Sheet feed shaft, manufacturing apparatus and manufacturing method thereof

Abstract

To provide a sheet feeding shaft capable of accurately conveying a desired sheet material by appropriately forming a protrusion shape suitable for various sheet materials, a manufacturing device thereof, and a manufacturing method thereof.SOLUTION: A manufacturing device includes: a V block 102 that supports a metallic round bar 2; a holding member 51 driven by a processing device 100 in a reciprocating direction opposite to the V block 102; a perforation member 52 attached to the holding member 51 and formed a projection 30 on a circumferential surface 2a of the metallic round bar 2 by plastic working so as to rise in a circumferential direction; and a control part 121 that, when an apex angle of the projection seen from the circumferential direction of the metallic round bar 2 is α, and the apex angle of the projection seen from an axial direction of the metallic round bar 2 is β, calculates β from a relational expression between α and β based on input information regarding α, obtains control information for forming the projection 30 having target α and β, and controls the processing device 100 to form the projection 30 having target α and β at a plurality of locations on the circumferential surface 2a of the metallic round bar 2 based on control information.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present invention relates to a sheet feed shaft, a manufacturing apparatus thereof, and a manufacturing method.

Background Art

[0002] Conventionally, for paper feeding in printers for office machines, etc., in order to achieve accurate paper feeding, a sheet is sandwiched between feed rollers, and a sheet feed shaft is used in which a plurality of protrusions rising in the circumferential direction are formed by plastic processing on the circumferential surface of a metal round bar facing this. As this protrusion shape, for example, the apex angle α of the cutting surface of the protrusion is formed to be 30 to 120 degrees, and further, a plurality of protrusions whose rising directions are opposite to each other are arranged in a row along the circumferential direction and the axial direction (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in order to accurately convey a wide variety of sheet materials, it is necessary to clearly define the apex angle β in the thickness direction of the protrusion. For example, the load applied to the paper may be different between the leading end portion and the trailing end portion of the sheet. If the apex angle β in the thickness direction of the protrusion is too large, the load applied to the paper is different, so the amount of penetration of the protrusion into the sheet material changes, and a difference occurs in the feeding amount of the sheet material. In particular, in recent color printer papers, this paper feeding deviation has become a problem.

[0005] To solve this problem, setting a small apex angle β in the thickness direction of the protrusion can improve the variation in the feed rate of the sheet material. However, if the apex angle β is too small, it can cause problems with the durability of the protrusion. Furthermore, if the apex angle β in the thickness direction of the protrusion is too small, the protrusion may dig too deeply into the sheet material, causing significant damage to the sheet material.

[0006] On the other hand, in terms of the shape in the thickness direction of the protrusions, the apex angle β in the thickness direction of the protrusions was set as appropriate based on the operator's experience and intuition. Because the machine was adjusted in this way based on the operator's experience and intuition, there were a great many combinations of sheet material and roller diameter, and in particular, when there was no experience with a combination, it took a lot of time to adjust the β value relative to the α value.

[0007] Therefore, the present invention has been made in view of the above problems, and by appropriately forming protrusion shapes suitable for various sheet materials, a sheet feeding shaft that can accurately convey a desired sheet material. to The purpose is to provide manufacturing equipment and manufacturing methods. [Means for solving the problem]

