanism 8. Each row describes the operation of the respective part. In Figures 11 to 14, the arrows represent the sequence of processes between the controller 12, the printer 1, and the crimping machine 100. The completion timing of the preceding process is the base of the arrow, and the start timing of the following process is the tip of the arrow.

[0062] As shown in Figure 11, when the controller 12 receives an instruction from the user to produce n (an integer n ≥ 2) button badges 200, it outputs a signal to the crimping machine 100 instructing it to produce n button badges 200. In the first job, when the controller 12 inputs a signal instructing the crimping machine 100 to produce n button badges 200, the first control unit 11 of the crimping machine 100 causes the first sensor 2d of the first supply mechanism 2 to detect the presence or absence of the first shell SE1 in the first stocker 2a. The crimping machine 100 also causes the second sensor 7d of the second supply mechanism 7 to detect the presence or absence of the first back part BE1 in the second stocker 7a. If the presence of the first shell SE1 and the first back part BE1 is detected, the crimping machine 100, as part of the SE1 supply process, in process #1, causes the first supply mechanism 2 to supply the first shell SE1 to the first mold M1. The crimping machine 100 outputs a signal to the controller 12 indicating that it has supplied the first shell SE1 to the first mold M1. After outputting this signal, the crimping machine 100 waits as part of the WF1 waiting process until the first backing paper WF1 is supplied from the printer 1.

[0063] When the crimping machine 100 signals that it has supplied the first shell SE1 to the first mold M1, the controller 12 outputs a signal to the printer 1 instructing it to print the first backing sheet WF1. When the printer 1 receives the signal to print the first backing sheet WF1, it starts feeding the first backing sheet WF1 from the first tray 20A. After starting to feed the first backing sheet WF1, if the third sensor 35 detects the first backing sheet WF1 within a predetermined time, the printer 1 executes printing of the first backing sheet WF1. Note that printing the backing sheet WF means printing blank data that does not require ink ejection, and does not print images that require ink ejection. After the printer 1 has finished printing the first backing sheet WF1 and supplied the first backing sheet WF1 to the crimping machine 100, it causes the ink level sensor 58 to detect the presence or absence of ink for each color. In the example in Figure 11, it is detected that all colors of ink are present.

[0064] When the crimping machine 100 detects the first backing paper WF1 supplied from the printer 1 using the fourth sensor 3b of the transport mechanism 3, it executes the WF1 transport process. In the WF1 transport process, in process #2, the crimping machine 100 has the transport mechanism 3 transport the first backing paper WF1 to the first mold M1. In process #3, the crimping machine 100 has the transport mechanism 3 and the peeling mechanism 4 peel the backing paper connection portion WFb of the first backing paper WF1 from the remaining backing paper portion WFa. In process #4, the crimping machine 100 has the transport mechanism 3 discharge the remaining backing paper portion WFa into the collection box 9. During the WF1 transport process, the crimping machine 100 has the first sensor 2d of the first supply mechanism 2 detect the presence or absence of the second shell SE2. When the first sensor 1d detects the presence of the second shell SE2, the controller 12 does not need to perform the operation shown in case 4(C3) in Figures 15 and 16, so the crimping machine 100 does not output a signal indicating the presence of the second shell SE2. After the completion of step #4, the crimping machine 100 outputs a signal to the controller 12 indicating that the peeling of the first backing paper WF1 has been completed. Furthermore, the crimping machine 100 waits as a WF1 waiting step until the first medium PF1 is supplied from the printer 1.

[0065] When the controller 12 receives a signal indicating that the peeling of the first backing paper WF1 is complete, it outputs a signal to the printer 1 instructing it to print the first medium PF1. When the printer 1 receives the signal to print the first medium PF1, it starts feeding the first medium PF1 from the second tray 20B. After starting to feed the first medium PF1, if the third sensor 35 detects the first medium PF1 within a predetermined time, the printer 1 executes printing of the first medium PF1. After printing the first medium PF1 is complete, the printer 1 supplies the first medium PF1 to the crimping machine 100 and then causes the ink level sensor 58 to detect the presence or absence of ink for each color. In the example in Figure 11, it is detected that ink of all colors is present.

[0066] When the crimping machine 100 detects the first medium PF1 supplied from the printer 1 using the fourth sensor 3b of the transport mechanism 3, it executes the PF1 transport process. As part of the PF1 transport process, the crimping machine 100 outputs a signal to the controller 12 indicating that the first medium PF1 has been detected. When the controller 12 receives the signal that the first medium PF1 has been detected, it outputs a signal to the printer 1 instructing it to print the second base paper WF2. In process #5, the crimping machine 100 instructs the transport mechanism 3 to transport the first medium PF1 to the first mold M1. In process #6, the crimping machine 100 instructs the transport mechanism 3 and the peeling mechanism 4 to peel the medium attachment portion PFb from the remaining medium portion PFa. In process #7 (see Figure 12), the crimping machine 100 instructs the transport mechanism 3 to discharge the remaining medium portion PFa into the recovery box 9.

