Optical Sensor Predictive Maintenance Device and Optical Sensor Predictive Maintenance Method

Abstract

To make it possible to acquire change which indicates a malfunction sign before function of an optical sensor for detecting a mark for positional alignment is lowered and operation thereof becomes failure in a packaging machine, and to achieve maintenance of the optical sensor.SOLUTION: An optical sensor sign maintenance device 20 comprises: a received light amount acquisition unit 21 which acquires a received light amount of light which an optical sensor 10 receives from light reflected on a mark for positional mark and a background unit of the mark for positional alignment; an initial received light amount storage unit 22b which stores an initial received light amount of the optical sensor 10; a sign determination unit 22a which compares a current received light amount acquired by the received light amount acquisition unit 21 during operation of a packaging machine with the initial received light amount stored in the initial received light amount storage unit 22b, and determines such a sign that malfunction occurs in the optical sensor 10; and an alarm unit 23 which outputs a determination result of the sign determination unit 22a.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an optical sensor predictive maintenance device and an optical sensor predictive maintenance method in packaging machines such as horizontal pillow packaging machines, vertical pillow packaging machines, overwrap packaging machines, and deep drawing packaging machines.

Background Art

[0002] In packaging machines, there are pillow packaging machines that sequentially fill cylindrical packaging materials with products to be packaged such as foods and pharmaceuticals, and then perform sealing, cutting, etc. to manufacture packages, overwrap packaging machines that cover one or more products to be packaged with thin packaging materials, and deep drawing packaging machines that form a flat sheet into a container shape, fill the product to be packaged, and then seal it with a lid material. Among the pillow packaging machines, there are vertical pillow packaging machines that send the packaging material in the vertical direction and fill the product to be packaged, and horizontal pillow packaging machines that send the packaging material in the horizontal direction and fill the product to be packaged. In such packaging machines, a continuous packaging material (packaging film) is fed out from a wound-up packaging material wound in a roll by a feed roller. After the product to be packaged is supplied, sealing and cutting are performed on the continuous packaging material at a certain timing, and a package filled with the product to be packaged is generated. In this case, in order to perform sealing and cutting at the sealing and cutting positions of the packaging material, alignment marks such as register marks printed on the packaging material are detected by an optical sensor, and the feed amount of the packaging material is adjusted. Here, when the packaging machine is used for a long time, due to deterioration, dirt, etc. of the optical sensor, the function of the optical sensor deteriorates, resulting in a malfunction where the optical sensor does not detect the alignment mark, and accidents such as sealing and cutting not being performed at the sealing and cutting positions of the packaging material occur, and the optical sensor has to be replaced, which may cause a major production hindrance. Therefore, it is desirable to predict malfunctions due to deterioration, etc. of the optical sensor, replace the optical sensor before it malfunctions, and prevent production hindrance of the packaging machine.

[0003] Incidentally, detecting a mark with an optical sensor for alignment is also performed in a printing apparatus, which is a device other than a packaging machine. It has also been proposed to detect deterioration of the optical sensor in a printing apparatus. For example, Patent Document 1 (Japanese Unexamined Patent Application Publication No. 2015-24505) discloses that in a printing apparatus (thermal printer) that detects a mark on a sheet with an optical sensor (photo sensor) and positions the sheet, deterioration of the photo sensor is detected based on the history of the output level of the photo sensor when there is no sheet (Claim 11, paragraph

[0054] of Patent Document 1), or deterioration of the light emitting part is detected by detecting a decrease in the light emission amount due to a voltage drop in the light emitting part of the photo sensor (Claim 10, paragraph

[0078] of Patent Document 1). However, in the printing apparatus (thermal printer) of Patent Document 1, deterioration of the photo sensor is detected in order to determine whether a decrease in the output level of the photo sensor is due to uneven density of the mark or due to deterioration of the photo sensor. The printing apparatus of Patent Document 1 does not predict a state in which the photo sensor malfunctions. In addition, in a packaging machine, a discontinuous mark is printed on a continuous packaging material (packaging film), and there is no state without a sheet (without a packaging material) as in the printing apparatus of Patent Document 1, so the method for detecting deterioration of the photo sensor in Patent Document 1 cannot be applied to a packaging apparatus. Furthermore, malfunction of the optical sensor of a packaging machine is also caused by deterioration of the light emitting part, dirt, deterioration of the light receiving part, or deterioration of the optical fiber in the case of an optical fiber sensor, etc. Merely detecting deterioration of the light emitting part as in Patent Document 1 cannot predict malfunction of the optical sensor.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] The problem to be solved by the present invention is to obtain a change indicating a sign before the function of an optical sensor for detecting an alignment mark deteriorates and malfunctions in a packaging machine, so as to enable maintenance of the optical sensor.

