Method for manufacturing a wound body

Abstract

To reduce the time required for an initial operation and an operation immediately after exchange of a wound body.SOLUTION: A packaging apparatus packages a packaging object using a wound body of a long sheet-shaped packaging material wound. The wound body comprises a recording medium for recording information. The information to be recorded in the recording medium includes residual quantity information showing the residual quantity of the packaging material in the wound body. The packaging apparatus comprises: a driving unit for generating driving force for rotating the wound body; an information reading unit for reading the residual quantity information stored in the recording medium; and a control unit for controlling the packaging apparatus. The control unit sets the rotational speed of the wound body based on the residual quantity information read by the information reading unit.SELECTED DRAWING: Figure 14

Description

Technical Field

[0001] The present disclosure relates to a packaging apparatus for packaging an object to be packaged in a packaging material. in the position used the winding manufacturing method of a wound body method related.

Background Art

[0002] Conventionally, a packaging apparatus sequentially packages objects to be packaged with a packaging material unwound from a wound body. The wound body is configured by winding a long sheet-like packaging material. Japanese Patent Application Laid-Open No. 2018-043875 (Patent Document 1) and Japanese Patent Application Laid-Open No. 2018-118778 (Patent Document 2) disclose configurations for detecting the remaining amount of the packaging material in the wound body.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the apparatus described in the above document, when the remaining amount of the packaging material is not known, from the viewpoint of reliably preventing deviation, the rotation speed of the wound body is set to the minimum speed, and the packaging material is unwound and wound up. At the initial operation immediately after starting the packaging apparatus and at the operation immediately after replacing the wound body, since there is no determination result of the remaining amount of the packaging material, the packaging material is unwound and wound up at the minimum speed, and a process for determining the remaining amount of the packaging material is performed. Therefore, it takes time until packaging can be started.

[0005] In the present disclosure, of the packaging device it is possible to shorten the time required for the initial operation and the operation immediately after replacing the wound body, manufacturing method of the winding body is provided.

Means for Solving the Problem

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

[0007] The above-described packaging apparatus further includes a transport unit and a tension applying unit. The transport unit transports the packaging material unwound from the wound body along a transport path. The tension applying unit has a displacement member that is displaceable in a direction intersecting the transport path. The tension applying unit applies tension to the packaging material by pressing the displacement member against the packaging material. A fixed position is set for the displacement member. When the power of the packaging apparatus is turned on or when a wound body is attached to the packaging apparatus, the control unit drives the drive unit to rotate the wound body at a rotation speed set based on the remaining amount information, and moves the displacement member to the fixed position.

[0008] The above-described packaging apparatus further includes a position detection unit that detects that the displacement member is in the fixed position. The control unit unwinds the packaging material from the wound body until the position detection unit detects the displacement member, and moves the displacement member to the fixed position. The control unit may wind the packaging material onto the wound body until the position detection unit that has detected the displacement member no longer detects the displacement member, and then unwind the packaging material from the wound body until the position detection unit detects the displacement member, and move the displacement member to the fixed position.

[0009] The above-described packaging apparatus further includes a position detection unit that detects that the displacement member is in the fixed position. The control unit winds the packaging material onto the wound body until the position detection unit detects the displacement member, and moves the displacement member to the fixed position.

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

[0011] In the above-described packaging device, a plurality of stages are set for the remaining amount of the packaging material. When it is determined that the remaining amount of the packaging material is smaller than the remaining amount at the current stage, the control unit controls the information reading unit to write the remaining amount reduced by one stage to the recording medium as the remaining amount information.

[0012] According to the present disclosure, a winding body used in the packaging device of any of the above aspects is provided. The winding body includes a core tube and a long sheet-shaped packaging material wound around the core tube. The core tube has a recording medium that stores information, and the information includes remaining amount information indicating the remaining amount of the packaging material on the winding body.

[0013] According to the present disclosure, a winding body used in the packaging device of any of the above aspects is provided. The winding body includes a core tube, a long sheet-shaped packaging material wound around the core tube, and a recording medium that stores information. The information includes remaining amount information indicating the remaining amount of the packaging material on the winding body.

[0014] According to the present disclosure, a core tube used for the above-described winding body is provided. The winding body includes a core tube and a long sheet-shaped packaging material wound around the core tube. The winding body has a recording medium that stores information. The information recorded on the recording medium includes remaining amount information indicating the remaining amount of the packaging material on the winding body.

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

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

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

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

[0019] According to the present disclosure, there is provided a wound product obtained by winding a long sheet-like packaging material around a hollow cylindrical portion, which is used in the above manufacturing method.

Advantages of the Invention

[0020] This disclo as shown According to this, of the packaging device The time required for the initial operation and the operation immediately after the replacement of the wound body can be shortened.

Brief Description of the Drawings

[0021]

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Embodiments for Carrying Out the Invention

[0022] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following drawings, the same or corresponding parts are denoted by the same reference numerals, and the description thereof will not be repeated.

[0023] FIG. 1 is a perspective view showing the appearance of the drug supply device 101. As shown in FIG. 1, the drug supply device 101 includes a housing 102 that constitutes the outer shell of the drug supply device 101. The housing 102 has an upper housing 103 and a lower housing 104. The upper housing 103 houses a drug storage and dispensing device that discharges each drug from a plurality of drug containers. The lower housing 104 houses a packaging device that packages the drug in a packaging material.

[0024] Doors 105a and 105b are attached to the front surface of the upper housing 103. The door 105a has a handle 106a, and the door 105b has a handle 106b. A user who uses the drug supply device 101 can open and close the door 105a by holding the handle 106a, and can open and close the door 105b by holding the handle 106b. An operation unit 107 is provided on the front surface of the upper housing 103. The operation unit 107 may include a display having a touch panel function, or may include physical buttons on an operation panel.

[0025] Doors 108 and 109 are provided on the front surface of the lower housing 104. The doors 108 and 109 are configured to be openable and closable. A user who uses the drug supply device 101 can open the doors 108 and 109 and take out the packaged article in which the drug is contained from inside the lower housing 104. An opening may be formed in the doors 108 and 109, and the packaged article in which the drug is contained may be configured to be taken out through this opening.

[0026] FIG. 2 is a schematic configuration diagram of the packaging device 1 according to the embodiment. The packaging device 1 is used to package an object to be packaged. The object to be packaged is a drug, specifically a solid drug. Examples of the solid drug include tablets, pills, and capsules. The solid drug may be a powder or a granule. The object to be packaged is not limited to solid drugs. The object to be packaged may be a semi-solid drug or a liquid drug.

[0027] The packaging device 1 is a pharmaceutical packaging device for packaging pharmaceuticals based on a prescription. The prescription is delivered by a doctor to a patient. The prescription contains patient information and pharmaceutical information. The patient information includes the patient's name and age. The pharmaceutical information includes the drug name, dosage, usage method, and dosage amount. The packaging device 1 is used to package the pharmaceuticals in single-dose portions based on such a prescription.

[0028] The packaging device 1 includes a packaging material conveyance unit 8. The packaging material conveyance unit 8 applies a driving force to the packaging material 2 and conveys the packaging material 2. The packaging material 2 is in the form of a long sheet. The packaging material 2 is conveyed in the longitudinal direction of the packaging material 2. The packaging material 2 is unwound from a winding body 3. The winding body 3 is formed by winding the packaging material 2 around a hollow tubular core pipe 3a in a roll shape. The arrow in FIG. 2 indicates the conveyance direction DR of the packaging material 2. Hereinafter, the conveyance direction DR of the packaging material 2 will be simply referred to as the "conveyance direction DR".

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

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

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

[0032] The packaging device 1 further includes a printing unit 4, a supply unit 5, and a housing portion forming unit 6. In the order of the printing unit 4, the supply unit 5, and the housing portion forming unit 6 from the upstream (the side closer to the wound body 3) to the downstream (the side away from the wound body 3) in the conveyance direction DR. The printing unit 4 prints predetermined information on the packaging material 2 conveyed by the packaging material conveyance unit 8. The predetermined information is information related to the drug. The supply unit 5 supplies the drug to the packaging material 2 conveyed by the packaging material conveyance unit 8. The drug is supplied in portions for one dose based on the prescription. The housing portion forming unit 6 forms a housing portion using the packaging material 2 conveyed by the packaging material conveyance unit 8. The drug is housed in the housing portion. After the drug is supplied from the supply unit 5, the housing portion forming unit 6 heat-seals the packaging material 2 to form a package in which the drug is housed inside.

[0033] The packaging device 1 further includes a perforation forming unit 7. The perforation forming unit 7 is provided in the housing portion forming unit 6. The perforation forming unit 7 forms perforations extending in a direction perpendicular to the conveyance direction DR in the packaging material 2 conveyed by the packaging material conveyance unit 8. The perforations are formed by a plurality of pores continuously arranged in the short side direction of the packaging material 2.