[0067] When printer 1 receives a signal to print the second backing sheet WF2, it executes printing of the second backing sheet WF2. Printer 1 starts feeding the second backing sheet WF2 from the first tray 20A, and when the third sensor 35 detects the second backing sheet WF2 within a predetermined time, it executes printing of the second backing sheet WF2. After printing of the second backing sheet WF2 is complete, printer 1 holds the second backing sheet WF2. The second backing sheet WF2 is held in a state where it can be detected by the fourth sensor 3b.

[0068] Next, in the SE1 crimping process, the crimping machine 100 moves the first mold M1 to the crimping position P2 using the rotating mechanism 5 in process #8. In process #9, the crimping machine 100 crimps the first shell SE1, the first backing paper WF1, and the first medium PF1 using the crimping mechanism 6 to produce the first surface material FM1. In the BE1 supply process, the crimping machine 100 supplies the first back part BE1 to the second mold M2 using the second supply mechanism 7 in process #10. In the BE1 crimping process, the crimping machine 100 moves the second mold M2 to the crimping position P2 using the rotating mechanism 5 in process #11. In process #12, the crimping machine 100 crimps the first surface material FM1 and the first back part BE1 to the crimping mechanism 6 to produce the first button badge 200.

[0069] In the crimping machine 100, as part of the product removal process, in step #13, the rotating mechanism 5 moves the second mold M2 to the supply position P1. After moving the second mold M2 to the supply position P1, the crimping machine 100 causes the second sensor 7d of the second supply mechanism 7 to detect the presence or absence of the second back part BE2. In the example in Figure 12, the presence of the second back part BE2 is detected. Subsequently, in step #14, the crimping machine 100 causes the removal mechanism 8 to remove the first button badge 200 from the second mold M2 and places the removed first button badge 200 into the button badge holder 10. In the crimping machine 100, as part of the initialization process, in step #15, the rotating mechanism 5 moves the first mold M1 to the supply position P1. This completes the first job.

[0070] In the second job, when the crimping machine 100 detects the second backing paper WF2 supplied from the printer 1 using the fourth sensor 3b of the transport mechanism 3, it starts executing the WF2 transport process before the completion of the first job, as shown in Figure 12. In the WF2 transport process, in process #2, the crimping machine 100 stops the transport mechanism 3 from transporting the second backing paper WF2 until the first supply mechanism 2 has finished supplying the second shell SE2 to the first mold M1.

[0071] After the initialization process of the first job is completed, the crimping machine 100, in the SE2 supply process, in process #1, has the first supply mechanism 2 supply the second shell SE2 to the first mold M1. After the supply of the second shell SE2 is completed, the crimping machine 100, as a continuation of process #2 of the WF2 transport process, has the transport mechanism 3 start transporting the second backing paper WF2, and transports the second backing paper WF2 to the first mold M1. In process #3, the crimping machine 100 has the transport mechanism 3 and the peeling mechanism 4 peel the backing paper connected portion WFb from the backing paper remaining portion WFa. In process #4, the crimping machine 100 has the transport mechanism 3 discharge the backing paper remaining portion WFa into the collection box 9.

[0072] The controller 12 acquires the printing time of the first medium PF1 in the first job, and instructs the printer 1 to print the second medium PF2 at a timing that precedes the completion of the WF2 transport process by the printing time of the first medium PF1. In Figure 16, which will be described later, this is the operation of printing by calculating the timing of C10 in reverse. As a result, the crimping machine 100 detects the second medium PF2 supplied from the printer 1 at the transport mechanism 3 without delay immediately after the completion of the WF transport process, and executes the transport process for the second medium PF2.

[0073] In the PF2 transport process, the crimping machine 100 instructs the transport mechanism 3 to transport the second medium PF2 to the first mold M1 in process #5. In process #6, the crimping machine 100 instructs the transport mechanism 3 and the peeling mechanism 4 to peel the medium connection portion PFb from the remaining medium portion PFa. In process #7, the crimping machine 100 instructs the transport mechanism 3 to discharge the remaining medium portion PFa into the recovery box 9.

