Method for manufacturing winding body and wound article

Abstract

To reduce the time required for an initial operation and an operation immediately after replacing a winding body.SOLUTION: A packaging device packages an object to be packaged using a winding body onto which a long sheet-like packaging material is wound. The winding body has a recording medium for storing information. The information recorded on the recording medium includes remaining amount information indicating the remaining amount of the packaging material on the winding body. The packaging device comprises a drive unit that generates driving force to rotate the winding body, an information reading unit that reads the remaining amount information stored on the recording medium, and a control unit that controls the packaging device. The control unit sets a rotational speed for the winding body on the basis of the remaining amount information read by the information reading unit.SELECTED DRAWING: Figure 14

Description

[Technical Field]

[0001] The present disclosure relates to a packaging device that packages an object to be packaged in a packaging material, a wound body used in the packaging device, a core tube used in the wound body, a method for manufacturing the wound body, and a wound object used in the manufacturing method. [Background technology]

[0002] Conventionally, a packaging device sequentially packages packaging objects with packaging material unwound from a roll. The roll is formed by rolling up a long sheet-like packaging material. Japanese Patent Laid-Open Publication No. 2018-043875 (Patent Document 1) and Japanese Patent Laid-Open Publication No. 2018-118778 (Patent Document 2) disclose a configuration for detecting the remaining amount of packaging material in the roll. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2018-043875 [Patent Document 2] Japanese Patent Application Publication No. 2018-118778 Summary of the Invention [Problem to be solved by the invention]

[0004] In the device described in the above document, when the remaining amount of packaging material is unknown, the rotation speed of the reel is set to the minimum speed and the packaging material is unwound and wound up to ensure loss of synchronization. During initial operation immediately after starting the packaging device or immediately after replacing the reel, there is no determination of the remaining amount of packaging material, so the packaging material is unwound and wound up at the minimum speed and the process of determining the remaining amount of packaging material is performed. As a result, it takes time before packaging can begin.

[0005] The present disclosure provides a packaging device that can reduce the time required for the initial operation and the operation immediately after replacing the wound body. [Means for solving the problem]

[0006] According to the present disclosure, there is provided a packaging device that packages an object to be packaged using a roll of long sheet-like packaging material. The roll has a recording medium for storing information. The information recorded on the recording medium includes remaining amount information indicating the remaining amount of packaging material in the roll. The packaging device includes a drive unit that generates a driving force for rotating the roll, an information reading unit that reads the remaining amount information stored on the recording medium, and a control unit that controls the packaging device. The control unit sets the rotation speed of the roll based on the remaining amount information read by the information reading unit.

[0007] The packaging device further includes a conveying unit and a tension applying unit. The conveying unit conveys the packaging material unwound from the wound body along a conveying path. The tension applying unit has a displacement member that is displaceable in a direction intersecting the conveying path. The tension applying unit applies tension to the packaging material by the displacement member pressing against the packaging material. The displacement member has a fixed position. When the packaging device is powered on or the wound body is loaded into the packaging device, the control unit drives the drive unit to rotate the wound body at a rotational speed set based on remaining amount information, thereby moving the displacement member to the fixed position.

[0008] The packaging device further includes a position detection unit that detects whether the displacement member is in a fixed position. The control unit unwinds the packaging material from the reel until the position detection unit detects the displacement member, and moves the displacement member to the fixed position. The control unit may wind the packaging material onto the reel until the position detection unit that detected the displacement member no longer detects the displacement member, and then unwinds the packaging material from the reel until the position detection unit detects the displacement member, and moves the displacement member to the fixed position.

[0009] The packaging device further includes a position detector that detects whether the displacement member is in a fixed position. The control unit winds the packaging material onto the reel until the position detector detects the displacement member, and moves the displacement member to the fixed position.

[0010] In the packaging device, the information reading unit is configured to be able to write remaining amount information to a recording medium. The control unit measures the drive amount of the drive unit while the drive unit is driving the wound body, and determines the remaining amount of packaging material in the wound body based on the measurement result. The control unit controls the information reading unit to write the determination result of the remaining amount of packaging material to the recording medium as remaining amount information.

[0011] In the packaging device, the remaining amount of packaging material is set to a plurality of levels, and when the control unit determines that the remaining amount of packaging material is less than the current level, the control unit controls the information reading unit to write the next level smaller remaining amount to the recording medium as remaining amount information.

[0012] According to the present disclosure, there is provided a roll for use in the packaging device of any of the above aspects. The roll includes a core tube and a long sheet-like packaging material wound around the core tube. The core tube has a recording medium for storing information, the information including remaining amount information indicating the remaining amount of packaging material in the roll.

[0013] According to the present disclosure, there is provided a roll for use in the packaging device of any of the above aspects. The roll includes a core tube, a long sheet-like packaging material wound around the core tube, and a recording medium for storing information. The information includes remaining amount information indicating the remaining amount of packaging material in the roll.

[0014] According to the present disclosure, there is provided a core tube for use in the above-described wound body. The wound body includes a core tube and a long sheet-like packaging material wound around the core tube. The wound body has a recording medium for storing information. The information recorded on the recording medium includes remaining amount information indicating the remaining amount of packaging material in the wound body.

[0015] According to the present disclosure, there is provided a method for manufacturing a wound body for use in the packaging device of any of the above aspects. The wound body includes a core tube and a long sheet-like packaging material wound around the core tube. The manufacturing method includes a step of preparing the core tube and a step of winding the packaging material around the core tube.

[0016] In the above manufacturing method, the wound body has a recording medium for storing information. The information includes remaining amount information indicating the remaining amount of packaging material in the wound body. The manufacturing method further includes a step of writing the amount of packaging material wound around the core tube in the winding step as remaining amount information on the recording medium.

[0017] According to the present disclosure, there is provided a method for manufacturing a wound body for use in the packaging device of any of the above aspects, the method including the steps of preparing a core tube, preparing a wound object by winding a long sheet-like packaging material around a hollow cylindrical portion, and inserting the core tube into the cylindrical portion to integrate the wound object and the core tube.

[0018] In the above manufacturing method, the roll has a recording medium for storing information. The information includes remaining amount information indicating the remaining amount of packaging material in the roll. The manufacturing method further includes a step of writing the amount of packaging material wound around the cylindrical portion as remaining amount information on the recording medium.

[0019] According to the present disclosure, there is provided a rolled article, which is used in the above-described manufacturing method and which has a long sheet-like packaging material wound around a hollow cylindrical portion. [Effects of the Invention]

[0020] According to the packaging device according to the present disclosure, it is possible to reduce the time required for the initial operation and the operation immediately after replacing the wound body. [Brief explanation of the drawings]

[0021] [Figure 1] FIG. 2 is a perspective view showing the appearance of the medicine supply device. [Figure 2] 1 is a schematic configuration diagram of a packaging device according to an embodiment. [Figure 3] FIG. 2 is a schematic perspective view of the packaging device. [Figure 4] FIG. [Figure 5] FIG. 2 is a perspective view of the packaging material supply unit as seen from the rear side. [Figure 6] FIG. [Figure 7]FIG. 10 is a front view of the packaging material supply unit when the dancer roller is in a fixed position. [Figure 8] FIG. 10 is a perspective view of the rear of the packaging material supply unit when the dancer roller is in a fixed position. [Figure 9] FIG. 10 is a front view of the packaging material supply unit when the dancer roller is in the transport position. [Figure 10] FIG. 10 is a perspective view of the rear of the packaging material supply unit when the dancer roller is in the transport position. [Figure 11] FIG. 10 is a front view of the packaging material supply unit when the dancer roller is in the retracted position. [Figure 12] FIG. 10 is a perspective view of the rear of the packaging material supply unit when the dancer roller is in the retracted position. [Figure 13] FIG. 2 is a block diagram showing the electrical configuration of the packaging device according to the embodiment. [Figure 14] 10 is a flowchart showing a setting operation for setting the rotation speed of the unwinding / winding motor. [Figure 15] 10 is a flowchart showing the operation of returning the dancer roller to its home position during the initial operation. [Figure 16] 10 is a flowchart showing the operation of returning the dancer roller to its home position during the initial operation. [Figure 17] 10A and 10B are schematic diagrams showing the movement of the dancer roller during the initial operation of returning the dancer roller to its home position; [Figure 18] 10 is a flowchart showing the operation of returning the dancer roller to its home position when the wound body is attached. [Figure 19] 10 is a flowchart showing the operation of returning the dancer roller to its home position when the wound body is attached. [Figure 20] 10 is a flowchart showing the operation of returning the dancer roller to its home position when the wound body is attached. [Figure 21] 10 is a schematic diagram showing the movement of the dancer roller during the return operation of the dancer roller to its home position when the wound body is installed. FIG. [Figure 22] 10 is a flowchart showing the operations of the unwinding / winding unit and the conveying unit in the packaging operation. [Figure 23] 10 is a flowchart showing a first example of an unwinding operation by the unwinding / take-up section. [Figure 24] 10 is a flowchart showing a second example of the unwinding operation by the unwinding / take-up section. [Figure 25] 10 is a flowchart showing a third example of the unwinding operation by the unwinding / take-up section. [Figure 26] 10 is a flowchart showing another example of the return operation of the dancer roller to its home position during the initial operation. [Figure 27] 10 is a schematic diagram showing the movement of the dancer roller during another example of the return operation of the dancer roller to its home position during the initial operation. FIG. [Figure 28] 10 is a flowchart showing another example of the operation of returning the dancer roller to its home position when the wound body is attached. [Figure 29] 10 is a schematic diagram showing the movement of the dancer roller during execution of another example of the operation of returning the dancer roller to its home position when the wound body is installed. FIG. [Figure 30] 10 is a flowchart showing a first example of a method for manufacturing a wound body. [Figure 31] 1A to 1C are diagrams schematically illustrating a first example of a method for manufacturing a wound body. [Figure 32] 10 is a flowchart showing a second example of a method for manufacturing a wound body. [Figure 33] 10A to 10C are diagrams schematically illustrating a second example of a method for manufacturing a wound body. DETAILED DESCRIPTION OF THE INVENTION

[0022] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In the following drawings, the same or corresponding parts are designated by the same reference numerals, and the description thereof will not be repeated.

[0023] Fig. 1 is a perspective view showing the appearance of medicine supply device 101. As shown in Fig. 1, medicine supply device 101 includes a housing 102 that forms the outer shell of medicine supply device 101. Housing 102 has an upper housing 103 and a lower housing 104. Upper housing 103 houses a medicine storage and dispensing device that discharges medicines from a plurality of medicine containers. Lower housing 104 houses a packaging device that packages medicines in packaging material.

[0024] Doors 105a and 105b are attached to the front of upper housing 103. Door 105a has a handle 106a, and door 105b has a handle 106b. A user of medicine supply device 101 can hold handle 106a to open and close door 105a, and can hold handle 106b to open and close door 105b. An operation unit 107 is provided on the front of upper housing 103. Operation unit 107 may be provided with a display having a touch panel function, or may be provided with physical buttons on an operation panel.

[0025] Doors 108 and 109 are provided on the front surface of lower housing 104. Doors 108 and 109 are configured to be openable and closable. A user of medicine supply device 101 can open doors 108 and 109 and remove packages containing medicines from inside lower housing 104. Doors 108 and 109 may be formed with openings through which the packages containing medicines can be removed.

[0026] FIG. 2 is a schematic diagram of a packaging device 1 according to an embodiment. The packaging device 1 is used to package an object to be packaged. The object to be packaged is a medicine, specifically a solid medicine. Examples of solid medicine include tablets, pills, and capsules. Solid medicines may also be powders and granules. The object to be packaged is not limited to a solid medicine. The object to be packaged may also be a semi-solid medicine or a liquid medicine.

[0027] The packaging device 1 is a drug packaging device for packaging drugs based on a prescription. A prescription is issued to a patient by a doctor. The prescription contains patient information and drug information. The patient information includes the patient's name and age. The drug information includes the drug name, amount, usage, and dosage. The packaging device 1 is used to package drugs into single doses based on such a prescription.

