Product processing system

Abstract

To provide a product processing system which can inhibit deterioration of the production capacity of an entire production line when including a plurality of product processing devices.SOLUTION: A packaging system S includes: an upstream side packaging device 1A and a downstream side packaging device 1B; an upstream side pusher 30A and a downstream side pusher 30B which respectively send products P1 transported by a first transport conveyor 10 to the upstream side packaging device 1A and the downstream side packaging device 1B; and a system controller 60 which controls the upstream side pusher 30A and the downstream side pusher 30B. The system controller 60 sends the products P1 to the upstream side packaging device 1A and the downstream side packaging device 1B when a planned number of the products to be produced for one shop is higher than or equal to a threshold value and sends the products P1 only to the downstream side packaging device 1B when the planned number of the products to be produced for the one shop is lower than the threshold value.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a merchandise processing system. [Background technology]

[0002] Patent Document 1 below discloses a packaging device that transports weighed products on a conveyor, transfers the products to an elevator installed inside and raises them, pushes the products up against a film stretched above the elevator, and folds the edge of the film covering the products into the bottom of the products to package them. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 9-183420 Summary of the Invention [Problem to be solved by the invention]

[0004] Because the technology in Patent Document 1 has limitations in terms of processing capacity, a system is being considered in which two of these devices are installed side by side to significantly increase the processing capacity of a single line. With this system, multiple products that are conveyed one after another are supplied to one of the packaging machines, packaged, and discharged, but because the operating cycles of the packaging machines are not synchronized, products that are supplied later may be discharged earlier than products that were supplied earlier, which can result in the conveying order being reversed on the downstream conveyor.

[0005] For example, when packaging a large number of products for each store, when the store switches, the conveying order on the downstream conveyor may be reversed, resulting in packaged products for the preceding store being mixed with packaged products for a subsequent store. To avoid this mixing, measures are taken such that once the planned number of products for one store has been supplied, the supply of products to each packaging machine is temporarily stopped (after a time interval), and after all products have been discharged from each packaging machine, products for the next store are sent to each packaging machine.

[0006] However, with the above method, when the number of items to be processed (or the number of items produced) per store is small, the time interval between stores has a significant impact, which can actually reduce the production capacity of the entire production line. Therefore, the present invention aims to provide a product processing system that can prevent a reduction in the production capacity of the entire production line when multiple product processing devices (e.g., packaging devices) are installed. [Means for solving the problem]

[0007] (1) A product processing system according to one aspect of the present invention is a product processing system that, when processing of the planned number of products for one store has been completed, switches to processing for the next store and processes the planned number of products for the next store, and comprises a first conveying section that conveys products; a plurality of product processing devices that are arranged in parallel along the conveying direction of the first conveying section and perform predetermined processing on the products; a plurality of feeding sections that are provided in each of the plurality of product processing devices and feed the products conveyed by the first conveying section into each of the plurality of product processing devices; a second conveying section that receives processed products discharged from each of the plurality of product processing devices and conveys them downstream; and a control section that controls the plurality of feeding sections; when the planned number of products for one store is equal to or greater than a predetermined number, the control section controls the plurality of feeding sections to feed the products to each of the plurality of product processing devices, and when the planned number of products for one store is less than the predetermined number, the control section controls the plurality of feeding sections to feed the products to only some of the plurality of product processing devices.

[0008] According to the product processing system described in (1) above, for stores with a planned production volume equal to or greater than a predetermined number, production is carried out using all of the multiple product processing devices, resulting in a high production capacity for that store. Furthermore, for stores with a planned production volume less than the predetermined number (i.e., stores that produce in small lots), production is carried out using only some of the product processing devices, reducing the waiting time required to switch to processing for the next store. As a result, a decline in the production capacity of the entire production line can be prevented.

[0009] (2) In the product processing system described in (1) above, the control unit may have a total number acquisition unit that acquires the total number of products sent by the multiple sending units. When the control unit controls the multiple sending units to send products to each of the multiple product processing devices, the control unit may stop sending products by the sending units when the total number reaches the planned production quantity for one store, and resume sending products by the sending units after the processed products have been discharged from the multiple product processing devices. In this case, it is possible to prevent processed products from different stores from being mixed together downstream.

[0010] (3) In the product processing system of (1) or (2), the control unit may have a planned quantity acquisition unit that acquires the planned production quantities set for each of the multiple stores. The control unit may then rearrange the production sequence for the multiple stores according to the size of each planned production quantity, and then control the sending unit. In this case, work efficiency downstream of the production line can be improved. [Effects of the Invention]

[0011] According to the present invention, when a system includes a plurality of product processing devices, it is possible to prevent a decrease in the production capacity of the entire production line. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 is a perspective view of a packaging system according to one embodiment. [Figure 2] FIG. 2 is a plan view of the packaging system of FIG. [Figure 3] FIG. 3 is a block diagram of the packaging system of FIG. [Figure 4] FIG. 4 is a diagram for explaining an example of production in the packaging system of FIG. [Figure 5] FIG. 5 is a diagram for explaining another production example in the packaging system of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0013] A packaging system (product processing system) S according to one embodiment will be described below with reference to the drawings. In the description of the drawings, identical elements are given the same reference numerals, and duplicated explanations will be omitted. In the following description, the terms "upper" and "lower" correspond to the vertical direction as shown in FIG. 1, and the terms "upstream" and "downstream" refer to the upstream and downstream sides in the conveying direction D1 of the product P1. In addition, the upstream side of the conveying direction D1 in FIGS. 1 and 2 may be referred to as the left side, and the downstream side of the conveying direction D1 may be referred to as the right side.

