Sheet processing device and packaging processing device

Abstract

This system enables the efficient placement of flexible sheets with poor shape retention inside containers using a robotic arm equipped with a suction unit. [Solution] The system comprises a suction pad 205, a robot 10, sheet storage sections 700, 780 for storing a sheet bundle SB made of stacked sheets S that are easily deformable and highly flexible, and a control means 900. The control means controls the robot to use the suction pad to adsorb the surface portion of the outermost sheet near the end in the pulling direction, then pull it out of the sheet storage section and drop it diagonally downward.

Description

Technical Field

[0001] The present invention relates to a sheet processing device and a package processing device.

Background Art

[0002] In a manufacturing line or a logistics line, when products or parts are stored in a cardboard box in multiple stages (multiple layers), in order to prevent losses due to interference between parts in a vertical positional relationship, a cushioning sheet is placed between each layer. When such sheet placement work is performed manually, the work efficiency is poor, and there is a problem that the work time becomes long when there are a large number of packages. Work is being done to lay sheets in boxes using industrial robots (robot arms). However, when the sheet used is a strong material such as cardboard or thick paper, it does not deform when gripped or adsorbed, and is easy to handle. Also, since it is difficult to deform when storing a strong sheet in a box, air easily escapes.

[0003] On the other hand, thin resin sheets or thin papers that are weak and easily deformed by their own weight have low shape retention. Therefore, when gripped by a robot arm or adsorbed by a suction pad, the parts that are not gripped or adsorbed easily sag due to their own weight and are easily deformed, making it extremely difficult to handle when packing in a box. For this reason, wrinkles and folds occur when placed in a box, and it no longer functions as a cushioning material. Even if it is successfully placed in a box in a stretched state, air remains between it and the already stored items, etc., making it easy to float, and it takes a long time to vent the air. Therefore, the next packing work cannot be performed until the air is vented and the sheet reaches the bottom, which causes the overall work time to become long.

[0004] Patent Document 1 discloses a box-packing device that uses a robot to automate the process of stacking packs containing multiple fruits in multiple layers within a storage box. Furthermore, it discloses a device that automatically places sheet-like dividers on top of the fruits in each pack using an air cylinder equipped with suction pads. The dividers are stacked horizontally on a support base, and the top divider is lifted up by suction pads, then moved horizontally above the fruits in adjacent storage boxes before being placed on top of the fruits.

[0005] However, in order to suction a horizontally positioned partition material, maintain its horizontal orientation while raising it vertically, and then move it laterally, selecting the suction position of the partition material by the suction pad is crucial. In other words, to satisfy the requirement of using a standard industrial robot to suction the center of the partition material and transport it while maintaining its horizontal orientation, it is necessary to select end effectors such as suction pads and teach the robot's movements, which clearly requires considerable effort in the design and programming of the device. For example, it was not easy to adjust the amount of suction force and the timing of suction and release. Furthermore, this partition material is a rigid sheet material such as cardboard, and it is not intended to handle thin resin sheets or thin paper that are weak and easily deformed by their own weight. Moreover, with this device configuration, it is difficult to quickly lower and fix in place a weak sheet material that tends to float inside the box.

[0006] Next, Patent Document 2 discloses a transport system in which the top sheet of a diagonally arranged sheet stack is picked up and lifted by a suction pad on a robot arm, its direction is changed, and finally transferred onto a conveyor. The part of the sheet to be picked up is below the top edge of the sheet, and the operation of lifting the sheet and changing its direction is complex. Before placing the picked-up sheet onto the conveyor, the sheet surface is supported by the tips of the two arm sections that constitute the placement device, and the arm sections are lowered while the sheet is placed onto the conveyor. As a result, there are many parts, and the configuration is complex and large. In addition, if the sheet is weak and easily deformed when supported by the two arm sections, it will be impossible to transfer it to the conveyor, so the sheets that can be handled are limited to thick cardboard or similar material that is strong and resistant to deformation. Furthermore, since the arm section is essential, and the arm section is configured to extend and retract from the gaps between multiple elongated rollers that constitute the conveyor, the arm section gets in the way when storing the sheets picked up by the suction pad in a box using this device configuration, making it impossible to repurpose this device configuration for packing sheets into boxes. [Prior art documents] [Patent Documents]

[0007] [Patent Document 1] Patent No. 2518105 [Patent Document 2] Patent No. 6948125 [Overview of the Initiative] [Problems that the invention aims to solve]

[0008] The present invention has been made in view of the above, and aims to provide a sheet processing device and a packaging processing device that enable the efficient placement of a flexible sheet with low shape retention properties inside a container by simple movements of a robot equipped with an suction pad. [Means for solving the problem]

[0009] To solve the above problems, the present invention comprises a robot equipped with a suction unit at its tip, a sheet storage unit that stores a sheet bundle made of stacked, highly flexible sheets that are easily deformable, with at least a portion of the main surface of the outermost sheet exposed, and control means for controlling the robot and the suction unit, wherein the control means controls the robot so that the suction unit adsorbs the surface portion of the outermost sheet near the end in the pulling direction, and then pulls it out of the sheet storage unit and drops it diagonally downward. [Effects of the Invention]

[0010] According to the present invention, the process of placing a flexible sheet with poor shape retention inside a container can be efficiently carried out by a robot equipped with a suction unit. [Brief explanation of the drawing]

