Arrangement and method for the edge-aligned collation of a plurality of films on a workpiece carrier

Abstract

The invention relates to an arrangement (100) for collating a plurality of films (106, 110, 134) on a workpiece carrier (102) with the same edges, comprising a first film stack (104) with first films (106) and at least one second film stack (108) with second films (110), a workpiece carrier (102) which is designed to receive a plurality of the films (106, 110) in a stacked manner, at least one gripping device (112) for removing one film (106, 110) from each of the film stacks (104, 108) and placing it on the workpiece carrier (102) or on a film (106) already present there, and a sensor-based control device (114) which is designed to detect a contour of the stack (116) of films (106, 110, 134) on the workpiece carrier (102) or a contour of the workpiece carrier (102) to record and check for themselves,whether an overhang (118) is present due to an incorrectly transported film (120) of the first film stack (104) or the second film stack (108). The invention further relates to a corresponding method.

Description

[0001] The invention relates to an arrangement and a method for gathering, in particular with equal edges and in particular without registration errors, a plurality of films on a workpiece carrier so that they can later be joined to form a laminate.

[0002] When producing data cards or identity cards from a laminated composite, the individual layers or plies are provided in the form of a film sheet. Only after the individual layers have been laminated to form a laminated composite are the cards cut to a final format. Depending on the film dimensions, it is possible for a card to be in its final format even after lamination. Preferably, a strip of raw cards in ID 1, ID 2, ID 3, or some other format is provided in a subsequent cut-to-size strip. These formats are standardized, for example, by ISO 10373, ISO / IEC 7810, and ISO 14443.

[0003] The individual films can preferably be formed from a polymer selected from a group comprising polycarbonate (PC), in particular bisphenol A polycarbonate or a polycarbonate formed with a geminal disubstituted bis(hydroxyphenyl)cycloalkane, polyethylene terephthalate (PET), and derivatives thereof, such as glycol-modified PET (PETG), polyethylene naphthalate (PEN), polyvinyl chloride (PVC), polyvinyl butyral (PVB), polymethyl methacrylate (PMMA), polyimide (PI), polyvinyl alcohol (PVA), polystyrene (PS), polyvinylphenol (PVP), polypropylene (PP), polyethylene (PE), thermoplastic elastomers (TPE), in particular thermoplastic polyurethane (TPU), acrylonitrile-butadiene-styrene copolymer (ABS), and derivatives thereof. Furthermore, the individual films can also be made from several of these materials. They are preferably made of PC or PC / TPU / PC. The polymers can be either filled or unfilled.In the latter case, they are preferably transparent or translucent. If the polymers are filled, they are opaque. The film booklet comprising several films is preferably produced from three to twelve, preferably four to ten, films. The films can also carry printing layers. A laminate formed in this way can also be coated on one or both sides with a protective or topcoat varnish or with a protective film. The films can, in particular, comprise a volume hologram or a surface hologram (for example, a cinemagraphic element). They can also be a scratch-resistant film. Overlay layers formed in this way additionally impart the required abrasion resistance to the substrate.

[0004] When gathering the individual film layers, it can happen that more than one film is lifted from the stack when the films are lifted, meaning that a second film is dragged along. The reason for this is the adhesive forces that prevail between the individual films, which arise, for example, due to electrostatic charging. The individual films are then not always placed in the correct or desired position on the workpiece carrier. This leads to significant disruptions and waste in the subsequent lamination step. In addition, the laminating sheets of a laminating device can be damaged. The further production process can also be disrupted or even stopped due to films that are not placed correctly on the workpiece carrier, and in particular, further damage to the production system can occur.

[0005] It is therefore the object of the present invention to provide an arrangement and a method which take into account the disadvantages mentioned above.

[0006] This object is achieved by an arrangement having the features of claim 1 and by a method having the features of claim 6. Advantageous embodiments with expedient further developments are specified in the dependent claims.

[0007] The arrangement according to the invention for collating a plurality of films with identical edges on a workpiece carrier comprises a first film stack with first films and at least one second film stack with second films. There can also be more than two film stacks, for example three, four, five film stacks or more than five film stacks. In most cases, a maximum of 25 film stacks are present. The arrangement also comprises a workpiece carrier which is configured to receive a plurality of the films in stacked form, as well as a gripping device for removing one film at a time from the respective film stack and placing it on the workpiece carrier or on a film already present there.Furthermore, a sensor-based control device is provided which is configured to detect a contour of the stack of films on the workpiece carrier or a contour of the workpiece carrier itself in order to check whether there is an overhang due to an incorrectly taken film of the first film stack or the second film stack.