[0028] The packaging device 1 is equipped with a packaging material conveying section 8. The packaging material conveying section 8 applies a driving force to the packaging material 2 to convey the packaging material 2. The packaging material 2 is in the form of a long sheet. The packaging material 2 is conveyed in the longitudinal direction of the packaging material 2. The packaging material 2 is unwound from a reel 3. The reel 3 is formed by winding the packaging material 2 around a core tube 3a, which is a hollow tube, to form a roll. The arrow in Figure 2 indicates the conveying direction DR of the packaging material 2. Hereinafter, the conveying direction DR of the packaging material 2 will be simply referred to as the "conveying direction DR".

[0029] A recording medium 3b is provided on the core tube 3a. The recording medium 3b may be provided directly or indirectly on the core tube 3a. The recording medium 3b may be attached, for example, to the beginning of the winding of the packaging material 2. The recording medium 3b includes a non-volatile memory and stores information. The information stored in the recording medium 3b includes remaining amount information that indicates the remaining amount of packaging material 2 wound around the core tube 3a. The recording medium 3b may also store other information such as the paper quality of the packaging material 2. The recording medium 3b may be, for example, an IC tag (RFID (Radio Frequency Identification) tag).

[0030] The core tube 3a and the recording medium 3b are reusable. The core tube 3a and the recording medium 3b may be reused after the packaging material 2 around which they were previously wound has been used up.

[0031] When the roll 3 is manufactured, the recording medium 3b may record the lot number, manufacturing date, customer information, paper quality information of the packaging material 2, remaining amount information, etc. In the case of a new roll 3, the remaining amount information recorded is the amount of packaging material 2 remaining wound around the core tube 3a in the new roll 3. After the roll 3 is attached to the packaging device 1, the date and time of start of use, environmental information, etc. may be additionally recorded in the recording medium 3b.

[0032] The packaging device 1 further includes a printing unit 4, a supplying unit 5, and a container forming unit 6. The printing unit 4, supplying unit 5, and container forming unit 6 are arranged in this order from upstream (closer to the wound body 3) to downstream (away from the wound body 3) in the conveying direction DR. The printing unit 4 prints predetermined information on the packaging material 2 conveyed by the packaging material conveying unit 8. The predetermined information is information related to the medicine. The supplying unit 5 supplies the medicine to the packaging material 2 conveyed by the packaging material conveying unit 8. The medicine is supplied at a dose based on the prescription. The container forming unit 6 forms a container using the packaging material 2 conveyed by the packaging material conveying unit 8. The medicine is contained in the container. After the medicine is supplied from the supplying unit 5, the container forming unit 6 heat-seals the packaging material 2 to form a package containing the medicine inside.

[0033] The packaging device 1 further includes a perforation forming unit 7. The perforation forming unit 7 is provided in the storage unit forming unit 6. The perforation forming unit 7 forms perforations that extend in a direction perpendicular to the conveying direction DR in the packaging material 2 conveyed by the packaging material conveying unit 8. The perforations are multiple pores that are lined up continuously in the short direction of the packaging material 2.

[0034] In such a packaging device 1, a packaging section 9 is made up of a storage section forming section 6, a perforation forming section 7, and a packaging material conveying section 8. In the packaging section 9, the medicines to be packaged are sequentially packaged using the packaging material 2 unwound from the roll 3.

[0035] 3 is a schematic perspective view of the packaging device 1. The packaging device 1 further includes a packaging material supply section 10, a direction-changing bar 11, a cutting section 12, a discharge section 13, and a frame 15. The components constituting the packaging device 1, including the supply section 5, the container forming section 6, and the packaging material conveying section 8, are attached to the frame 15. The packaging device 1 is configured to be reciprocally movable relative to a housing 102 (FIG. 1) in the thickness direction of the frame 15. The packaging device 1 is configured to be movable in the front-rear direction relative to a lower housing 104 (FIG. 1), and can be pulled out forward from a storage position in which it is stored within the lower housing 104.

[0036] The packaging material supply unit 10 has a substantially box-shaped casing 20 and an attachment portion 21 to which the wound body 3 shown in FIG. 2 is attached. The attachment portion 21 supports the wound body 3. The wound body 3 is attached to the attachment portion 21 so as to be unable to rotate relative to the attachment portion 21. The casing 20 has a planar outer surface 20a. The outer surface 20a forms part of the surface of the box-shaped casing 20. The attachment portion 21 protrudes from the outer surface 20a of the casing 20 and extends substantially perpendicular to the outer surface 20a.

[0037] A guide hole 22 is formed in the outer surface 20a of the casing 20. The guide hole 22 extends in a gentle curve. A dancer roller 23 is provided so as to be movable along the direction in which the guide hole 22 extends. Fixed rollers 24 and 25 are attached to the outer surface 20a. The dancer roller 23 and the fixed rollers 24 and 25 protrude from the outer surface 20a of the casing 20 and extend approximately perpendicular to the outer surface 20a. The dancer roller 23 and the fixed rollers 24 and 25 extend parallel to each other. Other components of the packaging material supply unit 10 will be described later.

[0038] The packaging material 2 unwound from the reel 3 is wound around the fixed roller 24, the dancer roller 23, and the fixed roller 25, in that order. The packaging material 2 is then wound around the direction-changing bar 11. The direction-changing bar 11 changes the conveying direction DR of the packaging material 2, moving the packaging material 2 in a direction toward the supply unit 5. The packaging material 2 then passes through the supply unit 5 and is wound around the packaging unit 9 (FIG. 2).

[0039] At the medicine supply position where supply unit 5 supplies medicine to packaging material 2, packaging material 2 is folded in half along the center line of the shorter side of this packaging material 2. Supply unit 5 has a hopper 151. Hopper 151 guides medicine dispensed from a medicine storage and dispensing device housed in upper housing 103 (FIG. 1) to packaging material 2. The tip of hopper 151 is positioned so as to enter the inside of the folded packaging material 2. The medicine is guided by hopper 151 and enters the inside of the folded packaging material 2.

[0040] The cutting unit 12 is provided downstream in the conveying direction DR of the containing portion forming unit 6 and the packaging material conveying unit 8, which constitute the packaging unit 9. The cutting unit 12 cuts the packaging material 2 containing a drug therein. The discharge unit 13 is provided downstream in the conveying direction DR of the cutting unit 12. The discharge unit 13 generates a driving force for conveying the packaging material 2 cut by the cutting unit 12, and discharges the packaging material 2 to the outside. Hereinafter, the path taken by the packaging material 2 as it is unwound from the roll 3 and conveyed to the discharge unit 13 is referred to as the "conveying path."

[0041] Fig. 4 is a front view of packaging material supply unit 10. Fig. 4 shows packaging material supply unit 10 as seen from the direction of arrow IV shown in Fig. 3. Dancer roller 23 moves relative to casing 20 along guide holes 22 formed in casing 20. Dancer roller 23 is configured to be displaceable in a direction intersecting the conveying path of packaging material 2.

[0042] The packaging material supply unit 10 includes a fixed position sensor 28. The fixed position sensor 28 detects the position of the dancer roller 23. The fixed position sensor 28 is a magnetic sensor. A magnet is attached to a main arm (described later) to which the dancer roller 23 is attached. The position where the dancer roller 23 overlaps with the fixed position sensor 28 in the direction perpendicular to the plane of FIG. 4 is referred to as the fixed position. The fixed position is on the conveyance path. When the dancer roller 23 is in the fixed position, the fixed position sensor 28 detects a magnetic force and turns on. When the dancer roller 23 moves away from the fixed position, the fixed position sensor 28 switches from on to off. This allows the fixed position sensor 28 to detect whether the dancer roller 23 is in the fixed position. The fixed position sensor 28 constitutes a position detection unit in this embodiment that detects whether the dancer roller 23 is in the fixed position.

[0043] The packaging material supply unit 10 has an unlocking unit 26. The main arm is locked by a locking unit, which will be described later. By manually operating the unlocking unit 26, the main arm is unlocked from the locking unit.

[0044] Fig. 5 is a perspective view of the rear of the packaging material supply unit 10. Fig. 6 is a rear view of the packaging material supply unit 10. Fig. 6 shows the packaging material supply unit 10 as seen from the direction of arrow VI shown in Fig. 3. In addition to the above-mentioned home position sensor 28, the packaging material supply unit 10 also includes a limit position sensor 27 and a retracted position sensor 29. The limit position sensor 27, the home position sensor 28, and the retracted position sensor 29 are supported by a sensor support part 30. The sensor support part 30 is fixed to the ceiling of the casing 20.

[0045] In FIG. 4, the position where the dancer roller 23 is located is called the limit position. The limit position is at one end of the guide hole 22. The position at the other end of the guide hole 22 is called the retracted position. The limit position sensor 27 and the retracted position sensor 29 are magnetic sensors. The limit position and the retracted position are off the conveying path. The limit position is farther from the conveying path than the normal position.

[0046] The limit position sensor 27 and the retracted position sensor 29 detect the position of the dancer roller 23. When the dancer roller 23 is at the limit position, the limit position sensor 27 detects a magnetic force and turns on. When the dancer roller 23 moves away from the limit position, the limit position sensor 27 switches from on to off. This allows the limit position sensor 27 to detect whether the dancer roller 23 is at the limit position. When the dancer roller 23 is at the retracted position, the retracted position sensor 29 detects a magnetic force and turns on. When the dancer roller 23 moves away from the retracted position, the retracted position sensor 29 switches from on to off. This allows the retracted position sensor 29 to detect whether the dancer roller 23 is at the retracted position.

[0047] The packaging material supply unit 10 has an unwinding / take-up motor 35. In this embodiment, the unwinding / take-up motor 35 is a stepping motor. The unwinding / take-up motor 35 is supported by the casing 20. The unwinding / take-up motor 35 generates a rotational driving force for rotating the mounting unit 21 to unwind the packaging material 2 from the reel 3 or to reel the packaging material 2 onto the reel 3. The driving force generated by the unwinding / take-up motor 35 is transmitted to the mounting unit 21 via an intermediate gear 72, an intermediate pinion gear 73, and a roller gear 74. The intermediate gear 72 and the intermediate pinion gear 73 are fixed so as to be rotatable as a unit around an intermediate gear shaft 75.

[0048] The packaging material supply unit 10 has a main arm 40, a sub-arm 50, and a gear positioning plate 55. The main arm 40 has a first arm 41, a second arm 42, and a bending portion 43. The first arm 41 and the second arm 42 shown in FIG. 6 each have a substantially linear shape. The first arm 41, the second arm 42, and the bending portion 43 are fixed to each other and rotatable as a unit. The main arm 40 is bent at the bending portion 43 and has a substantially L-shape.

[0049] The first arm 41 has a tip and a base end. The dancer roller 23 described above is fixed to the tip of the first arm 41. The first arm 41 is connected to the bent portion 43 at its base end. The second arm 42 has a tip and a base end. A gear positioning plate 55 is fixed to the base end of the second arm 42. The second arm 42 is connected to the bent portion 43 at its tip. A lock pin 47 is fixed to the bent portion 43. The main arm 40 is configured to be rotatable around an arm rotation shaft 44 as the center of rotation. The main arm 40 is supported by the casing 20 via the arm rotation shaft 44.

[0050] The sub-arm 50 has a base end 51 and a tip end 52. The base end 51 is in surface contact with the surface of the main arm 40 from the bent portion 43 of the main arm 40 to the second arm portion 42, and is fixed to the main arm 40 using a plurality of fixing members such as bolts. This allows the sub-arm 50 to rotate integrally with the main arm 40. A cylindrical portion 53 is attached to the tip end 52 of the sub-arm 50.

[0051] One of the multiple fixing members that fix the sub-arm 50 to the main arm 40 constitutes a spring hook portion 45. A spring hook portion 31 is also provided on the sensor support portion 30. The spring hook portion 31 is formed by a bolt attached to the sensor support portion 30. One end of a return spring 46 engages with the spring hook portion 31, and the other end of the return spring 46 engages with the spring hook portion 45. The return spring 46 is, for example, a coil spring.