[0074] In the SE2 crimping process, step #8 of the crimping machine 100 moves the first mold M1 to the crimping position P2 using the rotating mechanism 5. In step #9 of the crimping machine 100, the crimping mechanism 6 crimps the second shell SE2, the second backing WF2, and the second medium PF2 to produce the second surface material FM2. In the BE2 supply process, step #10 of the crimping machine 100 supplies the second back part BE2 to the second mold M2 using the second supply mechanism 7. In the BE2 crimping process, step #11 of the crimping machine 100 moves the second mold M2 to the rotating mechanism 5. In step #12 of the crimping machine 100, the crimping mechanism 6 crimps the second surface material FM2 and the second back part BE2 to produce the second button badge 200. As shown in Figure 14, in the product removal process, step #13, the crimping machine 100 moves the second mold to the supply position P1 using the rotating mechanism 5. In step #14, the crimping machine 100 has the removal mechanism 8 remove the second button badge 200 from the second mold M2 and place it in the button badge holder 10. Subsequently, in the initialization process, step #15, the crimping machine 100 moves the first mold M1 to the supply position P1 using the rotating mechanism 5. Once the processing in step #15 is completed, the second job is finished. The third job and subsequent jobs are the same as the second job.

[0075] [What happens when you run out of material for 200 can badges] Next, we will describe six cases of operation of the button badge manufacturing system 300 when the material for the button badge 200 runs out. Figures 15 and 16 are sequence diagrams illustrating the operation of the crimping machine 100, printer 1, sensors, and controller 12. The sensors are the first sensor 2d of the first supply mechanism 2, the second sensor 7d of the second supply mechanism 7, the third sensor 35 of printer 1, and the fourth sensor 3b of transport mechanism 3. Hereinafter, of the two or more button badges 200 to be manufactured, the first button badge 200 will be referred to as the first button badge 200, and the second button badge 200 will be referred to as the second button badge 200. The material of the first button badge 200 will be denoted as the first medium PF1, the first backing paper WF1, the first shell SE1, the first back part BE1, and the first surface material FM1. Similarly, the materials for the second button badge 200 are denoted as the second medium PF2, the second backing WF2, the second shell SE2, the second back part BE2, and the second surface material FM2. The crimping operation (K20) and subsequent operations for producing the second button badge 200 are the same as the crimping operation (K9) and subsequent operations for producing the first button badge 200. Furthermore, the operations for producing the third and subsequent button badges 200 are the same as the operations for producing the second button badge 200.

[0076] [Case 1 (When the first shell SE1 or first back part BE1 is missing)] As shown in Figure 15, when the controller 12 receives an instruction from the user to produce n (an integer n ≥ 2) button badges 200, it outputs a signal to the crimping machine 100 instructing it to produce n button badges 200 (C1). The crimping machine 100 causes the first sensor 2d of the first supply mechanism 2 to detect the presence or absence of the first shell SE1 in the first stocker 2a. The crimping machine 100 also causes the second sensor 7d of the second supply mechanism 7 to detect the presence or absence of the first back part BE1 in the second stocker 7a (S1). If it is detected that the first shell SE1 or the first back part BE1 is absent, the first control unit 11 of the crimping machine 100 outputs a signal to the controller 12 indicating that the first shell SE1 or the first back part BE1 is absent. When the controller 12 receives a signal indicating that the first shell SE1 or the first back part BE1 is missing, it outputs a signal to the crimping machine 100 instructing it to stop the production of the first button badge 200 (C2). When the crimping machine 100 receives the signal instructing it to stop the production of the first button badge 200, it stops the production of the first button badge 200 (K1).

[0077] [Case 2 (When the second backing board WF2 is not available)] After the first shell SE1 is supplied by the first supply mechanism 2 (K2), the controller 12 causes the printer 1 to detect the presence or absence of the first backing paper WF1 in the first tray 20A (S3). When the printer 1 receives a signal to instruct it to print the first backing paper WF1, it starts feeding the first backing paper WF1 from the first tray 20A (J1). If the third sensor 35 does not detect the first backing paper WF1 within a predetermined time after the start of feeding the first backing paper WF1 (S3), the printer 1 outputs a signal to the controller 12 indicating that the first backing paper WF1 is not present. When the controller 12 receives the signal that the first backing paper WF1 is not present, it outputs a signal to the printer 1 to instruct it to stop, and stops the printer 1 (C5). When the printer 1 stops printing the first backing paper WF1, the first mold M1 is in the state where the first shell SE1 has been supplied.