[0014] First, the basic configuration of a packaging system S according to this embodiment will be described with reference to Figures 1 to 3. A product P1 to be weighed and packaged in the packaging system S comprises, for example, a tray and food placed or contained on the tray. The packaging system S is a device that weighs the product P1, packages the product P1, issues a printed label on which information about the product P1 is printed, and affixes the printed label to the top surface of the packaged product P1.

[0015] The packaging system S comprises a first transport conveyor (first transport section) 10, an upstream packaging device (product processing device) 1A and a downstream packaging device (product processing device) 1B arranged in one direction, a second transport conveyor (second transport section) 20, a feed section 30, and a system controller (control section) 60.

[0016] The first transport conveyor 10 sequentially transports (supplies) a plurality of products P1 in the one direction (hereinafter also referred to as the transport direction D1). The first transport conveyor 10 includes a first conveyor 11, a second conveyor 12, a third conveyor 13, a fourth conveyor 16, a fifth conveyor 17, and a sixth conveyor 18, to which the products P1 are supplied. The first conveyor 11, the second conveyor 12, the third conveyor 13, the fourth conveyor 16, the fifth conveyor 17, and the sixth conveyor 18 are arranged in this order from upstream to downstream, and each has a well-known configuration as a belt conveyor. The transport surfaces of these conveyors are arranged on the same plane. Note that the number of conveyors constituting the first transport conveyor 10 is not limited to the above.

[0017] The second conveyor 12 is provided with a first sensor 12A that detects the product P1. The fourth conveyor 16 is provided with a second sensor 16A that detects the product P1. The first sensor 12A and the second sensor 16A each consist of, for example, a light-emitting unit and a light-receiving unit, and detect the presence or absence of a product based on whether the light-receiving unit receives light emitted from the light-emitting unit. The detection results of the first sensor 12A and the second sensor 16A are acquired by an information acquisition unit 61 of the system controller 60, which will be described in detail later.

[0018] The upstream packaging device 1A and the downstream packaging device 1B are weighing, packaging, and pricing devices having, for example, substantially the same functions. Therefore, in the following explanation, the configuration of one of the packaging devices (for example, the upstream packaging device 1A) will be explained as a representative, and explanations of the configurations that overlap between both packaging devices may be omitted.

[0019] An upstream packaging device 1A and a downstream packaging device 1B (hereinafter also referred to as packaging devices 1A, 1B) are arranged side by side along the one direction (conveying direction D1). Each packaging device 1A, 1B includes a weighing unit 2, a packaging unit 3, a printing unit (label issuing unit) 4, an application unit (label application unit) 5, and a device controller 6. Each packaging device 1A, 1B is a weighing, packaging, and pricing device that performs weighing, packaging, and pricing processes (weighing, packaging, and pricing processes: predetermined processes) on products P1. The upstream packaging device 1A and the downstream packaging device 1B have, for example, the same processing capacity per unit time as weighing, packaging, and pricing devices.

[0020] The upstream packaging device 1A includes a main housing 41A and an upstream accessory housing 42A that houses a film roll 9A. The downstream packaging device 1B includes a main housing 41B and a downstream accessory housing 42B that also houses a film roll 9B. Each packaging device 1A, 1B has an accessory housing 42A, 42B that houses the film rolls 9A, 9B, located outside the adjacent main housing 41A, 41B. Note that the mechanisms of each packaging device 1A, 1B have the same function and configuration except for being arranged in opposite directions. Therefore, in this specification, the modifiers "upstream" and "downstream" may be omitted from the terms "packaging device," "main housing," "accessory housing," and the "pusher" and "film roll" described below.

[0021] In each packaging device 1A, 1B, the weighing unit 2, packaging unit 3, and device controller 6 are mainly located inside the main housing 41A, 41B, while the printing unit 4 of the label printer and the label application unit 5 consisting of a label application machine are located above the packaging unit 3. Each packaging device 1A, 1B has a supply opening 43 at the front center of the main housing 41A, 41B for carrying products P1 into the device, and a discharge opening 44 at the top center of the front of the main housing 41A, 41B for discharging processed products P2 that have been packaged and labeled. In each packaging device 1A, 1B, the height of the supply opening 43 is approximately equal to the height of the conveying surface of the first transport conveyor 10, for example.