Means for Solving the Problem

[0006] The invention according to claim 1 is a prognostic maintenance device for an optical sensor that detects an alignment mark printed on a continuous packaging material supplied in a packaging machine, the device comprising: a light reception amount acquisition means for acquiring a light reception amount of light received by the optical sensor from the alignment mark and light reflected by a background portion of the alignment mark; an initial light reception amount storage means for storing an initial light reception amount which is the light reception amount acquired by the light reception amount acquisition means in an initial state of the optical sensor; a current light reception amount which is the light reception amount acquired by the light reception amount acquisition means during operation of the packaging machine, and comparing the current light reception amount with the initial light reception amount stored in the initial light reception amount storage means, when the current light reception amount is higher than the threshold value set based on the initial light reception amount in the initial state of the light sensor when the optical sensor is operating normally, before the function of the optical sensor deteriorates when the decrease in the current light reception amount with respect to the initial light reception amount exceeds a predetermined range when the current light reception amount the threshold value becomes lower and the optical sensor malfunctions determine that there is a sign a prognostic determination means, and a determination result output means for outputting a determination result of the prognostic determination means, to provide an optical sensor prognostic maintenance device for solving the above problems.

[0007] The invention according to claim 2 provides an optical sensor prognostic maintenance device, wherein the optical sensor is an optical fiber sensor, and the prognostic determination means determines a prognosis according to the degree of deterioration of the function of the optical sensor, to solve the above problems.

[0008] The invention according to claim 3 provides an optical sensor prognostic maintenance device, wherein the prognostic determination means when the difference between the current light reception amount and the threshold value becomes equal to or less than a certain ratio of the difference between the initial light reception amount and the threshold value determines that there is a sign of a malfunction occurring in the optical sensor when a decrease in the current light reception amount with respect to the initial light reception amount exceeds a predetermined range, to solve the above problems. as

[0009] ​The invention of claim 4 solves the above problem by providing an optical sensor predictive maintenance device further comprising a current light receiving amount display means for displaying the current light receiving amount, and a predetermined range setting means for setting the predetermined range.

[0010] The invention of claim 5 is a predictive maintenance method for an optical sensor that detects alignment marks printed on continuous packaging material supplied by a packaging machine, wherein a received light amount acquisition means acquires an amount of light received by the optical sensor from light reflected from the alignment marks and a background portion of the alignment marks while the packaging machine is in operation, and a predictive maintenance determination means compares a current received light amount, which is the amount of light acquired by the received light amount acquisition means, with an initial received light amount of the optical sensor acquired by the received light amount acquisition means in an initial state of the optical sensor, and when the current light reception amount is higher than the threshold value set based on the initial light reception amount in the initial state of the light sensor When the optical sensor is operating normally, the function of the optical sensor is deteriorated. when the decrease in the current light reception amount with respect to the initial light reception amount exceeds a predetermined range The current amount of received light the threshold value If the voltage drops below this level, the optical sensor will malfunction. with a sign The above-mentioned problem is solved by providing an optical sensor predictive maintenance method including a step of making a judgment by the predictive judgment means, and a judgment result output means outputting the judgment result of the predictive judgment means. Effect of the Invention

[0011] The optical sensor predictive maintenance device of the invention described in claim 1 has the effect of obtaining changes that indicate signs of a deterioration in the function of the optical sensor that detects the alignment mark and causing it to malfunction, thereby enabling the maintenance of the optical sensor.

[0012] The optical sensor predictive maintenance device of the invention described in claim 2 has the same effects as the invention described in claim 1.

[0013] The optical sensor predictive maintenance device of the invention described in claim 3 has the same effects as the invention described in claim 1.

[0014] The optical sensor predictive maintenance device of the invention described in claim 4 has the same effects as the invention described in claim 1.