[0078] [Case 3 (When ink or the first medium PF1 is not available)] When the printer 1 prints the first backing sheet WF1 (P1), the controller 12 causes the printer 1 to detect the presence or absence of ink (S4). After the printer 1 supplies the first backing sheet WF1 to the crimping machine 100, it causes the ink level sensor 58 to detect the presence or absence of ink for each color (S4). If it is detected that there is no ink of any color, the printer 1 outputs a signal to the controller 12 indicating that there is no ink. The controller 12 also causes the printer 1 to detect the presence or absence of the first medium PF1 in the second tray 20B (S6). After the printer 1 starts feeding the first medium PF1, if the third sensor 35 does not detect the first backing sheet WF1 within a predetermined time (S6), the controller 12 outputs a signal to the controller 12 indicating that there is no first medium PF1. When the controller 12 receives a signal that there is no ink or a signal that there is no first backing sheet WF1, it outputs a signal to the printer 1 to stop it (C6). When printer 1 stops printing on the first medium PF1, the first mold M1 is in a state where the first shell SE1 and the first backing paper WF1 are supplied.

[0079] [Case 4 (When the second shell SE2, ink, or second backing paper WF2 is missing)] When the controller 12 receives an instruction to produce n (an integer n ≥ 2) button badges 200, it outputs a signal to the crimping machine 100 instructing it to produce n button badges 200. When the crimping machine 100 receives a signal from the controller 12 instructing it to produce n button badges 200, it causes the first supply mechanism 2 to supply the first shell SE1 from the first stocker 2a to the first mold M1 (K1). After the first shell SE1 is supplied, the controller 12 causes the printer 1 to start printing the first backing sheet WF1 (C4). After printing the first backing sheet WF1, the printer 1 supplies the first backing sheet WF1 to the crimping machine 100 (J1), and causes the first sensor 2d of the first supply mechanism 2 to detect the presence or absence of the second shell SE2 in the first stocker 2a. The first sensor 2d may detect the presence or absence of the second shell SE2 after the first shell SE1 is supplied (K2) (S2), or when the first backing paper WF1 is peeled off (K3) (S5). If the absence of the second shell SE2 is detected, the crimping machine 100 outputs a signal to the controller 12 indicating that the second shell SE2 is absent. When the controller 12 receives the signal that the second shell SE2 is absent, it outputs a signal to the printer 1 instructing it to stop printing the second backing paper WF2, thereby stopping the printing of the second backing paper WF2 (J3).

[0080] Controller 12 instructs the transport mechanism 3 to supply the printed first base paper WF1 to the first mold M1 (C4). Controller 12 instructs the printer 1 to start printing the first medium PF1 (C7). After printing of the first medium PF1 is complete, Controller 12 instructs the printer 1 to supply the first medium PF1 to the crimping machine 100 (J2). After the supply of the first medium PF1 is complete, Controller 12 stops the printer 1 (C3) and instructs the transport mechanism 3 to supply the first medium PF1 supplied from the printer 1 to the first mold M1 (K4). Controller 12 instructs the crimping mechanism 6 to crimp the first shell SE1, the first base paper WF1, and the first medium PF1 to produce the first surface material FM1 (K6). Furthermore, after the first surface material FM1 is manufactured, or in parallel with the crimping of the first surface material FM1, the controller 12 instructs the second supply mechanism 7 to supply the first back part BE1 from the second stocker 7a to the second mold M2. After the first surface material FM1 is manufactured and the first back part BE1 has been supplied, the controller 12 instructs the crimping mechanism 6 to crimp the first surface material FM1 and the first back part BE1 together to manufacture the first button badge 200. After the first button badge 200 is manufactured, the controller 12 stops the operation of the crimping machine 100.

[0081] The controller 12 then instructs the transport mechanism 3 to supply the first base paper WF1 to the first mold M1. The controller 12 then instructs the printer 1 to start printing the first medium PF1 (C7). After printing of the first medium PF1 is complete, the controller 12 instructs the printer 1 to supply the first medium PF1 to the crimping machine 100 (J2). The controller 12 then instructs the transport mechanism 3 to supply the first medium PF1 supplied from the printer 1 to the first mold M1 (K4). The controller 12 then instructs the crimping mechanism 6 to crimp the first shell SE1, the first base paper WF1, and the first medium PF1 to produce the first surface material FM1 (K6). After printing of the first medium PF1 is complete (J2), the crimping machine 100 instructs the remaining amount sensor 58 to detect the presence or absence of ink for each color (S7). If it detects that any color of ink is out, printer 1 outputs a signal to controller 12 indicating that there is no ink. When controller 12 receives the signal that there is no ink, it outputs a signal to printer 1 instructing it to stop printing the second backing sheet WF2. As a result, printer 1 stops printing (J3) the second backing sheet WF2. After the production of the first surface material FM1 (K6) is completed, or in parallel with the production of the first surface material FM1 (K6), controller 12 instructs the second supply mechanism 7 to supply the first back part BE1 from the second stocker 7a to the second mold M2 (K7). After the production of the first surface material FM1 (K6) is completed and the first back part BE1 has been supplied (K7), controller 12 instructs the crimping mechanism 6 to crimp the first surface material FM1 and the first back part BE1 together to produce the first button badge 200 (K9).