[0034] In such a packaging device 1, the packaging unit 9 is constituted by the housing portion forming unit 6, the perforation forming unit 7, and the packaging material conveyance unit 8. In the packaging unit 9, the drug to be packaged is sequentially packaged using the packaging material 2 unwound from the wound body 3.

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

[0036] The packaging material supply unit 10 has a substantially box-shaped casing 20 and a mounted portion 21 to which the winding body 3 shown in FIG. 2 is mounted. The mounted portion 21 supports the winding body 3. The winding body 3 is attached to the mounted portion 21 in a non-rotatable manner relative to the mounted portion 21. The casing 20 has a flat outer surface 20a. The outer surface 20a constitutes a part of the surface of the box-shaped casing 20. The mounted portion 21 protrudes from the outer surface 20a of the casing 20 and extends substantially perpendicular to the outer surface 20a.

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

[0038] The packaging material 2 unwound from the winding body 3 is wound around the fixed roller 24, dancer roller 23, and fixed roller 25 in this order. The packaging material 2 is further wound around the direction-changing bar 11. The direction-changing bar 11 changes the conveyance direction DR of the packaging material 2 and moves the packaging material 2 in the direction toward the supply unit 5. The packaging material 2 is further wound around the packaging unit 9 (Figure 2) via the supply unit 5.

[0039] At the chemical supply position where the supply unit 5 supplies the chemical to the packaging material 2, the packaging material 2 is folded in half along the center line in the short side direction of the packaging material 2. The supply unit 5 has a hopper 151. The hopper 151 guides the chemical discharged from the chemical storage and dispensing device housed in the upper housing 103 (Figure 1) to the packaging material 2. The tip of the hopper 151 is arranged to enter the inside of the packaging material 2 folded in half. The chemical enters the inside of the packaging material 2 folded in half by being guided by the hopper 151.

[0040] The cutting unit 12 is provided downstream of the accommodation part forming unit 6 and the packaging material conveyance unit 8 that constitute the packaging unit 9 in the conveyance direction DR. The cutting unit 12 cuts the packaging material 2 with the chemical accommodated inside. The discharge unit 13 is provided downstream of the cutting unit 12 in the conveyance direction DR. The discharge unit 13 generates a driving force for conveying the packaging material 2 cut by the cutting unit 12 and discharges the packaging material 2 to the outside. Hereinafter, the path through which the packaging material 2 unwound from the winding body 3 and conveyed to the discharge unit 13 passes is referred to as the "conveyance path".

[0041] Figure 4 is a front view of the packaging material supply unit 10. Figure 4 shows the packaging material supply unit 10 as viewed from the direction of arrow IV shown in Figure 3. The dancer roller 23 moves relative to the casing 20 along the guide hole 22 formed in the casing 20. The dancer roller 23 is configured to be displaceable in a direction intersecting the conveyance path of the packaging material 2.

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

[0043] The packaging material supply unit 10 has a lock release unit 26. The above-mentioned main arm is locked by a lock unit, which will be described later. By manually operating the lock release unit 26, the lock of the main arm by the lock unit is released.

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

[0045] In FIG. 4, the position where the dancer roller 23 is arranged is referred to as the limit position. The limit position is at one end of the guide hole 22. The position of the other end of the guide hole 22 is referred to as the retracted position. The limit position sensor 27 and the retracted position sensor 29 are magnetic sensors. The limit position and the retracted position are outside the conveyance path. The limit position is farther from the conveyance path than the fixed position.

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

[0047] The packaging material supply unit 10 has a pay-off and take-up motor 35. The pay-off and take-up motor 35 of the present embodiment is a stepping motor. The pay-off and take-up motor 35 is supported by the casing 20. The pay-off and take-up motor 35 generates a rotational driving force for rotating the mounted portion 21 to pay off the packaging material 2 from the winding body 3 or wind the packaging material 2 onto the winding body 3. The driving force generated by the pay-off and take-up motor 35 is transmitted to the mounted portion 21 via the intermediate gear 72, the intermediate pinion gear 73, and the roller gear 74. The intermediate gear 72 and the intermediate pinion gear 73 are fixed integrally and rotatably about the intermediate gear shaft 75.

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

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

[0050] The sub-arm 50 has a base end part 51 and a tip end part 52. The base end part 51 is in surface contact with the surface of the main arm 40 from the bending part 43 of the main arm 40 to the second wrist part 42, and is fixed to the main arm 40 using a plurality of fixing members such as bolts. Thereby, the sub-arm 50 is configured to be rotatable integrally with the main arm 40. A cylindrical part 53 is attached to the tip end part 52 of the sub-arm 50.

[0051] One of the plurality of fixing members for fixing the sub-arm 50 to the main arm 40 constitutes a spring hanging part 45. A spring hanging part 31 is also provided on the sensor support part 30. The spring hanging part 31 is constituted by a bolt attached to the sensor support part 30. One end of a return spring 46 is engaged with the spring hanging part 31, and the other end of the return spring 46 is engaged with the spring hanging part 45. The return spring 46 is, for example, a coil spring.

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

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

[0054] The outer peripheral surface of the cylindrical portion 65 is slidable with respect to the arc edge 58a. The cylindrical portion 65 is also movable within the notch 59. When the outer peripheral surface of the cylindrical portion 65 comes into contact with the arc edge 58a, the intermediate gear 72 and the intermediate pinion gear 73 are positioned, and when the cylindrical portion 65 moves into the notch 59, the intermediate gear 72 and the intermediate pinion gear 73 are configured to change their positions.

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

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

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

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

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

[0060] The first hinge plate 91 is fixed to the lower housing 104 and is immovable. The second hinge plate 92 is relatively movable with respect to the first hinge plate 91 with the hinge shaft 93 as the rotation center. The second hinge plate 92 is disposed obliquely with respect to the vertical direction such that its upper end is relatively forward (rightward in the drawing) and its lower end is relatively rearward (leftward in the drawing).

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

[0062] The torsion spring 94 applies an elastic repulsive force between the first hinge plate 91 and the second hinge plate 92, and biases the second hinge plate 92 in a direction away from the first hinge plate 91 with the hinge axis 93 as the center of rotation. In a state where no external force other than the biasing force of the torsion spring 94 and gravity acts on the spring hinge 90, the first hinge plate 91 and the second hinge plate 92 extend substantially orthogonally. When viewed in the axial direction of the hinge axis 93, the first hinge plate 91 and the second hinge plate 92 are arranged in an L-shaped configuration.

[0063] The wrapper supply unit 10 is movable relative to the spring hinge 90 in the front-rear direction (left-right direction in FIG. 6) of the housing 102. In the arrangement shown in FIG. 6, the cylindrical portion 53 of the sub-arm 50 is separated from the second hinge plate 92, and the cylindrical portion 53 and the second hinge plate 92 are in a non-contact state. The cylindrical portion 53 is configured to slide relative to the second hinge plate 92 of the spring hinge 90, thereby rotating the sub-arm 50 and the main arm 40 around the arm rotation axis 44.

[0064] FIG. 7 is a front view of the wrapper supply unit 10 when the dancer roller 23 is in a fixed position. The dancer roller 23 shown in FIG. 7 has moved to the right in the figure along the guide hole 22 as compared with FIG. 4. The dancer roller 23 shown in FIG. 7 is located at a fixed position away from the limit position. Since the dancer roller 23 is away from the limit position shown in FIG. 4, the limit position sensor 27 is shown in FIG. 7. On the other hand, in FIG. 7, since the dancer roller 23 is in the fixed position, the dancer roller 23 overlaps the fixed position sensor 28, and the fixed position sensor 28 is not shown.

[0065] As described above, the packaging material 2 unwound from the winding body 3 (not shown in FIG. 7) is wound around the fixed roller 24, the dancer roller 23, and the fixed roller 25 in this order. When the dancer roller 23 is in a fixed position, a predetermined tension is applied to the packaging material 2. By applying tension to the packaging material 2, the occurrence of slack in the packaging material 2 is suppressed. As a result, when the packaging material conveying unit 8 (FIGS. 2 and 3) conveys the packaging material 2, displacement and wrinkling of the packaging material 2 are suppressed.

[0066] FIG. 8 is a perspective view of the back of the packaging material supply unit 10 when the dancer roller 23 is in a fixed position. The main arm 40 and the sub-arm 50 shown in FIG. 8 are rotated counterclockwise about the arm rotation axis 44 as compared with FIG. 5. The gear positioning plate 55 rotates together with the main arm 40, and the cylindrical portion 65 moves relative to the arc edge 58a of the gear positioning plate 55, so that the cylindrical portion 65 shown in FIG. 8 is closer to the notch 59 as compared with FIG. 5. The lock pin 47 shown in FIG. 8 has moved in a direction approaching the lock portion 78 as compared with FIG. 5. The return spring 46 shown in FIG. 8 has an increased length as compared with FIG. 5.