[0022] The weighing unit 2 is provided in the center of the front of the main housings 41A, 41B (at the supply port 43). The weighing unit 2 has a weighing platform (not shown) that weighs the mass of the product P1 when loaded by a load sensor such as a load cell, and a weighing conveyor 2a that transports the product P1 placed on the weighing platform to the packaging unit 3. When the product P1 is placed on the weighing platform, the mass of the product P1 is measured by the load sensor, and when the measured value stabilizes, the weighing conveyor 2a is driven to transport the product P1 to the packaging unit 3. The transport direction of the product P1 by the weighing conveyor 2a is the same as the supply direction D2 by the upstream pusher 30A and downstream pusher 30B described below, which is, for example, the front-to-back direction in the figure.

[0023] The packaging unit 3 has a lift mechanism that lifts the product P1 received from the weighing unit 2 to the packaging position, a film roll support mechanism that supports the film roll 9A or film roll 9B, a film delivery mechanism that delivers the stretch film pulled out from the film rolls 9A and 9B to the packaging position, a folding mechanism that folds the stretch film lifted together with the product P1 by the lift mechanism onto the bottom side of the product P1 at the packaging position, and a sealing mechanism that heat-seals the overlapping portion of the folded film (all not shown).

[0024] The packaging section 3 of each packaging device 1A, 1B includes film rolls 9A, 9B housed in accessory housings 42A, 42B. The film rolls 9A, 9B are arranged with their respective axes aligned along the supply direction D2. However, the two film rolls 9A, 9B are attached in opposite positions and orientations. As a result, the upstream packaging device 1A pays out film from the film roll 9A in the conveying direction D1 (i.e., to the right), while the downstream packaging device 1B pays out film from the film roll 9B in the direction opposite to the conveying direction D1 (i.e., to the left).

[0025] The printing unit 4 issues a printed label by printing product information about the product P1 and store information about the store (for example, the store name and the price for that store) on a label fed from a label roll. The printing unit 4 issues a printed label based on the information about the product P1 displayed on the operation display units 7A and 7B. The label may be a liner-attached label, or a linerless label that is not affixed to a liner.

[0026] The application unit 5 receives the label issued by the printing unit 4 and applies it to the top surface of the packaged product P1. To this end, the application unit 5 has an application head that receives the printed label at a label issuing port and transports it above the packaged product P1 to apply the label. The processed product P2 to which the label has been applied by the printing unit 4 and application unit 5 is discharged from the discharge port 44 onto the second transport conveyor 20 by a push-out mechanism (not shown).

[0027] The device controller 6 is configured as a computer, and controls various operations in each of the packaging devices 1A, 1B by reading and executing stored programs. This computer is configured, for example, with a processor such as a CPU (Central Processing Unit), a ROM (Read Only Memory), and a RAM (Random Access Memory). The device controller 6 also controls various operations in the packaging system S. The control of the packaging system S by the device controller 6 will be described in detail later.

[0028] For example, operation display units 7A, 7B are attached to the sides of the main housings 41A, 41B. Each operation display unit 7A, 7B is configured as a touch panel on which various information necessary for operation can be set, such as the product call number, the operating speed of each packaging device 1A, 1B, the transport speed (throughput per unit time) of the first transport conveyor 10, and the packaging size of the product P1. Each operation display unit 7A, 7B may also have physical buttons or the like for operation.

[0029] Each operation display unit 7A, 7B basically operates the corresponding packaging device 1A, 1B individually, but they are capable of wired or wireless communication, and from one of the operation display units 7A, 7B of the packaging devices 1A, 1B, it is possible to specify both packaging devices 1A, 1B, set their operating conditions, and start their operation simultaneously. In addition, various information set on the operation display unit 7A or operation display unit 7B is transmitted to the device controller 6 of the specified packaging device 1A, 1B.

[0030] Each packaging device 1A, 1B configured as described above lifts up products P1 supplied in the supply direction D2 to wrap them in film, and then sends the processed products P2 wrapped in film in the opposite direction (i.e., forward) D3 to the supply direction D2, where they are delivered to the second transport conveyor 20. In each packaging device 1A, 1B, the weighing unit 2 sequentially weighs multiple products P1, and the weighed products P1 are packaged and labeled in a predetermined cycle by the packaging unit 3, printing unit 4, and labeling unit 5. Therefore, in each packaging device 1A, 1B, the processing cycle from when one product P1 is supplied to the supply opening 43 to when the processed product P2 emerges from the discharge opening 44 is substantially the same.

[0031] The second transport conveyor 20 receives the multiple processed products P2 discharged from each of the packaging devices 1A and 1B and transports them sequentially downstream. The second transport conveyor 20 transports the processed products P2, for example, in the same (parallel) transport direction D1 as the first transport conveyor 10. The second transport conveyor 20 includes a first conveyor 21 located in front of the upstream packaging device 1A, an intermediate conveyor 22 located downstream (to the right of) the first conveyor 21, a second conveyor 23 located in front of the downstream packaging device 1B, and a discharge conveyor 26 located downstream (to the right of) the first conveyor 21. The first conveyor 21, intermediate conveyor 22, second conveyor 23, and discharge conveyor 26 are arranged in series from upstream to downstream, in this order, and each has a known belt conveyor configuration, thereby sequentially transporting the multiple processed products P2 in the transport direction D1. The transport surfaces of these multiple conveyors are maintained on the same plane. A transport conveyor 52 is provided downstream of the discharge conveyor 26 to send the products to a further downstream delivery line.