[0082] After printing (J2) of the first medium PF1 is completed, the controller 12 instructs the printer 1 to detect the presence or absence of the second backing paper WF2 in the first tray 20A. The printer 1 starts feeding the second backing paper WF2 from the first tray 20A, and if the third sensor 35 does not detect the second backing paper WF2 within a predetermined time, it detects that the second backing paper WF2 is missing (S8). When the printer 1 detects that the second backing paper WF2 is missing, it outputs a signal to the controller 12 indicating that the second backing paper WF2 is missing. When the controller 12 receives the signal that the second backing paper WF2 is missing, it restarts the printer 1 (C3). The printer 1 stops printing the second backing paper WF2.

[0083] After the printing of the first medium PF1 (J2) is completed, the controller 12 instructs the printer 1 to detect the presence or absence of the second backing paper WF2 in the first tray 20A. The printer 1 starts feeding the second backing paper WF2 from the first tray 20A, and if the third sensor 35 detects the second backing paper WF2 within a predetermined time, it detects that the second backing paper WF2 is present (S8). Once the printer 1 detects that the second backing paper WF2 is present, it outputs a signal to the controller 12 indicating that the second backing paper WF2 is present. When the controller 12 receives the signal that the second backing paper WF2 is present, it starts printing the second backing paper WF2 (J3). After the production of the first button badge 200 (K9) is completed, the controller 12 instructs the first supply mechanism 2 to supply the second shell SE2 from the first stocker 2a to the first mold M1 (K13). After the supply of the second shell (K13) is completed, the controller 12 instructs the printer 1 to supply the second backing paper WF2 to the crimping machine 100.

[0084] [Case 5 (When there is no second medium PF2)] After completing the printing of the second backing paper WF2 (J3), the controller 12 causes the printer 1 to detect the presence or absence of the second medium PF2 in the second tray 20B (S11). The printer 1 starts feeding the second medium PF2 (J5). If the third sensor 35 detects the second medium PF2 within a predetermined time after the start of feeding, the printer 1 detects that the second medium PF2 is present (S11). When the printer 1 detects that the second medium PF2 is present, it outputs a signal to the controller 12 indicating that the second medium PF2 is present. When the controller 12 receives the signal that the second medium PF2 is present, it starts printing the second medium PF2 (J5).

[0085] After completing the printing of the second backing paper WF2 (J3), the controller 12 instructs the printer 1 to detect the presence or absence of the second medium PF2 in the second tray 20B (S11). The printer 1 starts feeding the second medium PF2 (J5). If the third sensor 35 does not detect the second medium PF2 within a predetermined time after the start of feeding, the printer 1 detects that the second medium PF2 is absent (S11). When the printer 1 detects that the second medium PF2 is absent, it outputs a signal to the controller 12 indicating that the second medium PF2 is absent. When the controller 12 receives the signal that the second medium PF2 is absent, it outputs a signal to the printer 1 instructing it to stop printing the second medium PF2. The printer 1 stops printing the second medium PF2 (J5).

[0086] [Case 6 (When the second back part BE2 is missing)] After completing the production of the first button badge 200 (K9), the controller 12 causes the second sensor 7d of the second supply mechanism 7 to detect the presence or absence of the second back part BE2 in the second stocker 7a (S10). If it detects that the second back part BE2 is not present, the crimping machine 100 outputs a signal to the controller 12 indicating that the second back part BE2 is not present. The controller 12 causes the first supply mechanism 2 to supply the second shell SE2 from the first stocker 2a to the first mold M1 (K13). The controller 12 causes the printer 1 to supply the second backing paper WF2 and the second medium PF2 to the first mold M1 (J3, J5). The controller 12 causes the crimping mechanism 6 to crimp the second shell SE2, the second backing paper WF2, and the second medium PF2 together to produce the second surface material FM2 (K17). When the controller 12 receives a signal indicating that the second back part BE2 is missing, it outputs a signal to the crimping machine 100 instructing it to stop supplying the second back part BE2, and after the production of the second surface material FM2 (K17) is completed, it stops the operation of the crimping machine 100.