[0011] [Figure 1] This is an overall explanatory diagram of a sheet processing device and a packaging processing device according to one embodiment of the present invention. [Figure 2] This is an overall perspective view (when retracted) of an end effector, which is a suction device attached to the tip of a robot arm. (a) is a front right perspective view, (b) is a front left perspective view, (c) is a rear right perspective view, and (d) is a rear left perspective view. [Figure 3] This is a front right perspective view showing the overall configuration of the holding unit when it is extended (protruding). [Figure 4] Figure 3 is an exploded perspective view. [Figure 5] (a) and (b) are a front and rear perspective view, respectively, showing the air cylinder unit U1 and the retractable unit U2 separated. [Figure 6] (a) and (b) are a front-side longitudinal section view and a perspective view of the main part of the end effector EE when the suction unit is in the shortened (immersed) state. [Figure 7] (a) and (b) are a front-side longitudinal section view and a perspective view of the main part of the end effector EE when the suction unit is in the extended position (protruding state). [Figure 8] It is a perspective view showing the configuration of a sheet storage section (sheet storage device). [Figure 9] (a) and (b) are diagrams for explaining the procedure of pulling out the sheet and storing it in the container. [Figure 10] (a) and (b) are diagrams for explaining the procedure of pulling out the sheet and storing it in the container. [Figure 11] (a) and (b) are diagrams for explaining the procedure of pulling out the sheet and storing it in the container. [Figure 12] (a) and (b) are diagrams for explaining the procedure of pulling out the sheet and storing it in the container. [Figure 13] (a) and (b) are diagrams for explaining the procedure of pulling out the sheet and storing it in the container. [Figure 14] It is a flowchart showing the procedure of storing the package in the container to form a package layer and the procedure of storing and stacking the required number of sheets on the package layer. [Figure 15] (a) and (b) are perspective views showing the configuration of a modified embodiment of the sheet processing device and the pulling out and storing operations.

Embodiments for Carrying Out the Invention

[0012] Hereinafter, the present invention will be described in detail using the embodiments shown in the drawings. However, the components, types, combinations, shapes, relative arrangements, etc. described in this embodiment are merely illustrative examples and not intended to limit the scope of the present invention only to those, unless otherwise specifically described.

[0013] Hereinafter, embodiments of the present invention will be described in detail. FIG. 1 is an overall explanatory view of a sheet processing apparatus and a package processing apparatus according to an embodiment of the present invention. FIG. 2 is an overall perspective view (when shortened) of an end effector as a suction means attached to the tip of an articulated arm robot (robot arm). FIG. 2(a) is a front right perspective view, (b) is a front left perspective view, (c) is a rear right perspective view, and (d) is a rear left perspective view. FIG. 3 is a front right perspective view showing the overall configuration when the holding unit protrudes (extends). FIG. 4 is an exploded perspective view of FIG. 3. FIGS. 5(a) and (b) are front side perspective views and rear side perspective views showing a state in which the air cylinder unit U1 and the protruding / retracting unit U2 are separated.

[0014] [Basic Configuration of Sheet Processing Apparatus (Package Processing Apparatus)] The sheet processing apparatus (sheet processing system) 1 includes a robot arm (articulated arm robot) 10 driven by a drive source, a cylinder tube (cylinder chamber) 110 attached to the tip of the robot arm 10, an air cylinder 100 having a piston rod 150, a suction unit 200, a protruding / retracting unit U2 that is operated to protrude and retract by the piston rod, a suction unit 200 (holding unit U3) that is operated to protrude and retract by the piston rod, a pneumatic supply device (compressor) 500 that supplies compressed air to the air cylinder 100 (cylinder tube 110) and the suction unit 200, a sheet storage unit 700 that stores a sheet bundle SB in which flexible sheets S with low stiffness and easy deformation are stacked in a state where at least a part of the main surface of the outermost sheet S1 is exposed, a container 800 that receives the outermost sheet S1 that has fallen by being adsorbed by the suction pad 205 of the suction unit and pulled obliquely downward from the sheet storage unit, and a control means 900 that controls the articulated robot 10 and the pneumatic supply device 500.

[0015] The air cylinder unit U1 including the air cylinder 100 and the protruding / retracting unit U2 including the suction unit 200 and operating with respect to the air cylinder unit U1 constitute an end effector EE. The suction unit 200 includes a suction pad 205 and a vacuum generator 207 that supplies negative pressure to the suction pad. The sheet processing device 1 and the belt conveyor 850 that transports the packaged goods to be stored in the container 800 constitute a packaged goods processing device (packaged goods processing system) 1000.

[0016] <Robot Arm 10> As shown in Figure 1 and other figures, the robot arm 10 is a well-known articulated arm robot comprising a base 15 and a plurality of links 25 that are sequentially supported by joints 20 on the base so as to be rotatable in the direction of the arrows. An end effector EE according to the present invention is fixed to the link 25A at the tip of the robot arm 10. The control means 900 moves the entire arm up and down, left and right, diagonally, etc., by rotating each joint in a predetermined direction using a servo motor, which is the drive source of the robot arm, to adjust the height at which work is performed. The robot arm 10 moves its end effector EE onto a package (not shown) on the belt conveyor 850 to pick it up, then picks it up with the suction pad 205, moves it to a predetermined position inside the container 800, releases the suction from the package, and stops it in place.

[0017] Furthermore, the robot arm 10 uses the suction unit 200 to pick up the outermost sheet S1 of the sheet bundle SB held by the sheet storage unit 700, pulls it out, and stores it in the container 800 while allowing it to fall naturally diagonally downward. In addition, immediately after storing it in the container, the suction pad 205 presses down on the part of the sheet that is prone to floating inside the container, thereby quickly eliminating floating and enabling the subsequent sheet pulling and storage operations to be carried out continuously. Because the robot arm is only tasked with simple operations such as pulling out, storing items in containers, and holding down the rear of the seat, the programming and teaching for control can be simplified.