[0032] A third sensor 26A that detects processed products P2 is provided on the discharge conveyor 26. The third sensor 26A is composed of, for example, a light-emitting unit and a light-receiving unit, and detects the passage of processed products P2 based on whether the light-receiving unit receives light emitted from the light-emitting unit. The number of processed products P2 that have passed the third sensor 26A is counted by an information acquisition unit 61 of the system controller 60, which will be described in detail later.

[0033] In each of the packaging devices 1A, 1B, the height of the discharge outlet 44 is, for example, approximately equal to the height of the conveying surface of the second transfer conveyor 20. The conveying surface of the second transfer conveyor 20 is higher than the conveying surface of the first transfer conveyor 10. Furthermore, the second transfer conveyor 20 is disposed at a different position from the first transfer conveyor 10 in a plan view. In other words, the second transfer conveyor 20 is disposed at a different level from the first transfer conveyor 10. More specifically, the second transfer conveyor 20 is parallel to the first transfer conveyor 10 in a plan view, and is disposed between the packaging device 1A, 1B and the first transfer conveyor 10 in the front-to-rear direction.

[0034] The feeding section 30 is provided in each packaging device 1A, 1B and feeds the products P1 conveyed by the first transfer conveyor 10 into each packaging device 1A, 1B. The feeding section 30 includes an upstream pusher 30A that feeds the products P1 conveyed by the first transfer conveyor 10 in the feed direction D2 to supply them to the upstream packaging device 1A, and a downstream pusher 30B that feeds the products P1 conveyed by the first transfer conveyor 10 in the feed direction D2 to supply them to the downstream packaging device 1B.

[0035] The upstream pusher 30A and the downstream pusher 30B (hereinafter also referred to as pushers 30A and 30B) are provided at the same height above the conveying surface of the first transfer conveyor 10. The pushers 30A and 30B are provided at a position higher than the conveying surface of the first transfer conveyor 10 and lower than the conveying surface of the second transfer conveyor 20. The direction in which the pushers 30A and 30B send out the products P1, i.e., the supply direction D2, is, for example, horizontal and perpendicular to the conveying direction D1.

[0036] The upstream pusher 30A includes, for example, a guide unit 31 that is provided on the first transport conveyor 10 or the main housing 41A and extends in the front-rear direction, and a slide unit 32 that is movable in the front-rear direction along the guide unit 31 by a front-rear drive unit including a motor or the like. The upstream pusher 30A also includes, for example, an arm unit 34 that is fixed to the slide unit 32 and extends horizontally upstream (to the left), and a pusher plate 35 that is provided at the tip of the arm unit 34 and is movable in the up-down direction by a lift drive unit including a motor or the like. That is, the upstream pusher 30A includes a pusher plate 35 that is movable on two axes, that is, in the front-rear direction and the up-down direction.

[0037] The pusher plate 35 extends in the vertical and horizontal directions (i.e., directions perpendicular to the supply direction D2) and abuts against the product P1 on the first transport conveyor 10, sending (pushing) the product P1 in the supply direction D2, i.e., backward. The pusher plate 35 moves backward while lowered to its lowest position, transfers the product P1 onto the weighing conveyor 2a, and then rises to its highest position where it does not interfere with the product P1. The pusher plate 35 then moves forward while maintaining the level of the highest position, and then descends to its lowest position to wait for the next supply operation. In this way, the pusher plate 35 of the upstream pusher 30A moves while tracing a rectangular trajectory in a vertical plane along the supply direction D2.

[0038] The downstream pusher 30B is configured to be opposite to the upstream pusher 30A, for example, but the operation of the arm portion 34 and the pusher plate 35 is the same as that of the upstream pusher 30A.

[0039] The pushers 30A and 30B are controlled by a system controller 60. The system controller 60 is configured, for example, by a computer including a processor such as a CPU, a ROM, and a RAM. The system controller 60 realizes various functions by, for example, loading a program stored in the ROM onto the RAM and executing it on the CPU. As a result, the system controller 60 forms an information acquisition unit (acquisition unit) 61 that executes various processes in the packaging system S, a conveyor control unit 62, and a pusher control unit (control unit) 63, as shown in FIG. 3. The system controller 60 further includes a memory unit 65. The memory unit 65 is configured, for example, by a RAM, an SSD (Solid State Drive), an HDD (Hard Disk Drive), etc.

[0040] In this embodiment, the device controller 6 of the downstream packaging device 1B has the functions of the system controller 60. In a configuration including two packaging devices 1A and 1B, the downstream packaging device 1B, which is the packaging device that has the functions of the system controller 60, is referred to as the parent device, and the upstream packaging device 1A, which is the packaging device that does not have the functions of the system controller 60, is referred to as the child device.