[0052] The gear positioning plate 55 is fixed to the base end of the second arm portion 42 of the main arm 40 using a plurality of fixing members 56 such as bolts. A notch 59 is formed in the gear positioning plate 55. The gear positioning plate 55 has a first portion 57 and a second portion 58. The first portion 57 and the second portion 58 are separated by the notch 59. A part of the edge of the second portion 58 forms an arc edge 58a. The arc edge 58a has an arc shape centered on the arm rotation shaft 44.

[0053] A cylindrical portion 65 is provided in contact with the arc edge 58a. The cylindrical portion 65 is attached to the tip of the second portion 63 of the gear arm. The tip of the third portion 64 of the gear arm is engaged with the intermediate gear shaft 75 via a bearing. A spring hook portion 66 is formed on the third portion 64. One end of a return spring (not shown) is engaged with the spring hook portion 38, and the other end is engaged with the spring hook portion 66.

[0054] The outer peripheral surface of the cylindrical portion 65 is slidable relative to the arcuate edge 58a. The cylindrical portion 65 is also movable within the notch 59. The intermediate gear 72 and the intermediate pinion gear 73 are positioned when the outer peripheral surface of the cylindrical portion 65 abuts against the arcuate edge 58a, and the positions of the intermediate gear 72 and the intermediate pinion gear 73 are changed when the cylindrical portion 65 moves into the notch 59.

[0055] The packaging material supply unit 10 further includes a locking unit 78. The locking unit 78 has a locking member 79. The locking member 79 has an inclined portion 80 and an engaging portion 81 at one end (the left side in FIG. 6). The locking member 79 has a connecting piece at the other end (the right side in FIG. 6). The locking member 79 also has a protrusion 82.

[0056] The locking member 79 is held by a holding member 84. The holding member 84 is fixed to the casing 20. The holding member 84 holds the locking member 79 so that it can slide in its extending direction (left and right direction in FIG. 6). The holding member 84 has a protrusion. The protrusion 82 of the locking member 79 and the protrusion of the holding member 84 are arranged so that their tips face each other. A spring 86 is provided across the protrusion 82 of the locking member 79 and the protrusion of the holding member 84. The protrusion 82 supports one end of the spring 86 (the left end of the spring 86 shown in FIG. 6). The protrusion of the holding member 84 supports the other end of the spring 86 (the right end of the spring 86 shown in FIG. 6).

[0057] The locking member 78 also has a linear solenoid actuator 87. The linear solenoid actuator 87 is fixed to the casing 20 by a retaining member (not shown). The linear solenoid actuator 87 has a main body and a stem 88 that protrudes from the main body. The stem 88 is connected to a connecting piece of the locking member 79.

[0058] The locking portion 78 is configured to lock the main arm 40 by engaging with a locking pin 47 attached to the main arm 40 .

[0059] The packaging device 1 has a spring hinge 90. The spring hinge 90 has a first hinge plate 91, a second hinge plate 92, a hinge shaft 93, and a torsion spring 94. The first hinge plate 91 and the second hinge plate 92 are connected via the hinge shaft 93.

[0060] The first hinge plate 91 is fixed to the lower housing 104 and is immovable. The second hinge plate 92 is movable relative to the first hinge plate 91, with a hinge shaft 93 as the center of rotation. The second hinge plate 92 is disposed at an angle relative to the vertical direction, with its upper end relatively forward (to the right in the drawing) and its lower end relatively backward (to the left in the drawing).

[0061] The torsion spring 94 has a coil portion wound around the hinge shaft 93 and a pair of arms protruding from the coil portion. One of the pair of arms abuts against the first hinge plate 91. The other of the pair of arms abuts against the second hinge plate 92.

[0062] The torsion spring 94 applies an elastic repulsive force between the first hinge plate 91 and the second hinge plate 92, and urges the second hinge plate 92 in a direction in which the second hinge plate 92 moves away from the first hinge plate 91 around the hinge shaft 93 as the center of rotation. When no external forces other than the urging force of the torsion spring 94 and gravity act on the spring hinge 90, the first hinge plate 91 and the second hinge plate 92 extend substantially perpendicular to each other. When viewed in the axial direction of the hinge shaft 93, the first hinge plate 91 and the second hinge plate 92 are arranged in an L-shape.

[0063] The packaging material supply unit 10 is movable relative to the spring hinge 90 in the front-to-rear direction of the housing 102 (left-to-right direction in FIG. 6). In the arrangement shown in FIG. 6, the cylindrical portion 53 of the sub-arm 50 is separated from the second hinge plate 92, and the cylindrical portion 53 and the second hinge plate 92 are not in contact with each other. The cylindrical portion 53 slides relative to the second hinge plate 92 of the spring hinge 90, thereby causing the sub-arm 50 and the main arm 40 to rotate about the arm rotation axis 44.

[0064] Figure 7 is a front view of packaging material supply unit 10 when dancer roller 23 is in its home position. Compared to Figure 4, dancer roller 23 shown in Figure 7 has moved to the right in the figure along guide hole 22. Dancer roller 23 shown in Figure 7 is away from the limit position and is in its home position. Because dancer roller 23 is away from the limit position shown in Figure 4, limit position sensor 27 is shown in Figure 7. However, because dancer roller 23 is in its home position in Figure 7, dancer roller 23 overlaps home position sensor 28, and home position sensor 28 is not shown.

[0065] As described above, the packaging material 2 unwound from the reel 3 (not shown in Figure 7) is wound around the fixed roller 24, the dancer roller 23, and the fixed roller 25 in this order. When the dancer roller 23 is in its fixed position, a predetermined tension is applied to the packaging material 2. Applying tension to the packaging material 2 prevents the packaging material 2 from sagging. This prevents the packaging material 2 from shifting or wrinkling when it is conveyed by the packaging material conveying section 8 (Figures 2 and 3).

[0066] Figure 8 is a perspective view of the rear of the packaging material supply unit 10 when the dancer roller 23 is in its home position. Compared to Figure 5, the main arm 40 and sub-arm 50 shown in Figure 8 are rotating counterclockwise around the arm rotation shaft 44. As the gear positioning plate 55 rotates together with the main arm 40 and the cylindrical portion 65 moves relatively along the arc edge 58a of the gear positioning plate 55, the cylindrical portion 65 shown in Figure 8 is closer to the notch 59 compared to Figure 5. Compared to Figure 5, the lock pin 47 shown in Figure 8 has moved in a direction closer to the lock portion 78. The length of the return spring 46 shown in Figure 8 is increased compared to Figure 5.

[0067] Figure 9 is a front view of packaging material supply unit 10 when dancer roller 23 is in the transport position. Compared to Figure 7, dancer roller 23 shown in Figure 9 has moved to the right in the figure along guide hole 22. Dancer roller 23 shown in Figure 9 is away from its home position, and therefore both limit position sensor 27 and home position sensor 28 are also shown in Figure 9. The position at which dancer roller 23 is located in Figure 7 is referred to as the transport position. The transport position is on the transport path.

[0068] 9 shows the packaging material 2 being conveyed by the packaging material conveying unit 8 by the length of one package containing a medicine, and the dancer roller 23 having moved from its fixed position as the packaging material 2 is conveyed. While the packaging material conveying unit 8 is conveying the packaging material 2, the unwinding / take-up motor 35 is stopped. Therefore, the packaging material 2 is not unwound from the roll 3.

[0069] On the other hand, as the packaging material conveying section 8 conveys the packaging material 2 by one package of packages, the length of the packaging material 2 in the conveying direction DR from the roll 3 to the packaging material conveying section 8 is shortened by one package. This change in the length of the packaging material 2 is adjusted by moving the dancer roller 23 to shorten the distance between the dancer roller 23 and the fixed roller 24, and the distance between the dancer roller 23 and the fixed roller 25.

[0070] In other words, when comparing the length of the packaging material 2 wound between the dancer roller 23 and the fixed rollers 24, 25 in the fixed position shown in Fig. 7 and the length of the packaging material 2 wound between the dancer roller 23 and the fixed rollers 24, 25 in the position shown in Fig. 9, the length of the packaging material 2 in Fig. 9 is shorter. By making the change in the length of the packaging material 2 wound between the dancer roller 23 and the fixed rollers 24, 25 correspond to the length of one package of packaging material, the packaging material 2 can be conveyed while maintaining a constant state in which a predetermined tension is applied to the packaging material 2.

[0071] The length of one package of packaging in the conveying direction DR is not always constant and may be changed according to the amount of medicine contained in the package. The amount of packaging material 2 conveyed by the packaging material conveying unit 8 can also be changed depending on the dimensions of the package, and the movement position during conveying also varies. If the length of one package of packaging in the conveying direction DR is large, the movement position during conveying is set to a position relatively far from the fixed position. If the length of one package of packaging in the conveying direction DR is small, the movement position during conveying is set to a position relatively close to the fixed position.

[0072] The packaging material 2 is conveyed intermittently. After conveyance of the packaging material 2 has been completed, the unwinding / winding motor 35 is driven while conveyance of the packaging material 2 is stopped. The driving force of the unwinding / winding motor 35 is transmitted to the mounting portion 21, causing the winding body 3 to rotate, thereby unwinding the packaging material 2 from the winding body 3. At this time, conveyance of the packaging material 2 by the packaging material conveying unit 8 is stopped, so the packaging material 2 unwound from the winding body 3 is used to restore the length of the packaging material 2 wound between the dancer roller 23 and the fixed rollers 24, 25. In other words, when the packaging material 2 is unwound from the winding body 3, the dancer roller 23 moves from the conveyance movement position shown in FIG. 9 toward the home position shown in FIG. 7. When the dancer roller 23 has moved to the home position and the home position sensor 28 detects the dancer roller 23, the unwinding / winding motor 35 is stopped.

[0073] In this way, by alternately repeating the conveying of the packaging material 2 by the packaging material conveying section 8 and the unwinding of the packaging material 2 from the roll 3, the packaging material 2 can be properly conveyed while maintaining a state in which a predetermined tension is applied to the packaging material 2.

[0074] Figure 10 is a perspective view of the rear of the packaging material supply unit 10 when the dancer roller 23 is in the transport position. The main arm 40 and sub-arm 50 shown in Figure 10 are rotating counterclockwise around the arm rotation shaft 44, as compared to Figure 8. The gear positioning plate 55 rotates together with the main arm 40, and the cylindrical portion 65 moves relatively along the arc edge 58a of the gear positioning plate 55. As a result, the cylindrical portion 65 shown in Figure 10 is closer to the notch 59, as compared to Figure 8. The lock pin 47 shown in Figure 10 has moved closer to the lock portion 78, as compared to Figure 8. The return spring 46 shown in Figure 10 has an increased length, as compared to Figure 8.

[0075] As described above, when the packaging material 2 is being conveyed by the packaging material conveying section 8, the packaging material 2 is maintained in a tensioned state, and at this time the dancer roller 23 moves back and forth between its home position and the position to which it is moved during conveyance. When all of the packaging material 2 has been unwound from the reel 3, the upstream end of the packaging material 2 in the conveyance direction DR is no longer supported by the reel 3, and tension is no longer applied to the packaging material 2. Because the dancer roller 23 is no longer supported by the packaging material 2 in a tensioned state, the elastic force of the return spring 46 causes the main arm 40 to rotate, and the dancer roller 23 moves to the limit position.

[0076] Figure 11 is a front view of packaging material supply unit 10 when dancer roller 23 is in the retracted position. Compared to Figure 9, dancer roller 23 shown in Figure 11 has moved to the right in the figure along guide hole 22. Dancer roller 23 shown in Figure 11 is located at the retracted position at the other end of guide hole 22.

[0077] 7 and 9, the dancer roller 23 is located to the left of the fixed rollers 24 and 25. Therefore, the packaging material 2 wound around the fixed roller 24, dancer roller 23, and fixed roller 25 in this order is pressed by the dancer roller 23, thereby applying tension to the packaging material 2. In contrast, in FIG. 11, the dancer roller 23 is located to the right of the fixed rollers 24 and 25. The packaging material 2 unwound from the wound body 3 can pass through the gap between the dancer roller 23 and the fixed roller 24 in the left-right direction in FIG. 11, and can also pass through the gap between the dancer roller 23 and the fixed roller 25. At this time, no tension is applied to the packaging material 2.