[0087] Meanwhile, after the production of the first button badge 200 (K9), the controller 12 causes the second sensor 7d of the second supply mechanism 7 to detect the presence or absence of the second back part BE2 in the second stocker 7a (S10). If the second sensor 7d detects the presence of the second back part BE2, the crimping machine 100 outputs a signal to the controller 12 indicating the presence of the second back part BE2. The controller 12 causes the first supply mechanism 2 to supply the second shell SE2 from the first stocker 2a to the first mold M1 (K13). The controller 12 causes the printer 1 to supply the second backing paper WF2 and the second medium PF2 to the first mold (J3, J5). The controller 12 causes the crimping mechanism 6 to crimp the second shell, the second backing paper, and the second medium together to produce the second front material (K17). The controller 12 causes the second back part BE2 to be supplied from the second stocker 7a to the second mold M2 (K18). Furthermore, when the controller 12 receives a signal that the second back part BE2 is present, after the production of the second front material FM2 is completed (K17), it causes the second front material FM2 and the second back part BE2 to be crimped together to produce the second button badge 200 (K20).

[0088] [Effects of the Embodiment] (1) If the printer 1 prints the second backing paper WF2 while the first button badge 200 is being manufactured, the crimping machine 100 can complete the manufacture of the second button badge 200 early, provided that the first sensor 2d detects the presence of the second shell SE2. If the second shell SE2 is not present, the crimping machine 100 cannot manufacture the second button badge 200, so the printer 1 printing the second backing paper WF2 is wasted. To address this problem, as in case 4 above, the controller 12 stops the printer 1 from printing the second backing paper WF2, provided that the first sensor 2d detects the absence of the second shell SE2, thus eliminating the waste of the second backing paper WF2.

[0089] (2) As in case 4 above, if the printer 1 stops printing the second backing sheet WF2, the user of the button badge manufacturing system 300 may notice that the printer 1 has stopped, check the status of the crimping machine 100, and remove the material that makes up the first surface material FM1. If the material that makes up the first surface material FM1 is removed, the crimping machine 100 will not be able to manufacture the first button badge 200. To address this problem, the crimping machine 100 manufactures the first surface material FM1 and holds it in the upper die M0, thereby preventing the material from being removed and enabling the manufacture of the first button badge 200.

[0090] (3) As in case 4 above, the controller 12 stops the printer 1 when the first sensor 2d detects that the second shell SE2 is absent, and further stops the crimping machine 100 after the first button badge 200 has been created, thereby preventing the wasteful supply of material within the button badge manufacturing system 300.

[0091] (4) When the printer 1 prints the second backing paper WF2 in parallel with the production of the first button badge 200 by the crimping machine 100, if the production of the first button badge 200 is not completed when the printer 1 has finished printing the second backing paper WF2, there is a risk that the printer 1 will supply the second backing paper WF2 to the first mold M1 before the second shell SE2 has been supplied to the first mold M1. To address this problem, the controller 12 will instruct the printer 1 to supply the second backing paper WF2 to the crimping machine 100 after the supply of the second shell SE2 is complete, so that the second button badge 200 can be reliably produced.

[0092] (5) If a shell SE is present in the first stocker 2a but the bottom shell SE gets stuck midway and does not descend to the first supply slope 2b, the tip of the arm portion 2d1 of the first sensor 2d cannot push the shell SE downwards to the first stocker 2a. As a result, the first sensor 2d incorrectly detects that there is no shell SE. To address this problem, in case 4 above, the controller 12 causes the first sensor 2d of the first supply mechanism 2 to detect the presence or absence of the second shell SE2 in the first stocker 2a when the first backing paper WF1 is peeled off (K3). If the timing for detecting the presence or absence of the second shell SE2 is set later than when the first shell SE1 is supplied (K2), there is a possibility that the bottom shell SE may fall to the first supply slope 2b due to vibrations generated by the button badge manufacturing system 300 itself or external impacts before the first sensor 2d detects the second shell SE2. Therefore, the crimping machine 100 can increase the likelihood of successfully producing the second button badge 200.

[0093] (6) If a back part BE is present in the second stocker 7a, but the bottom back part BE gets stuck midway and does not descend to the second supply slope 7b, the second sensor 7d will incorrectly detect that there is no back part BE. To address this problem, in case 4 above, the controller 12 causes the second supply mechanism 7 to detect the presence or absence of the second back part BE2 in the second stocker 7a when the rotary support table 5a is rotating (K8). If the timing for detecting the presence or absence of the back part BE is set to be later than when the first back part BE1 is supplied (K7), there is a possibility that the bottom back part BE may fall to the second supply slope 7b due to vibrations generated by the button badge manufacturing system 300 itself or external impacts before the second sensor 7d detects the second back part BE2. Therefore, the possibility that the crimping machine 100 can successfully manufacture the second button badge 200 can be increased.