[0008] In this way, it is possible to determine before the lamination process whether an incorrectly stacked stack of individual films is present on the workpiece carrier, so that further processing can be stopped to avoid waste.

[0009] It is advantageous if a drive device is assigned to the workpiece carrier for intermittently adjusting the workpiece carrier along a trajectory which runs along all film stacks, wherein the trajectory provides a stop next to each of the film stacks at which the drive device of the workpiece carrier is temporarily stopped in order to remove a film from the film stack in question and to place it on the workpiece carrier or on a film already present there.

[0010] Thus, the workpiece carrier is moved along each foil stack, with each foil stack preferably being assigned its own gripping device, equipped, for example, with suction grippers. In this way, a foil booklet consisting of a plurality of foils is assembled on the workpiece carrier, which can later be laminated.

[0011] It has proven advantageous if the sensor-based inspection device is formed with a stationary line sensor, and if the contour can be detected by moving the workpiece carrier. However, it is also possible to hold the workpiece carrier stationary at one of its stops, in which case the line sensor is adjusted to detect the contour. Instead of a line sensor, for example, a camera-based contour inspection comprising a camera can be used, which optically detects the film sheet itself or the corresponding workpiece carrier and thus checks whether there is any overhang in the film sheet.

[0012] An overhang is a section of the contour that does not correspond to the usual specified contours, so that it can be determined that the overhang has led to incorrect stacking on the workpiece carrier.

[0013] It has proven advantageous to have an ejection station downstream of the film stacks, which is configured to eject the workpiece carrier and / or the stack of films on it when an overhang is detected. This prevents waste from being generated during the lamination process or even damage to the laminating sheets.

[0014] Furthermore, it is advantageous if a laminating station is arranged downstream of the film stacks, which is designed to combine the individual films of the stack present on the workpiece carrier into a laminate if no overhang has been detected.

[0015] The advantages, advantageous embodiments and technical effects explained in connection with the arrangement according to the invention apply equally to the method according to the invention.

[0016] The method according to the invention for assembling a plurality of films on a workpiece carrier with the same edges comprises in particular the following steps: - Providing a first stack of slides from the first slides; - Providing at least one second stack of second slides; - removing a first film from the first film stack by means of a gripping device and placing the removed first film on the workpiece carrier, - removing at least one second film from the second film stack by means of a gripping device and placing the removed second film onto the first film on the workpiece carrier, thereby forming a stack of films, thus a film booklet; and - Detecting a contour of the stack of films on the workpiece carrier or detecting a contour of the workpiece carrier itself by means of a sensor-based control device, and checking whether there is an overhang due to an incorrectly carried film of the first film stack or the second film stack.

[0017] Here, too, it is possible for more than two foil stacks to be present, and for more than two foils to be stacked on the workpiece carrier. The workpiece carrier preferably includes a positioning pin so that the individual foils are correctly aligned with each other and remain aligned.

[0018] The detection of exceeded or specified contours or dimensions of the film indicates multiple removal due to the excess detected by the sensor-based control device.

[0019] A particularly efficient process can be achieved by intermittently moving the workpiece carrier along a trajectory. The trajectory provides a stop next to each film stack, where the workpiece carrier temporarily stops and where a film from the respective stack is removed and placed on the workpiece carrier or on a film already present there. In this way, a film booklet is compiled on the workpiece carrier from all the films of the existing film stacks.

[0020] If the workpiece carrier is motor-adjustable, it has proven advantageous if the control device is formed with a stationary line sensor, and if the contour is detected by the movement of the workpiece carrier. The reverse variant would also be possible, whereby the workpiece carrier remains at one of its stops and the line sensor is moved relative to the stationary workpiece carrier in order to detect the contour of the film stack on the workpiece carrier or the contour of the workpiece carrier itself.

[0021] If rejects have been detected due to the presence of an overhang, it is preferable if the workpiece carrier and / or the stack of films on it are ejected at an ejection station, which is located downstream of the film stacks in particular.

[0022] In the opposite case, namely when no overhang has been detected, it is preferred that the individual films of the stack of films present on the workpiece carrier are combined to form a laminate at a laminating station.

[0023] This laminate can then be fed to the further process steps, for example, the laminate can comprise a plurality of individual identity card blanks, which are then punched or cut to their final dimensions.

[0024] It is generally noted that all features disclosed with respect to specific aspects or embodiments of the invention can also be combined with other aspects or embodiments of the invention in a technically reasonable manner. This also applies across different technical subject matters and subject matter categories. In particular, this also applies in part to individual features, unless explicitly stated herein or it is obvious from a technical contradiction that an inextricable functional-technical connection exists between certain features, which must be maintained to implement the invention.

