Badge making system and badge making method

Abstract

Provided is a badge creation system capable of automatically creating a badge in which a front-side member and a back-side member are connected. A badge production system (10) is provided with: a first loading unit (31) that loads a front-side member (A) into a first lower mold (35a); a printing unit (21) that performs printing on the printing medium (W); a transport unit (33) that transports the medium (W) to be printed from the printing unit (21) onto the first lower mold (35a); a mold unit (35) having the first lower mold (35a) and connecting the front-side member (A) and the back-side member (B), which are covered by the printing medium (W), to produce a badge (C); and a control unit that executes a badge manufacturing process including one or more manufacturing jobs for manufacturing one badge (C), the manufacturing jobs being performed before the printing medium (W) printed by the printing unit (21) is conveyed onto the first lower mold (35a) by the conveying unit (33), and the first lower mold (35a) is pressed by the printing unit (21) before the printing medium (W) is conveyed onto the first lower mold (35a) by the conveying unit (33). The front side member (A) is loaded in the first lower die (35a) by the first loading unit (31).

Description

Technical Field

[0001] This disclosure relates to a badge making system and a badge making method. Background Technology

[0002] As a conventional badge manufacturing system, a badge manufacturing apparatus is known, for example, as described in Patent Document 1. This badge manufacturing apparatus covers a front cover with a film printed with a prescribed image, and combines the front cover and back cover while clamping the portion of the film extending from the front cover between the front cover and the back cover to manufacture a badge.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2019-136210 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] In the aforementioned conventional badge-making apparatus, badge production is time-consuming because the printed film is manually placed onto the watch cover. On the other hand, if it is desired to automatically place the printed film onto the watch cover, the problem arises that the processes of supplying the watch cover and placing the printed film onto the watch cover must be performed in an appropriate sequence and at appropriate times.

[0008] Therefore, the purpose of this disclosure is to provide a badge manufacturing system and a badge manufacturing method that can automatically produce badges by connecting front and back components in existing printing devices.

[0009] Technical solutions for solving the problem

[0010] The badge manufacturing system disclosed herein comprises: a first loading unit for loading a front-side component into a first lower mold; a printing unit for printing a printable medium; a conveying unit for conveying the printable medium from the printing unit to the first lower mold; a mold unit having the first lower mold and connecting the front-side component and the back-side component covered by the printable medium to manufacture a badge; and a control unit that performs a badge manufacturing process including one or more manufacturing operations to manufacture one badge, wherein in the manufacturing operation, the control unit loads the front-side component into the first lower mold via the first loading unit before the printable medium printed by the printing unit is conveyed to the first lower mold by the conveying unit.

[0011] In the badge manufacturing method disclosed herein, the front component is loaded into the first lower mold by the first loading unit, the printing medium is printed by the printing unit, the printed medium is transported to the first lower mold by the conveying unit, and the front component and the back component covered by the printed medium are connected by the mold unit to manufacture the badge.

[0012] Invention Effects

[0013] According to this disclosure, after the front component is loaded into the first lower mold, the printing medium can be conveyed onto the front component. Thus, badges can be automatically produced by connecting the front component and the back component covered by the printing medium. Attached Figure Description

[0014] Figure 1 This is a block diagram illustrating the structure of the badge-making system according to an embodiment of the present disclosure.

[0015] Figure 2 It is a three-dimensional diagram showing the badge-making apparatus.

[0016] Figure 3 This is a diagram showing the badge-making apparatus from above.

[0017] Figure 4 This is a view of the printed medium from above.

[0018] Figure 5 This is a picture of the backing paper viewed from above.

[0019] Figure 6 middle, Figure 6 A is a three-dimensional view of the surface component. Figure 6 B is a three-dimensional view of the rear-side component.

[0020] Figure 7 This is a cross-sectional view of the badge.

[0021] Figure 8 This is a cross-sectional view of the conveyor unit.

[0022] Figure 9 This is a flowchart illustrating an example of the printing action of the first device in the badge production process.

[0023] Figure 10 This is a flowchart illustrating an example of the assembly action of the second device in the badge making process.

[0024] Figure 11 This is a flowchart illustrating an example of the badge creation process in a badge creation system.

[0025] Figure 12 This is a flowchart illustrating an example of the operation of the third control unit in a badge-making system.

[0026] Figure 13 This is another flowchart illustrating the operation of the third control unit in the badge making system. Detailed Implementation

[0027] Badge Crafting System

[0028] like Figure 1 As shown, one embodiment of the badge making system 10 of this disclosure includes a badge making C ( Figure 7 The badge-making device 11 and the third device 40 for controlling the badge-making device 11. (e.g.) Figure 2 and Figure 3 As shown, the badge making apparatus 11 has a first device 20 for printing on the backing paper F and the printing medium W, and a second device 30 for assembling the backing paper F, the printing medium W, the front side member A and the back side member B.

[0029] like Figure 1 As shown, the first device 20 includes a printing unit 21, a first control unit 22 for controlling the printing unit 21, and a housing 23. Figure 2 Additionally, the second device 30 includes a first filling unit 31, a second filling unit 32, a conveying unit 33, a cutting unit 34, a mold unit 35, a take-out unit 36, and a recycling container 37. Figure 2 ), Badge storage 38 ( Figure 2 ) and the second control unit 39 that controls them.

[0030] like Figure 2 and Figure 3 As shown, in the badge making apparatus 11, the housing 23 of the first device 20 has, for example, a generally rectangular parallelepiped shape, and its internal space houses the printing unit 21 and the first control unit 22. Figure 1 The second device 30's conveying unit 33, recycling container 37, and badge storage unit 38 are mounted on the front surface of the housing 23 of the first device 20. Additionally, the second device 30 includes a first loading unit 31, a second loading unit 32, a cutting unit 34, a mold unit 35, a removal unit 36, and a second control unit 39. Figure 1 The components of the second device 30 are mounted on the upper surface of the housing 23 of the first device 20. Thus, by mounting the components of the second device 30 onto the housing 23 of the first device 20, the badge-making apparatus 11 is constructed. Alternatively, the first device 20 and the second device 30 can be integrally constructed as the badge-making apparatus 11.

[0031] <Badge>

[0032] like Figure 7As shown, badge C is made by connecting (e.g., tightening) the front member A, which is covered by backing paper F and printing medium W, to the back member B using a badge making apparatus 11. Badge C is a product that uses can parts. The front member A and the back member B are can parts, for example, formed of a magnetic material such as tin-plated steel sheet.

[0033] like Figure 6 As shown in Figure A, the surface member A has a surface plate portion A1 that is circular when viewed from above, and a ring-shaped surface edge portion A2 that protrudes downward from the outer periphery of the surface plate portion A1. Figure 6 As shown in B, the back side member B has a back side plate portion B1 that is circular when viewed from above and a ring-shaped back side edge portion B2 that protrudes upward from the outer periphery of the back side plate portion B1.

[0034] like Figure 7 As shown, a first covering portion Fb of backing paper F is disposed on the surface of the face member A, and a second covering portion Wb of the printing medium W is disposed on the first covering portion Fb. The portions of the covering portions Fb and Wb extending from the surface of the face plate portion A1 are bent downwards from the outer periphery of the face plate portion A1, covering the surface of the face edge portion A2. Furthermore, the portions extending from the surface of the face edge portion A2 are bent upwards from the lower end of the face edge portion A2, and are sandwiched between the back surface of the face edge portion A2 and the surface of the back edge portion B2 of the back member B. Then, with the covering portions Fb and Wb sandwiched between the opposing face edge portion A2 and back edge portion B2, at least one of the face member A and the back member B is deformed (e.g., tightened) to create a badge C. Alternatively, the badge C may not use backing paper F, and the face member A may be covered by the printing medium W instead of backing paper F.

[0035] <Printing medium>

[0036] like Figure 4As shown, the printing medium W is, for example, a rectangular transparent sheet. The printing medium W has, for example, a transparent resin film and an ink receiving layer formed on one side of the resin film. The printing medium W has a downstream end We1 and an upstream end We2 in a first conveying direction D1, which is conveyed by the conveying unit 33 toward the mold unit 35. The printing medium W has a second covering portion Wb covering the surface member A and a second remaining portion Wa of the second covering portion Wb. Furthermore, the printing medium W is provided with a second connecting portion Wc connecting the second covering portion Wb and the second remaining portion Wa, and a second linear weak portion Wd extending linearly from the second connecting portion Wc to the downstream end We1. The second covering portion Wb has a circular first surface portion Wf1 covering the surface of the surface plate portion A1 of the surface member A, an annular second surface portion Wf2 covering the surface of the surface edge portion A2, and an annular clamped portion Wg clamped between the back side of the surface edge portion A2 and the back edge portion B2 of the back member B. The second connecting portion Wc and the second linear weak portion Wd are weak portions with a strength smaller than that of the perforated line, which is less than that of the second covering portion Wb and the second remaining portion Wa.

[0037] <lining paper>

[0038] like Figure 5 As shown, the backing paper F is, for example, a rectangular white sheet. The backing paper F has the same shape and size as the printing medium W, and except for the material, has a structure substantially the same as the printing medium W. The backing paper F has a downstream end Fe1 and an upstream end Fe2 in the first transport direction D1, a first covering portion Fb, a first remaining portion Fa, a first connecting portion Fc, and a first linear weak portion Fd. The first covering portion Fb has a first surface portion Ff1, a second surface portion Ff2, and a clamped portion Fg. The downstream end Fe1, the upstream end Fe2, the first covering portion Fb, the first remaining portion Fa, the first connecting portion Fc, and the first linear weak portion Fd of the backing paper F correspond to the downstream end We1 and the upstream end We2, the second covering portion Wb, the second remaining portion Wa, the second connecting portion Wc, and the second linear weak portion Wd of the printing medium W, respectively. Hereinafter, when both the backing paper F and the printing medium W are included without distinction, they are sometimes referred to as sheet F and W.