[0018] The direction in which the sheet is pulled out is inclined toward the interior of the container (the inner wall of the container's front wall 800a) located in front of and below the sheet storage section, but the angle of inclination varies depending on the position of the container and the height of the packages accumulated inside the container. Furthermore, since the packages transported from the conveyor belt are stacked in multiple layers inside the container, the height at which the leading edge of the sheet is guided into the container (the height within the container) will differ depending on the height of the packages already stored inside. In other words, the position at which the leading edge of the sheet is guided needs to be different when there is only one layer of packages compared to when there are multiple layers of packages.

[0019] In this embodiment, the size and height of the packages to be accumulated in the container are programmed in advance, and the position in which the leading edge of the sheet is guided is adjusted, such as a specific height position for the first layer and a different height position for the second layer. Alternatively, the position in which the sheet is guided may be adjusted while detecting changes in the situation using a sensor or camera 300 (Figure 1) that detects the actual height of the packages inside the container. Any robotic arm 10 can be used as long as it is a single-arm type and a suction unit can be attached to the link 25A at the tip. A standard six-axis type is sufficient, and it does not need to be able to perform any special movements. Furthermore, the articulated arm robot is just one example; any type of robot can be used as long as it can be equipped with a suction unit at the end of its arm and can transport and process packages or sheets picked up by the suction unit.

[0020] <End Effector EE> Figures 6(a) and (b) are a front longitudinal section view and a perspective view thereof of the main part of the end effector EE when the suction unit is in the shortened (immersed) state, and Figures 7(a) and (b) are a front longitudinal section view and a perspective view thereof of the main part of the end effector EE when the suction unit is in the extended (protruding) state. The end effector EE comprises an air cylinder unit U1 having an air cylinder 100 fixed to the tip link 25A, and a retractable unit U2 having a suction unit 200 that operates relative to the air cylinder unit U1.

[0021] <Air Cylinder Unit U1> As shown in Figures 6 and 7, the air cylinder 100 constituting the air cylinder unit U1 comprises two cylinder tubes 104 arranged adjacently and parallel to each other within a housing 102, and a piston rod 150 supported by each cylinder tube so as to be able to extend and retract. Each cylinder tube is connected to a first supply pipe 502 and a second supply pipe 504, respectively, extending from a pneumatic supply device (compressor) 500. By supplying compressed air from the first supply pipe 502 into each cylinder tube, each piston rod extends, and by supplying compressed air from the second supply pipe 504, each piston rod is retracted. Note that the air cylinder configuration shown in the illustration is just one example, and air cylinders with other configurations can also be used.

[0022] Alternatively, a camera, indicated by reference numeral 300 in Figure 1, may be attached to the tip link 25A to check the packaging or sheet that the suction pad is adsorbing, or to check the condition of the packaging or sheet inside the container. Since the retractable unit U2 is attached to the tip of the piston rod 150 via a connecting member 210, the retractable unit U2 retracts when the piston rod 150 moves in and out.

[0023] The robot arm 10 moves the end effector EE back and forth between the belt conveyor 850 and the container 800, and between the sheet storage section 700 and the container 800. The protruding length of the piston rod 150 is adjusted as needed to improve work efficiency. For example, when picking up packaged goods on the belt conveyor with the suction pad, the work is performed with the piston rod retracted, that is, with the suction unit 200 not protruding. On the other hand, when storing the suctioned packaged goods into a container 800 such as a cardboard box, if the suction unit is retracted, there is a risk that larger components located above the suction unit, such as the air cylinder 100 or other mounted items (such as the camera 300), may interfere with the side wall of the container, worsening work efficiency. Therefore, when storing packaged goods into the container, the piston rod is extended to protrude the suction unit further, preventing the air cylinder and other components from interfering with the side wall of the container.

[0024] Similarly, when the suction unit is retracted when suctioning a sheet from the sheet storage section 700 and storing it in the container, the air cylinder 100 and other mounted components located above it will interfere with the side wall of the container, making storage impossible. Therefore, when storing a sheet in the container, extending the piston rod to protrude the suction pad further prevents the air cylinder and other components from interfering with the side wall of the container. The air cylinder 100 is fixed to the tip link 25A of the robot arm. The housing 102 has two fixing protrusions 102a on its upper end surface, and two holes 110a provided on the upper surface of the cover 110 fit into each of the protrusions 102a, and the cover is fixed to the housing 102 using screws 110b provided on the front of the cover.

[0025] Note that the number of air cylinder units U1 (suction units 200) in a single end effector EE is not limited to one. That is, although the embodiment uses one suction unit to hold the sheet, it is also possible to arrange two or more suction units in the lateral direction to simultaneously hold a single sheet. By suctioning multiple points on the pull-out edge of a single sheet, the stability of holding the sheet can be increased, and deformation such as wrinkles and folds in the sheet can be prevented.

[0026] <Appearing Unit U2> As shown in each figure, the retractable unit U2 generally comprises a connecting member 210 made of an L-shaped plate member having an overhang 210a at the bottom for fixing the tips of both piston rods 150, a connecting block 215 integrated with the upper half of the back plate 210b of the connecting member 210, and a holding unit U3 equipped with a suction unit 200 at its tip. A cushioning member 210c is placed on the upper surface of the overhang 210a. The connecting block 215 and the holding unit U3 are integrated using screws via an L-shaped bracket 230. The vacuum generator 207, which constitutes the suction unit 200, is equipped with an IN port for receiving compressed air, a diffuser, etc., and generates a vacuum in the vacuum port by narrowing the compressed air received from the IN port with a nozzle and then flowing it into the diffuser at high speed. The vacuum port is in communication with the suction pad 205, and the suction end of the suction pad attracts the packaged material or sheet. A pipe 602 extending from the air pressure supply device 500 is connected to the vacuum generator 207. The control means 900 controls the air pressure supply device 500, allowing the suction force (suction power) of the suction pad to be turned on or off at any desired timing. Note that the pneumatic suction unit is just one example; other suction units utilizing static electricity, magnetism, etc., can also be applied.