[0025] The invention is explained below using an exemplary embodiment and its outline. Herein: Fig. 1 an arrangement for gathering, in particular with the same edges, a plurality of films on a workpiece carrier; Fig. 2 an illustration of the process steps of removing a film from a film stack by means of a gripping device and placing the removed film on the workpiece carrier, whereby this takes place without errors; Fig. 3 an illustration of the process steps of removing a film from a film stack by means of a gripping device and placing the removed film on the workpiece carrier, whereby this is carried out with errors; and Fig. 4 a bottom view of the workpiece carrier on which the foils are incorrectly positioned.

[0026] In Fig. 1 shows an arrangement 100 for collating a plurality of films 106, 110, 134 on a workpiece carrier 102 with their edges flush. Purely by way of example, a first film stack 104 with first films 106 and at least one second film stack 108 with second films 110 as well as five further film stacks 132 with further films 134 are provided. Each of the film stacks 104, 108, 132 is assigned a gripping device 112, which is implemented as a suction gripper ( Fig. 2 and Fig. 3).

[0027] Furthermore, several workpiece carriers 102 can be seen, which can be intermittently adjusted along a trajectory 122 using a drive device. The trajectory 122 has a stop 124 next to each of the film stacks 104, 108, 132, at which the drive device of the workpiece carrier 102 is temporarily stopped in order to remove a film 106, 110, 134 from the respective film stack 104, 108, 132 and place it on the workpiece carrier 102 or on a film 106, 110, 134 already present there. To ensure that the films 104, 108, 132 can be placed on the workpiece carrier 102 with their edges flush, a positioning pin, preferably even several of the positioning pins, is assigned to the workpiece carrier 102. In any case, each of the workpiece carriers 102 runs along the trajectory 122 in order to pick up a foil 106, 108, 134 from the respective foil stack 104, 108, 132, whereby a foil booklet is formed on the workpiece carrier 102.This foil booklet should then be laminated.

[0028] The arrangement 100 is additionally assigned a sensor-based control device 114, which is configured to detect a contour of the stack 116 of films 106, 110, 134 on the workpiece carrier 102 or a contour of the workpiece carrier 102 itself in order to check whether a protrusion 118 is present due to an incorrectly transported film 120 of the first film stack 104 or the second film stack 108 or one of the further film stacks 132. The control device 114 is preferably formed with a stationary line sensor 126, wherein the contour can be detected by the movement of the workpiece carrier 102. A camera-based contour check and an optical inspection for the presence of a protrusion 118 can also be used. It is also possible to use a light barrier as a sensor-based control device, wherein an interruption of the light barrier indicates the presence of a protrusion 118.

[0029] In any case, the arrangement 100 shown also has a laminating station 130, which is arranged downstream of the film stacks 104, 108, 132. The laminating station 130 is configured to combine the individual films 106, 110, 134 of the stack 116 present on the workpiece carrier 102 into a laminate. However, this only occurs if no overhang 118 has been detected by the sensor-based control device 114. If, however, such an overhang 118 has been detected, the stack 116 of films 104, 108, 134 or the workpiece carrier 102 itself is ejected at an ejection station 128, which is also arranged downstream of the film stacks 104, 108, 132.

[0030] Based on Fig. Figure 2 illustrates how the gripping device 112 removes a film 106, 110, 134 from a film stack 104, 108, 132 and places it on the workpiece carrier 102 or on a film 104, 108, 132 present there, or on a stack 116 present there. The gripping device 112 comprises a suction foot 136, in this case even several of the suction feet 136, in order to remove the respective film 106, 110, 134 individually from the film stack 104, 108, 132.

[0031] Fig. Figure 3 shows the situation in which this removal occurs incorrectly, namely because a film 120 that has been taken along adheres to the film 106, 110, 134 picked up by the gripping device 112, for example due to electrostatic charging. When the film 106, 110, 134 is placed on the workpiece carrier 102, the overhang 118 remains, which extends beyond the film stack, namely the stack 116, and in this case even extends beyond the contour of the workpiece carrier 102 itself. This overhang 118 can then be detected by the sensor-based control device 114, so that it can be concluded that the film stack has been incorrectly stacked on the workpiece carrier 102. A stack 116 formed in this way, in which an overhang 118 is present, is then discharged from the process via the discharge station 128, thus avoiding the production of further rejects or the damage of other constituents of the production plant.