[0039] <First Device>

[0040] like Figure 1As shown, the first device 20 is, for example, an inkjet printer, and includes a printing unit 21 and a first control unit 22. The printing unit 21 is a unit for printing on sheets F and W, and includes a head 21a and a moving device 21b. The printing unit 21 prints on the sheets F and W by ejecting (or not ejecting) liquid ink from the head 21a while moving the sheets F and W using the moving device 21b, and then moves (supplyes) from the printing unit 21 to the delivery unit 33 of the second device 30. This printing includes printing without ejecting liquid ink from the head 21a (e.g., blank printing). The printing operation of the printing unit 21, including the ejection of liquid ink by the head 21a and the movement of the sheets F and W by the moving device 21b, is controlled by the first control unit 22. Furthermore, the printing unit 21 is not limited to an inkjet printer as long as it prints an image on the printable medium W; it can also be a laser printer, a thermal printer, or other similar printer.

[0041] <Second Device>

[0042] like Figure 3 As shown, the first loading unit 31 of the second device 30 is a unit that loads the surface component A into the first lower mold 35a of the mold unit 35. The first lower mold 35a supports the surface component A from below. The first loading unit 31 includes a first storage container 31a, a first slider 31b, a first push rod 31c, and a first push rod motor 31d. Figure 1 The first storage container 31a houses a plurality of surface components A in a stacked manner along the vertical direction. The first slider 31b extends from below the first storage container 31a toward the first lower mold 35a disposed at the first mold position P1 of the mold unit 35. The first push rod 31c is driven by the first push rod motor 31d to reciprocate (forward and backward) along the first slider 31b. As a result, the surface components A are supplied from the first storage container 31a to the first slider 31b, and are pressed onto the first slider 31b by the first push rod 31c and filled into the first lower mold 35a.

[0043] The second loading unit 32 is a unit that loads the back-side member B into the second lower mold 35b of the mold unit 35. The second lower mold 35b is a mold different from the first lower mold 35a, and supports the back-side member B from below. The second loading unit 32 includes a second storage container 32a, a second slider 32b, a second push rod 32c, and a second push rod motor 32d. Figure 1 The second storage unit 32a houses multiple back-side components B in a stacked manner along the vertical direction.

[0044] The second slider 32b extends from below the second reservoir 32a toward the second lower mold 35b disposed at the first mold position P1 of the mold unit 35. The second push rod 32c reciprocates (forward and backward) along the second slider 32b by being driven by the second push rod motor 32d. As a result, the back member B is supplied from the second reservoir 32a to the second slider 32b, and is pressed onto the second slider 32b by the second push rod 32c and filled into the second lower mold 35b.

[0045] The conveying unit 33 is the unit that conveys the sheets F and W from the printing unit 21 to the first lower die 35a of the die unit 35. For example... Figure 8 As shown, the conveying unit 33 includes multiple drive rollers 33a, multiple driven rollers 33b, a conveying motor 33c, a first conveying sensor 33d, a second conveying sensor 33e, and a third conveying sensor 33f. The drive rollers 33a, holding sheets F and W between themselves and the driven rollers 33b, rotate forward when driven by the conveying motor 33c. As a result, sheets F and W are conveyed along the conveying path 33g and transported along the first conveying direction D1 to above the surface member A in the first lower die 35a. On the other hand, the drive rollers 33a, holding the remaining portions Fa and Wa of sheets F and W between themselves and the driven rollers 33b, rotate in reverse when driven by the conveying motor 33c. As a result, the remaining portions Fa and Wa are conveyed along the second conveying direction D2, which is opposite to the first conveying direction D1, to the recycling container 37.

[0046] A first transport sensor 33d is disposed between the drive roller 33a closest to the printing unit 21 and the printing unit 21. The first transport sensor 33d detects the sheets F and W after they are supplied from the printing unit 21 to the transport unit 33 and before they are transported by the drive roller 33a and the driven roller 33b. A second transport sensor 33e is disposed at a predetermined position in the transport unit 33 capable of detecting the sheets F and W transported in the first transport direction D1, and detects the sheets F and W transported in the first transport direction D1 by the forward-rotating drive roller 33a and the driven roller 33b. A third transport sensor 33f is disposed at a predetermined position in the transport unit 33 capable of detecting the sheets F and W transported in the second transport direction D2, and detects the sheets F and W transported in the second transport direction D2 by the reverse-rotating drive roller 33a and the driven roller 33b.

[0047] like Figure 3 As shown, the cutting unit 34 is a unit for cutting sheets F and W, and has a pressing head 34a and a pressing motor 34b. Figure 1The pressing head 34a moves between a pressing position and a separating position away from the pressing position of the covering portions Fb and Wb of the sheets F and W, driven by the pressing motor 34b. When the pressing head 34a moves from the separating position to the pressing position, the covering portions Fb and Wb of the sheets F and W are pressed by the pressing head 34a, thereby cutting off at least a portion of the connecting portions Fc and Wc between the covering portions Fb and Wb and the remaining portions Fa and Wa.

[0048] Mold unit 35 is a unit for producing badge C by connecting the front member A and the back member B, which are covered by sheets F and W. Mold unit 35 includes a first lower mold 35a supporting the front member A from below, a second lower mold 35b supporting the back member B from below, a rotary table 35c, a lifting device 35d, and an upper mold 35e. The rotary table 35c includes a rotary motor 35c1. Figure 1 The first lower mold 35a and the second lower mold 35b are rotated by a rotary motor 35c1. The first lower mold 35a and the second lower mold 35b are mounted on the rotary table 35c. With the rotation of the rotary table 35c, the first lower mold 35a and the second lower mold 35b move between a second mold position P2 and a first mold position P1. The second mold position P2 is the position opposite to the upper mold 35e in the vertical direction, and the first mold position P1 is a position different from the second mold position P2. When the first lower mold 35a is positioned in either the first mold position P1 or the second mold position P2, the second lower mold 35b is positioned in the other.

[0049] In addition, the lifting device 35d is connected to its lifting motor 35d1 ( Figure 1 Driven by the mechanism, the upper mold 35e rises and falls at the second mold position P2. The upper mold 35e descends towards the first lower mold 35a, which is configured with covering portions Fb and Wb and the front member A, and holds the covering portions Fb and Wb over the front member A. Furthermore, while holding the covering portions Fb, Wb, and the front member A, the upper mold 35e descends towards the second lower mold 35b, which is configured with the back member B, thereby tightening (connecting) the front member A and the back member B to create the badge C.

[0050] The retrieval unit 36 ​​has a swing arm 36a and a base 36b. A magnet is mounted on the top of the swing arm 36a. The base 36b is tilted downwards toward the badge storage unit 38. The swing arm 36a is oscillating via its swing motor 36a1. Figure 1Driven by the rocker arm 36a, the pin moves between the first mold position P1 and the base 36b of the mold unit 35. As a result, the badge C attaches to the top of the rocker arm 36a at the second lower mold 35b at the first mold position P1 and moves from the second lower mold 35b to the base 36b. The badge C separates from the top of the rocker arm 36a at the base 36b and slides down the downward-sloping base 36b into the badge storage 38, where it is received.

[0051] <Third Device>

[0052] like Figure 1 As shown, the third device 40 differs from the first device 20 and the second device 30; it is a device for controlling the badge-making device 11, such as using a personal computer. The third device 40 has a third control unit 41 and a display unit 42 and an input unit 43 electrically connected to the third control unit 41. The display unit 42 is a device for displaying information, such as a liquid crystal display (LCD). The display on the display unit 42 is controlled by the third control unit 41. The input unit 43 is a device for inputting information into the third control unit 41 by user operation, such as using a keyboard, mouse, or touchpad. The third control unit 41 will be described later.

[0053] <Control Department>

[0054] The first control unit 22, the second control unit 39, and the third control unit 41 are composed of computers. Alternatively, the first control unit 22, the second control unit 39, and the third control unit 41 may each be composed of a single device for individual control, or they may be composed of multiple devices for distributed control.

[0055] The first control unit 22 has a first arithmetic unit 22a, a first storage unit 22b electrically connected to the first arithmetic unit 22a, and a first communication interface 22c. The second control unit 39 has a second arithmetic unit 39a, a second storage unit 39b electrically connected to the second arithmetic unit 39a, and a second communication interface 39c. The third control unit 41 has a third arithmetic unit 41a, a third storage unit 41b electrically connected to the third arithmetic unit 41a, and a third communication interface 41c.

[0056] The first communication interface 22c is communicatively connected to the third communication interface 41c, and information is transmitted and received between the third communication interface 41c and the first control unit 22. The second communication interface 39c is communicatively connected to the third communication interface 41c, and information is transmitted and received between the third communication interface 41c and the second control unit 39. For example, the first communication interface 22c and the third communication interface 41c, as well as the second communication interface 39c and the third communication interface 41c, can also be connected via wired communication such as a USB cable or wireless communication such as a LAN.