[0015] In the optical sensor prognostic maintenance method of the invention according to claim 5, before the function of the optical sensor for detecting the alignment mark deteriorates and malfunctions, a change indicating the prognosis is acquired, and the effect that the optical sensor can be maintained is achieved.

Brief Description of the Drawings

[0016]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Embodiments for Carrying Out the Invention

[0017] [Configuration of Optical Sensor Prognostic Maintenance System, Prognostic Maintenance Device] FIG. 1 is a block diagram showing the configuration of an optical sensor prognostic maintenance system including the optical sensor prognostic maintenance device of the present invention. In the figure, 1 is an optical sensor predictive maintenance system, 10 is an optical sensor, 11 is an optical sensor body, 12 is a light receiving element, 13 is a light projecting element, 14 is a control unit, 15 is a fiber cable, 15a is a light receiving fiber, 15b is a light projecting fiber, 16 is a fiber head, 20 is an optical sensor predictive maintenance device, 21 is a light reception amount acquisition unit, 21a is a transmission unit, 21b is a reception unit, 21c is a communication line, 22 is an arithmetic control device, 22a is a prediction determination unit, 22b is an initial light reception amount storage unit, 23 is an alarm, and Fi is a packaging material (film). As shown in FIG. 1, the optical sensor predictive maintenance system 1 is composed of an optical sensor 10 and an optical sensor predictive maintenance device 20. The optical sensor 10 is composed of an optical sensor body 11, a fiber cable 15, and a fiber head 16. The optical sensor body 11 includes a light receiving element 12, a light projecting element 13, and a control unit 14. The light receiving element 12 receives the light entering from the light receiving fiber 15a of the fiber cable 15, converts it into an electrical signal, and outputs it. The light projecting element 13 is an LED, which emits light and projects it from the light projecting fiber 15b of the fiber cable 15. Based on the output signal output by the light receiving element 12, the control unit 14 outputs a detection signal for detecting the register mark printed on the packaging material Fi, controls the light emission of the light projecting element 13, and controls the overall operation of the optical sensor body 11. The fiber cable 15 includes a light receiving fiber 15a and a light projecting fiber 15b. The light receiving fiber 15a guides the light entering the fiber head 16 to the light receiving element, and the light projecting fiber 15b guides the light emitted by the light projecting element 13 to the fiber head 16. The fiber head 16 is installed close to the packaging material Fi, projects the light guided by the light projecting fiber 15b from its tip to the register mark (described later) of the packaging material Fi and its background, and receives the reflected light at the tip of the light receiving fiber 15a.

[0018] The optical sensor predictive maintenance device 20 is composed of computer devices such as a control computer for controlling the operation of the packaging machine and a computer of an operation panel, and includes a light reception amount acquisition unit 21, an arithmetic control device 22, and an alarm 23. The light reception amount acquisition unit 21 includes a transmission unit 21a, a reception unit 21b, and a communication line 21c, and acquires from the control unit 14 the light reception amount (hereinafter, appropriately referred to as the "light reception amount of the optical sensor 10") (numerical value), which is the amount of light received by the light receiving element 12. That is, in the light reception amount acquisition unit 21, the transmission unit 21a continuously acquires the light reception amount of the optical sensor 10 from the control unit 14, transmits it to the reception unit 21b via the communication line 21c, and the reception unit 15b sends the received light reception amount to the arithmetic control device 22. Instead of the one including the transmission unit 21a, the reception unit 21b, and the communication line 21c, this light reception amount acquisition unit 21 may be configured to extract the light reception amount of the optical sensor 10 from the control unit 14 as an analog signal and send it to the arithmetic control device 22 via a transmission line or the like. The arithmetic control device 22 includes a sign determination unit 22a and an initial light reception amount storage unit 22b, and controls the operations of the reception unit 21 and the alarm device 23. The initial light reception amount storage unit 22b stores, as the initial light reception amount, the light reception amount of the optical sensor 10 in the initial state acquired by the arithmetic control device 22 from the light reception amount acquisition unit 21. During the operation of the packaging machine (described later), the sign determination unit 22a compares the current light reception amount, which is the light reception amount of the optical sensor 10 acquired by the light reception amount acquisition unit 21, with the initial light reception amount stored in the initial light reception amount storage unit 22b. When the decrease in the current light reception amount with respect to the initial light reception amount exceeds a predetermined range, it determines that there is a sign of malfunction in the optical sensor 10. The alarm device 23 is composed of a display such as the control computer or the operation panel, and performs an alarm display such as indicating that there is a sign of malfunction in the optical sensor 10 based on the determination result of the sign determination unit 22a. Also, in the optical sensor sign maintenance device 20, a current light reception amount display unit (not shown) that displays the current light reception amount acquired by the light reception amount acquisition unit 21 on a display such as the control computer or the operation panel, and a predetermined range setting unit (not shown) that sets the predetermined range may be provided so that the predetermined range can be set from the current light reception amount displayed on the current light reception amount display unit.