[0032] In Fig. 4 is finally a bottom view of a workpiece carrier 102 from Fig. 3, in which the overhang 118 beyond the contour of the workpiece carrier 102 can be detected, so that incorrect stacking on the workpiece carrier 102 can be concluded here as well; this can also prevent rejects. In other words, the invention takes advantage of the fact that it is detected at an early stage whether the foil booklet or the stack 116 on the workpiece carrier 102 is faulty, to which an immediate response can then be made. List of reference symbols 100 arrangement 102 workpiece carriers 104 first stack of slides 106 first slide 108 second stack of slides 110 second slide 112 gripping device 114 Control device 116 stacks (on workpiece carrier) 118 overhang 120 foils taken 122 Trajectory 124 stop 126 line sensor 128 Discharge station 130 Laminating station 132 additional slide stacks 134 more slides 136 suction cups

Claims

[1] Arrangement (100) for the edge-aligned collation of a plurality of films (106, 110, 134) on a workpiece carrier (102), comprising a first film stack (104) with first films (106) and at least one second film stack (108) with second films (110), a workpiece carrier (102) which is configured to receive a plurality of the films (106, 110) in a stacked manner, at least one gripping device (112) for removing one film (106, 110) from each of the film stacks (104, 108) and placing it on the workpiece carrier (102) or on a film (106) already present there, and a sensor-based control device (114) which is configured to detect a contour of the stack (116) of films (106, 110, 134) on the workpiece carrier (102) or a contour of the workpiece carrier (102) to detect itself and to check whether there is an overhang (118) due to an incorrectly taken film (120) of the first film stack (104) or the second film stack (108). [2] Arrangement (100) according to claim 1, characterized by in that a drive device is assigned to the workpiece carrier (102) for intermittently adjusting the workpiece carrier (102) along a trajectory (122) which runs along all of the film stacks (104, 108, 132), wherein the trajectory (122) provides a stop (124) next to each of the film stacks (104, 108, 132), at which the drive device of the workpiece carrier (102) is temporarily stopped in order to remove a film (106, 110, 134) from the relevant film stack (104, 108, 132) and to place it on the workpiece carrier (102) or on a film (106, 110, 134) already present there. [3] Arrangement (100) according to claim 2, characterized by that the control device (114) is formed with a stationary line sensor (126), and that the contour can be detected by the movement of the workpiece carrier (102). [4] Arrangement (100) according to one of claims 1 to 3, characterized bythat the film stacks (104, 108, 132) are followed by an ejection station (128) which is designed to eject the workpiece carrier (102) and / or the stack (116) of films (104, 108, 134) present thereon when the presence of an overhang (118) has been detected. [5] Arrangement (100) according to one of claims 1 to 4, characterized by in that a laminating station (130) is arranged downstream of the film stacks (104, 108, 132), which laminating station is designed to combine the individual films (106, 110, 134) of the stack (116) present on the workpiece carrier (102) to form a laminate if no presence of an overhang (118) has been detected. [6] Method for assembling a plurality of films (106, 110, 134) on a workpiece carrier (102) with the same edges, comprising the following steps: - Providing a first foil stack (104) of first foils (106); - Providing at least one second foil stack (108) made of second foils (110); - removing a first film (106) from the first film stack (104) by means of a gripping device (112) and placing the removed first film (106) on the workpiece carrier (102), - removing at least one second film (110) from the second film stack (108) by means of a gripping device (112) and placing the removed second film (110) onto the first film (106) on the workpiece carrier (102), whereby a stack (116) of films (106, 110, 134) is formed; and - detecting a contour of the stack (116) of films (106, 110, 134) on the workpiece carrier (102) or detecting a contour of the workpiece carrier (102) itself by means of a sensor-based control device (114), and checking whether there is an overhang (118) due to an incorrectly carried film (120) of the first film stack (104) or the second film stack (108). [7] Method according to claim 6, characterized by in that the workpiece carrier (102) is intermittently adjusted along a trajectory (122), wherein the trajectory (122) provides a stop (124) next to each of the film stacks (104, 108, 132), at which the workpiece carrier (102) stops temporarily, and at which a film (106, 110, 134) of the relevant stack (104, 108, 132) is removed and placed on the workpiece carrier (102) or on a film (106, 110, 134) already present there. [8] Method according to claim 7, characterized by that the control device (114) is formed with a stationary line sensor (126), and that the contour is detected by the movement of the workpiece carrier (102). [9] Method according to one of claims 6 to 8, characterized bythat the workpiece carrier (102) and / or the stack (116) of films (106, 110, 134) present thereon is discharged at a discharge station (128) when the presence of an overhang (118) has been detected. [10] Method according to one of claims 6 to 9, characterized by that the individual films (106, 110, 134) of the stack (116) of films (106, 110, 134) present on the workpiece carrier (102) are combined to form a laminate at a laminating station (130) if no presence of an overhang (118) has been detected.

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