[0057] In this way, the third communication interface 41c sends and receives information between the first communication interface 22c, the second communication interface 39c, and the third control unit 41. Furthermore, these communication interfaces 22c, 39c, and 41c can also be connected to external devices other than the badge making system 10 in a communicative manner. Examples of such external devices include external servers, storage media, computers, and mobile terminals connected via communication networks such as the Internet.

[0058] The first storage unit 22b is a memory accessible by the first arithmetic unit 22a. The second storage unit 39b is a memory accessible by the second arithmetic unit 39a. The third storage unit 41b is a memory accessible by the third arithmetic unit 41a. The first storage unit 22b, the second storage unit 39b, and the third storage unit 41b each have, for example, RAM, ROM, flash memory, and / or a hard disk, storing programs for badge manufacturing processing and the data used for their execution.

[0059] The first arithmetic unit 22a, the second arithmetic unit 39a, and the third arithmetic unit 41a are each composed of a processor, such as a CPU. The first arithmetic unit 22a executes a program stored in the first storage unit 22b to control the printing unit 21 of the first device 20, thereby performing the printing operation of the printing unit 21. The second arithmetic unit 39a executes a program stored in the second storage unit 39b to control the operation of each part of the second device 30, thereby performing the assembly operation of assembling the sheets F and W, the front-side component A, and the back-side component B. The third arithmetic unit 41a executes a program stored in the third storage unit 41b to control each part of the third device 40, thereby performing the control operations of the first device 20 and the second device 30.

[0060] In this way, the third control unit 41 can communicate with both the first control unit 22 and the second control unit 39. The first control unit 22 communicates with the third control unit 41 but not with the second control unit 39. The second control unit 39 communicates with the third control unit 41 but not with the first control unit 22. Thus, the third control unit 41 sends a control signal based on a received signal from either the first control unit 22 or the second control unit 39 to the other, thereby enabling the first device 20 and the second device 30 to operate in conjunction. Therefore, by combining the second device 30, which connects the front-side member A and the back-side member B, with the first device 20, for example, a pre-existing printing device, a badge-making system 10 can be manufactured.

[0061] <Construction of the Badge Making Device>

[0062] The badge making device 11, which makes one badge C, has a production operation consisting of... Figure 9 The printing action performed by the first device 20 shown and by Figure 10 The assembly action performed by the second device 30 shown.

[0063] like Figure 9 As shown, during the printing operation of the first device 20, the first control unit 22 executes the printing operation of the backing paper F through the printing unit 21 based on white image data (step S12). During this printing operation of the backing paper F, the first control unit 22 moves the backing paper F via the moving device 21b while the backing paper F is facing the head 21a, and performs so-called blank printing on the backing paper F based on the white image data, without ejecting liquid ink from the head 21a. Then, the first control unit 22 discharges the unprinted backing paper F from the printing unit 21 via the moving device 21b and supplies it to the transport unit 33.

[0064] Next, after the printing action of the backing paper F, the first control unit 22 executes the printing action of the printed medium W through the printing unit 21 based on the image data specified by the user (step S14). During the printing action of the printed medium W, the first control unit 22 moves the printed medium W through the moving device 21b while the printed medium W is facing the head 21a, and sprays liquid ink from the head 21a onto the second covering portion Wb of the printed medium W based on the image data, printing an image on the second covering portion Wb. This image is inverted in such a way that it becomes a positive image when the user views the image from the side opposite to the side of the printed medium W. Moreover, the first control unit 22 discharges the printed medium W with the image printed on it from the printing unit 21 through the moving device 21b and supplies it to the delivery unit 33.

[0065] like Figure 10 As shown, during the assembly operation of the second device 30, the second control unit 39 performs a first loading operation for the surface component A as follows: the surface component A is loaded into the first lower mold 35a located at the first mold position P1 via the first loading unit 31 (step S22). In this first loading operation, when the second control unit 39 advances the first push rod 31c, the surface component A is pressed onto the first sliding member 31b by the first push rod 31c and loaded into the first lower mold 35a. Then, when the second control unit 39 retracts the first push rod 31c, the next surface component A descends from the first storage 31a onto the first sliding member 31b.

[0066] The first push rod motor 31d of the first push rod 31c is driven by the second control unit 39 based on the detection signal from the encoder of the first push rod motor 31d. Therefore, when the detection signal detects that the first push rod 31c has moved forward and then backward, the second control unit 39 determines that the first loading action has been completed, as the surface member A has been filled into the first lower mold 35a.

[0067] Next, the second control unit 39 performs the following first conveying operation: conveying the backing paper F, which has been printed by the printing unit 21, to the surface member A of the first lower die 35a via the conveying unit 33 (step S24). In this first conveying operation, when the backing paper F is supplied from the printing unit 21 to the conveying unit 33 and detected by the first conveying sensor 33d, the second control unit 39 starts to drive the roller 33a to rotate forward based on the detection signal. Then, the second control unit 39 causes the drive roller 33a to rotate, conveying the backing paper F from the detection position of the first conveying sensor 33d to the first lower die 35a of the die unit 35 along the first conveying direction D1 via the detection position of the second conveying sensor 33e.

[0068] The drive of the conveyor motor 33c of the drive roller 33a is controlled by the second control unit 39 based on the detection signals from the first conveyor sensor 33d and the second conveyor sensor 33e, and the detection signal from the encoder of the conveyor motor 33c. In this case, when the second conveyor sensor 33e detects the paper backing F being conveyed along the first conveying direction D1, the second control unit 39 obtains the detection position of the paper backing F based on the detection signal. Furthermore, the second control unit 39 obtains the position of the paper backing F being conveyed from the detection position into the first conveying direction D1 based on the detection signal from the encoder of the conveyor motor 33c. When the obtained position of the paper backing F coincides with the position of the first lower die 35a, the paper backing F is conveyed onto the first lower die 35a, and the second control unit 39 determines that the first conveying operation is completed and stops the rotation of the drive roller 33a.

[0069] Next, the second control unit 39 performs a first cutting action on the backing paper F as follows: the first covering portion Fb of the backing paper F is cut off on the first lower die 35a by the cutting unit 34 (step S26). In this first cutting action, the second control unit 39 moves the pressing head 34a from the separation position to the pressing position, thereby pressing the first covering portion Fb of the backing paper F by the pressing head 34a. As a result, at least a portion of the first connecting portion Fc between the first covering portion Fb of the backing paper F and the first remaining portion Fa is cut off. The driving of the pressing motor 34b of the pressing head 34a is controlled by the second control unit 39 based on the detection signal of the encoder of the pressing motor 34b. Therefore, when the pressing head 34a is detected to have moved from the separation position to the pressing position based on the detection signal, the second control unit 39 determines that the first cutting action is completed as the backing paper F is cut off.

[0070] Next, the second control unit 39 performs a second conveying operation as follows: the first remaining portion Fa of the liner paper F is conveyed from the first lower die 35a to the recycling container 37 via the conveying unit 33 (step S28). In this second conveying operation, the second control unit 39 causes the drive roller 33a to rotate in reverse while the first covering portion Fb of the liner paper F is pressed by the pressing head 34a. As a result, the first connecting portion Fc and the first linear weak portion Fd of the liner paper F are completely cut off, and the first covering portion Fb of the liner paper F is separated from the first remaining portion Fa. Moreover, while the first covering portion Fb remains above the surface member A of the first lower die 35a, the second control unit 39 conveys the first remaining portion Fa from the first lower die 35a to the recycling container 37 along the second conveying direction D2 via the detection position of the third detection signal.

[0071] The drive of the conveyor motor 33c of the drive roller 33a is controlled by the second control unit 39 based on the detection signal from the third conveyor sensor 33f and the detection signal from the encoder of the conveyor motor 33c. In this case, when the third conveyor sensor 33f detects the paper backing F being conveyed from the first lower die 35a toward the second conveying direction D2, the second control unit 39 obtains the detection position of the paper backing F based on the detection signal. Furthermore, the second control unit 39 obtains the position of the paper backing F conveyed from the detection position toward the second conveying direction D2 based on the detection signal from the encoder of the conveyor motor 33c. When the obtained position of the paper backing F coincides with the position of the recycling container 37, it is conveyed to the recycling container 37 as the first remaining portion Fa, and the second control unit 39 determines that the second conveying operation is completed and stops the rotation of the drive roller 33a. Then, the first remaining portion Fa is recycled to the recycling container 37 as waste.

[0072] Next, the second control unit 39 performs a third conveying operation: the printing medium W, which has been printed by the printing unit 21, is conveyed by the conveying unit 33 to the surface member A of the first lower die 35a (step S30). This third conveying operation of the printing medium W is the same as the first conveying operation of the backing paper F. Therefore, the second control unit 39 obtains the position of the printing medium W based on the detection signal of the second conveying sensor 33e and the detection signal of the encoder of the conveying motor 33c. When the position matches the position of the first lower die 35a, the third conveying operation is determined to be completed as the printing medium W is conveyed to the first lower die 35a, and the rotation of the drive roller 33a is stopped.

[0073] Next, the second control unit 39 performs a second cutting action as follows: the second covering portion Wb of the printing medium W is cut off on the first lower die 35a by the cutting unit 34 (step S32). This second cutting action of the printing medium W is the same as the second cutting action of the backing paper F. Therefore, when the second control unit 39 detects that the pressing head 34a has moved from the separation position to the pressing position based on the detection signal of the encoder of the pressing motor 34b, the second connecting portion Wc between the second covering portion Wb and the second remaining portion Wa of the printing medium W is cut off, and the second cutting action is determined to be completed.