[0067] FIG. 9 is a front view of the packaging material supply unit 10 when the dancer roller 23 is in a moving position during conveyance. The dancer roller 23 shown in FIG. 9 has moved rightward in the figure along the guide hole 22 as compared with FIG. 7. The dancer roller 23 shown in FIG. 9 is away from the fixed position, and therefore both the limit position sensor 27 and the fixed position sensor 28 are shown in FIG. 9. The position where the dancer roller 23 is arranged in FIG. 7 is referred to as a moving position during conveyance. The moving position during conveyance is on the conveyance path.

[0068] FIG. 9 shows the packaging material 2 being conveyed by the packaging material conveying unit 8 by a length corresponding to one package of the package containing the drug inside, and the dancer roller 23 after moving from the fixed position along with the conveyance of the packaging material 2. While the packaging material conveying unit 8 is conveying the packaging material 2, the winding and unwinding motor 35 is stopped. Therefore, the packaging material 2 is not unwound from the winding body 3.

[0069] On the one hand, when the packaging material conveying unit 8 conveys the packaging material 2 by one package amount of the packaged product, the length of the packaging material 2 in the conveying direction DR from the winding body 3 to the packaging material conveying unit 8 becomes shorter by one package amount. This change in the length of the packaging material 2 is adjusted by moving the dancer roller 23 and shortening the distances between the dancer roller 23 and the fixed roller 24, and between the dancer roller 23 and the fixed roller 25.

[0070] That is, when comparing the length of the packaging material 2 wound between the dancer roller 23 and the fixed rollers 24, 25 at the fixed position shown in FIG. 7 with the length of the packaging material 2 wound between the dancer roller 23 and the fixed rollers 24, 25 at the position shown in FIG. 9, the length of the packaging material 2 is shorter in FIG. 9. By making the change in the length of the packaging material 2 wound between the dancer roller 23 and the fixed rollers 24, 25 correspond to the length of one package amount of the packaged product, the packaging material 2 can be conveyed while constantly maintaining a state in which a predetermined tension is applied to the packaging material 2.

[0071] The length of one package amount of the packaged product in the conveying direction DR is not always constant and may be changed according to the amount of the drug contained in the packaged product. According to the dimensions of the packaged product, the conveying amount of the packaging material 2 by the packaging material conveying unit 8 can also be changed, and the moving position during conveyance also fluctuates. When the length of one package amount of the packaged product in the conveying direction DR is large, the moving position during conveyance is set at a position relatively far from the fixed position. When the length of one package amount of the packaged product in the conveying direction DR is small, the moving position during conveyance is set at a position relatively close to the fixed position.

[0072] The packaging material 2 is intermittently conveyed. After the conveyance of the packaging material 2 is executed, the winding and unwinding motor 35 is driven while the conveyance of the packaging material 2 is stopped. By transmitting the driving force of the winding and unwinding motor 35 to the mounted portion 21 and rotating the winding body 3, the packaging material 2 is unwound from the winding body 3. At this time, since the conveyance of the packaging material 2 by the packaging material conveyance unit 8 is stopped, the packaging material 2 unwound from the winding body 3 is used to restore the length of the packaging material 2 wound between the dancer roller 23 and the fixed rollers 24 and 25. That is, when the packaging material 2 is unwound from the winding body 3, the dancer roller 23 moves from the conveyance-time movement position shown in FIG. 9 toward the fixed position shown in FIG. 7. When the dancer roller 23 moves to the fixed position and the fixed position sensor 28 detects the dancer roller 23, the winding and unwinding motor 35 is stopped.

[0073] In this way, by alternately repeating the conveyance of the packaging material 2 by the packaging material conveyance unit 8 and the unwinding of the packaging material 2 from the winding body 3, the packaging material 2 can be appropriately conveyed while maintaining the state in which a predetermined tension is applied to the packaging material 2.

[0074] FIG. 10 is a perspective view of the back side of the packaging material supply unit 10 when the dancer roller 23 is at the conveyance-time movement position. The main arm 40 and the sub-arm 50 shown in FIG. 10 are rotating in the counterclockwise direction about the arm rotation axis 44 as compared with FIG. 8. The gear positioning plate 55 rotates together with the main arm 40, and the cylindrical portion 65 moves relative to the arc edge 58a of the gear positioning plate 55, so that the cylindrical portion 65 shown in FIG. 10 is closer to the notch 59 as compared with FIG. 8. The lock pin 47 shown in FIG. 10 is moving in a direction approaching the lock portion 78 as compared with FIG. 8. The return spring 46 shown in FIG. 10 has an increased length as compared with FIG. 8.

[0075] As described above, when the packaging material 2 is being conveyed by the packaging material conveyance unit 8, the state in which tension is applied to the packaging material 2 is maintained, and at this time, the dancer roller 23 reciprocates between a fixed position and a moving position during conveyance. When all of the packaging material 2 has been unwound from the winding body 3, the upstream end of the packaging material 2 in the conveyance direction DR is no longer supported by the winding body 3, so that tension is no longer applied to the packaging material 2. Since the dancer roller 23 is no longer supported by the packaging material 2 in a state where tension is applied, the main arm 40 rotates by the elastic force of the return spring 46, and accordingly, the dancer roller 23 moves to the limit position.

[0076] FIG. 11 is a front view of the packaging material supply unit 10 when the dancer roller 23 is in the retracted position. The dancer roller 23 shown in FIG. 11 has moved in the right direction in the figure along the guide hole 22 as compared with FIG. 9. The dancer roller 23 shown in FIG. 11 is located at the retracted position at the other end of the guide hole 22.

[0077] In FIGS. 7 and 9, the dancer roller 23 is located on the left side in the figure with respect to the fixed rollers 24 and 25. Therefore, the packaging material 2 wound around the fixed roller 24, the dancer roller 23, and the fixed roller 25 in this order is pressed by the dancer roller 23, whereby tension is applied to the packaging material 2. On the other hand, in FIG. 11, the dancer roller 23 is located on the right side in the figure with respect to the fixed rollers 24 and 25. The packaging material 2 unwound from the winding body 3 can pass through the gap between the dancer roller 23 and the fixed roller 24 in the left-right direction in FIG. 11 and also through the gap between the dancer roller 23 and the fixed roller 25. At this time, no tension is applied to the packaging material 2.

[0078] By passing the packaging material 2 through the gap between the dancer roller 23 and the fixed rollers 24 and 25 in the left-right direction in FIG. 11 and moving the dancer roller 23 to the fixed position in that state, tension is applied to the packaging material 2.

[0079] The dancer roller 23 and the fixed rollers 24 and 25 constitute a tension applying unit that applies tension to the packaging material 2 unwound from the winding body 3. The tension applying unit applies tension to the packaging material 2 by the dancer roller 23 pressing the packaging material 2. The dancer roller 23 constitutes a displacement member that is displaceable in a direction intersecting the conveyance path of the packaging material 2. The tension applying unit is switchable between an applied state in which tension is applied to the packaging material 2 and a non-applied state in which no tension is applied to the packaging material 2 by moving the dancer roller 23.

[0080] FIG. 12 is a perspective view of the back side of the packaging material supply unit 10 when the dancer roller 23 is in the retracted position. The main arm 40 and the sub-arm 50 shown in FIG. 12 are rotated counterclockwise about the arm rotation axis 44 as compared with FIG. 10. The cylindrical portion 65 shown in FIG. 12 is within the notch 59, away from the arc edge 58a of the gear positioning plate 55. The lock pin 47 shown in FIG. 12 is engaged with a lock portion 78 not shown in FIG. 12, whereby the main arm 40 is locked. The return spring 46 shown in FIG. 12 has an increased length as compared with FIG. 10 and is at its maximum length.

[0081] Next, control for executing the sub-packaging operation using the packaging device 1 will be described. FIG. 13 is a block diagram showing the electrical configuration of the packaging device 1 according to the embodiment. As shown in FIG. 13, the packaging device 1 includes an operation unit 107 and an overall control unit 200.

[0082] The operation unit 107 is operated by an operator who operates the packaging device 1. When the operation unit 107 is operated by the operator, information necessary for the packaging operation of the packaging device 1 is input to the overall control unit 200. Examples of the information necessary for the packaging operation of the packaging device 1 include prescription data based on a prescription form and various setting information. The setting information includes the length of one package of the packaging object in which the drug is contained. The information necessary for the packaging operation of the packaging device 1 may be input from an external computer to the overall control unit 200.