[0019] [Alignment mark] FIG. 2 is a plan view of a packaging material Fi on which an example of a register mark as an alignment mark is printed. In the figure, R1, R2, Rn are register marks, and BG is a background portion. As shown in FIG. 2, a background portion BG is printed in a strip shape at one end of the continuous packaging material Fi, and register marks R1, R2 ··· Rn are continuously printed at regular intervals L in the background portion BG, and the packaging material Fi moves from left to right. The background portion BG is generally printed in white or a whitish color, and is printed in a whitish gray in the figure. The register marks R1, R2, Rn are generally printed in a slit shape in black or a blackish color, and are shown in black in the figure. Note that the alignment mark printed on the packaging material Fi and the background portion only need to have a difference in the amount of light received by the photosensor 10 with respect to the reflected light, and the alignment mark may be white or a whitish color, and the background portion may be black or a blackish color.

[0020] [Amount of light received by photosensor 10] FIG. 3 is an explanatory diagram for explaining the amount of light received by the photosensor 10 with respect to the packaging material Fi on which the register marks R1, R2, Rn and the background portion BG are printed and the detection signal output by the control unit 14. FIG. (a) shows the relationship between the amount of light received by the photosensor 10 and the elapsed time, and FIG. (b) shows the relationship between the detection signals. In the figure, LR is the light reception amount curve, S1, S2, Sn are detection signals, SH is the threshold value, and t is the elapsed time. Taking the maximum value of the amount of light received by the photosensor 10 from the light reflected by the background portion BG (the amount of light received by the photosensor 10 in the initial state) as 100, the actual amount of light received by the photosensor 10 from the light reflected by the background portion BG is HI, and the amount of light received by the photosensor 10 from the light reflected by the register marks R1, R2, Rn is LO. Now, assume that the packaging material Fi moves, the optical sensor 10 receives the reflected light from the end of the packaging material Fi, and the registration marks R1, R2, Rn pass right below the fiber head 17 of the optical sensor 10 at elapsed times t1, t2, tn. While the optical sensor 10 is receiving the reflected light from the registration marks R1, R2, Rn, the light reception amount of the optical sensor 10 is LO, and otherwise, it receives the reflected light from the background part BG, and the light reception amount of the optical sensor 10 becomes HI. From this, the temporal change in the light reception amount of the optical sensor 10 is represented by the light reception curve LR shown in Fig. 3(a). At this time, a threshold value SH for the detection signal is set in the control unit 14 of the optical sensor 10. When the light reception amount of the optical sensor 10 changes from a state higher than the threshold value SH to a lower state, the control unit 14 outputs a detection signal, and the output detection signal is sent to a control device of a feed roller (described later) that feeds out and sends the packaging material Fi, and the feed amount of the packaging material Fi is adjusted. Assuming that the threshold value SH is set to 60 as shown in Fig. 3(a), since the light reception amount HI of the optical sensor 10 is higher than the threshold value SH and the light reception amount LO is lower than the threshold value SH, as shown in Fig. 3(b), the control unit 14 outputs detection signals S1, S2, Sn at elapsed times t1, t2, tn.