[0027] <Holding Unit U3> The holding unit U3, which serves as a means for holding the suction unit 200, generally comprises a lower bracket 250 for fixing the suction unit 200, two shafts 252a and 252b fixed to the upper surface of the lower bracket 250 and extending parallel upward, an upper bracket 255 with a U-shaped front surface through holes 255a' and 255b' provided in the lower plate 255a and upper plate 255b respectively, through which the shafts 252a and 252b are inserted so as to be able to move back and forth, and a coil spring (elastic member) 260 positioned on the outer surface of one of the shafts 252a located inside the upper bracket (between the lower plate 255a and the upper plate 255b). The coil spring constitutes an extension and retraction mechanism that elastically extends and retracts (expands and contracts) the suction unit. When pressure or impact is applied to the suction surface of the suction pad, the coil spring 260 absorbs and mitigates the pressure or impact applied via the shaft 252a by contracting. Furthermore, as the sheets are pulled out sequentially from the sheet storage section 700, the position of the sheet on the outermost surface of the sheet bundle moves backward, and the coil spring 260 also absorbs the resulting change in the distance between the suction pad and the outermost surface of the sheet.

[0028] <Seat storage compartment 700> Figure 8 is a perspective view showing the configuration of the seat storage section (seat storage device) 700. The seat storage section 700 generally comprises a frame 710 and two seat storage trays 750 and 760 arranged vertically (front and back) within the frame 710. The frame 710 has a structure in which side plates 717 and a top plate 718 are fixed to a frame 715 formed by assembling shape materials 712 to form a roughly rectangular parallelepiped. Sheet storage trays 750 and 760 are detachably arranged on a support member 720 provided inside the frame 710. The sheet storage trays 750 and 760 are equipped with horizontal members 752 and 762 and vertical members 654 and 754 that form a storage space EP for storing a sheet bundle SB consisting of rectangular sheets S. The size of the storage space can be changed to match the size of the sheet bundle to be stored by adjusting the horizontal position of each vertical member 654 and 754. Replenishing sheet bundles to each sheet storage tray 750 and 760 is done manually from the underside of each storage space EP.

[0029] In this embodiment, the sheet storage trays 750 and 760 tilt their bottom plates backward, thereby holding the main surface (surface) of the sheet bundle stored in each storage space EP in an upward-slanting position. Furthermore, the lower sheet storage tray 760 is located behind the upper sheet storage tray 750 and is positioned with a vertical offset. Therefore, the movement of the robot arm 10 does not hinder the suction pad 205 from adsorbing and pulling out the surface of the sheet S1 near the lower end (end in the pulling direction) of the outermost surface of the sheet bundle in each sheet storage tray.

[0030] The lower cross members (sheet stoppers) 752 and 762 function as stoppers that support the lower edge of the sheet bundle stored in the storage space and prevent it from falling. At the same time, when the robot arm 10 moves, the suction pad 205 adheres to the surface near the lower end of the outermost sheet S1 and pulls it into the container 800 located below, the members are configured not to hinder (guide) the sheet S1 from falling naturally over the cross members. It is preferable to chamfer the front surfaces of the cross members 752 and 762 that come into contact with the lower surface of the sheet being pulled out, or to place low-friction material on them to ensure good sliding with the sheet. The inclination angle of the storage space EP (bottom plate) of the sheet storage trays 750 and 760 should be such that the sheet does not fall out when not attached and is easy to pull out, and the inclination angle shown is just an example; it may be vertical or horizontal. An example of a configuration where the storage space EP is horizontal will be described later. Furthermore, by making the width of the storage compartment EP as narrow as possible and arranging each storage compartment with a front-to-back offset in their vertical position, the installation space for the seat storage unit can be reduced.

[0031] In this embodiment, one example is shown in which ordinary cardboard is stored in the upper sheet storage tray 750, and elastic cushioning material, Miramat (a registered trademark of JASP Co., Ltd.), is stored in the lower sheet storage tray 760. In this case, for example, Miramat, cardboard, and Miramat are stacked in three layers inside the container. Note that this is just one example; you could also store highly flexible sheets in the upper sheet storage tray 750 and cardboard in the lower sheet storage tray 760. The sheet processing apparatus 1 of the present invention is suitable for processing thin paper and other sheets that are weak enough to be easily deformed by their own weight, but it is also suitable for processing thick paper and other sheets with high hardness that are not easily deformed by their own weight. In this specification, "a sheet with weak rigidity and high flexibility" means a sheet that is so weak that when a part of the sheet is grasped or attached, for example, the central part of the sheet, the grasped part or the part of the sheet surrounding the attached part sags significantly due to its own weight.

[0032] <Container 800> The container 800 can be anything that can hold the packaged goods (workpieces) transported by the belt conveyor, such as a cardboard box. In this example, the container is positioned below and in front of the direction in which the sheet is pulled out from the sheet storage section 700, allowing it to smoothly receive the sheet and interpose it between the layers of the packaged goods. Furthermore, even if the container's position is slightly off from the sheet's extraction path, the robotic arm can make minor adjustments to the extraction direction and drop position. [Packaging Processing Equipment (Packaging Processing System) 1000] The sheet processing device 1 and the belt conveyor 850 that transports the packaged goods to be stored in the container 800 constitute a packaged goods processing device (packaged goods processing system) 1000. The robotic arm (articulated robot) 10 moves the end effector EE back and forth between the belt conveyor 850 and the container 800 to move the packaged items on the belt conveyor into the container, and moves the end effector EE forward and backward between the sheet storage section 700 and the container to store the items inside the container.