[0078] Packaging material 2 is passed through the gap between dancer roller 23 and fixed rollers 24, 25 in the left-right direction in FIG. 11, and in this state dancer roller 23 is moved to a fixed position, whereby tension is applied to packaging material 2.

[0079] The dancer roller 23 and the fixed rollers 24, 25 constitute a tension applying section that applies tension to the packaging material 2 unwound from the roll 3. The tension applying section applies tension to the packaging material 2 by the dancer roller 23 pressing against the packaging material 2. The dancer roller 23 constitutes a displacement member that is displaceable in a direction intersecting the conveyance path of the packaging material 2. By moving the dancer roller 23, the tension applying section can be switched between a tension applying state in which tension is applied to the packaging material 2 and a non-tensioning state in which tension is not applied to the packaging material 2.

[0080] Figure 12 is a perspective view of the rear of the packaging material supply unit 10 when the dancer roller 23 is in the retracted position. Compared to Figure 10, the main arm 40 and sub-arm 50 shown in Figure 12 are rotating counterclockwise around the arm rotation shaft 44. The cylindrical portion 65 shown in Figure 12 is located within the notch 59, away from the arc edge 58a of the gear positioning plate 55. The lock pin 47 shown in Figure 12 is engaged with a lock portion 78 (not shown in Figure 12), thereby locking the main arm 40. The return spring 46 shown in Figure 12 is longer than that shown in Figure 10 and is at its maximum length.

[0081] Next, we will explain the control for performing the packaging operation using the packaging device 1. Fig. 13 is a block diagram showing the electrical configuration of the packaging device 1 according to the embodiment. As shown in Fig. 13, the packaging device 1 includes an operation unit 107 and an overall control unit 200.

[0082] The operation unit 107 is operated by an operator who operates the packaging device 1. When the operator operates the operation unit 107, information necessary for the packaging operation of the packaging device 1 is input to the overall control unit 200. The information necessary for the packaging operation of the packaging device 1 includes prescription data based on a prescription and various setting information. The setting information includes the length of one packet of packaging containing medicines. The information necessary for the packaging operation of the packaging device 1 may be input to the overall control unit 200 from an external computer.

[0083] The overall control unit 200 controls the overall operation of the packaging device 1 based on information necessary for the packaging operation of the packaging device 1. The overall control unit 200 controls the supply unit 5 and the packaging unit 9.

[0084] The overall control unit 200 sends a control signal to the supply unit 5 to instruct the supply unit 5 on the type and quantity of medicines to be supplied. The overall control unit 200 sends a control signal to the packaging unit 9 so that the length of the package in the conveying direction DR becomes a predetermined value. The length of the package may be a value input via the operation unit 107, for example, or may be a value set by the overall control unit 200 based on the type and quantity of medicines.

[0085] The packaging unit 9 has a packaging control unit 201. The packaging control unit 201 receives detection signals from the fixed position sensor 28, the limit position sensor 27, and the retracted position sensor 29, and determines the current position of the dancer roller 23. The packaging control unit 201 controls the unwinding / winding motor 35, the pressure motor 6m, the heater 6h, the conveying motor 8m, and the reading / writing unit 3R based on control signals from the overall control unit 200. The unwinding / winding motor 35, the pressure motor 6m, the heater 6h, the conveying motor 8m, and the reading / writing unit 3R are appropriately driven and stopped to package the packaging material 2.

[0086] The pressure motor 6m and heater 6h are included in the container forming section 6 (Fig. 2). The heater 6h is built into one of a pair of pressure members arranged opposite each other with the packaging material 2 sandwiched therebetween. The pressure motor 6m drives the pair of pressure members, causing the pressure members to pressurize the packaging material 2 from both sides and to separate the pressure members from the packaging material 2. When the packaging material 2 is pressed from both sides, the heater 6h is driven to heat the packaging material 2, thereby heat-sealing a portion of the packaging material 2 and forming a package containing a drug inside.

[0087] The conveying motor 8m is included in the packaging material conveying unit 8. The conveying motor 8m rotates and drives a pair of conveying rollers that are arranged opposite each other with the packaging material 2 sandwiched between them. The packaging material 2 is conveyed by the conveying motor 8m rotating and driving the pair of conveying rollers. The packaging material conveying unit 8 intermittently conveys the packaging material 2. While the conveyance of the packaging material 2 is stopped, predetermined operations are performed, such as heat sealing of the packaging material 2 by the storage section forming unit 6, printing of predetermined information on the packaging material 2 by the printing unit 4 (Figure 2), formation of perforations in the packaging material 2 by the perforation forming unit 7 (Figure 2), and cutting of the packaging material 2 by the cutting unit 12 (Figure 3).

[0088] The reading and writing unit 3R performs data communication with the recording medium 3b (FIG. 2) under the control of the packaging control unit 201. Specifically, the reading and writing unit 3R accesses the recording medium 3b to read information recorded on the recording medium 3b and write information to the recording medium 3b. The reading and writing unit 3R adds new information to the recording medium 3b. The reading and writing unit 3R also overwrites and updates information already recorded on the recording medium 3b with the latest information.

[0089] If the operation unit 107 is equipped with a display and information about the remaining amount of packaging material 2 is recorded on the recording medium 3b, a command signal may be output from the overall control unit 200 to the operation unit 107 to display the remaining amount information read from the recording medium 3b on the display. A user of the packaging device 1 can know the remaining amount of packaging material 2 by looking at the display. For example, a user who knows that the remaining amount of packaging material 2 is low can arrange for a replacement packaging material 2 in advance.

[0090] 14 is a flowchart showing the setting operation for setting the rotation speed of the unwinding / winding motor 35. In the packaging device 1 of this embodiment, the unwinding / winding section is a component for unwinding the packaging material 2 from the wound body 3 or winding the packaging material 2 onto the wound body 3. The unwinding / winding section includes the unwinding / winding motor 35, the mounting section 21, a power transmission section that transmits the driving force generated by the unwinding / winding motor 35 to the mounting section 21, the dancer roller 23, sensors that detect the position of the dancer roller 23, and fixed rollers 24 and 25. The conveying section is a component for conveying the packaging material 2 along the conveying direction DR. The conveying section is made up of the packaging material conveying section 8.

[0091] The setting operation shown in Fig. 14 is executed when the packaging device 1 is powered on to start up, or when the rolled body 3 is attached to the attachment portion 21 when replacing the rolled body 3. When the setting operation starts, first in step S1, remaining amount information indicating the remaining amount of packaging material 2 in the rolled body 3 is obtained from the IC tag. The reading / writing unit 3R (Fig. 13) accesses the IC tag provided on the core tube 3a of the rolled body 3, i.e., the recording medium 3b (Fig. 2), and obtains the remaining amount information recorded on the recording medium 3b. The remaining amount information is input from the reading / writing unit 3R to the packaging control unit 201.

[0092] Next, in step S2, the rotation speed is set based on the remaining amount information. The packaging control unit 201 sets the rotation speed of the unwinding / winding motor 35 based on the remaining amount information read from the recording medium 3b by the reading / writing unit 3R.

[0093] When a large amount of packaging material 2 remains in the wound body 3 and the wound diameter of the packaging material 2 is large, the inertia of the wound body 3 is large. Therefore, if the rotation speed of the wound body 3 is too high, there is a possibility that the stepping motor will lose synchronization due to its characteristics. In addition, the large inertia of the wound body 3 causes slack in the packaging material 2, and this slack causes errors that reduce the accuracy of determining the wound diameter of the packaging material 2. Therefore, when a large amount of packaging material 2 remains, the rotation speed is reduced.

[0094] When the remaining amount of packaging material 2 in the wound body 3 is small and the wound diameter of the packaging material 2 is small, the inertia of the wound body 3 is small, and the possibility of loss of synchronization is reduced. Furthermore, compared to when the wound diameter is large, when the wound diameter is small, the wound body 3 needs to rotate more to unwind the same length of packaging material 2. Therefore, when the remaining amount of packaging material 2 is small, the rotation speed is increased.

[0095] In this way, the packaging control unit 201 sets the rotation speed of the unwinding / winding motor 35 in accordance with the remaining amount of packaging material 2 in the roll 3. Then, the setting operation ends ("End" in FIG. 14).

[0096] 15 and 16 are flowcharts showing the return operation of the dancer roller 23 to its home position during the initial operation. When a predetermined key is operated after the power to the packaging device 1 is turned on, the initial operation starts. As part of this initial operation, the return operation of the dancer roller 23 to its home position is executed.

[0097] First, in step S101, it is determined whether the retracted position sensor 29 is on. The packaging control unit 201 determines whether the retracted position sensor 29 is on based on whether a detection signal indicating that the retracted position sensor 29 is on is input. When a detection signal is input from the retracted position sensor 29, it is determined that the dancer roller 23 is in the retracted position (YES in step S101). In this case, the process proceeds to step S102, where the main arm 40 is unlocked.

[0098] As described with reference to FIG. 12 , when dancer roller 23 is in the retracted position, lock pin 47 is engaged with lock portion 78, and main arm 40 is locked. To allow dancer roller 23 to move, main arm 40 is unlocked. Linear solenoid actuator 87 pulls lock member 79, thereby releasing the lock of main arm 40 by lock portion 78. A user of packaging device 1 may manually operate lock release portion 26 to release the lock of main arm 40 by lock portion 78.

[0099] The return spring 46 biases the main arm 40 in a direction that moves the dancer roller 23 from the retracted position toward the limit position. When the main arm 40 is unlocked, the elastic force of the return spring 46 causes the main arm 40 to rotate, and the dancer roller 23 moves in a direction that moves from the retracted position toward the limit position. The position to which the dancer roller 23 moves after the main arm 40 is unlocked is determined according to the amount of packaging material 2 unwound from the roll 3 at that time.

[0100] In the determination in step S101, if it is determined that no detection signal is input from the retracted position sensor 29 and that the retracted position sensor 29 is not on (NO in step S101), in this case the dancer roller 23 is not in the retracted position and the main arm 40 is not locked. Since there is no need to unlock the main arm 40, step S102 is skipped.

[0101] Next, in step S103, it is determined whether the limit position sensor 27 is on. The packaging control unit 201 determines whether the limit position sensor 27 is on based on whether a detection signal indicating that the limit position sensor 27 is on is input. If no detection signal is input from the limit position sensor 27 and it is determined that the limit position sensor 27 is not on (NO in step S103), this means that the dancer roller 23 is in a position other than the limit position. In this case, a process is performed to move the dancer roller 23 to the limit position.

[0102] Specifically, in step S104, unwinding of the packaging material 2 from the roll 3 is started. The packaging control unit 201 sends a control signal to the unwinding / winding motor 35 to rotate the attached portion 21 in the direction in which the packaging material 2 is unwound from the roll 3.

[0103] Next, in step S105, it is determined whether the limit position sensor 27 is on. If it is determined that the limit position sensor 27 is not on and the dancer roller 23 is not at the limit position (NO in step S105), the determination in step S105 is repeated until it is detected that the limit position sensor 27 has turned on, during which time unwinding of the packaging material 2 continues. If it is detected that the limit position sensor 27 has turned on (YES in step S105), the process proceeds to step S106, where unwinding of the packaging material 2 from the roll 3 is terminated. The packaging control unit 201 sends a control signal to the unwinding / take-up motor 35 to stop it.

[0104] If it is determined in step S103 that the limit position sensor 27 is on (YES in step S103), the dancer roller 23 is at the limit position. When unwinding of the packaging material 2 is completed in step S106, the dancer roller 23 is at the limit position. When it is detected that the dancer roller 23 is at the limit position, the process proceeds to step S107 via the connector 1, and winding of the packaging material 2 onto the roll 3 begins. The packaging control unit 201 sends a control signal to the unwinding / take-up motor 35 to rotate the mounted portion 21 in the direction of winding the packaging material 2 onto the roll 3.