[0021] Fig. 4 is an explanatory diagram for explaining the change in the light reception curve when the optical sensor 10 detects the registration marks R1, R2, Rn. Fig. 4(a) represents the light reception curve in the initial state of the optical sensor 10, Fig. 4(b) represents the light reception curve in a state where the light reception amount of the optical sensor 10 has slightly decreased, and Fig. 4(c) represents the light reception curve in a state where the light reception amount of the optical sensor 10 has greatly decreased. As shown in Fig. 4(a), in the initial state of the optical sensor 10, if the light reception amount of the optical sensor 10 that receives the reflected light from the background part BG of the packaging material Fi is 100 and the light reception amount of the optical sensor 10 that receives the reflected light from the registration mark R1, etc. is 40, the light reception curve of the optical sensor 10 becomes the curve LR0. As shown in Fig. 4(b), when the light reception amount of the photosensor 10 has decreased from the initial state and its light reception curve has become curve LR1, the light reception amount of the photosensor 10 that receives the reflected light from the background portion BG is higher than the threshold value SH(60), and the photosensor 10 detects the registration mark R1 or the like and operates normally. However, as shown in Fig. 4(c), when the light reception amount of the photosensor 10 has significantly decreased from the initial state and its light reception curve has become curve LR2, the light reception amount of the photosensor 10 that receives the reflected light from the background portion BG becomes lower than the threshold value SH(60), and the photosensor 10 cannot detect the registration mark R1 or the like and will not operate normally. The photosensor prediction maintenance device 20 of the present invention is such that, in a state where the light reception amount of the photosensor 10 has decreased from the initial state but the photosensor 10 is detecting the registration mark and operating normally (the state in Fig. 4(b)), it indicates a prediction of a state where the function of the photosensor 10 deteriorates and malfunctions (the state in Fig. 4(c)).

[0022] [Horizontal Pillow Wrapping Machine] Fig. 5 is a diagram showing the schematic configuration of a horizontal pillow wrapping machine to which the photosensor prediction maintenance system 1 shown in Fig. 1 is attached. Fig. (a) of the same figure is a front view, and Fig. (b) of the same figure is a plan view. In the figure, 30 is a horizontal pillow wrapping machine, 31 is a packaging material supply unit, 32 is a packaging material feeding unit, 32a is a driving roller, 32b is a pressing roller, 33 is a product to be packaged supply unit, 33a is a supply conveyor, 34 is a tube forming unit, 34a is a tube former, 35 is a paper pulling unit, 35a is a driving roller, 35b is a pressing roller, 36 is a center seal unit, 36a and 36b are center seal blocks, 37 is a sizing unit, 37a and 37b are sizing rollers, 38 is an end seal and cutting unit, 38a and 38b are end seal blocks, 39 is a package discharge unit, 39a is a discharge conveyor, CP is the product to be packaged, gra, grb, and grc are guide rollers, MR is a wound packaging material, Pc is a package, TF is a tubular packaging material, cs is the center seal portion, and es is the end seal portion. As shown in Fig. 5, the horizontal pillow packaging machine 30 is composed of a packaging material supply unit 31, a packaging material feeding unit 32, a product to be packaged supply unit 33, a tube forming unit 34, a paper pulling unit 35, a center seal unit 36, a sizing unit 37, an end seal and cutting unit 38, a package discharging unit 39, etc. The packaging material supply unit 31 is equipped with a winding packaging material supply device (not shown) for feeding out the winding packaging material MR, and feeds out the packaging material Fi from the winding packaging material MR. The packaging material feeding unit 32 sandwiches the packaging material Fi between a driving roller 32a and a pressing roller 32b, rotates the driving roller 32a by a motor (not shown), and feeds out the packaging material Fi by a certain length. The tube forming unit 33 forms (forms a tube) the packaging material Fi into a tubular packaging material TF by a tube former 34a. The product to be packaged supply unit 34 places the product to be packaged CP on the belt conveyor 34a and fills the tubular packaging material TF with the product to be packaged CP. The paper pulling unit 35 sandwiches the overlapped ends of the tubular packaging material TF between a driving roller 35a and a pressing roller 35b, rotates the driving roller 35a by a motor (not shown), and feeds out the tubular packaging material TF by a certain length. The center seal unit 36 sandwiches the ends of the overlapped tubular packaging material TF with center seal blocks 36a, 36b heated by a heater (not shown), and applies a center seal cs to the tubular packaging material TF. The sizing unit 37 sandwiches the center seal cs of the tubular packaging material TF with sizing rollers 37a, 37b, rotates one of the sizing rollers 37a by a motor (not shown), and applies sizing to the center seal cs. The end seal and cutting unit 38 sandwiches the tip of the tubular packaging material TF with end seal blocks 38a, 38b heated by a heater (not shown), applies an end seal to form an end seal portion es, cuts the central portion of the end seal portion es, and generates a package Pc in which the product to be packaged CP is bagged. The package discharging unit 39 discharges the package Pc by a discharge conveyor 39a. Here, the fiber head 16 of the optical sensor 10 is installed near the packaging material Fi passing between the drive roller 32a and the guide roller grb, detects the register marks R1, R2, Rn, and a detection signal is output from the control unit 14. Then, the detection signal output from the control unit 14 is sent to the control units such as the packaging material feeding unit 32 and the paper pulling unit 35, and the feeding amount of the packaging material Fi and the cylindrical packaging material TF is adjusted.