[0008] [ 1 A support base for supporting a metal round bar, A holding member driven by a processing device in a reciprocating direction opposite to the support base, A perforating member is attached to the holding member and forms a projection on the circumferential surface of the metal round bar by plastic processing so as to rise in the circumferential direction, When the apex angle of the projection as viewed from the circumferential direction of the metal round bar is α, and the apex angle of the projection as viewed from the axial direction of the metal round bar is β, a control unit calculates β from a relationship between α and β based on the input information about α, obtains control information for forming the projection having the desired α and β, and controls the processing apparatus to form the projection having the desired α and β at multiple locations on the circumferential surface of the metal round bar based on the control information, Equipped with 、 The control information is the distance from the center line passing through the center of the metal rod to the path along which the perforating member travels back and forth, and the cutting stroke of the perforating member relative to the circumferential surface of the metal rod. Manufacturing equipment for sheet feed shafts. [2] The relationship between α and β is expressed by the following equations (a) and (b) in the range where α is 30 degrees or more and 110 degrees or less, in the manufacturing apparatus for a sheet feed shaft as described in [1]. (a)β 0 =-0.002α +0.854α-3.72 (b)0.85β 0 ≦β≦1.15β 0 3 On the circumferential surface of a metal round bar by a perforated member A method for manufacturing a sheet feed shaft in which protrusions are formed by plastic working so as to rise in the circumferential direction, comprising When the apex angle of the protrusion viewed from the circumferential direction of the metal round bar is α and the apex angle of the protrusion viewed from the axial direction of the metal round bar is β, β is calculated from the relational expression between α and β based on the input information regarding α, and control information for forming the protrusion having the target α and β is obtained; forming the protrusions having the target α and β at a plurality of locations in the circumferential direction and the axial direction of the metal round bar based on the control information. fruit, The control information is the distance from the center line passing through the center of the metal rod to the path along which the perforating member travels back and forth, and the cutting stroke of the perforating member relative to the circumferential surface of the metal rod. A method for manufacturing a sheet feed shaft. [4] The method for manufacturing a sheet feed shaft according to [3], wherein the relationship between α and β is expressed by the following equations (a) and (b) in the range where α is 30 degrees or more and 110 degrees or less. (a)β 0 =-0.002α 2 +0.854α-3.72 (b)0.85β 0 ≦β≦1.15β 0 [[Effects of the Invention]]

[0009] According to the present invention, by appropriately forming a protrusion shape suitable for various sheet materials, a desired sheet material can be accurately conveyed. [[Brief Description of the Drawings]]

[0010] [Figure 1] [[ID=5৪]]FIG. 1 is a perspective view showing a main part of a sheet feed apparatus having a sheet feed shaft according to an embodiment of the present invention. [Figure 2] FIG. 2 is a perspective view showing the sheet feed shaft in FIG. 1. [Figure 3]FIG. 3 is a perspective view schematically showing the protrusion in FIG. 2 in an enlarged manner. [Figure 4] FIG. 4 is a side view schematically showing the sheet feed shaft viewed from the axial direction. [Figure 5] FIG. 5 is a perspective view showing an example of a manufacturing apparatus for the sheet feed shaft. [Figure 6] FIG. 6 is a view showing an example of the spotting unit and is a cross-sectional view taken along line A-A in FIG. 7. [Figure 7] FIG. 7 is a view showing an example of the spotting unit viewed from the side of the metal round bar. [Figure 8] FIG. 8 shows the protrusion and its periphery in an enlarged manner, where (a) is a perspective view, (b) is a schematic view showing an example of the protrusion viewed from the circumferential direction, and (c) is a schematic view showing an example of the cross-section of the periphery of the protrusion viewed from the axial direction. [Figure 9] FIG. 9 is a plan view of the protrusion and its periphery shown in FIG. 8. [Figure 10] FIG. 10 is a block diagram showing an example of the control device. [Figure 11] FIGS. 11(a) and (b) are developed views showing an example of the arrangement pattern of the protrusions. [[ID=-1]] [Figure 12] FIG. 12 is a flowchart showing an example of the operation of the control device up to the calculation of L and S. [Figure 13] FIG. 13 is a view showing an example of the α-β table according to Modification 1. [Figure 14] FIG. 14 is a photograph showing the longitudinal section of the periphery of the protrusion, where (a) shows Example 5 and (b) shows Comparative Example 1. [Figure 15] FIG. 15 is a view showing a preferable combination of α and β according to the embodiment.