[0041] The information acquisition unit 61 detects the operating status (e.g., whether the packaging devices 1A and 1B are operating or stopped). The information acquisition unit 61 also acquires a first number N1, which is the total number of products P1 sent by the upstream pusher 30A and the downstream pusher 30B. For example, the information acquisition unit 61 acquires the number of products P1 sent to the downstream packaging device 1B based on the detection results of the second sensor 16A, and acquires the number of products P1 sent to the upstream packaging device 1A based on the detection results of the first sensor 12A and the second sensor 16A (i.e., by calculating the difference between the number of products P1 detected by the first sensor 12A and the number of products P1 detected by the second sensor 16A). The first number N1 is the sum of the number of products P1 sent to the upstream packaging device 1A and the number of products P1 sent to the downstream packaging device 1B. The information acquisition unit 61 also acquires a second number N2, which is the total number of processed products P2 transported by the second transport conveyor 20. The information acquisition unit 61 calculates the second number N2 based on the detection result of the third sensor 26A.

[0042] The conveyor control unit 62 controls the conveying speeds of the first transfer conveyor 10 and the second transfer conveyor 20 based on the operating speed (processing amount per unit time) set from the operation display units 7A and 7B. The conveyor control unit 62 may adjust the conveying speed of the first transfer conveyor 10 (at least one or all of the first conveyor 11, second conveyor 12, third conveyor 13, fourth conveyor 16, and fifth conveyor 17) depending on the operating state of the packaging devices 1A and 1B.

[0043] The conveyor control unit 62 may control the conveying operation of the second transfer conveyor 20 (at least one or all of the first conveyor 21, intermediate conveyor 22, second conveyor 23, and discharge conveyor 26) depending on the operating status of the packaging devices 1A, 1B. The conveyor control unit 62 controls the conveying operation of the intermediate conveyor 22 so that processed products P2 transferred from the intermediate conveyor 22 to the second conveyor 23 do not collide with processed products P2 transferred from the downstream packaging device 1B to the second conveyor 23 on the second conveyor 23. The conveyor control unit 62 may also adjust the conveying speeds of the first transfer conveyor 10 and the second transfer conveyor 20 depending on the feeding status of the pushers 30A, 30B.

[0044] The pusher control unit 63 controls the upstream pusher 30A and the downstream pusher 30B. More specifically, the pusher control unit 63 controls the feeding of the product P1 conveyed by the first transport conveyor 10 by the upstream pusher 30A and the downstream pusher 30B.

[0045] In the packaging system S of this embodiment, the planned production quantity for each store of a certain product is stored in the memory unit 65. When there are multiple types of products, the planned production quantity for each store is stored for each product. The planned production quantity for each store is, for example, information such as 1 unit for a specific product in store A and 10 units for store B (see FIG. 4). The planned production quantity for each store may be set (input) by an operator via the operation display unit 7A or 7B and stored in the memory unit 65, or may be transmitted via a network from a server or the like that stores the planned production quantities for multiple products for each store. The information stored in the memory unit 65 includes, in addition to the planned production quantity for each product in each store, information such as the name of each store and a special price (special offer) set for a certain store. The memory unit 65 may store information on, for example, 100 or more stores.

[0046] The packaging system S is configured to switch to weighing, packaging, and pricing for the next store after completing weighing, packaging, and pricing for the planned production quantity for one store. In particular, this embodiment employs two operating modes: dual operation, in which both packaging devices 1A and 1B are in operation (i.e., parent-child production or dual production), and single operation, in which only the downstream packaging device 1B is in operation (i.e., parent-only production or single-side production). The system controller 60 determines whether dual operation or single operation should be performed for each store based on the planned production quantity for each store. Specifically, the pusher control unit 63 controls the upstream pusher 30A and the downstream pusher 30B to implement either of the above operations. In other words, when switching from weighing, packaging, and pricing for one store to weighing, packaging, and pricing for the next store, the system controller 60 switches the number of operating devices depending on the planned production quantity for each store. The operation control by the system controller 60 will be described in detail below.

[0047] 4 is a diagram illustrating an example of production in the packaging system S. A threshold value (predetermined number) related to the planned production quantity for the above-mentioned determination is stored in the storage unit 65. This threshold value may be determined in advance based on the operating performance (empirical rule) of the packaging system S, or may be determined by calculation based on other operating conditions, etc.

[0048] If the threshold value is predetermined, the threshold value may be set (input) by an operator via the operation / display unit 7A or 7B and stored in the memory unit 65. If the threshold value is determined by calculation, the threshold value may be determined by the system controller 60 based on the production capacity (production capacity per unit) of each packaging device 1A, 1B and the downtime required when two packaging devices are operated (described later), and may be stored in the memory unit 65. The production capacity per unit is the number of weighing, packaging, and pricing processes that can be performed per minute. The processing cycle is the time required for one weighing, packaging, and pricing process and is calculated by dividing 60 seconds (i.e., one minute) by the production capacity. If each packaging device 1A, 1B is compatible with high-speed specifications, the production capacity will be greater and the processing cycle will be shorter than if it is compatible with low-speed specifications. The system controller 60 determines the threshold value by calculation based on, for example, the production capacity and the downtime required when two packaging devices are operated.