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

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

[0085] The packaging unit 9 has a packaging control unit 201. The packaging control unit 201 receives the detection signals of the fixed-position sensor 28, the limit-position sensor 27, and the retracted-position sensor 29, and determines the current position of the dancer roller 23. The packaging control unit 201 controls the unwind / rewind motor 35, the pressure motor 6m, the heater 6h, the conveyance motor 8m, and the read / write unit 3R based on the control signal from the overall control unit 200. By appropriately driving and stopping these unwind / rewind motor 35, pressure motor 6m, heater 6h, conveyance motor 8m, and read / write unit 3R, the packaging of the packaging material 2 is performed.

[0086] The pressure motor 6m and the heater 6h are included in the housing forming unit 6 (Figure 2). The heater 6h is built into one of a pair of pressure members arranged to face each other with the packaging material 2 sandwiched therebetween. The pressure motor 6m drives the pair of pressure members to press the packaging material 2 from both sides with the pressure members or to separate the pressure members from the packaging material 2. When the packaging material 2 is pressed from both sides, the heater 6h is driven to heat the packaging material 2, so that a part of the packaging material 2 is heat-sealed to form a package containing the drug inside.

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

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

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

[0090] FIG. 14 is a flowchart showing a setting operation for setting the rotational speed of the unwinding / winding motor 35. In the packaging apparatus 1 of the present embodiment, the unwinding / winding unit is a configuration for performing unwinding of the packaging material 2 from the winding body 3 or winding of the packaging material 2 onto the winding body 3. The unwinding / winding unit includes an unwinding / winding motor 35, a mounted portion 21, a power transmission unit that transmits the driving force generated by the unwinding / winding motor 35 to the mounted portion 21, a dancer roller 23, sensors for detecting the position of the dancer roller 23, and fixed rollers 24 and 25. The conveying unit is a configuration for conveying the packaging material 2 along the conveying direction DR. The conveying unit is constituted by a packaging material conveying unit 8.

[0091] The setting operation shown in FIG. 14 is executed when the packaging apparatus 1 is powered on at startup or when the winding body 3 is mounted on the mounted portion 21 when the winding body 3 is replaced. When the setting operation is started, first, in step S1, remaining amount information indicating the remaining amount of the packaging material 2 in the winding body 3 is acquired from the IC tag. The reading / writing unit 3R (FIG. 13) accesses the IC tag provided on the core tube 3a of the winding body 3, that is, the recording medium 3b (FIG. 2), and acquires the remaining amount information recorded on the recording medium 3b. The remaining amount information is input from the reading / writing unit 3R to the packaging control unit 201.

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

[0093] When the remaining amount of the packaging material 2 in the winding body 3 is large and the winding diameter of the packaging material 2 is large, the inertia of the winding body 3 is large. Therefore, if the rotational speed of the winding body 3 is too high, there is a possibility of out-of-step due to the characteristics of the stepping motor. Also, because the inertia of the winding body 3 is large, the packaging material 2 may become loose, and this looseness becomes an error, reducing the accuracy of the winding diameter determination of the packaging material 2. Therefore, when the remaining amount of the packaging material 2 is large, the rotational speed is decreased.

[0094] When the remaining amount of the packaging material 2 in the winding body 3 is small and the winding diameter of the packaging material 2 is small, the inertia of the winding body 3 is small, so the possibility of out-of-tune is reduced. Also, when compared with the case where the winding diameter is large, when the winding diameter is small, it is necessary to rotate the winding body 3 more times to unwind the same length of the packaging material 2. Therefore, when the remaining amount of the packaging material 2 is small, the rotation speed is increased.

[0095] In this way, the packaging control unit 201 sets the rotation speed of the unwinding and winding motor 35 according to the remaining amount of the packaging material 2 in the winding body 3. Then, the setting operation is terminated ("End" in FIG. 14).

[0096] FIGS. 15 and 16 are flowcharts showing the positioning return operation of the dancer roller 23 during the initial operation. After the power of the packaging device 1 is turned on, when a predetermined key is operated, the initial operation is started. As one of the initial operations, the positioning return operation of the dancer roller 23 is executed.

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

[0098] As described with reference to FIG. 12, when the dancer roller 23 is in the retracted position, the lock pin 47 is engaged with the lock portion 78, and the main arm 40 is locked. To make the dancer roller 23 movable, the lock of the main arm 40 is released. The linear solenoid actuator 87 pulls the locking member 79, thereby releasing the lock of the main arm 40 by the lock portion 78. The lock of the main arm 40 by the lock portion 78 may also be released by the user of the packaging device 1 manually operating the unlocking portion 26.

[0099] The return spring 46 biases the main arm 40 in the direction in which the dancer roller 23 moves from the retracted position toward the limit position. When the lock of the main arm 40 is released, the main arm 40 rotates by the elastic force of the return spring 46, and accordingly, the dancer roller 23 moves in the direction from the retracted position toward the limit position. The position to which the dancer roller 23 moves after the lock of the main arm 40 is released is defined according to the amount of unwinding of the packaging material 2 from the winding body 3 at that time.

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

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

[0102] Specifically, in step S104, the unwinding of the packaging material 2 from the winding body 3 is started. The packaging control unit 201 transmits a control signal to the unwinding and winding motor 35 so as to rotationally drive the mounted portion 21 in the direction of unwinding the packaging material 2 from the winding body 3.

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

[0104] If it is determined in the determination of step S103 that the limit position sensor 27 is on (YES in step S103), the dancer roller 23 is at the limit position. When the unwinding of the packaging material 2 ends in step S106, the dancer roller 23 is at the limit position. When it is detected that the dancer roller 23 is at the limit position, the process proceeds to step S107 via the coupler 1, and the winding of the packaging material 2 onto the winding body 3 is started. The packaging control unit 201 transmits a control signal to the unwind / rewind motor 35 so as to rotationally drive the mounted portion 21 in the direction of winding the packaging material 2 onto the winding body 3.

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

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

[0107] While the determinations in step S108 and step S109 are repeated, the winding of the packaging material 2 is continued. When it is determined that the fixed-position sensor 28 is turned off and the dancer roller 23 has deviated from the fixed position (YES in step S109), the process proceeds to step S110 to end the winding of the packaging material 2 around the winding body 3. The packaging control unit 201 transmits a control signal to stop to the unwinding and winding motor 35.

[0108] When the winding of the packaging material 2 around the winding body 3 is completed, the dancer roller 23 has moved beyond the fixed position from the limit position, and the dancer roller 23 has moved between the fixed position and the retracted position. From this state, a process of moving the dancer roller 23 back to the fixed position is performed.

[0109] Specifically, in step S111, the unwinding of the packaging material 2 from the winding body 3 is started. The packaging control unit 201 transmits a control signal to the unwinding and winding motor 35 so as to rotationally drive the mounted portion 21 in the direction of unwinding the packaging material 2 from the winding body 3.

[0110] Subsequently, in step S112, it is determined whether the fixed-position sensor 28 is on. When it is determined that the fixed-position sensor 28 is not on and the dancer roller 23 is not in the fixed position (NO in step S112), the determination in step S112 is repeated until it is detected that the fixed-position sensor 28 is turned on, and during that time, the unwinding of the packaging material 2 is continued. When it is detected that the fixed-position sensor 28 is turned on (YES in step S112), the process proceeds to step S113 to end the unwinding of the packaging material 2 from the winding body 3. The packaging control unit 201 transmits a control signal to stop to the unwinding and winding motor 35.

[0111] In this way, the fixed-position return operation of the dancer roller during the initial operation is performed. Then, the fixed-position return operation is ended ("End" in FIG. 16).

[0112] Figure 17 is a schematic diagram showing the movement of the dancer roller 23 during the execution of the positioning return operation of the dancer roller 23 at the initial operation. In Figure 17, the line segment extending in the left-right direction in the figure indicates the movement range of the dancer roller 23. The three double-headed arrows indicate, in order from left to right in the figure, the detection range of the limit position sensor 27, the detection range of the positioning sensor 28, and the detection range of the retracted position sensor 29. The limit position sensor 27, the positioning sensor 28, and the retracted position sensor 29 are turned on by detecting the magnetic force of the magnet attached to the main arm 40 as described above. Therefore, the limit position sensor 27, the positioning sensor 28, and the retracted position sensor 29 each have a detection range with a predetermined width.

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

[0114] When attempting to stop the winding and unwinding motor 35 upon detection of the positioning sensor 28 being turned on, the dancer roller 23 moves even after the positioning sensor 28 is turned on for the time it takes to decelerate until the winding and unwinding motor 35 stops. Since the positioning sensor 28 has a predetermined detection range, there is a possibility that the position where the dancer roller 23 stops when moving the dancer roller 23 to the positioning while unwinding the winding body 3 and the position where the dancer roller 23 stops when moving the dancer roller 23 to the positioning while winding up the winding body 3 may deviate.