[0023] [Operation of the Optical Sensor Predictive Maintenance Device 20] FIG. 6 is a flowchart showing the operation of the optical sensor predictive maintenance device 20. Hereinafter, the operation of the optical sensor predictive maintenance device 20 will be described. First, the horizontal pillow packaging machine 30 is operated, the optical sensor 10 detects the register mark printed on the packaging material Fi and outputs a detection signal. In a state where it is operating normally, the light reception amount acquisition unit 21 acquires the light reception amount (current light reception amount) of the optical sensor 10 from the control unit 14 and sends the acquired light reception amount (current light reception amount) to the arithmetic control device 22 (S1). Specifically, in the light reception amount acquisition unit 21, the transmission unit 21a continuously acquires the light reception amount (current light reception amount) of the optical sensor 10 from the control unit 14 and transmits it to the reception unit 21b via the communication line 21c, and the reception unit 15b sends the received light reception amount (current light reception amount) to the arithmetic control device 22. Also, the current light reception amount acquired by the light reception amount acquisition unit 21 and sent to the arithmetic control device 22 is represented by, for example, the curve LR1 in FIG. 4(b). Next, the predictive determination unit 22a of the arithmetic control device 22 compares the light reception amount (current light reception amount) of the optical sensor 10 acquired by the light reception amount acquisition unit 21 with the initial light reception amount stored in the initial light reception amount storage unit 22b, and determines whether the decrease in the current light reception amount relative to the initial light reception amount exceeds a predetermined range (S2). If it is determined that it exceeds, it is determined that there is a sign of malfunction in the optical sensor 10 (S3). This determination result is sent to the alarm 27, and in the alarm 23, an alarm such as the presence of a sign of malfunction is displayed (S4), and the process ends. On the other hand, in step S2, when the prediction determination unit 22a determines that the decrease in the current light reception amount with respect to the initial light reception amount does not exceed a predetermined range, it determines that there is no sign of malfunction in the optical sensor 10 (S5), ends the process without performing a warning display on the alarm 23. In this case, a specific example of the predetermined range in the determination in step S2 is 20 percent of the difference between the initial light reception amount and the threshold value SH. That is, when the difference between the current light reception amount and the threshold value SH becomes 20 percent or less of the difference between the initial light reception amount and the threshold value SH, the prediction determination unit 22a determines that the decrease in the current light reception amount with respect to the initial light reception amount exceeds the predetermined range. Also, the determination that there is a sign of malfunction in the optical sensor 10 in step S3 may be performed step by step. Specifically, when the difference between the current light reception amount and the threshold value SH becomes 30 percent or less of the difference between the initial light reception amount and the threshold value SH, it is determined that there is a sign of level 1 malfunction, and when the difference between the current light reception amount and the threshold value SH becomes 20 percent or less of the difference between the initial light reception amount and the threshold value SH, it is determined that there is a sign of level 2 malfunction, and when the difference between the current light reception amount and the threshold value SH becomes 10 percent or less of the difference between the initial light reception amount and the threshold value SH, it may be determined that there is a sign of level 3 malfunction. Furthermore, the current light reception amount display unit may display the current light reception amount as represented by the curve LR1 in FIG. 4(b), and the predetermined range setting unit may set a predetermined range that serves as a criterion for the prediction determination unit 22a to determine that there is a sign of malfunction in the optical sensor 10. Even when the optical sensor 10 is operating normally in this way, as the function of the optical sensor 10 begins to decline, its light reception amount decreases. Therefore, if the decrease in the light reception amount of the optical sensor 10 exceeds a predetermined range, it is determined that there is a sign of malfunction in the optical sensor 10, and the maintenance of the optical sensor 10 can be achieved.