[0105] Subsequently, in step S108, it is determined whether or not the fixed position sensor 28 is on. If it is determined that the fixed position sensor 28 is not on and the dancer roller 23 is not in the fixed position (NO in step S108), the determination in step S108 is repeated until it is detected that the fixed position sensor 28 has turned on.

[0106] If it is detected that the fixed position sensor 28 has turned on (YES in step S108), then in step S109 it is determined whether the fixed position sensor 28 is off. If it is determined that the fixed position sensor 28 is on and not off, and the dancer roller 23 is in the fixed position (NO in step S109), the determination in step S109 is repeated until it is detected that the fixed position sensor 28 has turned off.

[0107] While the determinations in steps S108 and S109 are repeated, the winding of the packaging material 2 continues. When the fixed position sensor 28 turns off and it is determined that the dancer roller 23 has moved out of the fixed position (YES in step S109), the process proceeds to step S110, where the winding of the packaging material 2 onto the roll 3 is terminated. The packaging control unit 201 sends a control signal to the unwinding / winding motor 35 to stop it.

[0108] When the winding of the packaging material 2 onto the roll 3 is completed, the dancer roller 23 has moved beyond the limit position and has moved to a position between the fixed position and the retreated position. From this state, a process is performed to move the dancer roller 23 back to the fixed position.

[0109] Specifically, in step S111, unwinding of the packaging material 2 from the roll 3 is started. The packaging control unit 201 sends a control signal to the unwinding / winding motor 35 to rotate the attached portion 21 in the direction in which the packaging material 2 is unwound from the roll 3.

[0110] Next, in step S112, it is determined whether the fixed position sensor 28 is on. If it is determined that the fixed position sensor 28 is not on and the dancer roller 23 is not in the fixed position (NO in step S112), the determination in step S112 is repeated until it is detected that the fixed position sensor 28 has turned on, during which time the unwinding of the packaging material 2 continues. If it is detected that the fixed position sensor 28 has turned on (YES in step S112), the process proceeds to step S113, where the unwinding of the packaging material 2 from the roll 3 is terminated. The packaging control unit 201 sends a control signal to the unwinding / take-up motor 35 to stop it.

[0111] In this way, the dancer roller returns to its home position during the initial operation. Then, the home position returning operation is completed ("END" in FIG. 16).

[0112] FIG. 17 is a schematic diagram showing the movement of the dancer roller 23 while it is returning to its home position during initial operation. In FIG. 17, the line segments extending left and right in the figure indicate the movement range of the dancer roller 23. The three double-headed arrows indicate, from left to right in the figure, the detection range of the limit position sensor 27, the detection range of the home position sensor 28, and the detection range of the retracted position sensor 29. As described above, the limit position sensor 27, the home position sensor 28, and the retracted position sensor 29 detect the magnetic force of the magnet attached to the main arm 40 and turn on. Therefore, the limit position sensor 27, the home position sensor 28, and the retracted position sensor 29 each have a detection range of a predetermined width.

[0113] In steps S104 to S106 described above, dancer roller 23 moves to the limit position as shown by the arrow indicated by symbol A in Fig. 17. In steps S107 to S110, dancer roller 23 moves from the limit position beyond the fixed position as shown by the arrow indicated by symbol B in Fig. 17. In steps S111 to S113, dancer roller 23 moves to the fixed position as shown by the arrow indicated by symbol C in Fig. 17.

[0114] When attempting to stop unwinding / take-up motor 35 upon detection that fixed position sensor 28 is on, movement of dancer roller 23 continues even after fixed position sensor 28 is turned on, corresponding to the time it takes for unwinding / take-up motor 35 to decelerate before stopping. Because fixed position sensor 28 has a predetermined detection range, there is a possibility that the position at which dancer roller 23 stops when dancer roller 23 is moved to the fixed position while unwinding wound body 3 will differ from the position at which dancer roller 23 stops when dancer roller 23 is moved to the fixed position while winding wound body 3.

[0115] In this embodiment, the wound body 3 is unwound to stop the dancer roller 23 at a fixed position. By setting the direction of movement of the dancer roller 23 to one direction when stopping the dancer roller 23 at the fixed position, the position at which the dancer roller 23 stops can be made constant. This ensures that the dancer roller 23 returns to its fixed position.

[0116] The rotation speed of the wound body 3 when unwinding the wound body 3 in steps S104 to S106, when winding the wound body 3 in steps S107 to S110, and when unwinding the wound body 3 in steps S111 to S113 is set to a rotation speed set based on the information on the remaining amount of packaging material 2 acquired from the recording medium 3b, which was set in step S2 shown in Fig. 14. The unwinding / winding motor 35 is driven to rotate the wound body 3 at the rotation speed set based on the information on the remaining amount of packaging material 2, and a return-to-position operation is performed.

[0117] As a result, there is no need to rotate the unwinding / winding motor 35 at the minimum speed during the return-to-home operation, and the unwinding / winding motor 35 can be rotated at an appropriate rotation speed. There is also no need for processing to determine the remaining amount of packaging material 2. Therefore, the return-to-home operation can be performed in a short time, and the time required for the return operation during the initial operation can be shortened.

[0118] The return operation of dancer roller 23 to its home position during initial operation also serves as a sensor check operation to check whether there is an abnormality in home position sensor 28 and limit position sensor 27. Dancer roller 23 is moved to the limit position in steps S103 to S106, and then moved to the home position in steps S107 to S113. By checking whether home position sensor 28 and limit position sensor 27 can detect this movement of dancer roller 23, the sensor check operation can be carried out reliably.

[0119] 18, 19, and 20 are flowcharts showing the return-to-position operation of dancer roller 23 when the wound body is attached. When replacing the wound body 3, if a predetermined key is operated after the wound body 3 is attached to the attachment portion 21, the return-to-position operation of dancer roller 23 is executed.

[0120] First, in step S201, it is determined whether or not the retracted position sensor 29 is on. In step S202, the main arm 40 is unlocked. The processing of steps S201 and S202 is the same as the processing of steps S101 and S102 described with reference to Figure 15, and therefore a description thereof will be omitted.

[0121] Next, in step S203, it is determined whether or not fixed position sensor 28 is on. Packaging control unit 201 determines whether or not fixed position sensor 28 is on based on the presence or absence of a detection signal indicating that fixed position sensor 28 is on. When a detection signal is input from fixed position sensor 28 and it is determined that fixed position sensor 28 is on (YES in step S203), dancer roller 23 is in its fixed position, but a process is performed to further align the position at which dancer roller 23 stops.

[0122] Specifically, the process proceeds to step S210 via connector 2, and the winding of packaging material 2 onto roll 3 begins. The process of step S210 is the same as the process of step S107 described with reference to Figure 16, and therefore a description thereof will be omitted.

[0123] Next, in step S211, it is determined whether or not fixed position sensor 28 is off. In step S212, winding of packaging material 2 onto winding body 3 is completed. In step S213, unwinding of packaging material 2 from winding body 3 is started. In step S214, it is determined whether or not fixed position sensor 28 is on. In step S215, unwinding of packaging material 2 from winding body 3 is completed. The processing of steps S211 to S215 is the same as the processing of steps S109 to S113 described with reference to FIG. 16, and therefore description thereof will be omitted. By unwinding winding body 3 and stopping dancer roller 23 at a fixed position, the position at which dancer roller 23 stops can be made constant within the detection range of fixed position sensor 28.

[0124] If it is determined in step S203 that the home position sensor 28 is not on and that the dancer roller 23 is in a position other than the home position (NO in step S203), then it is determined in step S204 whether the limit position sensor 27 is on. The processing in step S204 is the same as step S103 described with reference to Figure 15, and therefore a description thereof will be omitted.

[0125] If it is determined that the limit position sensor 27 is on (YES in step S204), the dancer roller 23 is moved from the limit position beyond the home position and then further moved to the home position.

[0126] Specifically, the process proceeds to step S216 via connector 3, where winding of the packaging material 2 onto the roll 3 begins. In step S217, it is determined whether the fixed position sensor 28 is on. In step S218, it is determined whether the fixed position sensor 28 is off. In step S219, winding of the packaging material 2 onto the roll 3 is completed. The processes of steps S216 to S219 are the same as the processes of steps S107 to S110 described with reference to FIG. 16, and therefore their description will be omitted. Next, the processes of steps S213 to S215 are performed via connector 4.

[0127] If it is determined in step S204 that the limit position sensor 27 is not on and that the dancer roller 23 is in a position other than the home position or the limit position (NO in step S204), unwinding of the packaging material 2 from the roll 3 is started in step S205. The packaging control unit 201 sends a control signal to the unwinding / winding motor 35 to rotate the mounted portion 21 in the direction in which the packaging material 2 is unwound from the roll 3.

[0128] Next, in step S206, it is determined whether or not home position sensor 28 is ON. If it is determined that home position sensor 28 is not ON and dancer roller 23 is not in the home position (NO in step S206), then in step S208, it is determined whether or not limit position sensor 27 is ON. If it is determined that limit position sensor 27 is not ON and dancer roller 23 is still in a position other than the home position or the limit position, the process returns to the determination in step S206. The determinations in steps S206 and S207 are repeated until either home position sensor 28 or limit position sensor 27 is ON, during which time unwinding of the packaging material continues.

[0129] If it is determined in step S206 that the fixed position sensor 28 has turned on (YES in step S206), the process proceeds to step S207, where the unwinding of the packaging material 2 from the wound body 3 is terminated. In this case, when the return-to-fixed position operation is initiated, the dancer roller 23 is between the fixed position and the retracted position, and unwinding the wound body 3 moves the dancer roller 23 in a direction toward the limit position, thereby stopping the dancer roller 23 at the fixed position. As a result, the positions at which the dancer rollers 23 stop are aligned, so the process proceeds to Fig. 19 via connector 5, and the process ends without moving the dancer roller 23 to the limit position.

[0130] If it is determined in step S208 that limit position sensor 27 has turned on (YES in step S208), the process proceeds to step S209, where unwinding of packaging material 2 from wound body 3 is terminated. In this case, when the return-to-home operation is started, dancer roller 23 is between the limit position and the home position, and unwinding wound body 3 moves dancer roller 23 in the direction toward the limit position, causing dancer roller 23 to stop at the limit position. Therefore, the processes of steps S216 to S219 described above, followed by the processes of steps S213 to S215, are performed, wound body 3 is unwound, and dancer roller 23 is stopped at the home position.

[0131] In this way, the return operation of the dancer roller 23 to the fixed position when the wound body is attached is performed. Then, the return operation to the fixed position is completed ("END" in FIG. 19).

[0132] Fig. 21 is a schematic diagram showing the movement of dancer roller 23 while it is returning to its home position when the wound body is attached. Similar to Fig. 17, Fig. 21 shows the movement range of dancer roller 23 and the detection ranges of limit position sensor 27, home position sensor 28, and retracted position sensor 29.

[0133] As explained in steps S203, S210 to S215 above, when the dancer roller 23 is in its home position at the start of the home position return operation, the dancer roller 23 moves from its home position to the retracted position and then back to its home position, as indicated by the arrow D in Figure 21.

[0134] As explained in steps S204, S216 to S219, and S213 to S215, when the dancer roller 23 is at the limit position at the start of the return-to-home operation, the dancer roller 23 moves from the limit position beyond the home position and then moves back to the home position, as indicated by the arrow E in Figure 21.

[0135] As explained in steps S205 to S207, when the dancer roller 23 is between the home position and the retracted position at the start of the home position return operation, the dancer roller 23 moves to the home position as indicated by the arrow indicated by symbol F in Figure 21.

[0136] As explained in steps S205, S208 to S209, S216 to S219, and S213 to S215, when the dancer roller 23 is between the limit position and the fixed position at the start of the return to fixed position operation, the dancer roller 23 first moves to the limit position, moves from the limit position beyond the fixed position, and then moves back to the fixed position, as shown by the arrow indicated by symbol G in Figure 21.