[0115] In this embodiment, it is set so that the dancer roller 23 is stopped at a fixed position by unwinding the winding body 3. By defining the moving direction of the dancer roller 23 in one direction when trying to stop the dancer roller 23 at a fixed position, the positions where the dancer roller 23 stops can be made uniform. Thereby, the fixed-position return operation of the dancer roller 23 can be surely executed.

[0116] During the unwinding of the winding body 3 in steps S104 to S106, the winding of the winding body 3 in steps S107 to S110, and the unwinding of the winding body 3 in steps S111 to S113, the rotational speed of the winding body 3 is the rotational speed set based on the remaining amount information of the packaging material 2 acquired from the recording medium 3b and set in step S2 shown in FIG. 14. The winding and unwinding motor 35 is driven so that the winding body 3 rotates at the rotational speed set based on the remaining amount information of the packaging material 2, and the fixed-position return operation is executed.

[0117] Thereby, it is not necessary to rotate the winding and unwinding motor 35 at the lowest speed during the fixed-position return operation, and the winding and unwinding motor 35 can be rotated at an appropriate rotational speed. Also, the process for determining the remaining amount of the packaging material 2 becomes unnecessary. Therefore, the fixed-position return operation can be executed in a short time, and the time required for the return operation during the initial operation can be shortened.

[0118] The fixed-position return operation of the dancer roller 23 during the initial operation also serves as a sensor confirmation operation for checking whether there is an abnormality in the fixed-position sensor 28 and the limit position sensor 27. The dancer roller 23 is moved to the limit position in steps S103 to S106 and is moved to the fixed position in steps SS107 to S113. By checking whether the movement of the dancer roller 23 can be detected by the fixed-position sensor 28 and the limit position sensor 27, the sensor confirmation operation can be surely executed.

[0119] Figures 18, 19, and 20 are flowcharts showing the operation of the dancer roller 23 to return to a fixed position when the winding body is mounted. When replacing the winding body 3, when a predetermined key is operated after the winding body 3 is mounted on the mounted portion 21, the operation of the dancer roller 23 to return to the fixed position is executed.

[0120] First, in step S201, it is determined whether the retracted position sensor 29 is on. In step S202, the lock of the main arm 40 is released. The processes of steps S201 and S202 are the same as the processes of steps S101 and S102 described with reference to FIG. 15, so the description is omitted.

[0121] Next, in step S203, it is determined whether the fixed position sensor 28 is on. The packaging control unit 201 determines whether the fixed position sensor 28 is on based on the presence or absence of a detection signal indicating that the fixed position sensor 28 is in the on state. When an input of a detection signal is received from the fixed position sensor 28 and it is determined that the fixed position sensor 28 is on (YES in step S203), although the dancer roller 23 is in the fixed position, a process is performed to further align the positions where the dancer roller 23 stops more precisely.

[0122] Specifically, it proceeds to step S210 via the coupler 2, and the winding of the packaging material 2 around the winding body 3 is started. The process of step S210 is the same as the process of step S107 described with reference to FIG. 16, so the description is omitted.

[0123] Subsequently, in step S211, it is determined whether the fixed-position sensor 28 is off. In step S212, the winding of the packaging material 2 around the winding body 3 is terminated. In step S213, the unwinding of the packaging material 2 from the winding body 3 is started. In step S214, it is determined whether the fixed-position sensor 28 is on. In step S215, the unwinding of the packaging material 2 from the winding body 3 is terminated. The processes of steps S211 to S215 are the same as the processes of steps S109 to S113 described with reference to FIG. 16, and thus the description is omitted. By unwinding the winding body 3 and stopping the dancer roller 23 at a fixed position, the position where the dancer roller 23 stops within the detection range of the fixed-position sensor 28 can be made constant.

[0124] If in the determination of step S203, it is determined that the fixed-position sensor 28 is not on and the dancer roller 23 is at a position other than the fixed position (NO in step S203), then in step S204, it is determined whether the limit-position sensor 27 is on. The process of step S204 is the same as step S103 described with reference to FIG. 15, and thus the description is omitted.

[0125] If it is determined that the limit-position sensor 27 is on (YES in step S204), a process is performed to move the dancer roller 23 from the limit position beyond the fixed position and then to the fixed position.

[0126] Specifically, proceeding to step S216 via the connector 3, the winding of the packaging material 2 around the winding body 3 is started. In step S217, it is determined whether the fixed-position sensor 28 is on. In step S218, it is determined whether the fixed-position sensor 28 is off. In step S219, the winding of the packaging material 2 around the winding body 3 is terminated. The processes of steps S216 to S219 are the same as the processes of steps S107 to S110 described with reference to FIG. 16, and thus the description is omitted. Subsequently, the processes of steps S213 to S215 are performed via the connector 4.

[0127] In the determination of step S204, if it is determined that the limit position sensor 27 is not on and the dancer roller 23 is at a position other than the fixed position and the limit position (NO in step S204), in step S205, the unwinding of the packaging material 2 from the winding body 3 is started. The packaging control unit 201 transmits a control signal to the unwinding and winding motor 35 so as to rotationally drive the mounted part 21 in the direction of unwinding the packaging material 2 from the winding body 3.

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

[0129] If it is detected in the determination of step S206 that the fixed position sensor 28 has been turned on (YES in step S206), the process proceeds to step S207, and the unwinding of the packaging material 2 from the winding body 3 is terminated. In this case, when the fixed position return operation is started, the dancer roller 23 is between the fixed position and the retracted position, and by unwinding the winding body 3, the dancer roller 23 is moved in the direction toward the limit position and stopped at the fixed position. As a result, the positions where the dancer roller 23 stops are aligned, so the process proceeds to FIG. 19 via the coupling 5, and the process is terminated without moving the dancer roller 23 to the limit position.

[0130] When it is detected in the determination of step S208 that the limit position sensor 27 has turned on (YES in step S208), the process proceeds to step S209 to terminate the unwinding of the packaging material 2 from the winding body 3. In this case, when the fixed-position return operation is started, the dancer roller 23 is between the limit position and the fixed position, and by unwinding the winding body 3, the dancer roller 23 is moved in the direction toward the limit position and stopped at the limit position. Therefore, the processes of steps S216 to S219 described above and subsequently the processes of steps S213 to S215 are performed to unwind the winding body 3 and stop the dancer roller 23 at the fixed position.

[0131] In this way, the fixed-position return operation of the dancer roller 23 when the winding body is mounted is performed. Then, the fixed-position return operation is terminated (``End'' in FIG. 19).

[0132] FIG. 21 is a schematic diagram showing the movement of the dancer roller 23 during the execution of the fixed-position return operation of the dancer roller 23 when the winding body is mounted. In FIG. 21, similar to FIG. 17, the movement range of the dancer roller 23 and the detection ranges of the limit position sensor 27, the fixed-position sensor 28, and the retracted position sensor 29 are shown.

[0133] As described in steps S203, S210 to S215 above, when the dancer roller 23 is at the fixed position at the start of the fixed-position return operation, as shown by the arrow indicated by the symbol D in FIG. 21, the dancer roller 23 moves from the fixed position to the retracted position once and then moves back to the fixed position.

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

[0135] As described in steps S205 to S207, when the dancer roller 23 is between the fixed position and the retracted position at the start of the fixed-position return operation, the dancer roller 23 moves to the fixed position as indicated by the arrow denoted by reference symbol F in FIG. 21.

[0136] As described in steps S205, S208 to S209, S216 to S219, and S213 to S215, when the dancer roller 23 is between the limit position and the fixed position at the start of the fixed-position return operation, the dancer roller 23 first moves to the limit position and then moves beyond the fixed position and then returns to the fixed position as indicated by the arrow denoted by reference symbol G in FIG. 21.

[0137] In this way, the winding body 3 is unwound to stop the dancer roller 23 at the fixed position, and the moving direction of the dancer roller 23 when attempting to stop the dancer roller 23 at the fixed position is defined in one direction. By aligning the positions where the dancer roller 23 stops, the fixed-position return operation of the dancer roller 23 can be surely executed.

[0138] During the unwinding of the winding body 3 in steps S205 to S207 and steps S205 to S209, the winding of the winding body 3 in steps S210 to S212, the unwinding of the winding body 3 in steps S213 to S215, and the winding of the winding body 3 in steps S216 to S219, the rotational speed of the winding body 3 is the rotational speed set based on the remaining amount information of the packaging material 2 obtained from the recording medium 3b and set in step S2 shown in FIG. 14. The winding and unwinding motor 35 is driven to rotate the winding body 3 at the rotational speed set based on the remaining amount information of the packaging material 2, and the fixed-position return operation is executed.