Industrial Applicability

[0024] The optical sensor prognostic maintenance device and the optical sensor prognostic maintenance method for drive equipment of the present invention can obtain changes indicating the prognosis before the function of the optical sensor for detecting the alignment mark deteriorates and malfunctions in a packaging machine, and can achieve the maintenance of the optical sensor. It can be used in horizontal pillow packaging machines, vertical pillow packaging machines, top wrapping packaging machines, deep drawing packaging machines, etc.

Explanation of Signs

[0025] 1 Optical sensor prognostic maintenance system 10 Optical sensor 11 Optical sensor body 12 Light receiving element 13 Light projecting element 14 Control unit 15 Fiber optic cable 15a Light receiving fiber optic 15b Light projecting fiber optic 16 Fiber optic head 20 Optical sensor prognostic maintenance device 21 Light reception amount acquisition unit 21a Transmitter 21b Receiver 21c Communication line 22 Arithmetic control device 22a Prognosis determination unit 22b Initial light reception amount storage unit 23 Warning device 30 Horizontal pillow packaging machine 31 Packaging material supply unit 32 Packaging material feeding unit 32a Driving roller 32b Pressing roller 33 Product to be packaged supply unit 33a Supply conveyor 34 Tube forming unit 34a Tube former 35 Paper pulling unit 35a Driving roller 35b Pressing roller 36 Center seal unit 36a, 36b Center seal block 37 Marking unit 37a and 37b facing rollers 38 is the end seal - cutting part 38a and 38b end - seal blocks 39 is the package discharge part 39a discharge conveyor Fi packaging material R1, R2, Rn register marks BG background part LR light - receiving amount curve S1, S2, Sn detection signals SH threshold value

Claims

1. A prognostic maintenance device for an optical sensor that detects alignment marks printed on a continuous packaging material supplied in a packaging machine, a light reception amount acquisition means for acquiring the light reception amount of the light received by the optical sensor from the alignment marks and the light reflected by the background portion of the alignment marks, an initial light reception amount storage means for storing the initial light reception amount which is the light reception amount acquired by the light reception amount acquisition means in the initial state of the optical sensor, a prognostic determination means for comparing the current light reception amount which is the light reception amount acquired by the light reception amount acquisition means during the operation of the packaging machine with the initial light reception amount stored in the initial light reception amount storage means, and when the current light reception amount is higher than a threshold value set based on the initial light reception amount in the initial state of the optical sensor and the function of the optical sensor deteriorates and the decrease in the current light reception amount with respect to the initial light reception amount exceeds a predetermined range, determining that there is a sign that the current light reception amount will be lower than the threshold value and the optical sensor will malfunction, and a determination result output means for outputting the determination result of the prognostic determination means An optical sensor prognostic maintenance device characterized by comprising the above.

2. The optical sensor is an optical fiber sensor, and the prognostic determination means determines a prognosis according to the degree of deterioration of the function of the optical sensor. The optical sensor prognostic maintenance device according to claim 1.

3. The prognostic determination means determines that there is a sign that a malfunction will occur in the optical sensor when the difference between the current light reception amount and the threshold value becomes equal to or less than a certain ratio of the difference between the initial light reception amount and the threshold value, and it is determined that the decrease in the current light reception amount with respect to the initial light reception amount exceeds the predetermined range. The optical sensor prognostic maintenance device according to claim 1 or claim 2.

4. The optical sensor prognostic maintenance device according to claim 3, further comprising a current light reception amount display means for displaying the current light reception amount and a predetermined range setting means for setting the predetermined range.

5. A prognostic maintenance method for an optical sensor that detects alignment marks printed on a continuous packaging material supplied in a packaging machine, a light reception amount acquisition means acquires the light reception amount of the light received by the optical sensor from the alignment marks and the light reflected by the background portion of the alignment marks during the operation of the packaging machine, The prediction determination means compares the current received light amount, which is the received light amount acquired by the received light amount acquisition means, with the initial received light amount of the optical sensor acquired by the received light amount acquisition means in the initial state of the optical sensor. When the current received light amount is higher than a threshold value set based on the initial received light amount in the initial state of the optical sensor and the optical sensor is operating normally, and when the function of the optical sensor deteriorates and the decrease in the current received light amount with respect to the initial received light amount exceeds a predetermined range, it is determined that there is a sign that the current received light amount will be lower than the threshold value and the optical sensor will malfunction. The determination result output means outputs the determination result of the prediction determination means. An optical sensor prediction maintenance method characterized by comprising the step.

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