[0033] Figure 14 is a flowchart illustrating the procedure for placing the packaged goods inside a container to form a packaged goods layer, and the procedure for stacking the required number of sheets on the formed packaged goods layer. The above procedure is as follows: The control means 900 sequentially performs the following steps to complete the storage of one package into the container: step S1 (bringing the suction pad 205 into contact with the package on the belt conveyor 850 using the robot arm 10; step S3 (applying the package with the suction pad); step S5 (moving the robot arm to transfer and store (seat, set) the package inside the container while it is being held in place by the suction pad; step S7 (releasing the package from the suction pad when the package has been fully stored inside the container); and step S9 (moving the robot arm to release the suction pad from inside the container). The above operations are repeated for each package to form the first layer of packages inside the container (step S11). Next, sheets S1 and SS1, which serve as cushioning materials, are sequentially stacked on top of the first layer of packaged goods (group of packaged goods) according to the procedure described later. Once the required number of sheets have been stacked, the process of placing the second layer of packages into the container begins. After the second layer of packages has been placed, the sheets are pulled out and stacked again. In this way, the packaging process is completed by forming a buffer layer consisting of multiple sheets on the top surface of all the layers of packaged material.

[0034] [Instructions for pulling out and storing the seat] <Example of a sheet bundle tilted upwards> After the packaging processing device (packaging processing system) 1000 has finished the operation of storing the first layer of packaging items (groups) into the container 800, the subsequent sheet pulling and stacking operations are carried out in the following procedure. The control means 900 includes the steps of: using the robot arm 10 to bring the suction pad 205 into contact with the surface portion of the outermost sheet S1 of the sheet bundle SB, which is stored in the sheet storage section at an upward angle, near the end in the pulling direction (step S13); supplying compressed air from the air pressure supply device 500 to the vacuum generator 207 to generate negative pressure inside the suction pad and causing the surface portion of the sheet S1 to adhere (step S15); and sliding the suction pad along the surface of the next sheet S2, which remains attached to the sheet S1, towards the container 800 located below. Steps include: operating the robot arm 10 to lower the sheet (step S17); guiding the end of the sheet in the pulling direction to a predetermined position inside the container 800 (inside the front wall 800a) and fixing it in place, and at the timing when the other end of the sheet in the pulling direction enters the container (when the entire sheet enters the sheet container), shutting off the compressed air from the air pressure supply device 500 to detach the sheet from the suction pad (step S19); and moving the suction pad to the upper surface of the other end (rear) of the sheet in the pulling direction and pressing the upper surface to release the air and eliminate the floating (step S21).

[0035] The procedure for pulling out the sheets and storing them in the container is explained below with reference to Figures 9 through 13. Please also refer to the flowchart in Figure 14. Figure 9(a) shows the steps of the following steps: step S13, which involves moving the suction pad 205 to the center of the width direction of the outermost sheet S1 of the sheet bundle SB stored in the upper sheet storage section 750, and bringing it into contact with the surface portion (the portion to be adsorbed) near the end in the pulling direction; and step S15, which involves supplying compressed air to the vacuum generator 207 to adsorb the surface portion of the sheet S1. The robot arm 10 moves the suction pad 205 to the portion to be adsorbed of the sheet stored in the sheet storage section 750, bringing the adsorption end into contact with the sheet surface. Subsequently, the vacuum generator 207 generates negative pressure inside the suction pad to adsorb the sheet. Specifically, with the piston rod 150 of the air cylinder of the end effector EE extended, the robot arm is operated so that the suction pad moves toward the lower end (the part to be suctioned) of the sheet in the sheet storage section, and then the sheet is gripped by suction. At this time, the elastic member 260 of the end effector absorbs any variation in the distance between the sheet bundle surface and the suction pad 205. The optimal position (the part to be attached) for the suction pad to attach to the sheet stored in the storage cavity EP is not limited to the center of the sheet in the width direction and slightly above the lower edge of the sheet. However, if the distance between the attachment position and the lower edge of the sheet is too large, the part of the sheet below the attachment end of the suction pad will get caught on the cross members 752 and 762, which act as stoppers, when the sheet is pulled out. Therefore, a position should be selected that does not cause such problems.

[0036] Furthermore, there are no particular restrictions on the suction force of the suction pad, the diameter of the suction end, or the area; you should select one that does not interfere with operation. Figure 9(b) corresponds to step S17, in which the robot arm 10 is operated to allow the sheet S1 to be attracted by the suction pad, and then to fall naturally toward the container 800 located diagonally below, while sliding (contacting, sliding) along the surface of the next sheet S2 directly below and the transverse member 752. The direction in which the sheet is pulled out is diagonally downward when viewed from the horizontal members (sheet stoppers) 752 and 762 of the sheet storage tray. By pulling the sheet out diagonally downward from the horizontal members and guiding the leading edge of the sheet into the container, it becomes easier to release the air between the underside of the sheet and the packaged items, allowing it to be placed stably on top of the packaged items.

[0037] Furthermore, the diagonal downward direction includes directions that are inclined downward from the horizontal plane extending from the horizontal members (sheet stoppers) 752 and 762 of the sheet storage tray. The trajectory of the suction pad when pulling out the sheet may be straight or curved downward. The speed at which the robotic arm pulls out the sheet should not reduce the speed at which the sheet would naturally fall due to its own weight. This is because if the sheet is made of a highly flexible (weak) material, forcing it out too quickly can cause wrinkles, folds, and other deformations. However, if the sheet's flexibility allows for pulling it out faster than its natural fall speed without causing deformation or other problems, then it is acceptable to pull it out faster. The portion of the outermost sheet S1 that is adsorbed by the suction pad is positioned slightly above the lower horizontal member (sheet stopper) 752 of the sheet storage tray 750 in the sheet storage section. By selecting the adsorption position in this way, the lower edge of the sheet can be pulled forward to avoid getting caught on the horizontal member, allowing it to pass over the horizontal member and then fall downward along the horizontal member (hard, low friction). In other words, the sheet is guided (extended) by the horizontal member as it falls, so the flexible sheet can be dropped in an unfolded state without deformation or wrinkling. Furthermore, at this time, the outermost sheet S1 moves downward while sliding (contacting, sliding) along the surface of the next sheet S2 that remains, thus maintaining its unfolded state. As shown in Figure 9(b), whether the sheet S1 is made of thick, deformation-resistant cardboard or thin, highly flexible paper, it can be pulled out without wrinkles or twists, as illustrated, and stored in the container while maintaining its shape. Figure 12(a) shows a highly flexible sheet SS1 being pulled out from the lower sheet storage tray 760, and in actual operation, the sheet SS1 can be laid in the container without deformation such as wrinkles or twists.