[0139] Thereby, it is not necessary to rotate the winding and unwinding motor 35 at the lowest speed during the fixed-position return operation, and the winding and unwinding motor 35 can be rotated at an appropriate rotational speed. Also, the process for determining the remaining amount of the packaging material 2 becomes unnecessary. Therefore, the fixed-position return operation can be executed in a short time, and the time required for the return operation when the winding body is mounted can be shortened.

[0140] When the dancer roller 23 is mounted on the winding body, the positioning return operation of the dancer roller 23 is different from that during the initial operation and does not include the sensor confirmation operation. In steps S203 and S206, if the positioning sensor 28 is on, the return operation is terminated without moving the dancer roller 23 to the limit position. By reducing the movement of the dancer roller 23, the time required for the positioning return operation can be surely shortened.

[0141] FIG. 22 is a flowchart showing the operations of the unwinding / winding unit and the conveying unit in the subcontracting operation. As shown in FIG. 22, when the subcontracting operation of the object to be packaged by the packaging device 1 is started, first, in step S301, the remaining amount information indicating the remaining amount of the packaging material 2 in the winding body 3 is acquired from the IC tag. In step S302, the rotation speed is set based on the remaining amount information. Since the processes of steps S301 to S302 are the same as the processes of steps S1 to S2 described with reference to FIG. 14, the description thereof is omitted.

[0142] Next, in step S303, it is determined whether the number of packages packaged by the packaging device 1 has reached the specified number of packages since the start of packaging. If it is determined that the specified number of packages has not been reached (NO in step S303), then in step S304, the conveying operation of the packaging material 2 by the conveying unit is started. The packaging control unit 201 transmits a control signal for driving the conveying motor 8m to the conveying motor 8m. During the conveying operation of the packaging material 2, the packaging control unit 201 transmits a control signal for maintaining the stop of the unwinding / winding motor 35 to the unwinding / winding motor 35. Therefore, the unwinding of the packaging material 2 from the winding body 3 is not performed.

[0143] Subsequently, in step S305, it is determined whether or not the conveying operation has ended. The packaging control unit 201 calculates the conveying distance of the packaging material 2 based on the driving amount of the conveying motor 8m. When the packaging material 2 is conveyed by the length of one package of the packaged object, the conveying operation of the packaging material 2 ends. The packaging control unit 201 transmits a control signal for stopping the conveying motor 8m to the conveying motor 8m. When the conveying operation of the packaging material 2 ends, the dancer roller 23 has moved from the fixed position to the moving position during conveyance. Next, in step S306, the unwinding operation by the unwinding and winding unit is started.

[0144] FIG. 23 is a flowchart showing a first example of the unwinding operation by the unwinding and winding unit. In FIG. 23, a flowchart showing an example of a subroutine of the unwinding operation performed in step S306 is illustrated.

[0145] Referring to FIG. 23, first, in step S401, the unwinding of the packaging material 2 from the winding body 3 is started. The packaging control unit 201 transmits a control signal to the unwinding and winding motor 35 so as to rotationally drive the mounted portion 21 in the direction of unwinding the packaging material 2 from the winding body 3. At this time, the packaging control unit 201 rotationally drives the unwinding and winding motor 35 at a rotational speed based on the remaining amount information of the packaging material 2 set in step S302.

[0146] Subsequently, in step S402, it is determined whether or not the fixed position sensor 28 is on. If it is determined that the fixed position sensor 28 is not on and the dancer roller 23 is not in the fixed position (NO in step S402), the determination in step S402 is repeated until it is detected that the dancer roller 23 is in the fixed position, and during that time, the unwinding of the packaging material 2 continues. If it is determined that the dancer roller 23 is in the fixed position (YES in step S402), the process proceeds to step S403, and the unwinding of the packaging material 2 from the winding body 3 ends. The packaging control unit 201 transmits a control signal for stopping to the unwinding and winding motor 35.

[0147] In the unwinding operation, the dancer roller 23 moves from the moving position during conveyance to a fixed position. The moving position during conveyance changes according to the length of one package of the packaging material in the conveyance direction DR. The relationship between the length of one package of the packaging material and the moving position during conveyance is stored in the packaging control unit 201 in advance. The packaging control unit 201 derives the moving distance of the dancer roller 23 in the unwinding operation according to the length of one package of the packaging material.

[0148] When the unwinding operation ends, next, in step S404, the remaining amount of the wrapping material 2 on the winding body 3 is determined. The number of steps of the stepping motor is counted from when the driving of the winding body 3 by the unwind / rewind motor 35 is started in step S401 until it is detected in step S402 that the dancer roller 23 is in the fixed position. By counting the number of steps of the stepping motor while the dancer roller 23 moves from the moving position during conveyance to the fixed position, the winding diameter of the wrapping material 2 on the winding body 3 is determined. By obtaining the winding diameter of the wrapping material 2 based on the number of steps of the unwind / rewind motor 35, the remaining amount of the wrapping material 2 on the winding body 3 can be determined.

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

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

[0151] In the first example shown in FIG. 23, every time the unwinding operation for one package is executed, the remaining amount information is written into the IC tag. Then, the unwinding process is terminated ("End" in FIG. 23).

[0152] FIG. 24 is a flowchart showing a second example of the unwinding operation by the unwinding / winding unit. In FIG. 24, a flowchart showing another example of the subroutine of the unwinding operation performed in step S306 is illustrated.

[0153] Referring to FIG. 24, first, in step S501, the unwinding of the packaging material 2 from the winding body 3 is started. The packaging control unit 201 transmits a control signal to the unwinding / winding motor 35 so as to rotationally drive the mounted portion 21 in the direction of unwinding the packaging material 2 from the winding body 3. At this time, the packaging control unit 201 rotationally drives the unwinding / winding motor 35 at a rotational speed based on the remaining amount information of the packaging material 2 set in step S302.

[0154] Subsequently, in step S502, it is determined whether or not the fixed-position sensor 28 is on. If it is determined that the fixed-position sensor 28 is not on and the dancer roller 23 is not in the fixed position (NO in step S502), the determination in step S502 is repeated until it is detected that the dancer roller 23 is in the fixed position, and during that time, the unwinding of the packaging material 2 is continued. If it is determined that the dancer roller 23 is in the fixed position (YES in step S502), the process proceeds to step S503, and the unwinding of the packaging material 2 from the winding body 3 is terminated. The packaging control unit 201 transmits a control signal for stopping to the unwinding / winding motor 35.

[0155] When the unwinding operation ends, next, in step S504, the remaining amount of the packaging material 2 in the winding body 3 is calculated. After starting the drive of the winding body 3 by the unwind / rewind motor 35 in step S501, the number of steps of the stepping motor is counted until it is detected in step S502 that the dancer roller 23 is in the fixed position. Based on the number of steps of the stepping motor while the dancer roller 23 moves from the moving position during conveyance to the fixed position, the remaining amount of the packaging material 2 in the winding body 3 can be calculated.

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

[0157] If it is determined that the calculation result of the remaining amount of the packaging material 2 is smaller than the current remaining amount information (YES in step S405), next, in step S506, 1 is added to the number of times it is determined that the calculation result of the remaining amount of the packaging material 2 is smaller than the current remaining amount information. More specifically, if the number of times it is determined at the time of step S405 that the calculation result of the remaining amount of the packaging material 2 is smaller than the current remaining amount information is N (N is an integer of zero or more), the number of times is set to (N + 1) times in step S506. For example, if the number of times it is determined at the time of step S505 that the calculation result of the remaining amount of the packaging material 2 is smaller than the current remaining amount information is 2 times, the number of times is set to 3 times in step S506.

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

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

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

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

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

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

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

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

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

[0167] For example, when the threshold value used for the determination in step S507 is 5, if it is determined that the calculation results of the remaining amount of the packaging material 2 are smaller than the current remaining amount information four times in a row, and it is determined in the fifth determination that the calculation result of the remaining amount of the packaging material 2 is larger than the current remaining amount information, and it is determined in the sixth determination that the calculation result of the remaining amount of the packaging material 2 is smaller than the current remaining amount information, the number of times the calculation result of the remaining amount of the packaging material 2 is determined to be smaller than the current remaining amount information is accumulated to be equal to or greater than the threshold value, so the remaining amount information recorded on the recording medium 3b is updated.

[0168] In the second example shown in FIG. 24, the remaining amount information is written into the IC tag only when the determination result of the remaining amount changes. Then, the unrolling process is terminated ("End" in FIG. 24).

[0169] FIG. 25 is a flowchart showing a third example of the unrolling operation by the unrolling / rewinding unit. In FIG. 25, a flowchart showing still another example of the subroutine of the unrolling operation performed in step S306 is illustrated.