[0049] When two machines are operating to process N items simultaneously, one packaging machine will process them (N / 2) times. For example, if the processing time for one machine to process one item is t [hours], then the processing time for two machines to process N items will be (N / 2) times x t [hours]. However, if N is an odd number, then it will take ((N+1) / 2) times x t [hours]. And when two machines are operating, if the time to switch stores (downtime) after processing N items is A [hours], then the processing time for two machines operating is (i) If N is an even number, it takes (N / 2)t+A [time]. (ii) If N is odd, it takes ((N+1) / 2)t+A [hours]. On the other hand, when processing N items using one machine, the processing time is N times x t [hours].

[0050] Therefore, when comparing the processing times for two-machine operation and one-machine operation, (i) When N is an even number, if (N / 2)t+A>Nt ∴ A>Nt / 2 holds, then the processing time will be shorter when two units are operated simultaneously. (ii) When N is odd, ((N+1) / 2)t+A>Nt ∴ A>(N-1)t / 2 If this holds, the processing time for simultaneous operation of two units will be shorter. Therefore, if the above t [time] and A [time] are calculated in advance during test operation, the above threshold value can be set.

[0051] When the planned production quantity for one store is equal to or greater than the threshold, the pusher control unit 63 controls the pushers 30A and 30B to send the product P1 to each packaging device 1A and 1B. In this two-machine operation, the pusher control unit 63 executes both the upstream pusher 30A to send the product P1 and the downstream pusher 30B to send the product P1. When the planned production quantity for one store is less than the threshold (in the case of a store that produces small lots), the pusher control unit 63 controls the pushers 30A and 30B to send the product P1 only to the downstream packaging device 1B (i.e., the parent machine). In this single-machine operation, the pusher control unit 63 stops the upstream pusher 30A so that the upstream pusher 30A does not send the product P1. The pusher control unit 63 operates only the downstream pusher 30B, and executes only the sending of the product P1 by the downstream pusher 30B. In the example shown in FIG. 4, the threshold is three.

[0052] The operation modes (production methods) for two-machine operation and one-machine operation will be described in detail. As described above, the information acquisition unit 61 acquires the first number N1, which is the total number of products P1 sent by the upstream pusher 30A and the downstream pusher 30B. The information acquisition unit 61 functions as a total number acquisition unit that acquires the total number of products P1 sent by the upstream pusher 30A and the downstream pusher 30B. If the total number exceeds a threshold, the system controller 60 sets printing information such as the store name and price of the one store to be processed in the printing unit 4 of each packaging device 1A, 1B.

[0053] First, a case where two pushers are operated for the store will be described. Each pusher 30A, 30B is controlled by a pusher control unit 63, and sequentially supplies products P1 conveyed by the first transport conveyor 10 to each packaging device 1A, 1B. When the pusher control unit 63 determines that the first number N1 has reached the planned production number preset for each store, it stops the pushers 30A, 30B from feeding the products P1 (stop control). When the pusher control unit 63 executes stop control, the conveyor control unit 62 may stop the first transport conveyor 10 from conveying the products P1, or may cause the products P1 to be conveyed at a slower speed than the conveying speed before the pusher control unit 63 executed the stop control.

[0054] Meanwhile, the processed products P2 sent from each packaging device 1A, 1B to the second transport conveyor 20 are detected by the third sensor 26A. The number of times this detection is detected is acquired by the information acquisition unit 61 as the second number N2. When the pusher control unit 63 determines that the second number N2 has reached the planned production number preset for each store, it reads the planned production number for the next store from the memory unit 65 and resumes control of the pushers 30A, 30B according to the operation mode of the next store (two-machine operation or single-machine operation) (resume control). At the same time, the system controller 60 sets the printing information of the next store, such as the store name and price, in the printing unit 4 of each packaging device 1A, 1B. The conveyor control unit 62 also resumes operation of the first transport conveyor 10, which had been stopped.

[0055] That is, when two machines are operated, the pusher control unit 63 stops the pushers 30A, 30B from sending products P1 when the first number N1 reaches the planned production quantity for one store. The device controllers 6 of each packaging device 1A, 1B eject the processed products P2 from the packaging devices 1A, 1B. The pusher control unit 63 then resumes sending products P1 by both pushers 30A, 30B (if the planned production quantity for the next store is equal to or greater than the threshold). Alternatively, the pusher control unit 63 resumes sending products P1 by only the downstream pusher 30B (if the planned production quantity for the next store is less than the threshold).

[0056] As described above, when two-machine operation ends, the above-mentioned stop control and subsequent restart control are executed to prevent processed products P2 that have been weighed, packaged, and priced for one store from being mixed with processed products P2 that have been weighed, packaged, and priced for the next store from being mixed on the second transport conveyor 20. In other words, control is executed to prevent processed products from different stores from being mixed. As a result, when two-machine operation ends, a certain amount of stop time inevitably occurs before operation for the next store begins.