MODE FOR CARRYING OUT THE INVENTION

[0011] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In each figure, components having substantially the same function are denoted by the same reference numerals, and the overlapping description thereof is omitted. [[ID=-i]]

[0012] [Summary of the Embodiment] A manufacturing apparatus according to an embodiment of the present invention comprises: a support base for supporting a metal round bar; a holding member driven by a processing device in a reciprocating direction opposite to the support base; a perforating member attached to the holding member that forms a projection on the circumferential surface of the metal round bar so as to rise in the circumferential direction by plastic deformation; and a control unit that, when α is the apex angle of the projection viewed from the circumferential direction of the metal round bar and β is the apex angle of the projection viewed from the axial direction of the metal round bar, calculates β from a relationship between α and β based on input information about α, obtains control information for forming a projection having the desired α and β, and controls the processing device to form a plurality of projections having the desired α and β on the circumferential surface of the metal round bar based on the control information.

[0013] Input can include selections. For example, one α may be selected and entered from multiple αs. The information about the entered α includes not only α itself, but also information that indirectly indicates α. For example, instead of α, it may be size information that shows the magnitude of α in stages, or a predetermined sheet type or sheet identification information corresponding to α.

[0014] [Embodiment] (Configuration of the sheet feeding device) Figure 1 is a perspective view showing the main parts of a sheet feeding device having a sheet feeding shaft according to an embodiment of the present invention. This sheet feeding device 10 comprises a feed roller 11 made of hard rubber, a metal sheet feeding shaft 1 positioned opposite the feed roller 11 with a sheet 12 in between and having a plurality of protrusions 30, and a drive unit that conveys the sheet 12 in the front-rear direction indicated by the arrow by rotating the sheet feeding shaft 1 in the forward and reverse directions using a motor (not shown).

[0015] The sheet feeding device 10 ensures that the sheet 12 is securely gripped by the projection 30 and transported with high feeding accuracy, as the feed roller 11 contacts the printing surface 12a of the sheet 12, and the projection 30 of the sheet feeding shaft 1 contacts the back surface 12b opposite to the printing surface 12a. Depending on the characteristics of the sheet 12, there is a preferred range for the apex angle α viewed from the circumferential direction and the apex angle β viewed from the axial direction of the projection 30. The projection 30 having apex angles α and β within the preferred range can be manufactured by the manufacturing apparatus according to this embodiment, which will be described later. Furthermore, the sheet feeding device 10 can be applied to printers such as dye-sublimation printers and inkjet printers, as well as cutting machines, etc.

[0016] (Sheet structure) The sheets 12 have various properties and can be classified into several types based on an index indicating resistance to penetration by the protrusions 30 (for example, strength in the thickness direction). For example, they can be classified into three types: Type 1 sheets with relatively high strength in the thickness direction, Type 2 sheets with moderate strength in the thickness direction, and Type 3 sheets with relatively low strength in the thickness direction.

[0017] Examples of Type 1 sheets include polypropylene sheets and polystyrene sheets. Examples of Type 2 sheets include printed paper and cutting paper (e.g., polyvinyl chloride resin sheets). Examples of Type 3 sheets include pongee cloth sheets made of polyester. Note that the number of classifications is not limited to three. Here, Type 1 sheets, Type 2 sheets, and Type 3 sheets are examples of sheet types or sheet identification information.

[0018] (Configuration of the sheet feed shaft) Figure 2 is a perspective view showing the sheet feed shaft 1 in Figure 1. Figure 3 is a schematic, enlarged perspective view showing the projection 30 in Figure 2. Figure 4 is a schematic side view showing the sheet feed shaft 1 as seen from the axial direction.

[0019] As shown in Figure 2, the sheet feed shaft 1 comprises a metal round bar 2 formed from a plastic metal material such as steel or copper, and a plurality of protrusions 30 formed on the circumferential surface 2a of the metal round bar 2 by plastic deformation so as to rise in the circumferential direction. The plurality of protrusions 30 are formed, for example, on the circumferential surface 2a of the metal round bar 2 in three longitudinal regions 3a, 3b, and 3c, within the width of the sheet 12.