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

[0171] After calculating the remaining amount of the packaging material 2 in the winding body 3, in step S605, the calculation result of the remaining amount of the packaging material 2 calculated in step S604 is compared with the current remaining amount information to determine whether the calculation result of the remaining amount of the packaging material 2 is different from the current remaining amount. That is, it is determined whether the remaining amount of the packaging material 2 recorded on the recording medium 3b at this time, which was obtained from the recording medium 3b in step S301, is different from the remaining amount of the packaging material 2 calculated this time.

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

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

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

[0175] Next, in step S608, it is determined whether the number of times after addition in step S607 is equal to or greater than the threshold value. If it is determined that the number of times is equal to or greater than the threshold value (YES in step S608), the process proceeds to step S609, and the calculation result of the remaining amount of Packaging Material 2 calculated in step S504 is recorded on the recording medium 3b as new remaining amount information. For example, when the threshold value used in the determination of step S608 is 5, when it can be determined that the calculation result of the remaining amount of Packaging Material 2 has matched the previous calculation result 5 times in a row, the 5th calculation result is written to the recording medium 3b as new remaining amount information, and the remaining amount information recorded on the recording medium 3b is updated.

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

[0177] In the determination of step S608, if it is determined that the number of times is less than the threshold value (NO in step S608), the unwinding operation is terminated without reflecting the calculation result of the remaining amount of the packaging material 2 in the remaining amount determination result.

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

[0179] Also in the third example shown in FIG. 25, the remaining amount information is written to the IC tag only when the determination result of the remaining amount changes. Then, the unwinding process is terminated ("End" in FIG. 25).

[0180] Returning to FIG. 22, when the unwinding operation in step S306 is completed, next in step S307, it is determined whether or not all of the above-described predetermined operations such as heat fusion, printing, perforation formation, and cutting, which should be performed while the packaging material 2 is stopped by the conveying unit, have been completed. The determination in step S307 is repeated until all of the predetermined operations are completed.

[0181] When all of the predetermined operations are completed (YES in step S307), the process returns to the process of step S301. After the process of obtaining the remaining amount information of the packaging material 2 in step S301 and the process of setting the rotation speed in step S302, it is again determined whether or not the number of packages packaged up to the current point in step S303 has reached the specified number of packages. Until the number of packages packaged by the packaging device 1 reaches the specified number of packages, the conveyance of the packaging material 2 and the unwinding of the packaging material 2 from the winding body 3 are repeated according to steps S304 to S307. When it is determined that the specified number of packages has been reached (YES in step S303), a series of sub-packaging operations by the unwinding and winding unit and the conveying unit are terminated ("End" in FIG. 22).

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

[0183] The packaging device 1 according to the present embodiment calculates the moving distance of the dancer roller 23 based on the detection result by the position detection unit, and also measures the driving amount of the pay-off and take-up motor 35, which is a stepping motor, during the movement of the dancer roller 23 by counting the number of steps of the pay-off and take-up motor 35. The remaining amount of the packaging material 2 on the winding body 3 is calculated from the driving amount of the pay-off and take-up motor 35 with respect to the moving amount of the dancer roller 23.

[0184] The remaining amount of the packaging material 2 is calculated using a position detection unit provided to detect that the dancer roller 23 is at a fixed position or a limit position, and a pay-off and take-up motor 35 that generates a driving force for rotating the winding body 3 to unwind the packaging material 2 from the winding body 3. The remaining amount of the packaging material 2 on the winding body 3 can be calculated using only parts for other purposes, in other words, without adding dedicated parts for calculating the remaining amount of the packaging material 2. Therefore, the configuration of the packaging device 1 can be simplified.

[0185] There may be a case where the packaging material 2 adheres to the winding body 3 due to static electricity or the like, and the packaging material 2 cannot be unwound even when the winding body 3 is rotated. If the amount of the packaging material 2 unwound from the winding body 3 is less than the original amount, the driving amount of the pay-off and take-up motor 35 for moving the dancer roller 23 by a predetermined distance increases, and the calculation result of the remaining amount of the packaging material 2 becomes less than the actual remaining amount. If it is determined based on the calculation result that is less than the actual remaining amount of the packaging material 2 that the remaining amount of the packaging material 2 has decreased and the rotation speed of the pay-off and take-up motor 35 is increased, the winding body 3 may rotate at an excessive speed, resulting in out-of-step of the stepping motor, loosening of the packaging material 2, etc.

[0186] Therefore, in the packaging apparatus 1 of the present embodiment, the remaining amount determination result is updated based on a plurality of calculation results. Even if it is once detected that the rotational speed of the unwinding and winding motor 35 when calculating the remaining amount of the packaging material 2 is large and the remaining amount of the packaging material 2 is small, the calculation result of the remaining amount of the packaging material 2 at that time is not used as the remaining amount determination result. Instead, the remaining amount determination result is updated when it is possible to determine a plurality of times that the remaining amount of the packaging material 2 has decreased. By doing so, temporary fluctuations in the calculation result of the remaining amount of the packaging material 2 are not reflected in the remaining amount determination result, and the detection accuracy of the remaining amount of the packaging material 2 can be improved. Therefore, it is possible to suppress the occurrence of an event in which the winding body 3 is rotated at an excessive speed with respect to the actual remaining amount of the packaging material 2.

[0187] Even if the amount of the packaging material 2 unwound from the winding body 3 is small due to, for example, the sticking of the packaging material 2 to the winding body 3, if the sticking of the packaging material 2 is eliminated, the original unwinding according to the rotation of the winding body 3 is restored, and the original remaining amount of the packaging material 2 is calculated.

[0188] In updating the remaining amount information of the packaging material 2, an update is made such that the remaining amount of the packaging material 2 in the winding body 3 decreases. As the packaging operation is executed, the packaging material 2 is unwound from the winding body 3, so the newly written remaining amount of the packaging material 2 is always smaller than the remaining amount of the packaging material 2 already recorded on the recording medium 3b.

[0189] FIG. 26 is a flowchart showing another example of the positioning return operation of the dancer roller 23 during the initial operation. FIG. 27 is a schematic diagram showing the movement of the dancer roller 23 during the execution of another example of the positioning return operation of the dancer roller 23 during the initial operation.

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

[0191] When it is detected that the fixed-position sensor 28 is turned on in step S708 (YES in step S108), next in step S709, the winding of the wrapping material 2 around the winding body 3 is terminated. As shown in the example of FIG. 16, instead of moving the dancer roller 23 beyond the fixed position, it is set to wind up the wrapping material 2 and stop the dancer roller 23 at the fixed position.

[0192] In the example shown in FIG. 26, the processes of steps S109, S111 to S113 shown in FIG. 16 are omitted. Compared with FIG. 17, in FIG. 27, as indicated by the arrow denoted by symbol B, the dancer roller 23 stops when reaching the fixed position from the limit position, and there is no movement of the dancer roller 23 corresponding to the arrow denoted by symbol C in FIG. 17. Thus, by shortening the moving distance of the dancer roller 23, the fixed-position return operation can be completed in a shorter time.

[0193] FIG. 28 is a flowchart showing another example of the fixed-position return operation of the dancer roller 23 when the winding body is mounted. FIG. 29 is a schematic diagram showing the movement of the dancer roller 23 during the execution of another example of the fixed-position return operation of the dancer roller 23 when the winding body is mounted.

[0194] Another example of the fixed-position return operation of the dancer roller 23 when the winding body is mounted, shown in FIGS. 28 and 29, is different from the examples shown in FIGS. 18 to 21 in the movement of the dancer roller 23 when stopping the dancer roller 23 at the fixed position. In steps S801 to S809, the same processes as steps S201 to S209 shown in FIG. 18 are performed.

[0195] When it is detected that the fixed-position sensor 28 is on in step S803 (YES in step S803), the return operation is terminated as it is without winding or unwinding the wrapping material 2.

[0196] When it is detected that the limit position sensor 27 is on in step S804 (YES in step S804), the process proceeds to step S810, and the winding of the wrapping material 2 around the winding body 3 is started, similar to step S216 shown in FIG. 20. In step S811, the determination of whether the fixed position sensor 28 is on is repeated until it is detected that the fixed position sensor 28 has turned on.

[0197] When it is detected that the fixed position sensor 28 has turned on (YES in step S811), next in step S812, the winding of the wrapping material 2 around the winding body 3 is terminated. It is set such that, unlike the example shown in FIG. 20, the dancer roller 23 is not moved beyond the fixed position, but the wrapping material 2 is wound up to stop the dancer roller 23 at the fixed position.

[0198] When the unwinding of the wrapping material 2 from the winding body 3 is completed in step S809, the process of winding up the wrapping material 2 until the dancer roller 23 reaches the fixed position in steps S810 to S812 is performed, and the return operation is terminated.