[0038] Figure 10(a) corresponds to step S19, in which the compressed air from the air pressure supply device 500 is shut off when the end of the sheet in the pulling direction settles at a predetermined position inside the container 800 and the other end of the sheet in the pulling direction enters the container, thereby detaching the sheet from the suction pad. By operating the robot arm 10 as required, the suction unit 200 is moved to the far end of the inner bottom surface of the container (inside the front wall 800a), at which point the sheet is detached from the suction pad. At the time the sheet is detached, the other edge of the sheet is inside the container, so if left as is, the entire sheet will fit inside the container. In particular, because the sheet is pulled out diagonally downward from the sheet storage tray and dropped in the same direction, air can easily escape when it enters the container. When a sheet is pulled out diagonally downwards and dropped into a container, the phenomenon of air escaping more easily from the bottom of the sheet is the same whether the sheet is made of cardboard or a flexible sheet with little stiffness. However, flexible sheets are more easily deformed than cardboard, so air tends to be less able to escape.

[0039] Figure 10(b) corresponds to step S21, in which the suction unit 200 is moved to the upper surface of the other end of the sheet in the pulling direction and pressed against the upper surface to eliminate the floating. After moving the suction point of the sheet to the far end of the container and releasing the suction to detach it from the suction pad, move the suction pad to the front end of the container and lower it to push down the other end of the sheet. This allows the other end of the sheet, which tends to float up, to quickly settle into the container (on top of the already stored packaging). This allows for a quick transition to the suction and transfer operation of the next sheet. Even without pushing down the other end of the sheet, air can easily escape from below the sheet as it enters from above at an angle downwards, but performing this pushing operation can further speed up the settling of the sheet. If the sheet is made of a highly flexible material, the other end of the sheet tends to lift, but this pressing process can speed up the fixing process.

[0040] Following the above procedure, the first sheet S1 in the sheet storage tray 750 is removed from the sheet storage tray 750 and placed in the container. Then, following the procedures in Figures 11(a), (b), 12(a), (b), and 13(a)(b), the sheets in the sheet storage tray 760 are removed from the sheet storage tray 760 and placed in the container. The processing procedure for sheet SS1 is the same as that for sheet S1 and will not be described in detail.

[0041] In this embodiment, a highly flexible sheet, such as the resilient Miramat® used for cushioning, stored in the lower sheet storage tray 760, and ordinary cardboard stored in the upper sheet storage tray 750 are sequentially and alternately stacked in a triple layer within the container. In other words, the layers are stacked in the order of Miramat, cardboard, Miramat, so the above process is repeated three times when taking out and storing a single sheet. Specifically, first, the highly flexible sheet SS1 is taken out of the lower sheet storage tray 760 and laid in the container, then the cardboard S1 is taken out of the upper sheet storage tray 750 and laid on top of the previously laid sheet SS1, and then the highly flexible sheet SS1 is taken out of the lower sheet storage tray 760 and laid on top of the cardboard S1 to complete the triple layering process. Note that this is just one example; if cardboard is stored in the lower sheet storage tray 760 and highly flexible sheets are stored in the upper sheet storage tray 750, the triple-layer storage process described above will begin with the upper sheet storage tray 750. In steps S23 and S25 of Figure 14, the storage of the packages and sheets is completed when all layers of packages are stored and the stacking of sheet layers on each package layer is completed.

[0042] As described above, the sheet processing device 1 and packaging processing device 1000 of the present invention automate the insertion of cushioning sheets during the boxing process, thereby automating the entire boxing process, including the process of placing the packaged items into boxes.

[0043] <Example of setting a sheet bundle horizontally within the storage space EP> Figures 15(a) and 15(b) are perspective views showing the configuration of a modified embodiment of the sheet processing device 1 (packaging processing device 1000), as well as its drawer and storage operations. The same reference numerals are used for parts identical to those in the above embodiments, and descriptions of redundant configurations and operations are omitted. A key feature of the sheet processing apparatus 1 according to this embodiment is that it uses a sheet storage section 780 (sheet storage tray 785) that stores sheet bundles SB in a horizontal position within a storage space EP. In the above embodiment, an example configuration was shown in which the sheet bundle is set in an upward-tilted position within the sheet storage tray. However, using the same sheet processing device 1, it is also possible to pull out the outermost sheet S1 of the horizontally arranged sheet bundle SB and store it in the container 800.

[0044] Figure 15(a) shows the state in which the suction pad 205 is brought into contact with the end of the sheet S1 in the pulling direction and suction has begun. Figure 15(b) shows the state in which the adsorbed sheet S1 is being pulled out toward the inside of the container 800. The procedure from this step onward is the same as the procedure shown in Figures 10(a) and 10(b), so the explanation is omitted. Reference numeral 785a denotes a stopper portion that locks the end of the sheet bundle in the direction of withdrawal to prevent it from falling, while also allowing the outermost sheet to slide over it as it is pulled out, thus acting as a guide for withdrawal (natural fall).