[0020] Multiple protrusions 30 are formed by plastic deformation using a pair of perforated members 52A and 52B (see Figure 6), described later, which are spaced smaller than the diameter of the metal round bar 2. As shown in Figure 3, they consist of pairs of protrusions 30A and 30B whose rising directions are opposite to each other. As shown in Figure 2, the protrusions 30A rising in one direction are formed in a row along the axial direction of the circumferential surface 2a to constitute a first group of protrusions 3A, and the protrusions 30B rising in the other direction are formed in a row along the axial direction of the circumferential surface 2a to constitute a second group of protrusions 3B. The first group of protrusions 3A and the second group of protrusions 3B are arranged in rows at multiple locations along the circumferential and axial directions of the metal round bar 2.

[0021] As shown in Figure 4, the first group of protrusions 3A and the second group of protrusions 3B are formed such that their tips are spaced at equal angles θ (circumferential pitch Z / 2 in the case of Figure 11(a)) in the circumferential direction, and are formed in rows along the axial direction. Note that Figure 4 exaggerates and enlarges the first group of protrusions 3A and the second group of protrusions 3B, and the number of the first group of protrusions 3A and the second group of protrusions 3B is not limited to the number shown in the figure. By forming a pair of protrusions 30A and 30B with opposing rising directions, the sheet 12 can be securely gripped and conveyed in the front-rear direction with high feeding accuracy.

[0022] The sheet feeding device 10 may also be configured to transport the sheet 12 only forward. In this case, only the first group of protrusions 3A or the second group of protrusions 3B may be used. When the first group of protrusions 3A is used, the cutting surface 30a side faces the rotational direction, which helps to suppress damage to the sheet 12. When the second group of protrusions 3B is used, the rising surface 30b side faces the rotational direction, which allows the sheet 12 to be securely gripped and transported.

[0023] <Manufacturing equipment configuration> Figure 5 is a perspective view showing an example of a manufacturing apparatus for a sheet feed shaft 1. This manufacturing apparatus comprises a processing device 100 for processing a metal round bar 2 to be processed, and a control device 120 for controlling the processing device 100.

[0024] (Configuration of the processing equipment) The processing apparatus 100 comprises a base 101, a V-block 102 as an example of a support stand placed on the base 101, a lifter 103 that pushes up the metal round bar 2 to be processed, which is supported on the V-block 102, from the V-block 102, a retaining bush 106 fixed to one end of the metal round bar 2, a setting gear 107 integrally attached to the retaining bush 106, and a stepping motor 108 that drives a drive gear 109 that meshes with the setting gear 107.

[0025] Furthermore, the processing device 100 is equipped with a perforation unit 50, which is driven by a press machine 114 in a reciprocating direction opposite to the V-block 102 under the control of a control device 120. The perforation unit 50 comprises a holding member 51 and a pair of perforation members 52A and 52B which are fixed to the holding member 51 by fasteners 53 such as bolts and screws.

[0026] (Configuration of the punching unit) Figure 6 is a diagram showing an example of the awl unit 50, and is a cross-sectional view taken along line AA of Figure 7, which will be described later. The awl unit 50 comprises a holding member 51 that is supported so as to be able to move up and down, and a pair of awl members 52A and 52B that are attached to the holding member 51 and have an awl cutting blade 52a with an acute angle (for example, 60 degrees) at the tip.

[0027] In Figure 6, d is the diameter of the metal round bar 2, L is the distance between the perforating members 52A and 52B, S is the cutting depth of the perforating blade 52a (cutting stroke of the perforating unit 50), γ is the angle of incidence of the perforating blade 52a to the circumferential surface 2a of the metal round bar 2, and μ1 is the circumferential length of the cutting recess 31 (see Figure 8), which will be described later. The distance from the center line CL passing through the center C of the metal round bar 2 to the path through which the perforating members 52A and 52B reciprocate is L / 2.