[0094] (7) In case 1 above, when the first back part BE1 is unavailable and the first button badge 200 cannot be manufactured, it is possible to prevent the first shell SE1 from being supplied unnecessarily. When the first shell SE1 is unavailable, the first button badge 200 cannot be manufactured, so it is appropriate to stop the start of manufacturing the first button badge 200.

[0095] (8) In the case described in (2) above, after supplying the first backing paper WF1 to the first tray 20A of the printer 1, the production of the first button badge 200 can be continued. Therefore, the first shell SE1 supplied to the first mold M1 is not wasted.

[0096] (9) In the case described in 3 above, after supplying the first medium PF1 to the second tray 20B of the printer 1, the production of the first button badge 200 can be continued. Therefore, the first shell SE1 and the first backing paper WF1 supplied to the first mold M1 are not wasted.

[0097] (10) In the case described in 6 above, after supplying the second back part BE2 to the second stocker 7a of the second supply mechanism 7 of the crimping machine 100, the production of the second button badge 200 can be continued. Therefore, the second surface material FM2 held in the first mold M1 is not wasted.

[0098] [Differentiation] (1) In the above embodiment, an example of printer 1 being an inkjet printer was described, but this disclosure is not limited thereto, and printer 1 may be a printer other than an inkjet printer. Also, the colorant used for printing on the backing paper WF and media PF may be something other than ink. Printer 1 is equipped with a sensor to detect the remaining amount of colorant, even if the colorant is something other than ink.

[0099] (2) In Figure 12, an example is shown in which the second supply mechanism 7 supplies the first back part BE1 from the second stocker 7a to the second mold M2 after the first surface material FM1 has been manufactured. However, the disclosure is not limited to this, and the second supply mechanism 7 may supply the first back part BE1 from the second stocker 7a to the second mold M2 in parallel with the manufacturing of the first surface material FM1. In this way, the manufacturing of the first button badge 200 can be completed earlier.

[0100] (3) In the above embodiment, an example was described in which the printer 1 has a first tray 20A and a second tray 20B, but the number of trays may be three or more. A manual feed tray may also be used.

[0101] (4) In the above embodiment, an example was described in which the presence or absence of the backing paper WF in the first tray 20A and the presence or absence of the media PF in the second tray 20B are detected by the third sensor 35. However, the sensor that detects the presence or absence of the backing paper WF in the first tray 20A and the sensor that detects the presence or absence of the media PF in the second tray 20B may be separate sensors. Also, the third sensor 35 may be a mechanical sensor or an optical sensor.

[0102] (5) In the above embodiment, an example was described in which the first sensor 2d of the first supply mechanism 2 and the second sensor 7d of the second supply mechanism 7 are both mechanical sensors. However, the disclosure is not limited thereto, and the first sensor 2d and the second sensor 7d may be sensors other than mechanical sensors, such as optical sensors. Furthermore, the first sensor 2d and the second sensor 7d may be sensors of different types. [Explanation of symbols]

[0103] 1. Printer 2...1st supply mechanism 2a...First Stocker 2d...1st sensor 3. Conveying mechanism 3b...Fourth sensor 4. Peeling mechanism 5. Rotation mechanism 6. Crimping mechanism 7...Second supply mechanism 7a...Second Stocker 7d...Second sensor 8. Removal mechanism 10. Button badge holder 11. First Control Unit 12. Controller 20A...Tray 1 20B...Tray 2 35. Third sensor 50...Second Control Unit 100 crimping machines 200... Button badges 300... Button badge making system BE... Back Parts FM...Surface material M0...upper mold M1...First mold M2... Second mold PF...medium SE...shell WF... backing card

Claims

1. A button badge manufacturing system comprising a printer, a crimping machine, and a controller, The above crimping machine is, A first stocker capable of holding multiple shells, First supply mechanism, Having a first mold, The above controller is Conditional on receiving orders to manufacture two or more button badges, the first supply mechanism is instructed to supply the first shell from the first stocker to the first mold. After supplying the first shell as described above, the printer is instructed to start printing the first backing sheet. After printing the first backing sheet, the printer is instructed to supply the first backing sheet to the crimping machine, and the first supply mechanism is instructed to detect the presence or absence of the second shell in the first stocker. A button badge manufacturing system that starts or stops printing the second backing sheet depending on whether the second shell described above is present or not.

2. The above controller is The button badge manufacturing system according to claim 1, wherein printing of the second backing sheet is stopped on the condition that the above-mentioned second shell is detected to be absent.