[0137] In this way, the wound body 3 is unwound and the dancer roller 23 is stopped at a fixed position, and the direction of movement of the dancer roller 23 when attempting to stop the dancer roller 23 at the fixed position is set to one direction. By aligning the position at which the dancer roller 23 stops, the operation of the dancer roller 23 to return to the fixed position can be reliably executed.

[0138] The rotation speed of the wound body 3 during the unwinding of the wound body 3 in steps S205 to S207 and steps S205 to S209, the winding of the wound body 3 in steps S210 to S212, the unwinding of the wound body 3 in steps S213 to S215, and the winding of the wound body 3 in steps S216 to S219 is set to the rotation speed set based on the remaining amount information of the packaging material 2 acquired from the recording medium 3b, which was set in step S2 shown in Fig. 14. The unwinding / winding motor 35 is driven to rotate the wound body 3 at the rotation speed set based on the remaining amount information of the packaging material 2, and a return-to-position operation is performed.

[0139] As a result, there is no need to rotate the unwinding / winding motor 35 at the minimum speed during the return-to-fixed position operation, and the unwinding / winding motor 35 can be rotated at an appropriate rotation speed. There is also no need for processing to determine the remaining amount of packaging material 2. Therefore, the return-to-fixed position operation can be performed in a short time, and the time required for the return operation when the roll is attached can be shortened.

[0140] Unlike the initial operation, the return operation of dancer roller 23 to its home position when the wound body is installed does not also serve as a sensor check operation. If home position sensor 28 is on in steps S203 and S206, the return operation ends without moving dancer roller 23 to its limit position. By reducing the movement of dancer roller 23, the time required for the return operation to its home position can be reliably shortened.

[0141] Fig. 22 is a flowchart showing the operations of the unwinding / winding unit and the conveying unit in the packaging operation. As shown in Fig. 22, when the packaging device 1 starts packaging the objects to be packaged, first, in step S301, remaining amount information indicating the remaining amount of packaging material 2 in the roll 3 is obtained from the IC tag. In step S302, the rotation speed is set based on the remaining amount information. The processing of steps S301 to S302 is the same as the processing of steps S1 to S2 described with reference to Fig. 14, and therefore description thereof will be omitted.

[0142] Next, in step S303, it is determined whether the number of packages that the packaging device 1 has packaged since the start of packaging has reached the designated number of packages. If it is determined that the designated number of packages has not been reached (NO in step S303), then in step S304, the conveying unit starts conveying the packaging material 2. The packaging control unit 201 sends a control signal to the conveying motor 8m to drive the conveying motor 8m. During the conveying operation of the packaging material 2, the packaging control unit 201 sends a control signal to the unwinding / take-up motor 35 to keep the unwinding / take-up motor 35 stopped. Therefore, the packaging material 2 is not unwound from the roll 3.

[0143] Next, in step S305, it is determined whether the conveying operation has ended. The packaging control unit 201 calculates the conveying distance of the packaging material 2 based on the drive amount of the conveying motor 8m. When the packaging material 2 has been conveyed the length of one package of packaging material, the conveying operation of the packaging material 2 ends. The packaging control unit 201 sends a control signal to the conveying motor 8m to stop it. When the conveying operation of the packaging material 2 has ended, the dancer roller 23 has moved from its home position to its conveying movement position. Next, in step S306, the unwinding operation by the unwinding / winding unit is started.

[0144] Fig. 23 is a flowchart showing a first example of the unwinding operation by the unwinding / winding unit. Fig. 23 shows a flowchart showing an example of the subroutine of the unwinding operation performed in step S306.

[0145] 23, first, in step S401, unwinding of the packaging material 2 from the roll 3 is started. The packaging control unit 201 sends a control signal to the unwinding / take-up motor 35 to rotate the fitted portion 21 in the direction of unwinding the packaging material 2 from the roll 3. At this time, the packaging control unit 201 drives the unwinding / take-up motor 35 to rotate at a rotation speed based on the remaining amount information of the packaging material 2 set in step S302.

[0146] Next, in step S402, it is determined whether the fixed position sensor 28 is on. If it is determined that the fixed position sensor 28 is not on and the dancer roller 23 is not in the fixed position (NO in step S402), the determination in step S402 is repeated until it is detected that the dancer roller 23 is in the fixed position, during which time the unwinding of the packaging material 2 continues. If it is determined that the dancer roller 23 is in the fixed position (YES in step S402), the process proceeds to step S403, where the unwinding of the packaging material 2 from the roll 3 is terminated. The packaging control unit 201 sends a control signal to the unwinding / take-up motor 35 to stop it.

[0147] During the unwinding operation, the dancer roller 23 moves from a movement position during transport to a fixed position. The movement position during transport changes depending on the length of one package of the package in the transport direction DR. The relationship between the length of one package of the package and the movement position during transport is stored in advance in the packaging control unit 201. The packaging control unit 201 derives the movement distance of the dancer roller 23 during the unwinding operation depending on the length of one package of the package.

[0148] Once the unwinding operation is complete, next, in step S404, the remaining amount of packaging material 2 on the roll 3 is determined. The number of steps of the stepping motor is counted from when the unwinding / winding motor 35 starts driving the roll 3 in step S401 until it is detected in step S402 that the dancer roller 23 is in its home position. The winding diameter of the packaging material 2 on the roll 3 is determined by counting the number of steps of the stepping motor while the dancer roller 23 moves from its transport position to its home position. The remaining amount of packaging material 2 on the roll 3 can be determined by finding the winding diameter of the packaging material 2 based on the number of steps of the unwinding / winding motor 35.

[0149] If the wound diameter of the packaging material 2 is small, the number of rotations of the packaging material 2 required to move the dancer roller 23 a certain distance increases, and at this time the number of steps of the stepping motor increases. If the wound diameter of the packaging material 2 is large, the number of rotations of the packaging material 2 required to move the dancer roller 23 a certain distance decreases, and at this time the number of steps of the stepping motor decreases. Therefore, by storing in advance in the packaging control unit 201 the relationship between the number of steps of the stepping motor and the remaining amount of packaging material 2, it is possible to determine the remaining amount of packaging material 2 in the wound body 3 based on the number of steps of the unwinding / winding motor 35.

[0150] Next, in step S405, the determination result of the remaining amount of packaging material 2 determined in step S404 is written to the IC tag as remaining amount information. The reading / writing unit 3R (FIG. 13) accesses the IC tag provided on the core tube 3a of the wound body 3, i.e., the recording medium 3b (FIG. 2), and writes the remaining amount information to the recording medium 3b. This updates the remaining amount information recorded on the recording medium 3b.

[0151] In the first example shown in Fig. 23, remaining amount information is written to the IC tag every time one packet is unwound, and then the unwound process ends ("End" in Fig. 23).

[0152] Fig. 24 is a flowchart showing a second example of the unwinding operation by the unwinding / winding unit. Fig. 24 shows a flowchart showing another example of the subroutine for the unwinding operation performed in step S306.

[0153] 24, first, in step S501, unwinding of the packaging material 2 from the roll 3 is started. The packaging control unit 201 sends a control signal to the unwinding / take-up motor 35 to rotate the fitted portion 21 in the direction of unwinding the packaging material 2 from the roll 3. At this time, the packaging control unit 201 drives the unwinding / take-up motor 35 to rotate at a rotation speed based on the remaining amount information of the packaging material 2 set in step S302.

[0154] Next, in step S502, it is determined whether the fixed position sensor 28 is on. If it is determined that the fixed position sensor 28 is not on and the dancer roller 23 is not in the fixed position (NO in step S502), the determination in step S502 is repeated until it is detected that the dancer roller 23 is in the fixed position, during which time the unwinding of the packaging material 2 continues. If it is determined that the dancer roller 23 is in the fixed position (YES in step S502), the process proceeds to step S503, where the unwinding of the packaging material 2 from the roll 3 is terminated. The packaging control unit 201 sends a control signal to the unwinding / take-up motor 35 to stop it.

[0155] Once the unwinding operation is complete, the remaining amount of packaging material 2 in the roll 3 is calculated in step S504. The number of steps of the stepping motor is counted from when the unwinding / take-up motor 35 starts driving the roll 3 in step S501 until it is detected in step S502 that the dancer roller 23 is in its home position. The remaining amount of packaging material 2 in the roll 3 can be calculated based on the number of steps of the stepping motor taken while the dancer roller 23 moves from its transport position to its home position.

[0156] Next, in step S505, the calculation result of the remaining amount of packaging material 2 calculated in step S504 is compared with the current remaining amount information to determine whether the calculation result of the remaining amount of packaging material 2 is smaller than the current remaining amount information. In other words, it is determined whether the currently calculated remaining amount of packaging material 2 is smaller than the remaining amount of packaging material 2 recorded on recording medium 3b at this point in time, which was obtained from recording medium 3b in step S301.

[0157] If it is determined that the calculation result of the remaining amount of packaging material 2 is smaller than the current remaining amount information (YES in step S405), then in step S506, 1 is added to the number of times it has been determined that the calculation result of the remaining amount of packaging material 2 is smaller than the current remaining amount information. More specifically, if the number of times it has been determined that the calculation result of the remaining amount of packaging material 2 is smaller than the current remaining amount information as of step S405 is N (N is an integer greater than or equal to zero), the number of times in step S506 is set to (N+1). For example, if the number of times it has been determined that the calculation result of the remaining amount of packaging material 2 is smaller than the current remaining amount information as of step S505 is two, the number of times in step S506 is set to three.

[0158] Next, in step S507, it is determined whether the number of times after the addition in step S506 is equal to or greater than a threshold value. If it is determined that the number of times is equal to or greater than the threshold value (YES in step S507), the process proceeds to step S508, where the determination result of the remaining amount of packaging material 2 determined in step S504 is written to the IC tag as remaining amount information. For example, if the threshold value used in the determination in step S507 is 5, and it is determined that the calculation result of the remaining amount of packaging material 2 is smaller than the current remaining amount information five consecutive times, the remaining amount information is written to recording medium 3b, and the remaining amount information recorded on recording medium 3b is updated.

[0159] The remaining amount information may be updated by using the latest calculation result of the remaining amount of packaging material 2 calculated in step S504 as the remaining amount determination result. For example, if the threshold value used in the determination in step S507 is 5, and it is determined that the calculation result of the remaining amount of packaging material 2 is smaller than the current remaining amount information five times in a row, the fifth calculation result may be recorded on recording medium 3b as new remaining amount information.

[0160] Alternatively, the remaining amount information may be updated by using the largest calculation result among the multiple calculation results of the remaining amount of packaging material 2 calculated in step S504 as the remaining amount information. For example, if the threshold value used in the determination in step S507 is 5, and it is determined that the calculation results of the remaining amount of packaging material 2 are smaller than the current remaining amount information five times in a row, the largest calculation result among the five calculation results may be recorded on recording medium 3b as new remaining amount information.

[0161] Alternatively, the remaining amount information may be updated by using the most frequently occurring calculation result among the multiple calculation results of the remaining amount of packaging material 2 calculated in step S504 as the remaining amount information. For example, if the threshold value used in the judgment in step S507 is 5 and it is determined that the calculation results of the remaining amount of packaging material 2 are smaller than the current remaining amount information five times in a row, and four of the five calculation results are the same value but the other one is different, the same value as the four calculation results excluding the one calculation result with a different value may be recorded on recording medium 3b as new remaining amount information.

[0162] Alternatively, if multiple levels are set for the remaining amount of packaging material 2, the remaining amount information may be updated by decreasing the remaining amount by one level. For example, if the threshold value used for the determination in step S507 is 5, and it is determined that the calculation results for the remaining amount of packaging material 2 five times in a row are smaller than the remaining amount at the current level, the remaining amount may be decreased by one level regardless of the five calculation results, and this may be recorded on recording medium 3b as new remaining amount information.

[0163] In this way, the remaining amount information recorded on the recording medium 3b is updated. In step S509, the number of times that it has been determined that the calculation result of the remaining amount of the packaging material 2 is smaller than the current remaining amount information is initialized. In other words, the number is set to zero. Then, the unwinding operation is terminated.