[0028] The awl unit 50 is configured to allow adjustment of the spacing L between the awl members 52A and 52B. As a method for adjusting the spacing L, for example, the number of thin plates interposed between the holding member 51 and the awl members 52A and 52B may be adjusted, or the awl members 52A and 52B may be moved relative to each other by rotating a screw member having a right-hand thread on one side and a left-hand thread on the other side.

[0029] As shown in Figure 7, which will be described later, multiple perforating blades 52a are continuous in the axial direction of the metal round bar 2, but a single perforating blade 52a may also be used. Furthermore, when manufacturing a sheet feeding shaft 1 having only one of the first projection group 3A and the second projection group 3B, a configuration using only one of the pair of perforating members 52A and 52B may also be used.

[0030] Figure 7 shows an example of the perforation unit 50 as seen from the metal round bar 2 side. The perforation members 52A and 52B each have multiple (for example, 12) perforation cutting blades 52a formed vertically (parallel to the center line CL shown in Figure 6) on one side facing each other. The perforation members 52A and 52B face each other while maintaining a distance L, and these opposing perforation cutting blades 52a are positioned with an axial offset of P / 2, which is half the pitch P of the V-shape. This makes it possible to increase the density of the protrusions 30 compared to when the positions of the perforation members 52A and 52B are not offset.

[0031] (Shape of the protrusion and its surrounding area) Figure 8 shows a magnified view of the protrusion and its surroundings, where (a) is a perspective view, (b) is a schematic diagram showing an example of the protrusion viewed from the circumferential direction, and (c) is a schematic diagram showing an example of a cross-section of the area around the protrusion viewed from the axial direction. Figure 9 is a plan view of the protrusion and its surroundings shown in Figure 8.

[0032] As shown in Figure 8, the cutting blade 52a for piercing creates a cutting recess 31 on the circumferential surface 2a of the metal round bar 2. This causes the cutting surface 30a to be exposed from the circumferential surface 2a and curve upward, and the rising surface 30b on the opposite side of the cutting surface 30a rises from the circumferential surface 2a at approximately 90 degrees, forming a projection 30. The projection 30 has an apex angle α as viewed from the circumferential direction Y of the metal round bar 2, an apex angle β as viewed from the axial direction X of the metal round bar 2, and a height h. Furthermore, as shown in Figures 8(b), (c), and 9, the length of the bottom surface of the cutting recess 31 in the circumferential direction Y is μ1, the length of the projection 30 in the circumferential direction Y is μ2, and the length of the projection 30 in the axial direction X is μ3, and the explanation follows.

[0033] (Preferred range of the apex angle of the projection) The preferred range for the apex angles α and β of the projection 30 was discovered through experiments conducted by the inventors. The experiment involved fabricating projections 30 with apex angles α and β of various sizes, applying tension equivalent to the actual transport load applied to the sheet 12, feeding the sheet 12 forward, and measuring the pitch of the traces of the projections 30 formed on the back surface 12b of the sheet 12.

[0034] In response to the actual change in tension, the pitch of the traces of the protrusions 30 was measured as L1 when the tension was high and as L2 when the tension was low. The difference ΔL (=L1-L2) between the two pitches L1 and L2 was calculated, and a preferred range (also called the usable range) for the apex angles α and β of the protrusions 30 was found, taking into consideration the durability of the protrusions 30, the damage to the sheet 12, etc., for the protrusions 30 where the difference ΔL was within the allowable range for uneven feeding (for example, 10 μm or less).