[0074] Next, the second control unit 39 performs a fourth conveying operation: the second remaining portion Wa of the printed medium W is conveyed from the first lower die 35a to the recycling container 37 via the conveying unit 33 (step S34). This fourth conveying operation of the printed medium W is the same as the second conveying operation of the backing paper F. Therefore, the second control unit 39 obtains the position of the printed medium W based on the detection signal of the third conveying sensor 33f and the detection signal of the encoder of the conveying motor 33c. When this position coincides with the position of the recycling container 37, it determines that the fourth conveying operation is completed by indicating that the second remaining portion Wa has been conveyed to the recycling container 37, and stops the rotation of the drive roller 33a. Then, the second remaining portion Wa is recycled into the recycling container 37 as a waste portion.

[0075] Next, the second control unit 39 performs the following first rotation operation: rotating the first lower mold 35a from the first mold position P1 to the second mold position P2 via the rotary table 35c of the mold unit 35 (step S36). In this first rotation operation, with the surface member A and the covering portions Fb and Wb positioned on the first lower mold 35a, the second control unit 39 rotates the first lower mold 35a from the first mold position P1 to the second mold position P2 via the rotary table 35c. The drive of the rotary motor 35c1 of the rotary table 35c is controlled by the second control unit 39 based on the detection signal from the encoder of the rotary motor 35c1. Therefore, when the first lower mold 35a is detected to have rotated from the first mold position P1 to the second mold position P2 based on this detection signal, the second control unit 39 determines that the first rotation operation is complete.

[0076] Next, the second control unit 39 performs the following lifting action: The surface member A is raised using the lifting device 35d of the mold unit 35 (step S38). During this lifting action, the second control unit 39 uses the lifting device 35d at the second mold position P2 to lower the upper mold 35e towards the first lower mold 35a, thereby pressing the covering portions Fb and Wb on the first lower mold 35a against the surface member A. As a result, the surface member A is covered by the covering portions Fb and Wb, moves from the first lower mold 35a to the upper mold 35e, and remains on the upper mold 35e. Then, the second control unit 39 raises the upper mold 35e from the first lower mold 35a via the lifting device 35d. As the upper mold 35e rises, the surface member A held on the upper mold 35e rises. The lifting motor 35d1 of the lifting device 35d is driven by the second control unit 39 based on the detection signal from the encoder of the lifting motor 35d1. Therefore, when the upper mold 35e is detected to rise after falling based on the detection signal, the second control unit 39 determines that the rising action is completed, as the surface component A has risen.

[0077] In step S36 above, the first lower die 35a moves from the first die position P1 to the second die position P2, thereby moving the second lower die 35b from the second die position P2 to the first die position P1. Therefore, the second control unit 39 performs a second loading operation as follows: loading the back-side member B into the second lower die 35b positioned at the first die position P1 via the second loading unit 32 (step S40). During this second loading operation of the back-side member B, when the second control unit 39 advances the second push rod 32c, the back-side member B is pressed onto the second sliding member 32b by the second push rod 32c and loaded into the second lower die 35b. Then, when the second control unit 39 retracts the second push rod 32c, the next back-side member B descends from the second reservoir 32a onto the second sliding member 32b.

[0078] The second push rod motor 32d of the second push rod 32c is driven by the second control unit 39 based on the detection signal from the encoder of the second push rod motor 32d. Therefore, when the second control unit 39 detects that the second push rod 32c is moving forward and backward based on the detection signal, it determines that the second loading action is completed by loading the back side member B into the second lower mold 35b.

[0079] Next, the second control unit 39 performs a second rotation operation as follows: the second lower mold 35b is rotated from the first mold position P1 to the second mold position P2 via the rotary table 35c of the mold unit 35 (step S42). In this second rotation operation, with the back member B positioned on the second lower mold 35b, the second control unit 39 rotates the second lower mold 35b from the first mold position P1 to the second mold position P2 via the rotary table 35c. When the encoder detection signal of the rotary motor 35c1 based on the rotary table 35c detects that the second lower mold 35b has rotated from the first mold position P1 to the second mold position P2, the second control unit 39 determines that the second rotation operation is completed.

[0080] Next, the second control unit 39 performs the following connection operation: connecting the front member A and the back member B via the lifting device 35d of the mold unit 35 (step S44). In this connection operation, the second control unit 39 lowers the upper mold 35e, which holds the front member A, towards the second lower mold 35b, which supports the back member B, via the lifting device 35d, thereby pressing the front member A, covered by the covering portions Fb and Wb, against the back member B. Then, with the clamped portions Fg and Wg of the covering portions Fb and Wb clamped between the front edge A2 of the front member A and the back edge B2 of the back member B, the second control unit 39 tightens (connects) the front member A and the back member B, and then raises the upper mold 35e via the lifting device 35d. When the encoder of the lifting motor 35d1 based on the lifting device 35d detects the descent and ascent of the upper mold 35e, the front member A and the back member B are connected, and the second control unit 39 determines that the connection operation is complete. Through this connection operation, the badge C is produced.

[0081] Next, the second control unit 39 performs a third rotation operation as follows: the second lower mold 35b, on which the badge C is mounted, is rotated from the second mold position P2 to the first mold position P1 via the rotary table 35c of the mold unit 35 (step S46). In this third rotation operation, when the encoder detection signal of the rotary motor 35c1 based on the rotary table 35c detects the rotation of the second lower mold 35b from the second mold position P2 to the first mold position P1, the second control unit 39 determines that the third rotation operation is completed as the badge C has rotated to the first mold position P1.

[0082] Next, the second control unit 39 executes a holding action (step S48) by causing the badge C, located in the second lower mold 35b at the first mold position P1, to be attracted to the magnet of the swing arm 36a of the extraction unit 36, thereby holding the badge C on the swing arm 36a. Through this holding action, the second control unit 39 moves the tip of the swing arm 36a from the seat 36b towards the second lower mold 35b, causing the tip of the swing arm 36a to attach to the badge C located in the second lower mold 35b, thus holding the badge C. The drive of the swing motor 36a1 of the swing arm 36a is controlled by the second control unit 39 based on the detection signal from the encoder of the swing motor 36a1. Therefore, when the second control unit 39 detects that the tip of the swing arm 36a has moved from the seat 36b towards the second lower mold 35b based on the detection signal, it determines that the holding action is complete as the badge C has been held (e.g., attached).

[0083] Next, the second control unit 39 executes a discharge action (step S50) to discharge the badge C held at the top of the swing motor 36a1 to the badge storage 38 using the extraction unit 36. Through this discharge action, the second control unit 39 moves the top of the swing arm 36a from the second lower mold 35b to the seat 36b, thereby moving the badge C attached to the top towards the seat 36b. The badge C separates from the top at the seat 36b and slides down the downward-sloping seat 36b into the badge storage 38, where it is received. The second control unit 39 determines that the discharge action is complete when it detects that the top of the swing arm 36a has moved from the second lower mold 35b to the seat 36b based on the detection signal from the encoder of the swing motor 36a1 of the swing arm 36a.

[0084] Next, the second control unit 39 executes a fourth rotation operation (step S52) by rotating the second lower mold 35b, which has removed the badge C, from the first mold position P1 to the second mold position P2 using the rotary table 35c of the mold unit 35. In this fourth rotation operation, the second control unit 39 determines that the fourth rotation operation is complete when the encoder detection signal based on the rotary motor 35c1 of the rotary table 35c detects that the second lower mold 35b has rotated from the first mold position P1 to the second mold position P2. Thus, by rotating the first lower mold 35a from the second mold position P2 to the first mold position P1, the surface component A can be loaded into the first lower mold 35a at the first mold position P1 in the subsequent manufacturing operation.

[0085] <Badge Crafting Processing in the Badge Crafting System>

[0086] Badge creation system 10 badge creation process according to Figure 11 An example of the flowchart is executed by the first control unit 22, the second control unit 39, and the third control unit 41. This badge-making process has one or more production jobs, including... Figure 9 Printing action and Figure 10 The assembly process. Figure 11 In the reference numbers for each action in the first production task of making the first badge C, the correct action is used. Figure 9 and Figure 10 The reference number is obtained by adding 100 to the reference number of each action. For Figure 11 The reference numbers for each action in the second production task of making the second badge C are used to... Figure 9 and Figure 10 The reference number is obtained by adding 200 to the reference number of each action. For Figure 11 The reference numbers for each action in the third production task of making the third badge C are used to... Figure 9 and Figure 10 The reference number is obtained by adding 300 to the reference number of each action.

[0087] For example, the user inputs the image to be printed on the printing medium W, the quantity of one or more badges C to be produced, and the production requirements for the badges C via the input unit 43, etc. Then, the third control unit 41 obtains image data corresponding to the image specified by the user from the third storage unit 41b and the third communication interface 41c, etc. Furthermore, the third control unit 41 sets the production quantity of badges C as the number of production jobs, and executes badge production processing including that number of production jobs according to the production requirements of the badges C.

[0088] like Figure 11 As shown, in the badge production process, the third control unit 41 starts the first production operation and sends a production instruction signal for badge C to the second control unit 39 (step S121). The second device 30 performs the first loading action of the surface member A according to the production instruction signal (step S122). When it is determined that the first loading action is completed, a first loading completion signal indicating the completion is sent to the third control unit 41 (step S123).