[0045] As described above, the sheet bundle does not necessarily need to be tilted when set. As long as the bottom of the outermost sheet of the easily deformable laminate can be adsorbed and smoothly pulled out and stored in the container, there are no restrictions on the set state or setting orientation of the sheet bundle.

[0046] [Summary of Embodiments, Functions, and Effects of the Invention] The first sheet processing apparatus 1 according to the present invention comprises a robot 10 equipped with a suction unit, sheet storage sections 700, 780 that store a sheet bundle SB made of stacked sheets S which are easily deformable and highly flexible, with at least a portion of the main surface of the outermost sheet exposed, and a control means 900 that controls the robot and the suction unit, wherein the control means controls the robot so that the suction unit adsorbs the surface portion of the outermost sheet near the end in the pulling direction, then pulls it out of the sheet storage section and drops it diagonally downward.

[0047] For example, when a robot is used to transport products (packaged goods) on a conveyor belt and pack them into a box in multiple layers, the robot can automate the process of placing at least one sheet of highly flexible cushioning material between the layers of products. Specifically, the robot can consistently dispense highly flexible sheets from the sheet storage unit and feed them one by one into packaging boxes (containers) without significantly deforming the sheets (while they remain unfolded). Furthermore, by pulling the sheets diagonally downwards, air can be released from beneath the sheets when they are laid in the container, allowing them to be stably placed on top of the packaged items. Moreover, the destination for the sheets is not limited to packaging boxes; this system can be applied to any storage location for sheets in any process that involves laying them out.

[0048] In addition to highly flexible sheets such as cushioning Miramat (polyethylene-based) and thin paper, we can also handle thick paper (cardboard) and other types of sheets. When pulling out the sheet using the suction pad, the lower edge of the sheet is held in place and pulled out diagonally downwards. If necessary, you may lift it slightly at the beginning of the pulling process. After pulling out the sheet, its free fall is effectively utilized to slide it along the stopper on the underside of the sheet storage tray. This makes it difficult for air to enter between the underside of the sheet and the product below it as it enters the container. In other words, it can fall without resistance and without floating, while allowing air to escape. Once the sheet is pulled diagonally downwards by attaching one or more points on the leading edge with the suction pad, the underside of the sheet slides along the stopper, making it difficult to bend, wrinkle, or otherwise deform. This allows the sheet to maintain its unfolded state not only while it is extended but also when stored in a container.

[0049] Furthermore, unlike the box-packing device described in Patent Document 1, the robot's movements are simple, eliminating the need to teach complex movements. It is also easy to adjust the suction force, timing, and release of suction, thus reducing the effort required for device design and programming.

[0050] In the second sheet processing apparatus 1 according to the present invention, the control means 900 is characterized by performing the following steps: having the robot 10 bring the suction pad 205 into contact with the surface portion of the outermost sheet S1 of the sheet bundle SB stored in the sheet storage section 700, near the end in the pulling direction; adsorbing the surface portion of the sheet with the suction pad; operating the robot to slide (sliding, contacting) the sheet along the surface of the next sheet S2 while the sheet is adsorbed by the suction pad, and dropping it toward the container; releasing the suction by the suction pad and detaching the sheet when the end of the sheet in the pulling direction reaches a predetermined position (set) inside the container and the other end of the sheet in the pulling direction enters the container (the entire sheet enters the sheet container); and moving the suction pad to the upper surface of the other end of the sheet in the pulling direction and pressing the upper surface to eliminate any floating.

[0051] The container 800 is a means having a recess to receive the outermost sheet that has fallen out of the sheet storage section when the surface portion near the end in the pulling direction is attracted by the suction pad and pulled out, and its shape and material are not limited. The system is configured to use a robot to feed sheets from the sheet storage unit 700 onto the packages already laid out in the packaging box. By arranging multiple sheet storage trays in the sheet storage unit with staggered positions in the front-to-back and up-to-down directions, it is possible to handle multiple types of sheets and sequentially stack them within the container. Sheet gripping is performed using an end effector EE with a suction unit equipped with an expandable / contractible mechanism.

[0052] When the leading edge of the sheet is inserted into the container, the trailing edge of the sheet tends to float due to the air. After the leading edge of the sheet is released inside the container and the forward movement of the entire sheet stops, the floating of the sheet can be quickly eliminated by pushing down from above on the side opposite to the side that was being held in place. If the trailing edge of the sheet is not held down, it takes time for the trailing edge to settle on the packaged goods. Ideally, the next sheet should be dropped and stored once the entire preceding sheet has flattened and settled on the bottom, but if it takes time for the preceding sheet to settle, the start of pulling out and dropping the next sheet will be delayed. In this invention, the operation of holding down the trailing edge of the sheet is performed by a robot in succession to the operation of pulling out the sheet, thereby speeding up the operation without complicating the device configuration. The sheet processing apparatus of the present invention can be applied to general packaging operations where sheets are required to be inserted between layers when packaging goods in a stacked (multi-layered) state, and to other general operations in which a process of laying sheets is involved.

[0053] In the third sheet processing apparatus 1 according to the present invention, the robot is a multi-jointed arm robot, and the suction unit performs its suction function based on the supply of air pressure from a pneumatic supply device. Various types of work robots capable of being fitted with suction units can be used as robots. Articulated robots are one example. Other suction methods such as electrostatic or magnetic suction can also be used as suction units, and pneumatic suction is just one example.