[0057] On the other hand, when single-machine operation is performed for a single store to be processed, even if product P1 is placed on the second conveyor 12 or third conveyor 13 near and upstream of the upstream packaging device 1A, the pusher control unit 63 stops the upstream pusher 30A and does not supply product P1 to the upstream packaging device 1A. The pusher control unit 63 operates only the downstream pusher 30B. Therefore, the product P1 passes through the upstream pusher 30A and is supplied to the downstream packaging device 1B by the downstream pusher 30B. Even if the pusher control unit 63 determines that the first quantity N1 has reached the planned production quantity preset for each store, it does not execute stop control as it does when dual-machine operation ends. Instead, it reads the planned production quantity for the next store from the memory unit 65 and transitions to control the pushers 30A and 30B according to the operation method (dual-machine operation or single-machine operation) of the next store. In other words, even if the second quantity N2 has not reached the planned production quantity (without waiting for it to reach that number), the system controller 60 starts operation for the next store. No transport stop control or slow-speed transport control is performed on the first transport conveyor 10. In this way, with single-machine operation, the order of the products P1 (processed products P2) is maintained, and there is no possibility of processed products P2 from different stores being mixed together, so no downtime is required when the single-machine operation ends.

[0058] Next, an example of production in the packaging system S will be described with reference to Figure 4. As shown in Figure 4, the storage unit 65 of the system controller 60 stores the planned production quantities for each type of product for multiple stores (e.g., 100 or more stores). For example, the planned production quantities for multiple stores are stored together with a predetermined production sequence. For simplicity of explanation, Figure 4 shows a production example where there are 10 stores.

[0059] When the preceding process of placing products on trays transmits information indicating that the next product P1 to be conveyed is the product in question, the operator operates the operation display unit 7B of the parent machine to access the product information. Alternatively, if the production order quantity for each store for the next product P1 is transmitted from the store server, the system controller 60 retrieves the planned production quantity for that product and the store name for all stores from the storage unit 65. The system controller 60 determines whether each store is operating in a two-machine or one-machine mode. For example, in the example shown in FIG. 4, the threshold is three units. Therefore, stores with a planned production quantity of three or more units are normal lot stores, and stores with a planned production quantity of less than three units, i.e., two units or less, are small lot stores. Therefore, it is determined that store a with a small lot will operate in a one-machine mode, store b with a normal lot will operate in a two-machine mode, and store c with a small lot will operate in a single-machine mode. When the product is conveyed by the first conveyor 10, the pushers 30A and 30B are controlled according to the operation mode (two-machine or single-machine mode) of each store. As a result, each of the packaging devices 1A and 1B weighs, packages, and prices the products, and sends them out to the second transfer conveyor 20.

[0060] According to the packaging system S of this embodiment, for stores whose planned production volume is equal to or greater than a threshold, production is carried out by both packaging devices 1A and 1B (two devices in operation), thereby increasing the production capacity of that store. Furthermore, for stores whose planned production volume is less than a predetermined number (i.e., stores that produce in small lots), production is carried out by only the downstream packaging device 1B, i.e., the parent machine, thereby reducing the wait time when switching to processing for the next store. As a result, a decrease in the production capacity of the entire production line can be prevented.

[0061] When two-machine operation is performed, the pusher control unit 63 stops the pushers 30A, 30B from sending products P1 when the first number N1 reaches the planned production quantity for one store. After the processed products P2 are discharged from the packaging devices 1A, 1B, the pusher control unit 63 resumes control of the pushers 30A, 30B according to the operation method (two-machine operation or single-machine operation) of the next store. This prevents processed products from different stores from being mixed together downstream.

[0062] Another example of production in the packaging system S will now be described with reference to FIG. 5. FIG. 5 is a diagram illustrating another example of production in the packaging system S. While a predetermined production sequence was determined for multiple stores in the example of FIG. 4, in this example, the production sequence is further rearranged from the example of FIG. 4. That is, the information acquisition unit 61 functions as a planned quantity acquisition unit and acquires the planned production quantities set for each of the multiple stores. The system controller 60 rearranges the production sequences for the multiple stores according to the magnitude of each planned production quantity, and stores the updated production sequence, the planned production quantities for each store, the store names of each store, and other information in the storage unit 65 (see FIG. 5). The pusher control unit 63 controls the pushers 30A and 30B in an operation mode corresponding to the planned production quantities for each store according to the rearranged production sequence. Note that even if the production sequence is rearranged, the production capacity of each packaging device 1A and 1B remains unchanged, so the same thresholds are maintained. Therefore, the determination result regarding the operation mode for each store is also maintained.