[0164] If it is determined in step S507 that the number of times is less than the threshold value (NO in step S507), the unwinding operation is terminated without updating the remaining amount information.

[0165] If it is determined in step S505 that the calculation result of the remaining amount of packaging material 2 is equal to or greater than the current remaining amount information (NO in step S505), the process proceeds to step S510, where the number of times that the calculation result of the remaining amount of packaging material 2 was determined to be smaller than the current remaining amount information is initialized. In other words, the number is set to zero. Then, the unwinding operation ends without updating the remaining amount information.

[0166] Alternatively, if it is determined in step S505 that the calculation result of the remaining amount of packaging material 2 is equal to or greater than the current remaining amount information, the unwinding operation may be terminated without any further action. In other words, if the result in step S505 is NO, step S510 shown in FIG. 24 may be skipped and the unwinding operation may be terminated directly. In this case, even if it is determined that the calculation result of the remaining amount of packaging material 2 is equal to or greater than the current remaining amount information, the number of times that the calculation result of the remaining amount of packaging material 2 is determined to be smaller than the current remaining amount information is not initialized. As a result, when the cumulative number of times that the calculation result of the remaining amount of packaging material 2 is determined to be smaller than the current remaining amount information reaches a threshold value or greater, the remaining amount information is updated.

[0167] For example, if the threshold value used in the judgment in step S507 is 5, and the calculation result of the remaining amount of packaging material 2 is judged to be smaller than the current remaining amount information four consecutive times, and the calculation result of the remaining amount of packaging material 2 is judged to be larger than the current remaining amount information on the fifth judgment, and the calculation result of the remaining amount of packaging material 2 is judged to be smaller than the current remaining amount information on the sixth judgment, the cumulative number of times that the calculation result of the remaining amount of packaging material 2 is judged to be smaller than the current remaining amount information will exceed the threshold value, and the remaining amount information recorded on recording medium 3b will be updated.

[0168] In the second example shown in Fig. 24, the remaining amount information is written to the IC tag only when the determination result of the remaining amount changes, and then the unwinding process ends ("End" in Fig. 24).

[0169] Fig. 25 is a flowchart showing a third example of the unwinding operation by the unwinding / winding unit. Fig. 25 shows a flowchart showing yet another example of the subroutine for the unwinding operation performed in step S306.

[0170] In steps S601 to S604 shown in FIG. 25, the same processing as in steps S501 to S504 described with reference to FIG. 24 is performed.

[0171] After calculating the remaining amount of packaging material 2 in the roll 3, in step S605, the calculation result of the remaining amount of packaging material 2 calculated in step S604 is compared with the current remaining amount information to determine whether the calculation result of the remaining amount of packaging material 2 differs from the current remaining amount. In other words, it is determined whether the remaining amount of packaging material 2 obtained from recording medium 3b in step S301 and recorded on recording medium 3b at this point in time differs from the currently calculated remaining amount of packaging material 2.

[0172] If it is determined that the calculation result of the remaining amount of packaging material 2 differs from the current remaining amount information (YES in step S605), then in step S606 it is determined whether the calculation result of the remaining amount of packaging material 2 calculated in step S604 matches the calculation result of the remaining amount of packaging material 2 calculated in the previous unwinding operation.

[0173] If it is determined that the calculation result of the remaining amount of packaging material 2 matches the previous calculation result (YES in step S606), then in step S607, 1 is added to the number of times it has been determined that the calculation result of the remaining amount of packaging material 2 matches the previous calculation result. More specifically, if the number of times it has been determined that the calculation result of the remaining amount of packaging material 2 matches the previous calculation result as of step S606 is N (N is an integer greater than or equal to zero), the number of times in step S607 is incremented to (N+1). For example, if the number of times it has been determined that the calculation result of the remaining amount of packaging material 2 matches the previous calculation result as of step S606 is 2, the number of times in step S607 is incremented to 3.

[0174] If it is determined in step S606 that the calculation result of the remaining amount of packaging material 2 does not match the previous calculation result (NO in step S606), the process of incrementing the number of times in step S607 is skipped.

[0175] Next, in step S608, it is determined whether the number of times after the addition in step S607 is equal to or greater than a threshold value. If it is determined that the number of times is equal to or greater than the threshold value (YES in step S608), the process proceeds to step S609, where the calculation result of the remaining amount of packaging material 2 calculated in step S504 is recorded on recording medium 3b as new remaining amount information. For example, if the threshold value used in the determination in step S608 is 5, and it is determined that the calculation result of the remaining amount of packaging material 2 matches the previous calculation result five consecutive times, the fifth calculation result is written to recording medium 3b as new remaining amount information, and the remaining amount information recorded on recording medium 3b is updated.

[0176] In step S610, the number of times that it has been determined that the calculation result of the remaining amount of packaging material 2 matches the previous calculation result is initialized, that is, the number is set to zero, and the unwinding operation is then terminated.

[0177] If it is determined in step S608 that the number of times is less than the threshold value (NO in step S608), the calculation result of the remaining amount of packaging material 2 is not reflected in the remaining amount determination result, and the unwinding operation is terminated.

[0178] If it is determined in step S605 that the calculation result of the remaining amount of packaging material 2 is the same as the current remaining amount information (NO in step S605), the process proceeds to step S611, where the number of times that it has been determined that the calculation result of the remaining amount of packaging material 2 matches the previous calculation result is initialized. In other words, the number is set to zero. Then, the unwinding operation is terminated without reflecting the calculation result of the remaining amount of packaging material 2 in the remaining amount information.

[0179] In the third example shown in Fig. 25, remaining amount information is written to the IC tag only when the determination result of the remaining amount changes, and then the unwinding process ends ("End" in Fig. 25).

[0180] 22, once the unwinding operation in step S306 is completed, a determination is made in step S307 as to whether or not all of the predetermined operations, such as the heat sealing, printing, perforation, and cutting, that should be performed while the conveying unit is stopped from moving the packaging material 2, have been completed. The determination in step S307 is repeated until all of the predetermined operations have been completed.

[0181] When all the predetermined operations are completed (YES in step S307), the process returns to step S301. After the process of acquiring information about the remaining amount of packaging material 2 in step S301 and the process of setting the rotation speed in step S302, a determination is again made in step S303 as to whether the number of packages packaged up to this point has reached the designated number of packages. The conveyance of packaging material 2 and the unwinding of packaging material 2 from the roll 3 are repeated in accordance with steps S304 to S307 until the number of packages packaged by the packaging device 1 reaches the designated number of packages. When it is determined that the designated number of packages has been reached (YES in step S303), the series of packaging operations by the unwinding / winding unit and the conveying unit ends ("End" in FIG. 22).

[0182] In steps S301 and S302, the setting of the rotation speed based on the remaining amount information of the packaging material 2 may be performed only at the beginning of the packaging operation. In other words, when it is determined in step S307 that all predetermined operations have been completed, the series of processes related to the packaging operation may be performed so that the process returns to the determination in step S303.

[0183] The packaging device 1 of this embodiment calculates the movement distance of the dancer roller 23 based on the detection result by the position detection unit, and also counts the number of steps of the unwinding / winding motor 35, which is a stepping motor, to measure the drive amount of the unwinding / winding motor 35 while the dancer roller 23 is moving. The remaining amount of packaging material 2 in the roll 3 is calculated from the drive amount of the unwinding / winding motor 35 relative to the movement amount of the dancer roller 23.

[0184] The remaining amount of packaging material 2 is calculated using a position detector provided to detect whether dancer roller 23 is at a fixed position or a limit position, and unwinding / winding motor 35 that generates a driving force to rotate winding body 3 and unwind packaging material 2 from winding body 3. The remaining amount of packaging material 2 in winding body 3 can be calculated using only parts that have other uses, in other words, without the need to add any parts dedicated to calculating the remaining amount of packaging material 2. This allows the configuration of packaging device 1 to be simplified.

[0185] Static electricity or other factors can cause the packaging material 2 to stick to the reel 3, preventing the packaging material 2 from being unwound even when the reel 3 is rotated. If the amount of packaging material 2 unwound from the reel 3 is less than it should be, the drive amount of the unwinding / winding motor 35 for moving the dancer roller 23 a predetermined distance increases, causing the calculation result of the remaining amount of packaging material 2 to be less than the actual remaining amount. If it is determined that the remaining amount of packaging material 2 is low based on a calculation result that shows a smaller amount than the actual remaining amount of packaging material 2, and the rotation speed of the unwinding / winding motor 35 is increased, the reel 3 will rotate at an excessive speed, which may cause the stepping motor to lose synchronism or the packaging material 2 to become loose.

[0186] Therefore, in the packaging device 1 of this embodiment, the remaining amount determination result is updated based on multiple calculation results. Even if the rotation speed of the unwinding / winding motor 35 is high when calculating the remaining amount of packaging material 2 and it is detected once that the remaining amount of packaging material 2 is low, the calculation result of the remaining amount of packaging material 2 at that time is not used as the remaining amount determination result. Rather, the remaining amount determination result is updated when it is determined multiple times that the remaining amount of packaging material 2 is low. In this way, temporary fluctuations in the calculation result of the remaining amount of packaging material 2 are no longer reflected in the remaining amount determination result, and the accuracy of detecting the remaining amount of packaging material 2 can be improved. Therefore, it is possible to prevent the occurrence of an event in which the roll 3 is rotated at an excessive speed compared to the actual remaining amount of packaging material 2.

[0187] Even if the amount of packaging material 2 unwound from the roll 3 is small due to the packaging material 2 sticking to the roll 3, once the sticking of the packaging material 2 is resolved, the original unwinding rate according to the rotation of the roll 3 is restored and the original remaining amount of packaging material 2 is calculated.

[0188] When updating the remaining amount information of the packaging material 2, the update is performed so as to decrease the remaining amount of packaging material 2 in the roll 3. As the packaging operation is performed, the packaging material 2 is unwound from the roll 3, so the newly written remaining amount of packaging material 2 is always smaller than the remaining amount of packaging material 2 already recorded in the recording medium 3b.

[0189] Fig. 26 is a flow chart showing another example of the return-to-home position operation of dancer roller 23 during the initial operation. Fig. 27 is a schematic diagram showing the movement of dancer roller 23 during the execution of another example of the return-to-home position operation of dancer roller 23 during the initial operation.

[0190] Another example of the return operation of dancer roller 23 to its home position during initial operation shown in Figures 26 and 27 differs from the example shown in Figures 15 to 17 in the movement of dancer roller 23 when stopping dancer roller 23 at its home position. In steps S701 to S708, the same processing as in steps S101 to S108 shown in Figures 15 and 16 is performed.

[0191] If it is detected in step S708 that the fixed position sensor 28 has been turned on (YES in step S108), then in step S709, the winding of the packaging material 2 onto the roll 3 is completed. Instead of moving the dancer roller 23 beyond the fixed position as in the example shown in Fig. 16, the packaging material 2 is wound up and the dancer roller 23 is stopped at the fixed position.

[0192] In the example shown in Fig. 26, the processes of steps S109 and S111 to S113 shown in Fig. 16 are omitted. Compared to Fig. 17, in Fig. 27, dancer roller 23 stops when it reaches the home position from the limit position, as shown by the arrow indicated by symbol B, and there is no movement of dancer roller 23 corresponding to the arrow indicated by symbol C in Fig. 17. In this way, the movement distance of dancer roller 23 is shortened, so that the home position return operation can be completed in a shorter time.

[0193] Fig. 28 is a flowchart showing another example of the return-to-home operation of dancer roller 23 when a wound body is attached. Fig. 29 is a schematic diagram showing the movement of dancer roller 23 during execution of another example of the return-to-home operation of dancer roller 23 when a wound body is attached.

[0194] Another example of the return operation of dancer roller 23 to its fixed position when a wound body is attached, shown in Figures 28 and 29, differs from the example shown in Figures 18 to 21 in the movement of dancer roller 23 when stopping dancer roller 23 at its fixed position. In steps S801 to S809, the same processing as in steps S201 to S209 shown in Figure 18 is performed.