[0089] Next, when the third control unit 41 receives the first filling completion signal from the second control unit 39 (step S123), it sends a second printing instruction signal and white image data for printing the first sheet of backing paper F to the first control unit 22 (step S111). When the first control unit 22 of the first device 20 receives the second printing instruction signal and the white image data, it executes the printing operation of the first sheet of backing paper F based on the white image data (step S112). Figure 11 As shown by the single-dotted line, the first sheet of backing paper F that has undergone the printing action is supplied from the first device 20 to the second device 30.

[0090] Therefore, when the liner paper F is detected by the first conveying sensor 33d, the second control unit 39 of the second device 30 executes a first conveying action of the liner paper F (step S124), and when it is determined that the first conveying action is completed, it sends a first conveying completion signal to the third control unit 41 (step S125). Then, the second control unit 39 executes a first cutting action of the liner paper F conveyed to the first lower die 35a by the first conveying action (step S126), and when it is determined that the first cutting action is completed, it sends a first cutting completion signal to the third control unit 41 (step S127). Then, the second control unit 39 executes a second conveying action of the liner paper F that has cut the first connecting portion Fc by the first cutting action (step S128), and when it is determined that the second conveying action is completed, it sends a second conveying completion signal to the third control unit 41 (step S129).

[0091] Furthermore, when the third control unit 41 receives the first delivery completion signal from the second control unit 39 in step S125, it correspondingly sends a first print instruction signal for printing the printable medium W and user-specified image data to the first control unit 22 (step S113). When the first control unit 22 receives the first print instruction signal from the third control unit 41, it correspondingly performs the printing operation of the first printable medium W based on the user-specified image data (step S114). Figure 11 As shown by the single-dotted line, the printing medium W, which has undergone the printing action, is supplied from the first device 20 to the second device 30.

[0092] Therefore, when the printing medium W is detected by the first transport sensor 33d, the second control unit 39 of the second device 30 executes a third transport operation of the printing medium W (step S130), and when it is determined that the third transport operation is completed, it sends a third transport completion signal to the third control unit 41 (step S131). Then, the second control unit 39 executes a second cutting operation of the printing medium W that has been transported to the first lower die 35a by the third transport operation (step S132), and when it is determined that the second cutting operation is completed, it sends a second cutting completion signal to the third control unit 41 (step S133). Then, the second control unit 39 executes a fourth transport operation of the printing medium W that has cut off the first connecting portion Fc by the second cutting operation (step S134), and when it is determined that the fourth transport operation is completed, it sends a fourth transport completion signal to the third control unit 41 (step S135).

[0093] Thus, during the period from receiving the first delivery completion signal of the backing paper F from the second control unit 39 in step S125 to receiving the third delivery completion signal of the printed medium W from the second control unit 39 in step S131, the third control unit 41 executes the printing operation of the printed medium W in step S114 in the first device 20. Since this printing operation takes time, a completion waiting time for the printing operation of the printed medium W is generated between the completion of the second delivery operation of the backing paper F in step S128 and the start of the third delivery operation of the printed medium W in step S130. Therefore, in order to shorten the waiting time, it is considered to execute the printing operation of the printed medium W in a manner that starts the third delivery operation of the printed medium W as quickly as possible after the completion of the second delivery operation of the backing paper F.

[0094] However, since the completion signal of the printing action of the printed medium W is not sent from the first control unit 22 to the third control unit 41, the third control unit 41 cannot obtain the printing time of the printed medium W. Furthermore, since the printing action of the printed medium W is performed based on user-specified image data, it cannot be obtained in advance. Moreover, the printed medium W cannot be supplied to the transport unit 33 while the backing paper F is being transported by the transport unit 33.

[0095] Therefore, the third control unit 41 measures the time from the receipt of the first delivery completion signal in step S125 to the receipt of the third delivery completion signal in step S131. Then, the third control unit 41 obtains the difference between this measured time and the predetermined time required for the third delivery operation as the printing time of the printable medium W, and stores it in the storage unit 71. This predetermined time for the third delivery operation is independent of image data used in the printing operation of the printable medium W and is predetermined as a fixed time. Then, the third control unit 41 uses this printing time to determine the start timing of the printing operation of the printable medium W in the second production job. This will be described later.

[0096] Furthermore, to shorten the waiting time for the second printed medium W, the third control unit 41 initiates the printing of the second backing paper F, which occurs before the printing of the first printed medium W, as quickly as possible after the printing of the first printed medium W is completed. However, since the first control unit 22 does not send a completion signal for the printing of the first printed medium W, the third control unit 41 cannot obtain the completion of the printing action. Therefore, when the third control unit 41 receives the third delivery completion signal from the second control unit 39 in step S131, it can determine that the printing of the first printed medium W is complete because the first printed medium W has been delivered in the second device 30. Therefore, when the third control unit 41 receives the third delivery completion signal in step S131, it begins the second production operation and sends the second printing instruction signal for the second backing paper F and the white image data to the first control unit 22 (step S211).

[0097] When the first control unit 22 receives the second print instruction signal and white image data from the third control unit 41, it executes the printing action of the second sheet of backing paper F based on the white image data (step S212). Thus, the printing action of the backing paper F is executed in parallel with the second cutting action (step S132) and the fourth conveying action (step S134) of the first printed medium W in the second device 30. Therefore, after the first printed medium W is conveyed by the conveying unit 33, the first control unit 22 can quickly supply the printed second sheet of backing paper F to the conveying unit 33. Then, as... Figure 11 As shown by the single-dotted line, when the second sheet of backing paper F is supplied from the first device 20 to the conveying unit 33 of the second device 30 and detected by the first conveying sensor 33d, the second control unit 39 determines that the second sheet of backing paper F has been supplied based on the detection signal.

[0098] Furthermore, in the second device 30, following the fourth conveying operation in step S134, the second control unit 39 executes the first rotation operation of the surface member A (step S136), and when it is determined that the first rotation operation is completed, it sends a first rotation completion signal to the third control unit 41 (step S137). Next, the second control unit 39 executes the lifting operation of the surface member A, which has moved to the second mold position P2 by the first rotation operation (step S138), and when it is determined that the lifting operation is completed, it sends a lifting completion signal to the third control unit 41 (step S139).

[0099] Next, the second control unit 39 executes the second loading action of the back-side member B (step S140). When it is determined that the second loading action is completed, the second loading completion signal is sent to the third control unit 41 (step S141). Then, the second control unit 39 executes the second rotation action of the back-side member B loaded into the second lower mold 35b by the second loading action (step S142). When it is determined that the second rotation action is completed, the second rotation completion signal is sent to the third control unit 41 (step S143). Then, the second control unit 39 executes the connection action between the back-side member B, which has moved to the second mold position P2 by the second rotation action, and the front-side member A (step S144). When it is determined that the connection action is completed, the connection completion signal is sent to the third control unit 41 (step S145).

[0100] Next, the second control unit 39 executes a third rotation action of the badge C created by the connecting action (step S146), and when it determines that the third rotation action is completed, it sends a third rotation completion signal to the third control unit 41 (step S147). Then, the second control unit 39 executes a holding action of the badge C, which has moved to the first mold position P1 by the third rotation action (step S148), and when it determines that the holding action is completed, it sends a holding completion signal to the third control unit 41 (step S149).

[0101] Then, the second control unit 39 executes the ejection action of the badge C held in the holding action (step S150), and when it is determined that the ejection action is completed, it sends an ejection completion signal to the third control unit 41 (step S151). Then, the second control unit 39 executes a fourth rotation action of the second lower mold 35b that ejected the badge C in the ejection action (step S152), and when it is determined that the fourth rotation action is completed, it sends a fourth rotation completion signal to the third control unit 41 (step S153). Then, when the third control unit 41 receives the fourth rotation completion signal from the second control unit 39 (step S153), it ends the first production operation.

[0102] In the case where the badge making process includes a production operation to make a second badge C, the third control unit 41 sends a production instruction signal for the second production operation to the second control unit 39 (step S221). As a result, when the second device 30 receives the production instruction signal, it performs the first loading action of the surface member A (step S222) and sends the first loading completion signal (step S223).

[0103] Next, the second control unit 39 executes the first feeding action of the second sheet of backing paper F, which underwent printing in step S212 (step S224), and sends the first feeding completion signal (step S225). Then, the second control unit 39 executes the first cutting action of the backing paper F (step S226), and sends the first cutting completion signal (step S227). Then, the second control unit 39 executes the second feeding action of the backing paper F (step S228), and sends the second feeding completion signal (step S229).

[0104] In steps S224 to S228, the conveying unit 33 is used to convey the backing paper F. After the second conveying operation in step S228, if the conveying unit 33 quickly starts conveying the second printable medium W, the printing waiting time of the printable medium W can be shortened. Therefore, the third control unit 41 uses the printing time of the first printable medium W obtained as described above to obtain the printing start time of the second printable medium W in a manner that allows the conveying of the printable medium W to begin after the second conveying operation.

[0105] That is, the third control unit 41 obtains the predetermined time for each operation of the second device 30 from the storage unit 71, and obtains the completion time t1 of the second conveying operation in step S228 based on the predetermined time. The time required for each operation of the second device 30 is predetermined as a fixed time. Moreover, the third control unit 41 obtains the time t2 obtained by subtracting the printing time from the completion time t1 of the second conveying operation. Then, the third control unit 41 obtains the operation of the second device 30 corresponding to time t2, in Figure 11 In the example, the discharge action in step S150 is used to determine the start timing of printing on the printed medium W by receiving the discharge completion signal (step S151).