[0035] From the experimental results shown in Table 1, described later, it was found that in the range where α is between 30° and 110°, the apex angles α and β of the projection 30 are within the usable range if α and β satisfy the following relationships (a) and (b). Here, equation (a) is an example of a relationship between α and β defined such that β increases as α increases. β0 = -0.002α 2 +0.854α-3.72 ···(a) 0.85β0≦β≦1.15β0 (b)

[0036] If β is greater than the upper limit (e.g., 1.15β0) relative to α, the amount of penetration into the sheet 12 changes when the load applied to the paper changes between the leading and trailing ends of the sheet 12 (for example, when feeding the sheet 12 while it is in contact with another sheet 12), resulting in a difference in the amount the sheet 12 is fed. If β is less than the lower limit (e.g., 0.85β0), the difference in the amount the sheet 12 is fed can be improved, but this may lead to durability issues with the protrusion 30, or the protrusion 30 may penetrate deeply into the sheet 12, causing greater damage to the sheet 12.

[0037] (Control device configuration) Figure 10 is a block diagram showing an example of a control device 120. The control device 120 comprises a control unit 121 consisting of a CPU (Central Processing Unit), an interface, etc., a storage unit 122 consisting of a ROM (Read Only Memory), RAM (Random Access Memory), a hard disk, etc., and an operation display unit 123 consisting of a touch display, etc.

[0038] The memory unit 122 stores a program 122a for executing the manufacturing method of the sheet feed shaft according to this embodiment, calculation formula information 122b, an α-γ table 122c, processing conditions 122d, and the like. Here, the α-γ table 122c is an example of relationship information showing the relationship between the apex angle α and the incident angle γ.

[0039] Formula information 122b includes, for example, formulas (1), (2), (3), (4), etc. β = -0.002α 2 +0.854α-3.72 ···(1) μ² = (1 / k)·h·tanβ (where k is the correction factor) ···(2) μ3 = 2h·tan(α / 2) ···(3) Volume of projection 30 = Volume of cut recess 31 ... (4)

[0040] Equation (1) above is an approximate curve obtained by a quadratic function using the least squares method or the like, from the data of α and β in Examples 1 to 10 of Table 1, which are described later, and whose apex angles α and β of projection 30 are within the usable range. Note that equation (1) may be a linear function (straight line) or an nth degree function of degree 3 or higher.

[0041] Equation (2) above can be obtained using trigonometric functions from the lengths of the parts shown in Figures 8(c) and 9. Equation (3) above can be obtained using trigonometric functions from the lengths of the parts shown in Figures 8(b) and 9.

[0042] The above equation (4) is based on the fact that when the cutting recess 31 is formed, its volume is exposed outward from the circumferential surface 2a, forming the projection 30. The projection 30 and the cutting recess 31 have a shape that approximates a tetrahedron, and the volume of the projection 30 can be calculated from μ2, μ3, and h. The volume of the cutting recess 31 can be calculated from μ1, μ3, and depth, since the depth of the cutting recess 31 is proportional to μ3.

[0043] The α-γ table 122c records multiple combinations of the apex angle α of the projection 30 and the incidence angle γ of the perforating blade 52a of the perforating unit 50 relative to the circumferential surface 2a of the metal round bar 2, such that the incidence angle γ increases as the apex angle α increases. Once the apex angle α is determined, the incidence angle γ corresponding to the apex angle α can be calculated based on the α-γ table 122c, and the spacing L of the perforating members 52A and 52B, described later, can be determined from the incidence angle γ. This allows a desired apex angle α to be formed by adjusting the incidence angle γ even when using the same perforating blade 52a. Note that perforating members 52A and 52B with different tip angles may be used depending on the desired apex angle α. Also, if only one of the pair of perforating members 52A and 52B is used instead of the pair, various calculations are performed using L / 2.

[0044] Processing conditions 122d include, for example, the following conditions: Condition 1: The spacing L of the perforated members 52A and 52B is such that the tips of adjacent protrusions 30, viewed from the axial direction X, are at equal angular intervals θ (circumferential pitch Z / 2 in the case of Figure 11(a)). Condition 2: The length μ1 of the cutting recess 31 and the cutting stroke S satisfy the following relationship. S≒μ1 Condition 3: The interval L and the incident angle γ' (a value obtained by adjusting the incident angle γ), as described later, satisfy the following relationship. L≒dcosγ Please note that the conditions are not limited to those listed above.