[0063] In the example shown in FIG. 5, the production order for stores with normal lots (stores b, d, f, g, and j) is moved up, while the production order for stores with small lots (stores a, c, e, h, and i) is moved down. This type of control improves work efficiency downstream of the production line. For example, if a store labeler is installed downstream of the production line, when the next store is switched to, a label for that store is printed and affixed to an empty container. When the products from that store arrive, they are placed in a container. Production order rearrangement control improves work efficiency by consolidating container replacement work at the end. Furthermore, it is possible to check the number of stores with small planned production quantities (stores with small lots), making it easy to determine the timing for switching to single-machine operation. For example, in the example shown in FIG. 5, there are five stores with small planned production quantities (stores with small lots). When switching from weighing, packaging, and pricing processing for the fifth store to weighing, packaging, and pricing processing for the sixth store, the system controller 60 switches the operation mode from two-machine operation to single-machine operation. In the weighing, packaging, and pricing process from the sixth store onwards, the processed products P2 are not mixed in, so the process continues continuously without the above-mentioned downtime.

[0064] The above-described rearrangement control is not limited to the case where small lot production is postponed and consolidated at the end as described above. For example, small lot production for a store may be consolidated at any part of the overall production sequence.

[0065] Although the embodiments of the present disclosure have been described above, the present invention is not limited to the above embodiments. For example, in the packaging system S of the above embodiment, the first transfer conveyor 10 and the second transfer conveyor 20 are both disposed in front of the packaging devices 1A and 1B, but the layout of the first transfer conveyor 10 and the second transfer conveyor 20 may be changed as appropriate. Furthermore, in the packaging system S of the above embodiment, the transfer directions of the first transfer conveyor 10 and the second transfer conveyor 20 are the same (parallel), but the transfer directions of the first transfer conveyor 10 and the second transfer conveyor 20 may also be changed as appropriate.

[0066] In the packaging system S of the above embodiment, stop control and restart control are executed when two machines finish operating, but the stop control and restart control when two machines finish operating may be omitted. If processed products P2 from different stores are mixed, the mixed state can be detected or discovered in some way, and the mixed state can be resolved downstream.

[0067] In the packaging system S of the above embodiment, an example has been described in which the device controller 6 of the downstream packaging device 1B has the functions of the system controller 60, but the device controller 6 of the upstream packaging device 1A may also have the functions of the system controller 60. Furthermore, the system controller 60 may be provided independently of the upstream packaging device 1A and the downstream packaging device 1B.

[0068] In the packaging system S of the above embodiment, an example was described in which two pushers 30A, 30B and two packaging devices 1A, 1B are provided, but three or more pushers and three or more packaging devices may be provided. In this case, if the planned production quantity for one store is equal to or greater than a threshold, the system controller 60 (controller) controls the three or more pushers to send products to each of the three or more packaging devices. If the planned production quantity for one store is less than the threshold, the system controller 60 (controller) controls the three or more pushers (stopping one of the pushers) to send products to only some of the three or more packaging devices.

[0069] In the packaging system S of the above embodiment, an example was given in which a weighing, packaging, and pricing device was used as the product processing device, but a product processing device having at least one of the functions of weighing, packaging, and pricing may also be used. In other words, the content of the product processing (predetermined processing) can be changed as appropriate. [Explanation of symbols]

[0070] 1A...upstream packaging device (product processing device), 1B...downstream packaging device (product processing device), 2...weighing section, 6...device controller, 10...first transport conveyor (first transport section), 20...second transport conveyor (second transport section), 30...feed section, 30A...upstream pusher, 30B...downstream pusher, 60...system controller, 61...information acquisition section, 62...conveyor control section, 63...pusher control section (control section), 65...memory section, P1...product, P2...processed product, S...packaging system (product processing system).

Claims

1. A product processing system that switches to processing for the next store when processing of the planned number of products to be produced for one store is completed, and processes the planned number of products to be produced for the next store, a first conveying unit that conveys the product; a plurality of product processing devices arranged side by side along the conveying direction of the first conveying section, the product processing devices performing predetermined processing on the products; a plurality of feeding units provided in the plurality of product processing devices, each feeding the product conveyed by the first conveying unit into each of the plurality of product processing devices; a second conveying unit that receives the processed products discharged from each of the plurality of product processing devices and conveys them downstream; a control unit that controls the plurality of feeding units, A product processing system in which the control unit controls the multiple sending units to send the products to each of the multiple product processing devices when the planned production quantity for the one store is equal to or greater than a predetermined number, and controls the multiple sending units to send the products to only some of the multiple product processing devices when the planned production quantity for the one store is less than the predetermined number.

2. the control unit includes a total number acquisition unit that acquires a total number of the products sent by the plurality of sending units, The product processing system of claim 1, wherein the control unit controls the multiple feeding units to feed the products to each of the multiple product processing devices, and when the total number reaches the planned production number for the one store, stops the feeding unit from feeding the products, and resumes the feeding of the products by the feeding unit after the processed products have been discharged from the multiple product processing devices.

3. the control unit has a planned quantity acquisition unit that acquires a planned production quantity set for each of a plurality of stores, 3. The product processing system according to claim 1, wherein the control unit controls the sending unit after rearranging the production sequence for the plurality of stores in accordance with the magnitude of each planned production quantity.

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