[0106] Therefore, when the third control unit 41 receives the discharge completion signal from the second control unit 39 in step S151, it sends a first print instruction signal for printing the second printable medium W and user-specified image data to the first control unit 22 (step S213). The first control unit 22 executes the printing operation of the second printable medium W according to the first print instruction signal (step S214). Thus, as Figure 11 As shown by the dashed line, the second printable medium W is supplied from the first device 20 to the second device 30. After the second conveying action in step S228, the third conveying action (step S230) performed by the conveying unit 33 quickly begins. In this way, the printing waiting time of the printable medium W between steps S220 and S230 can be shortened.

[0107] Then, when the third transport operation of the second printable medium W in step S230 is completed, the second control unit 39 sends the third transport completion signal (step S231). Then, the second control unit 39 executes the second cutting operation (step S232) to the fourth rotation operation (step S252) of the printable medium W, and sends the fourth rotation completion signal to the third control unit 41. In contrast, the third control unit 41, upon receiving the fourth rotation completion signal from the second control unit 39 (step S253), ends the second production operation. Thus, the badge production system 10 performs a number of production operations corresponding to the number of badges C input by the user.

[0108] <Functions and Effects>

[0109] Thus, during the can-making process, before the printed medium W, printed by the printing unit 21, is conveyed to the first lower mold 35a via the conveying unit 33 (steps S130, S230), the second control unit 39 fills the front component A into the first lower mold 35a via the first filling unit 31 (steps S122, S222). Therefore, at the moment the printed medium W is conveyed, the front component A is already filled into the first lower mold 35a, allowing the printed medium W to be conveyed onto the front component A without waiting for it to be filled. This reduces the production time of the badge C and enables the badge C to be automatically produced by connecting the front component A covered by the printed medium W to the back component B.

[0110] Furthermore, in the badge production process, the second control unit 39, during the production operation, before the printing of the printing medium W is completed (steps S114, S214), loads the front component A into the first lower mold 35a via the first loading unit 31 (steps S122, S222). Thus, at the moment the printing of the printing medium W is completed, the front component A is already loaded into the first lower mold 35a, allowing the printed printing medium W to be transported onto the front component A without waiting for its loading. Therefore, the production time of the badge C can be shortened, and the badge C can be automatically produced by connecting the front component A covered by the printing medium W to the back component B.

[0111] Furthermore, in the badge manufacturing process, after the first control unit 22 completes the loading of the front component A into the first lower mold 35a during the initial manufacturing operation (step S122), the printing unit 21 begins printing on the printing medium W (step S114). Thus, at the moment the printing of the printing medium W is completed, the front component A has already been loaded into the first lower mold 35a. The printed printing medium W can be conveyed onto the front component A without waiting for the loading of the front component A. Therefore, the manufacturing time of the badge C can be shortened, and the badge C can be automatically manufactured by connecting the front component A covered by the printing medium W to the back component B.

[0112] Furthermore, in the badge manufacturing process, the second control unit 39 conveys the backing paper F to the first lower die 35a via the conveying unit 33 (steps S124, S224), cuts the first covering portion Fb and the first remaining portion Fa of the backing paper F between the cutting unit 34 (steps S126, S226), and conveys the first remaining portion Fa cut from the first covering portion Fb via the conveying unit 33 (steps S128, S228). In addition, before the conveying of the first remaining portion Fa is completed, the first control unit 22 starts printing the printing medium W via the printing unit 21 (steps S114, S214). Thus, printing of the printing medium W begins at the moment the conveying of the first remaining portion Fa is completed. This allows for the printing of the printed medium W as quickly as possible after the conveying of the first remaining portion Fa is completed. Therefore, the waiting time for printing the printing medium W can be minimized, thereby reducing the production time of the badge C.

[0113] Furthermore, in the badge production process, the first control unit 22, in subsequent production operations, begins printing on the printing medium W via the printing unit 21 before the immediate preceding production operation is completed (step S152) (step S214). Thus, printing on the printing medium W for the current production operation begins at the moment the immediate preceding production operation is completed. Therefore, the printed printing medium W can be delivered as quickly as possible after the immediate preceding production operation is completed. This reduces the waiting time for printing the printing medium W, thereby shortening the badge C production time.

[0114] Furthermore, in the badge manufacturing process, during subsequent manufacturing operations, the first control unit 22 begins printing the printing medium W via the printing unit 21 before the surface member A is loaded into the first lower mold 35a (step S222). Thus, printing of the printing medium W begins at the moment the surface member A is loaded. Therefore, the printed printing medium W can be transported onto the surface member A as quickly as possible after loading. This shortens the waiting time for printing the printing medium W, thereby reducing the manufacturing time of the badge C.

[0115] In addition, during the badge manufacturing process, when the first lower mold 35a is positioned at the first mold position P1, the second control unit 39 loads the surface component A into the first lower mold 35a via the first loading unit 31 (steps S122, S222), and the printing medium W is conveyed onto the first lower mold 35a via the conveying unit 33 (steps S130, S230). The second covering portion Wb and the second remaining portion Wa of the printing medium W are cut between them via the cutting unit 34 (S132, S232). The second remaining portion Wa after being cut from the second covering portion Wb is conveyed via the conveying unit 33 (S134, S234). With the surface component A and the second covering portion Wb in place, the first lower mold 35a is moved from the first mold position P1 to the second mold position P2 via the mold unit 35 (S136, S236). Thus, by using each unit to perform a series of actions, the filling of the surface member A into the surface member A and the movement of the second covering part Wb toward the second mold position P2 can be carried out, thereby enabling the automatic production of the badge C.

[0116] Furthermore, in the badge manufacturing process, after the second control unit 39 moves the first lower mold 35a from the first mold position P1 to the second mold position P2 with the front panel member A and the second covering portion Wb configured (S136, S236), the upper mold 35e is raised and lowered relative to the first lower mold 35a via the mold unit 35 (S138, S238), thereby moving the front panel member A and the second covering portion Wb from the first lower mold 35a to the upper mold 35e. Thus, at the second mold position P2, the first lower mold 35a and the upper mold 35e are opposite each other in the vertical direction, and their relative positions are accurately determined. Therefore, by lowering the upper mold 35e positioned above the first lower mold 35a, the upper mold 35e can press the second covering portion Wb positioned on the first lower mold 35a against the front panel member A. Therefore, the front panel member A is more reliably covered by the second covering portion Wb and held by the upper mold 35e.

[0117] Furthermore, in the badge manufacturing process, when the second control unit 39 is positioned at the first mold position P1 with the second lower mold 35b (steps S136 and S236), the second loading unit 32 loads the back side member B into the first lower mold 35a (steps S140 and S240), and the mold unit 35 moves the second lower mold 35b, on which the back side member B is disposed, from the first mold position P1 to the second mold position P2 (steps S142 and S242).

[0118] Then, after the second lower mold 35b, on which the back side member B is disposed, moves to the second mold position P2 (steps S142, S242), the second control unit 39 raises and lowers the upper mold 35e relative to the second lower mold 35b via the mold unit 35, thereby connecting the back side member B disposed on the second lower mold 35b with the front side member A and the second covering portion Wb that have moved to the upper mold 35e (steps S144, S244).

[0119] Therefore, at the second mold position P2, the second lower mold 35b is opposite the upper mold 35e in the vertical direction, and thus the relative positions of the second lower mold 35b and the upper mold 35e are accurately determined. Therefore, by lowering the upper mold 35e, which is positioned above the second lower mold 35b, the upper mold 35e presses the front member A against the back member B positioned on the second lower mold 35b. This allows for a more reliable connection between the front member A and the back member B to create the badge C.

[0120] Furthermore, in this badge manufacturing system 10, the third control unit 41 sends a manufacturing instruction signal for badge C to the second control unit 39 (step S121). The third control unit 41 receives from the second control unit 39 a first filling completion signal indicating that the front component A is filled into the first lower mold 35a according to the manufacturing instruction signal (step S123). After receiving the first filling completion signal, the third control unit 41 sends a first printing instruction signal to the first control unit 22 to print the printing medium W (step S113). Thus, at the start of printing the printing medium W, the front component A is already filled into the first lower mold 35a, so the printed medium W can be transported onto the front component A without waiting for the front component A to be filled. Therefore, the manufacturing time of badge C can be shortened, and badge C can be automatically manufactured by connecting the front component A covered by the printing medium W to the back component B.

[0121] Furthermore, in the badge production system 10, after receiving the first loading completion signal from the second control unit 39 (step S123), the third control unit 41 sends a second printing instruction signal for printing the backing paper F to the first control unit 22 (step S111). After receiving a signal from the second control unit 39 that the printed backing paper F has arrived at the transport unit 33 (step S125), the third control unit 41 sends the first printing instruction signal to the first control unit 22 (step S113). Thus, at the start of printing the printed medium W, the backing paper F has already been discharged from the printing unit 21 and supplied to the transport unit 33. Therefore, the printed medium W can be printed by the printing unit 21 without waiting for the backing paper F to be discharged from the printing unit 21. Therefore, the production time of the badge C can be shortened.