[0195] If it is detected in step S803 that the fixed position sensor 28 is on (YES in step S803), the return operation ends without winding or unwinding the packaging material 2.

[0196] If it is detected in step S804 that the limit position sensor 27 is on (YES in step S804), the process proceeds to step S810, where winding of the packaging material 2 onto the roll 3 begins, similar to step S216 shown in Fig. 20. In step S811, a determination as to whether the fixed position sensor 28 is on is repeated until it is detected that the fixed position sensor 28 has turned on.

[0197] When it is detected that the fixed position sensor 28 has been turned on (YES in step S811), then in step S812, the winding of the packaging material 2 onto the roll 3 is completed. Instead of moving the dancer roller 23 beyond the fixed position as in the example shown in Figure 20, the packaging material 2 is wound up and the dancer roller 23 is stopped at the fixed position.

[0198] When unwinding of packaging material 2 from roll 3 is completed in step S809, steps S810 to S812 are carried out to wind up packaging material 2 until dancer roller 23 reaches a fixed position, and then the return operation is completed.

[0199] In the example shown in Fig. 28, the processes of steps S210 to S215 and S218 shown in Figs. 19 and 20 have been omitted. Compared to Fig. 21, in Fig. 29, at symbol D, dancer roller 23 does not move and remains stopped in its fixed position, and as shown by the arrows shown by symbols E and G, dancer roller 23 stops when it reaches its fixed position from its limit position, completing its return operation. In this way, the movement distance of dancer roller 23 during the return operation is shortened, so that the return operation to its fixed position can be completed in a shorter time.

[0200] Next, a method for manufacturing the wound body 3 will be described. Fig. 30 is a flowchart showing a first example of the method for manufacturing the wound body 3. Fig. 31 is a diagram schematically showing a first example of the method for manufacturing the wound body 3.

[0201] In the method for manufacturing the wound body 3, first, a core tube 3a is prepared (step S1001), as shown in Fig. 30. As shown in Fig. 31, a core tube 3a having a recording medium 3b as described with reference to Fig. 2 is prepared. Alternatively, in an example in which the recording medium 3b is attached to the beginning of the winding of the packaging material 2, a core tube 3a without a recording medium 3b may be prepared.

[0202] Next, the packaging material 2 is wound around the core tube 3a (step S1002). As shown in Fig. 31, the packaging material 2 is wound around the core tube 3a to form a wound body 3.

[0203] Finally, the amount of packaging material 2 wound around the core tube 3a in step S1002 is written to the recording medium 3b as remaining amount information indicating the remaining amount of packaging material 2 in the wound body 3 (step S1003). This makes it possible to rotate the wound body 3 at an appropriate rotation speed set based on the remaining amount information of packaging material 2 recorded on the recording medium 3b when the wound body 3 is loaded into the packaging device 1. This reduces the time required for the return operation when loading the wound body. Then, the process for manufacturing the wound body 3 ends ("End" in Figure 30).

[0204] In step S1001, a core tube 3a is prepared after the previously wound packaging material 2 has been used up, and in step S1002, new packaging material 2 may be wound around the core tube 3a. In this case, in step S1003, the amount of packaging material 2 wound around the core tube 3a in step S1002 is written to the recording medium 3b as remaining amount information indicating the remaining amount of packaging material 2 in the wound body 3, thereby overwriting and updating the remaining amount information already recorded on the recording medium 3b.

[0205] Furthermore, if the amount of packaging material 2 to be wound around the core tube 3a is predetermined, the order of steps S1002 and S1003 may be reversed.

[0206] Fig. 32 is a flowchart showing a second example of the method for manufacturing the wound body 3. Fig. 33 is a diagram schematically showing the second example of the method for manufacturing the wound body 3.

[0207] In a second example of the method for manufacturing the wound body 3, as shown in Fig. 32, first, a core tube 3a is prepared (step S1101). As shown in Fig. 33, a core tube 3a having a recording medium 3b as described with reference to Fig. 2 is prepared. Alternatively, in an example in which the recording medium 3b is attached to the beginning of the winding of the packaging material 2, a core tube 3a without a recording medium 3b may be prepared.

[0208] Meanwhile, a hollow cylindrical tube portion 3c is prepared (step S1102). The tube portion 3c has an inner diameter slightly larger than the outer diameter of the core tube 3a. Next, the packaging material 2 is wound around the tube portion 3c (step S1103) to form a wound object 3X (step S1104). The preparation of the core tube 3a in step S1101 and the preparation of the wound object 3X in steps S1102 to S1104 may be performed in parallel, or one process may be performed before the other. The wound object 3X may be formed at a location different from the location of the manufacturing equipment for the wound object 3.

[0209] Next, the core tube 3a is inserted into the tube portion 3c to integrate the wound object 3X and the core tube 3a (step S1105). For example, the wound object 3X and the core tube 3a can be integrated by inserting the core tube 3a with a rubber band wrapped around it into the hollow portion of the hollow cylindrical tube portion 3c. In this way, the wound body 3 is produced.

[0210] Finally, the amount of packaging material 2 wound around the cylindrical portion 3c in step S1103 is written to the recording medium 3b as remaining amount information indicating the remaining amount of packaging material 2 in the wound body 3 (step S1106). This makes it possible to rotate the wound body 3 at an appropriate rotation speed set based on the remaining amount information of packaging material 2 recorded on the recording medium 3b when the wound body 3 is attached to the packaging device 1. This reduces the time required for the return operation when the wound body is attached. Then, the process for manufacturing the wound body 3 ends ("End" in FIG. 32).

[0211] In step S1101, a core tube 3a is prepared after the previously wound packaging material 2 has been used up, and in step S1105, the core tube 3a and the wound object 3X are integrated. In this case, in step S1106, the amount of packaging material 2 wound around the cylindrical portion 3c in step S1103 is written to the recording medium 3b as remaining amount information indicating the remaining amount of packaging material 2 in the wound object 3, thereby overwriting and updating the remaining amount information already recorded on the recording medium 3b.

[0212] Furthermore, if the amount of packaging material 2 to be wound around the cylindrical portion 3c is predetermined, the order of steps S1105 and S1106 may be reversed.

[0213] Although the embodiments of the present invention have been described above, the embodiments disclosed herein are illustrative in all respects and should not be considered limiting. The scope of the present invention is defined by the claims rather than the above description, and it is intended to include meanings equivalent to the claims and all modifications within the scope of the claims. [Explanation of symbols]

[0214] 1 packaging device, 2 packaging material, 3 roll, 3R reading / writing unit, 3a core tube, 3b recording medium, 5 supply unit, 6 storage unit forming unit, 6h heater, 6m pressure motor, 8 packaging material conveying unit, 8m conveying motor, 9 packaging unit, 10 packaging material supply unit, 11 direction change bar, 12 cutting unit, 13 discharge unit, 15 frame, 20 casing, 20a outer surface, 21 mounting unit, 22 guide hole, 23 dancer roller, 24, 25 fixed roller, 26 unlocking unit, 27 limit position sensor, 28 fixed position sensor, 29 retracted position sensor, 30 sensor support unit, 31, 38, 45, 66 spring hook unit, 35 unwinding / winding motor, 40 main arm, 41 first arm unit, 42 second arm unit, 43 bending unit, 44 Arm rotation axis, 46 return spring, 47 lock pin, 50 sub-arm, 51 base end, 52 tip end, 53, 65 cylindrical portion, 55 gear positioning plate, 72 intermediate gear, 73 intermediate pinion gear, 74 roller gear, 75 intermediate gear shaft, 78 lock portion, 90 spring hinge, 101 drug supply device, 102 housing, 104 lower housing, 108, 109 door, 200 overall control unit, 201 packaging control unit, DR conveying direction.

Claims

1. A packaging device that packages an object to be packaged using a roll of a long sheet-like packaging material, the roll has a recording medium for storing information, the information including remaining amount information indicating the remaining amount of the packaging material in the roll, The packaging device a driving unit that generates a driving force for rotating the wound body; an information reading unit that reads the remaining amount information stored in the recording medium; a control unit that controls the packaging device, The control unit sets the rotation speed of the wound body based on the remaining amount information read by the information reading unit.

2. a conveying section that conveys the packaging material unwound from the roll along a conveying path; a tension applying unit having a displacement member that is displaceable in a direction intersecting the conveying path, and the displacement member applies tension to the packaging material by pressing the packaging material, The displacement member has a fixed position, 2. The packaging device according to claim 1, wherein when the packaging device is powered on or when the wound body is attached to the packaging device, the control unit drives the drive unit to rotate the wound body at a rotational speed set based on the remaining amount information, thereby moving the displacement member to the fixed position.

3. a position detector for detecting whether the displacement member is at the fixed position; The packaging device according to claim 2 , wherein the control unit unwinds the packaging material from the wound body until the position detection unit detects the displacement member, and moves the displacement member to the fixed position.

4. 4. The packaging device according to claim 3, wherein the control unit winds the packaging material around the winding body until the position detection unit, which has detected the displacement member, no longer detects the displacement member, and then unwinds the packaging material from the winding body until the position detection unit detects the displacement member, thereby moving the displacement member to the fixed position.

5. a position detector for detecting whether the displacement member is at the fixed position; The packaging device according to claim 2 , wherein the control unit winds the packaging material onto the reel until the position detection unit detects the displacement member, and moves the displacement member to the fixed position.

6. the information reading unit is configured to be able to write the remaining amount information to the recording medium, the control unit measures the drive amount of the drive unit while the drive unit is driving the wound body, and determines the remaining amount of the packaging material in the wound body based on the measurement result; 6. The packaging device according to claim 1, wherein the control unit controls the information reading unit to write the determination result of the remaining amount of the packaging material to the recording medium as the remaining amount information.

7. The remaining amount of the packaging material is set to a plurality of stages, The packaging device according to claim 6, wherein the control unit controls the information reading unit to write a remaining amount that is one step smaller to the recording medium as the remaining amount information when it is determined that the remaining amount of the packaging material is smaller than the remaining amount at the current stage.

8. A roll used in the packaging device according to any one of claims 1 to 7, The core tube and a long sheet-like packaging material wound around the core tube, The core tube has a recording medium for storing information, and the information includes remaining amount information indicating the remaining amount of the packaging material in the wound body.

9. A roll used in the packaging device according to any one of claims 1 to 7, The core tube and a long sheet-like packaging material wound around the core tube; a recording medium for storing information; The information includes remaining amount information indicating the remaining amount of the packaging material in the roll.

10. A core tube for use in the wound body according to claim 8, the wound body includes the core tube and a long sheet-like packaging material wound around the core tube, A core tube having a recording medium for storing information, the information including remaining amount information indicating the remaining amount of the packaging material in the wound body.

11. A method for manufacturing a wound body used in the packaging device according to any one of claims 1 to 7, comprising: The wound body includes a core tube and a long sheet-like packaging material wound around the core tube, The manufacturing method includes: preparing the core tube; and winding the packaging material around the core tube.

12. the roll has a recording medium for storing information, the information including remaining amount information indicating the remaining amount of the packaging material in the roll, The method for manufacturing a wound body according to claim 11 , further comprising the step of writing the amount of the packaging material wound around the core tube in the winding step as the remaining amount information in the recording medium.

13. A method for manufacturing a wound body used in the packaging device according to any one of claims 1 to 7, comprising: preparing a core tube; a step of preparing a roll by winding a long sheet-like packaging material around a hollow cylindrical portion; and inserting the core tube into the cylindrical portion to integrate the wound material and the core tube.

14. the roll has a recording medium for storing information, the information including remaining amount information indicating the remaining amount of the packaging material in the roll, The method for manufacturing a wound body according to claim 13 , further comprising the step of writing the amount of the packaging material wound around the cylindrical portion as the remaining amount information onto the recording medium.

15. 15. A roll used in the manufacturing method according to claim 13 or 14, comprising a long sheet-like packaging material wound around a hollow cylinder.

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