[0199] In the example shown in FIG. 28, the processes of steps S210 to S215 and S218 shown in FIGS. 19 and 20 are omitted. Compared with FIG. 21, in FIG. 29, at D, the movement of the dancer roller 23 is not present and it remains stopped at the fixed position, and when the dancer roller 23 reaches the fixed position from the limit position as shown by the arrows at E and G, the dancer roller 23 stops and the return operation is terminated. Thus, since the movement distance of the dancer roller 23 during the return operation is shortened, the fixed position return operation can be completed in a shorter time.

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

[0201] In the method for manufacturing the wound body 3, as shown in FIG. 30, first, a core tube 3a is prepared (step S1001). As shown in FIG. 31, a core tube 3a having the recording medium 3b described with reference to FIG. 2 is prepared. Alternatively, a core tube 3a without the recording medium 3b may be prepared, such as in the case where the recording medium 3b is attached to the starting portion of the wrapping material 2.

[0202] Next, the wrapping material 2 is wound around the core tube 3a (step S1002). As shown in FIG. 31, by winding the wrapping material 2 around the core tube 3a, the wound body 3 is created.

[0203] Finally, the amount of the wrapping material 2 wound around the core tube 3a in step S1002 is written to the recording medium 3b as remaining amount information indicating the remaining amount of the wrapping material 2 in the wound body 3 (step S1003). As a result, when the created wound body 3 is attached to the packaging device 1, the wound body 3 can be rotated at an appropriate rotational speed set based on the remaining amount information of the wrapping material 2 recorded on the recording medium 3b. Therefore, the time required for the return operation when the wound body is attached can be shortened. Then, the process related to the manufacture of the wound body 3 is terminated ("End" in FIG. 30).

[0204] In step S1001, a core tube 3a after using up the previously wound wrapping material 2 may be prepared, and in step S1002, a new wrapping material 2 may be wound around the core tube 3a. In this case, in step S1003, by writing the amount of the wrapping material 2 wound around the core tube 3a in step S1002 to the recording medium 3b as remaining amount information indicating the remaining amount of the wrapping material 2 in the wound body 3, the remaining amount information already recorded on the recording medium 3b is overwritten and updated.

[0205] Also, when the amount of the wrapping material 2 wound around the core tube 3a is predetermined, the order of step S1002 and step S1003 may be interchanged.

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

[0207] In the second example of the method for manufacturing the wound body 3, as shown in FIG. 32, first, a core tube 3a is prepared (step S1101). As shown in FIG. 33, a core tube 3a having the recording medium 3b described with reference to FIG. 2 is prepared. Alternatively, a core tube 3a without the recording medium 3b may be prepared, such as in the case where the recording medium 3b is attached to the starting portion of the wrapping material 2.

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

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

[0210] Finally, the amount of the wrapping material 2 wound around the tube portion 3c in step S1103 is written to the recording medium 3b as remaining amount information indicating the remaining amount of the wrapping material 2 in the wound body 3 (step S1106). As a result, when the created wound body 3 is attached to the packaging device 1, it becomes possible to rotate the wound body 3 at an appropriate rotational speed set based on the remaining amount information of the wrapping material 2 recorded on the recording medium 3b. Therefore, the time required for the return operation when the wound body is attached can be shortened. Then, the process related to the manufacture of the wound body 3 is terminated ("End" in FIG. 32).

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

[0212] Also, when the amount of the packaging material 2 wound around the cylindrical portion 3c is predetermined, the order of step S1105 and step S1106 may be interchanged.

[0213] As described above, the embodiments of the present invention have been described. However, the embodiments disclosed this time should be considered to be illustrative in all respects and not restrictive. The scope of this invention is shown not by the above description but by the claims, and it is intended that all modifications within the meaning and scope equivalent to the claims are included.

Explanation of Reference Numerals

[0214] 1 Packaging device, 2 Packaging material, 3 Rewinding body, 3R Reading and writing unit, 3a Core tube, 3b Recording medium, 5 Supply unit, 6 Accommodation part forming unit, 6h Heater, 6m Pressing motor, 8 Packaging material conveying unit, 8m Conveying motor, 9 Packaging unit, 10 Packaging material supply unit, 11 Direction changing bar, 12 Cutting unit, 13 Discharge unit, 15 Frame, 20 Casing, 20a Outer surface, 21 Mounted part, 22 Guide hole, 23 Dancer roller, 24, 25 Fixed rollers, 26 Lock release unit, 27 Limit position sensor, 28 Fixed position sensor, 29 Retracted position sensor, 30 Sensor support part, 31, 38, 45, 66 Spring hanging parts, 35 Pay-off and take-up motor, 40 Main arm, 41 First arm part, 42 Second arm part, 43 Bending part, 44 Arm rotation shaft, 46 Return spring, 47 Lock pin, 50 Sub-arm, 51 Base end part, 52 Tip end part, 53, 65 Cylindrical parts, 55 Gear positioning plate, 72 Intermediate gear, 73 Intermediate pinion gear, 74 Roller gear, 75 Intermediate gear shaft, 78 Lock part, 90 Spring hinge, 101 Drug supply device, 102 Housing, 104 Lower housing, 108, 109 Doors, 200 Overall control unit, 201 Packaging control unit, DR Conveying direction.

Claims

1. A method for manufacturing a wound body that can be attached to a packaging device, in which a long sheet-like packaging material is wound, wherein the packaging device packages an object to be packaged using the wound body, the wound body includes a core tube having a recording medium for storing information, and the packaging material wound around the core tube, remaining amount information indicating the remaining amount of the packaging material in the wound body is written by the packaging device on the recording medium, the packaging device includes a drive unit that generates a driving force for rotating the wound body, a transport unit that transports the packaging material unwound from the wound body along a transport path, a tension applying unit having a displacement member displaceable in a direction intersecting the transport path, the displacement member having a set position, and the displacement member applying tension to the packaging material by pressing the packaging material, a set position sensor that detects that the displacement member is in the set position, when the packaging device performs the set position return operation of the displacement member after the wound body is attached to the packaging device, first, the rotation speed of the wound body is set based on the remaining amount information, and then the drive unit is driven to rotate the wound body at the set rotation speed to move the displacement member to the set position, when the packaging device performs the sub-packaging operation, the rotation speed of the wound body is set based on the remaining amount information, the transport unit intermittently transports the packaging material, and while the transport unit is transporting the packaging material, the drive of the wound body by the drive unit is stopped, and while the transport of the packaging material by the transport unit is stopped, the drive unit drives the wound body to unwind the packaging material from the wound body until the set position sensor detects that the displacement member is in the set position, each time the drive unit drives the wound body, the drive amount of the drive unit from the start of driving the wound body by the drive unit until the set position sensor detects that the displacement member is in the set position is measured, and based on the measurement result, the remaining amount of the packaging material in the wound body is determined, the determination result of the remaining amount of the packaging material is written by the packaging device as the remaining amount information on the recording medium, the remaining amount information stored in the recording medium is read by the packaging device during the set position return operation of the displacement member and during the sub-packaging operation, and is used to set the rotation speed of the wound body in the packaging device, the manufacturing method includes A step of preparing the core tube after using up the previously wound packaging material; A step of winding a new packaging material around the core tube; Before or after the winding step, a step of overwriting and updating the remaining amount information already recorded on the recording medium by writing the amount of the packaging material wound around the core tube in the winding step as the remaining amount information on the recording medium. A method for manufacturing a wound body, comprising:

2. The packaging device further comprises a limit position sensor that detects that the displacement member is at a limit position that is farther from the transport path than the fixed position; When the displacement member is not detected by the fixed position sensor during the fixed position return operation of the displacement member, the packaging material is unwound from the wound body until the fixed position sensor or the limit position sensor detects the displacement member; The packaging device When the fixed position sensor detects the displacement member, the fixed position return operation of the displacement member is terminated; When the limit position sensor detects the displacement member, the fixed position sensor detects the displacement member, and the packaging material is wound around the wound body again until the displacement member is no longer detected. Thereafter, the packaging material is unwound from the wound body until the fixed position sensor detects the displacement member, and the fixed position return operation of the displacement member is terminated; When the fixed position sensor detects the displacement member during the fixed position return operation of the displacement member, the packaging material is wound around the wound body until the fixed position sensor no longer detects the displacement member. Thereafter, the packaging material is unwound from the wound body until the fixed position sensor detects the displacement member, and the fixed position return operation of the displacement member is terminated. The method for manufacturing a wound body according to claim 1.

3. A plurality of stages are set for the remaining amount of the packaging material; When the packaging device determines that the remaining amount of the packaging material is smaller than the remaining amount at the current stage, the remaining amount reduced by one stage is written as the remaining amount information on the recording medium by the packaging device. The method for manufacturing a wound body according to claim 1 or 2. ​

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