[0122] Furthermore, "printing of the backing paper F" includes the case where the backing paper F is ejected from the printing unit 21 without any printing on it. Additionally, the case described above, where nothing is printed on the backing paper F, refers to the case where a blank image is printed on the backing paper F based on white image data and then the backing paper F is ejected (e.g., blank printing), but printing the backing paper F is not limited to this. For example, printing the backing paper F may also include the case where the backing paper F is ejected from the printing unit 21 without printing a blank image on it.

[0123] Furthermore, in the above description, the signal indicating that the printed backing paper F has arrived at the conveying unit 33 uses the first conveying completion signal indicating that the backing paper F has been conveyed to the first lower die 35a, but it is not limited to this. For example, the second control unit 39 may also send the detection signal as the signal indicating that the backing paper F has arrived when the backing paper F is detected by the first conveying sensor 33d or the second conveying sensor 33e.

[0124] Furthermore, in the badge making system 10, the third control unit 41 obtains the printing time required for the printing unit 21 to perform the printing action on the printing medium W based on the detection signal of the sensor. The third control unit 41 sends a first printing instruction signal (step S212) to the first control unit 22 at a timing determined based on the printing time, instructing the printing unit 21 to perform the next printing action.

[0125] Therefore, based on the printing time of the printing medium W in the previous printing action, the printing of the printing medium W in the current printing action begins. Thus, after the backing paper F is fed, the printed printing medium W can be fed quickly. Therefore, the printing waiting time of the printing medium W can be minimized, thereby reducing the production time of the badge C.

[0126] In addition, Figure 11In this example, the printing time is obtained as the difference between the measured time from receiving the first transport completion signal (step S125) to receiving the third transport completion signal (step S131) ​​and the predetermined time of the third transport operation (step S130). The first transport completion signal in step S125 is based on detection signals from sensors such as the second transport sensor 33e and the encoder of the transport motor 33c. Similarly, the third transport completion signal in step S131 is based on detection signals from sensors such as the third transport sensor 33f and the encoder of the transport motor 33c. Therefore, the printing time is obtained based on the sensor detection signals.

[0127] <Variation Example 1>

[0128] In the badge making system 10 of Modified Example 1, in the above embodiment, the third control unit 41 receives first information indicating the operation status of the printing unit 21 from the first control unit 22, and receives second information indicating the operation status of the conveying unit 33 and the mold unit 35 from the second control unit 39, and displays the first information and the second information on the display unit 42.

[0129] Specifically, such as Figure 9 As shown in the example, the first control unit 22 controls the printing unit 21 of the first device 20 to perform the printing action of the backing paper F (step S12) and the printing action of the printed medium W (step S14). In each printing action, the first control unit 22 controls the driving of the head 21a and the moving device 21b based on image data, thereby performing the movement of the backing paper F or the printed medium W based on the moving device 21b and the ejection of liquid ink based on the head 21a.

[0130] Here, the first control unit 22 sends, for example, first information indicating the start and stop of the driving of the mobile device 21b and the start and stop of the driving of the head 21a to the third control unit 41. The third control unit 41 displays the first information received from the first control unit 22 on the display unit 42. By observing this first information, the user can know the operating status of the first device 20 and the progress status of the badge making process. For example, if the driving of the head 21a has started but has not yet stopped, the user can know that the ink ejection process is underway.

[0131] In addition, such as Figure 10As shown in the example, the second control unit 39 controls the driving of each unit of the second device 30, executing each action in steps S22 to S52. In each action, the second control unit 39, for example, drives and stops the motor of each unit based on the detection signals of the encoder and the sensor of each unit, and sends second information indicating the action information to the third control unit 41. The third control unit 41 displays the second information received from the second control unit 39 on the display unit 42. By observing this second information, the user can know the operation status of the second device 30 and the progress status of the badge making process. For example, if the second push rod motor 32d of the second loading unit 32 has started but has not yet stopped, the user can know that the second loading action is in progress.

[0132] <Variation Example 2>

[0133] In the badge making system 10 of Modification 2, in the above-described embodiment and Modification 1, the third control unit 41 receives error information indicating malfunction of the printing unit 21 from the first control unit 22, and error information indicating malfunction of the conveying unit 33 and the mold unit 35 from the second control unit 39. If the third control unit 41 receives error information from either the first control unit 22 or the second control unit 39, it sends a stop signal to the other to stop the operation.

[0134] Specifically, in the badge-making system 10 of Variation Example 2, in Figure 11 In the example of badge production processing, the second control unit 39 sends an action completion signal to the third control unit 41, indicating the completion of each action of the second device 30. Furthermore, when a malfunction occurs during any action, the second control unit 39, along with sending the action completion signal, sends an error message indicating the malfunction to the third control unit 41. In contrast, the third control unit 41... Figure 12 The flowchart shown is an example of a control method for handling error messages.

[0135] That is, the third control unit 41 determines whether an error message has been received (step S60). For example, in the first conveying operation of the conveying unit 33 of the second device 30, after the second control unit 39 starts driving the conveying motor 33c, when it determines that the liner paper F is being conveyed onto the first lower die 35a based on the detection signal of the second conveying sensor 33e and the detection signal of the encoder of the conveying motor 33c, it stops driving the conveying motor 33c. Here, if it is assumed that the conveying of the liner paper F stops midway, and it is not detected by the second conveying sensor 33e within a predetermined time from the start of driving the conveying motor 33c, the second control unit 39 sends an error message indicating that the conveying operation of the liner paper F is malfunctioning to the third control unit 41, and stops the operation of the conveying unit 33 and other units of the second control unit 39.

[0136] Furthermore, for example, in the first rotation operation of the mold unit 35 of the second device 30, after the drive of the rotary motor 35c1 begins, when the detection signal of the encoder of the rotary motor 35c1 determines that the first lower mold 35a is rotating from the first mold position P1 to the second mold position P2, the drive of the rotary motor 35c1 is stopped. Here, if it is assumed that the rotation of the first lower mold 35a stops midway, and no rotation to the second mold position P2 is detected within a predetermined time from the start of the drive of the rotary motor 35c1, the second control unit 39 sends an error message indicating a malfunction in the rotation operation to the third control unit 41, and stops the operation of the mold unit 35 and other units of the second control unit 39.

[0137] Furthermore, for example, during the printing operation of the printing unit 21 of the first device 20, the first control unit 22 drives the head 21a to eject liquid ink. If the first device 20 is equipped with a sensor that detects the liquid ink, when the first control unit 22 detects that the liquid ink is not being ejected based on the detection signal, it sends an error message indicating that the head 21a is malfunctioning to the third control unit 41 and stops the operation of the printing unit 21.

[0138] In the determination process of step S60, the third control unit 41 monitors the reception of error information during the period when no error information is received (step S60: No). On the other hand, when the third control unit 41 receives error information (step S60: Yes), it determines whether the error information has been received from the first control unit 22 (step S61).

[0139] Here, if the third control unit 41 receives an error message from the first control unit 22 (step S61: Yes), it sends a stop signal to the second control unit 39 (step S62). When the stop signal is received, the second control unit 39 stops the assembly operation being performed at this time or the assembly operation to be performed thereafter.

[0140] On the other hand, in the determination process of step S61, if the third control unit 41 receives an error message from the second control unit 39 (step S61: No), it sends a stop signal to the first control unit 22 (step S63). When the first control unit 22 receives the stop signal, it stops the printing operation being performed at this time or the printing operation to be performed thereafter.

[0141] Thus, for example, in the event of a malfunction in the printing unit 21 of the first device 20, stopping the operation of the transport unit 33 of the second device 30 can reduce unnecessary operations such as the transport unit 33 operating when no printed media W is supplied to it. Furthermore, for example, in the event of a malfunction in the transport unit 33 of the second device 30, stopping the operation of the printing unit 21 of the second device 30 can reduce unnecessary operations such as the printing unit 21 operating when the printed media W is not being transported by the transport unit 33.

[0142] Furthermore, in the above structure, the third control unit 41 receives error information from the second control unit 39 indicating a malfunction in the operation of a unit in the second device 30. Conversely, the third control unit 41 may also receive error information from the second device 30 based on the operation completion signals of each unit in the second device 30. In this case, the third control unit 41 may also determine that an error message has been received (step S60: Yes) if it receives an operation completion signal from the second control unit 39 for a predetermined period from that reception and does not receive a next operation completion signal from the second control unit 39. Additionally, suppose the first control unit 22 sends operation completion signals, such as the ejection completion signal of the head 21a in the printing unit 21 of the first device 20 and the movement completion signal of the moving device 21b, to the third control unit 41. In this case, the third control unit 41 may also determine that an error message has been received (step S60: Yes) if it receives an operation completion signal from the first control unit 22 for the printing unit 21 and does not receive a next operation completion signal from the first control unit 22 for a predetermined period from that reception.

[0143] <Variation Example 3>

[0144] In the badge making system 10 of Modification 3, in Modification 2, after receiving a first filling completion signal from the second control unit 39 indicating that the front-side component A is filled into the first lower mold 35a and a third conveying completion signal indicating that the printing medium W is conveyed to the first lower mold 35a and the front-side component A, and after receiving an error message from the first control unit 22, the third control unit 41 sends a stop signal to the second control unit 39 to stop the operation of the conveying unit 33 and the mold unit 35 after receiving a production completion signal indicating that the badge C is made by connecting the front-side component A covered by the printing medium W and the back-side component B by the mold unit 35.

[0145] Specifically, in variant example 3, the badge-making system 10 is controlled by the third control unit 41 according to... Figure 13 The flowchart shown is an example of a control method used for control. Figure 13 The flowchart in Figure 12The processing of steps S64 and S65 is performed between steps S61 and S62 in the flowchart.