[0054] A fourth sheet processing apparatus 1 according to the present invention further comprises a retractable unit that can be extended and retracted by a piston rod of an air cylinder, and the control means 900 is characterized in that, when pulling out a sheet that has been adsorbed by the adsorption unit and moving it toward a container, the adsorption unit is extended in advance by the piston rod 150. When transferring sheets or products held by suction pads into a container, larger components such as air cylinders and cameras located closer to the robot arm than the suction pads may interfere with the container's side walls. In particular, when placing products close to the inner wall of the container, these larger components may hit the edge or inner wall, hindering the storage process. Therefore, when inserting the suction pads into the container, the piston rod is extended beforehand to increase the distance between the suction pads and the larger components. This configuration prevents larger components from hitting the container's side walls and hindering the process of loading the products or sheets held by the suction pads into the container. The length of the piston rod is not a problem when the suction pad is adsorbing the sheet. However, since the piston rod is lengthened when inserting the adsorbed sheet into the container, it is easier to control if it is also lengthened during the suction phase.

[0055] The fifth sheet processing apparatus 1 according to the present invention is characterized in that the sheet storage section includes sheet storage trays 750, 760, 785 that support the main surface of the sheet bundle so that it faces upward within a range from an inclined position at a predetermined angle to a horizontal position, and stopper sections 752, 762, 785a that normally lock the ends of the sheet bundle in the pulling direction to prevent it from falling, while allowing the outermost sheet to slide over and act as a guide for pulling out (natural fall). The sheets are pulled out at an angle downwards, but the orientation of the sheet bundle before being pulled out may be inclined toward the front where the container is located, or it may be in a horizontal position with the main surface facing upwards. Furthermore, by making the width of the seat storage space in the seat loading device adjustable, it can be used in a common way to accommodate different seat sizes.

[0056] The packaging processing device (processing system) 1000 according to the present invention comprises any of the sheet processing devices 1 described above, and a belt conveyor 850 for transporting packaging to be stored in a container. The control means 900 is characterized by sequentially performing the following steps: bringing a suction pad 205 into contact with the packaging on the belt conveyor using a robot 10; using the suction pad to pick up the packaging; operating the robot to transport (seat, set) the packaging into the container 800 while it is being picked up by the suction pad; releasing the packaging from the suction pad when the packaging has been transported into the container; and operating the robot to release the suction pad from inside the container, thereby placing a predetermined number of the packaging inside the container, after which the robot lays the sheet on top of the packaging inside the container. According to this, a single robot can be used to process both the packaged goods and the sheets. [Explanation of Symbols]

[0057] 1…Sheet processing device, 10…Robot arm (articulated arm robot), 15…Base, EE…End effector, U1…Air cylinder unit, U2…Retractable unit, 150…Piston rod, 100…Air cylinder, 102…Housing, 102a…Protrusion, 104…Cylinder tube, 110…Cover, 110a…Hole, 200…Suction unit, 2015…Suction pad, 207…Vacuum generator, 210…Connecting member, 210b…Back plate, 215…Connecting block, 23 0...bracket, 250...lower bracket, 252a, 252b...shaft, 255...upper bracket, 255a...bottom plate, 255b...top plate, 255a', 255b'...through hole, 260...coil spring (elastic member), 700...sheet storage section, 710...frame, 712...profile, 715...frame body, 717...side plate, 718...top plate, 750, 760...sheet storage tray, 752, 762...cross member (sheet stopper), 800...container, 900...control means, 1000...packaging processing device.

Claims

1. The system comprises a robot equipped with a suction unit at its tip, a sheet storage unit that stores a sheet bundle made of stacked, highly flexible sheets that are easily deformable, with at least a portion of the main surface of the outermost sheet exposed, and control means for controlling the robot and the suction unit. The sheet processing apparatus is characterized in that the control means controls the robot so that the suction unit adsorbs the surface portion of the outermost sheet near the end in the pulling direction, and then pulls it out of the sheet storage section and drops it diagonally downward.

2. The control means is characterized by performing the steps of: using the robot to bring the suction unit into contact with the surface portion of the outermost sheet of the sheet bundle stored in the sheet storage section, near the end in the pulling direction; using the suction unit to adsorb the surface portion of the sheet; operating the articulated robot to drop the sheet toward the container while sliding it along the surface of the next sheet while the sheet is adsorbed by the suction unit; releasing the suction by the suction unit and detaching the sheet when the end of the sheet in the pulling direction is guided to a predetermined position in the container and the other end of the sheet in the pulling direction enters the container; and moving the suction unit to the upper surface of the other end of the sheet in the pulling direction and pressing the upper surface to eliminate any floating.

3. The sheet processing apparatus according to claim 2, characterized in that the robot is a multi-jointed arm robot and the suction unit performs its suction function based on the supply of air pressure from a pneumatic supply device.

4. The sheet processing apparatus according to claim 3, further comprising a retractable unit that allows the suction unit to be extended and retracted by a piston rod of an air cylinder, wherein the control means, at least when pulling out a sheet adsorbed by the suction unit and moving it toward the container, extends the suction unit in advance by the piston rod.

5. The sheet storage unit comprises a sheet storage tray that supports the main surface of the sheet bundle so that it faces upward within a range from an inclined position at a predetermined angle to a horizontal position, and a stopper that locks the end of the sheet bundle in the pulling direction to prevent it from falling, while also allowing the outermost sheet to slide over it when it is pulled out, thus acting as a guide for pulling out.

6. A packaging processing apparatus comprising a sheet processing apparatus according to any one of claims 1 to 5, and a belt conveyor for transporting a package to be stored in the container, The control means is characterized by sequentially performing the following steps to place a predetermined number of packages inside the container: bringing the suction unit into contact with the packages on the belt conveyor using the robot; using the suction unit to pick up the packages; operating the robot to transfer the packages into the container while they are being picked up by the suction unit; releasing the packages from the suction unit when they reach inside the container; and operating the robot to release the suction unit from inside the container, thereby placing a predetermined number of packages inside the container, and then using the robot to lay the sheet on top of the packages inside the container.

Images