3. The above crimping machine is, Conveying mechanism, It has a crimping mechanism, The above controller is The transport mechanism is used to supply the printed first base sheet to the first mold. Start printing the first medium on the above printer. After printing on the first medium is complete, the printer is instructed to supply the first medium to the crimping machine. After the supply of the first medium described above is complete, the printer described above will be stopped. The transport mechanism is used to supply the first medium supplied from the printer to the first mold. The button badge manufacturing system according to claim 2, wherein the crimping mechanism is used to crimp the first shell, the first backing paper, and the first medium together to produce a first surface material.

4. The above crimping machine is, A second stocker capable of holding multiple back parts, The second supply mechanism, It has a second mold, The above controller is After the first front material has been manufactured, or in parallel with the manufacturing of the first front material, the second supply mechanism is instructed to supply the first back part from the second stocker to the second mold. After the first front material has been manufactured and the first back part has been supplied, the crimping mechanism is used to crimp the first front material and the first back part together to produce the first button badge. The button badge manufacturing system according to claim 3, wherein the operation of the crimping machine is stopped after the manufacturing of the first button badge is completed.

5. The above crimping machine is, Conveying mechanism, It has a crimping mechanism, The above controller is The transport mechanism is used to supply the first base sheet to the first mold. Start printing the first medium on the above printer. After printing on the first medium is complete, the printer is instructed to supply the first medium to the crimping machine. The transport mechanism is used to supply the first medium, supplied from the printer, to the first mold. A button badge manufacturing system according to claim 1, wherein the first shell, the first backing paper, and the first medium are crimped together using the crimping mechanism to produce a first surface material.

6. The above controller is The button badge manufacturing system according to claim 5, wherein the printer stops printing the second backing sheet on the condition that it detects that there is no colorant in the printing of the first medium.

7. The above crimping machine is, A second stocker capable of holding multiple back parts, The second supply mechanism, It has a second mold, The above controller is After the completion of the production of the first table material described above, or in parallel with the production of the first table material described above, The second supply mechanism is used to supply the first back part from the second stocker to the second mold. After the completion of the production of the first front material and after the supply of the first back part, The button badge manufacturing system according to claim 5, wherein the first front material and the first back part are crimped together using the crimping mechanism to produce a first button badge.

8. The above printer has a first tray capable of holding multiple sheets of paper, The above controller is After printing of the first medium is complete, the printer is instructed to detect the presence or absence of the second backing sheet in the first tray. The can badge manufacturing system according to claim 5, wherein printing of the second backing sheet is stopped on the condition that the second backing sheet is not present.

9. The above printer has a first tray capable of holding multiple sheets of paper, The above controller is After printing of the first medium is complete, the printer is instructed to detect the presence or absence of the second backing sheet in the first tray. If the presence of the second backing sheet is detected, the printing of the second backing sheet will be started. After the production of the first button badge is completed, the first supply mechanism is instructed to supply the second shell from the first stocker to the first mold. The button badge manufacturing system according to claim 7, wherein, after the supply of the second shell is completed, the printer is instructed to supply the second backing paper to the crimping machine.

10. The above printer has a second tray capable of holding multiple media, The above controller is After printing the second sheet mentioned above is complete, the printer will then print the following: The presence or absence of the second medium in the second tray is detected. The button badge manufacturing system according to claim 9, wherein printing of the second medium is started on the condition that the presence of the second medium is detected.

11. The above printer has a second tray capable of holding multiple media, The above controller is After printing the second sheet mentioned above is complete, the printer will then print the following: The presence or absence of the second medium in the second tray is detected. The button badge manufacturing system according to claim 9, wherein printing of the second medium is stopped on the condition that the second medium is detected as absent.

12. The above controller is After the production of the first button badge is completed, the second supply mechanism is instructed to detect the presence or absence of the second back part in the second stocker. The first supply mechanism is used to supply the second shell from the first stocker to the first mold. The printer is used to supply the second base sheet and the second medium to the first mold. The second shell, the second backing, and the second medium are crimped together using the crimping mechanism described above to produce the second surface material. A can badge manufacturing system according to claim 10, wherein, on the condition that the above-mentioned second back part is detected to be absent, the operation of the crimping machine is stopped after the manufacturing of the above-mentioned second front material is completed.

13. The above controller is After the production of the first button badge is completed, the second supply mechanism is instructed to detect the presence or absence of the second back part in the second stocker. The first supply mechanism is used to supply the second shell from the first stocker to the first mold. The printer is used to supply the second base sheet and the second medium to the first mold. The crimping mechanism described above is used to create a second surface material comprising the second shell, the second backing paper, and the second medium, by crimping them together. The second back part is supplied from the second stocker to the second mold. A button badge manufacturing system according to claim 10, wherein, on the condition that the presence of the second back part is detected, after the manufacturing of the second front material is completed, the second front material and the second back part are crimped together to produce a second button badge.

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