[0146] That is, in Figure 11 In the example of badge production processing, during the execution of the production operation, whenever an action in the production operation is completed, the second control unit 39 sends an action completion signal indicating that the action has been completed to the third control unit 41. In turn, the third control unit 41 stores the presence or absence of completed actions in the third storage unit 41b based on the action completion signal. Here, when the third control unit 41 receives an action completion signal from the second control unit 39, it adds an action completion flag to that action. Then, when the production operation ends, the third control unit 41 removes and resets all action completion flags included in the production operation. Furthermore, when an action malfunction occurs during the production operation, the first control unit 22 and the second control unit 39 send an error message to the third control unit 41. Therefore, the third control unit 41 determines whether it has received an error message (step S60).

[0147] If the third control unit 41 receives an error message from the first control unit 22 (step S60: Yes, S61: Yes), it determines, with reference to the flags in the third storage unit 41b, whether the first loading completion signal and the third delivery completion signal have been received from the second control unit 39 (step S64). Here, based on the flags for the first loading operation and the third delivery operation, if at least one of these signals has not been received (step S64: No), the third control unit 41 sends a stop signal to the second control unit 39 (step S62). Thus, the operation of the second device 30 stops based on the stop signal.

[0148] On the other hand, in the determination process of step S64, the third control unit 41, based on the flags of the first loading action and the third conveying action, and having received both the first loading completion signal and the third conveying completion signal (step S64: Yes), has supplied the printed medium W printed by the first device 20 to the second device 30. Therefore, even if the first device 20 malfunctions, the badge C can still be produced through the assembly action of the second device 30. Therefore, the third control unit 41 determines whether to stop the assembly action of the second device 30 on the component and receives a connection completion signal from the second control unit 39 (step S65). Then, during the period when the connection completion signal is not received (step S64: No), the third control unit 41 performs the component assembly action through the second device 30. Then, when the second device 30 completes the component assembly action and produces the badge C, and the third control unit 41 receives the connection completion signal (step S64: Yes), it sends a stop signal to the second control unit 39 (step S62). Thus, the operation of the second device 30 stops based on the stop signal.

[0149] Thus, even if the printing unit 21 of the first device 20 malfunctions, in the second device 30, with the front member A loaded onto the first lower die 35a and the printing medium W conveyed to the first lower die 35a and the front member A, the front member A covered by the printing medium W can be connected to produce the badge C. In this case, after the badge C is produced, the second control unit 39 stops the operation of the conveying unit 33 and the die unit 35 based on an error message indicating a malfunction in the printing unit 21. Therefore, adjustments for restarting operation are not required if the conveying unit stops immediately after receiving an error message, and badge C can be produced.

[0150] <Other variations>

[0151] In the badge making system 10 described in the above embodiments and variations, the display unit 42 is provided on the third control unit 41, but the configuration of the display unit 42 is not limited thereto. For example, the display unit 42 may also be provided on at least one of the first device 20, the second device 30, and the third device 40. Furthermore, the display unit 42 may also be provided on an external device (e.g., a user's portable terminal) capable of communicating with the third control unit 41 via the third communication interface 41c of the third device 40. In this case, the user interface is displayed on the display unit 42 of the external device, and information input by the user from the input unit 43 of the external device is input to the third control unit 41 via the third communication interface 41c.

[0152] In the badge-making system 10 described in the above-described embodiments and variations, the lifting device 35d raises and lowers the upper mold 35e without raising or lowering the first lower mold 35a and the second lower mold 35b. However, the lifting device 35d only needs to be able to raise and lower the upper mold 35e relative to the first lower mold 35a and the second lower mold 35b. Therefore, the lifting device 35d may also raise and lower the first lower mold 35a and the second lower mold 35b without raising or lowering the upper mold 35e. Alternatively, the lifting device 35d may also raise and lower the first lower mold 35a, the second lower mold 35b, and the upper mold 35e.

[0153] In the badge manufacturing system 10 described in the above embodiments and variations, the cutting unit 34 presses the covering portions Fb and Wb of the sheets F and W using the pressing head 34a, thereby cutting off at least a portion of the connecting portions Fc and Wc between the covering portions Fb and Wb and the remaining portions Fa and Wa. However, the cutting unit 34 is not limited to this. For example, the cutting unit 34 may also be an NC engraving machine provided in the first lower mold 35a, a cutter provided in the upper mold 35e, etc.

[0154] In the badge manufacturing system 10 described in the above embodiments and variations, the first lower mold 35a and the second lower mold 35b rotate and move between the first mold position P1 and the second mold position P2 by rotating the rotary table 35c. However, the movement of the first lower mold 35a and the second lower mold 35b between the first mold position P1 and the second mold position P2 is not limited to this. For example, the first lower mold 35a and the second lower mold 35b can also move linearly between the first mold position P1 and the second mold position P2 by the linear motion of the linear actuator.

[0155] Furthermore, based on the foregoing description, many improvements and other embodiments of this disclosure will be apparent to those skilled in the art. Therefore, the foregoing description should be interpreted as illustrative only and is provided to teach those skilled in the art the best mode for performing this disclosure. Details regarding how the construction and / or function can be substantially changed without departing from the spirit of this disclosure are also included.

[0156] Explanation of icon numbers

[0157] 10: Badge Crafting System; 21: Printing unit; 31: First loading unit; 32: Second loading unit; 33: Conveying unit; 34: Cut-off unit; 35: Mold unit; 35a: First lower die; 35b: Second lower die; 35e: Upper mold.

Claims

1. A badge making system, wherein, have: The first filling unit fills the surface component into the first lower mold; The printing unit prints onto the medium being printed. The conveying unit conveys the medium to be printed from the printing unit to the first lower mold; A mold unit having the first lower mold, and connecting the front and back members covered by the printing medium to produce a badge; as well as Control Department The control unit performs a badge making process that includes one or more badge making operations, in which the control unit loads the surface component into the first lower mold via the first loading unit before the printing medium printed by the printing unit is conveyed to the first lower mold by the conveying unit.

2. The badge making system according to claim 1, wherein, In the manufacturing process, the control unit loads the surface component into the first lower mold via the first loading unit before the printing of the printed medium is completed.

3. The badge making system according to claim 1, wherein, In the first production operation of the badge making process, after the front component is filled into the first lower mold, the control unit starts printing the printed medium through the printing unit.

4. The badge making system according to claim 1, wherein, The printing unit supplies the printing medium and backing paper to the conveying unit. The badge-making system also includes a cutting unit that cuts between a first covering portion of the backing paper that covers the surface member and the remaining first residual portion. The control unit conveys the backing paper onto the first lower die via the conveying unit. The control unit cuts the first covering portion and the first remaining portion of the backing paper between the cutting unit. The control unit conveys the first remaining portion, which has been cut from the first covered portion, via the conveying unit. Before the first remaining portion is delivered, the control unit starts printing the printed medium via the printing unit.

5. The badge making system according to claim 1, wherein, In the badge making process, after the second production operation, the control unit starts printing the printed medium through the printing unit before the immediate production operation is completed.

6. The badge making system according to claim 1, wherein, In the badge making process, after the second production operation, the control unit starts printing the printed medium through the printing unit before the surface component is filled into the first lower mold.

7. The badge making system according to claim 1, wherein, The badge-making system also includes a cutting unit that cuts between the second covering portion covering the surface member and the remaining second residual portion in the printed medium. The mold unit moves the first lower mold between a first mold position for supplying the printing medium and a second mold position for connecting the front component and the back component. When the first lower mold is positioned at the first mold position, the control unit loads the surface component into the first lower mold via the first loading unit. The control unit conveys the printing medium onto the first lower mold via the conveying unit. The control unit cuts the second covered portion and the second remaining portion of the printed medium through the cutting unit. The control unit conveys the second remaining portion, which has been cut off from the second covered portion, via the conveying unit. With the surface member and the second covering portion configured, the first lower mold is moved from the first mold position to the second mold position by the mold unit.

8. The badge making system according to claim 7, wherein, The mold unit has a first lower mold and an upper mold that can be raised and lowered relative to the first lower mold. After the control unit moves from the first mold position to the second mold position with the surface member and the second covering part configured thereon in the first lower mold, the upper mold is raised and lowered relative to the first lower mold by the mold unit, thereby moving the surface member and the second covering part from the first lower mold to the upper mold.

9. The badge making system according to claim 8, wherein, The mold unit has a second lower mold that is different from the first lower mold. The badge making system also includes a second loading unit, which loads the back component into the second lower mold located at the first mold position. When the first lower mold is positioned at the second mold position, the second lower mold is positioned at the first mold position. When the second lower mold is positioned at the first mold position, the control unit uses the second filling unit to fill the back-side component into the first lower mold. The control unit moves the second lower mold, on which the back side member is disposed, from the first mold position to the second mold position via the mold unit. After the second lower mold, on which the back side member is disposed, moves to the second mold position, the control unit connects the back side member disposed on the second lower mold to the front side member and the second covering portion that have moved to the upper mold by raising and lowering the upper mold relative to the second lower mold through the mold unit.

10. A method for making a badge, wherein, The surface components are filled into the first lower mold using the first filling unit. The printing unit prints the medium. The printed medium is conveyed to the first lower mold via a conveying unit. Badges are made by connecting the front and back components covered by the printing medium using a die unit.

Images