[0045] (Configuration of the control unit) The control unit 121 has a calculation function that calculates control information L and S for forming a protrusion 30 on the circumferential surface 2a of the metal round bar 2 to be processed by the CPU executing the program 122a, and a control function that controls the processing device 100 based on L and S.

[0046] The calculation function of the control unit 121 will now be described. The control unit 121 calculates β from α received from the operation display unit 123 using equation (1), calculates μ2 from the calculated β using equation (2), calculates μ3 from the received α using equation (3), calculates μ1 from the calculated μ2 and μ3 using equation (4), and calculates the incident angle γ from the received α based on the α-γ table 122c.

[0047] Once the angle of incidence γ is determined, the spacing L between the perforation members 52A and 52B is determined. However, the number of protrusions 30 visible from the axial direction X that are located inside the spacing L between the perforation members 52A and 52B (hereinafter referred to as "number of protrusions inside L") must be an integer. Therefore, the calculated angle of incidence γ needs to be adjusted. Accordingly, the control unit 121 determines an angle of incidence γ' that satisfies condition 1 included in the processing condition 122d, such that the number of protrusions inside L is an integer, and that is closest to the previously calculated γ.

[0048] The control unit 121 calculates control information L and S to satisfy conditions 2 and 3 included in machining conditions 122d, based on the number of protrusions on one row along the defined d, h and circumferential direction Y (hereinafter referred to as "circumferential protrusion count"), the calculated μ1, L internal protrusion count, and incident angle γ' (value obtained by adjusting the incident angle γ). In the case shown in Figure 4, the circumferential protrusion count is 12. Here, α is an example of information related to α.

[0049] Next, the control function of the processing device 100 provided by the control unit 121 will be described. Based on the calculated cutting stroke S, the control unit 121 controls the processing device 100 and causes the metal round bar 2 to be plastically deformed by the perforating cutting blade 52a of the perforating unit 50, thereby forming protrusions 30A and 30B having the input α and the corresponding β.

[0050] Specifically, the control information L is displayed on the operation display unit 123, for example, to allow the operator to adjust the spacing L between the perforating members 52A and 52B. The control unit 121 also controls the press machine 114 to drive the perforating unit 50 in a reciprocating direction opposite to the V-block 102, thereby controlling the cutting stroke S of the perforating unit 50. The control unit 121 also controls the formation position of the circumferential projection 30 by controlling the rotation of the stepping motor 108. The value of L may also be adjusted by the control unit 121 controlling the rotation of a screw member having a right-hand thread on one side and a left-hand thread on the other side.

[0051] (Manufacturing method for sheet feed shafts) Next, an example of a manufacturing method for the sheet feed shaft 1 using a manufacturing apparatus will be described with reference to Figures 11 and 12. First, the arrangement pattern of the protrusions will be described with reference to Figure 11.

[0052] (Arrangement pattern of protrusions) Figures 11(a) and (b) are unfolded diagrams showing examples of projection arrangement patterns. Figure 11(a) shows the projection arrangement pattern explained using Figures 2, 4, and 6 (hereinafter referred to as "alternating arrangement"). Figure 11(b) shows an arrangement pattern in which the first projection group 3A and the second projection group 3B are arranged in a staggered pattern (hereinafter referred to as "alternating staggered pattern"). Note that the projection arrangement patterns are not limited to these.

[0053] The alternating arrangement shown in Figure 11(a) involves arranging the first group of protrusions 3A and the second group of protrusions 3B alternately in rows along the axial direction X (rows along the circumferential direction Y), while also arranging the second group of protrusions 3B offset from the first group of protrusions 3A by half a pitch (Z / 2) in the circumferential direction Y.

[0054] Specifically, the first group of protrusions 3A and the second group of protrusions 3B are arranged in the circumferential direction Y with a pitch Z, and the space between the first group of protrusions 3A and the second group of protrusions 3B is a pitch Z / 2 in the circumferential direction Y. Furthermore, the first group of protrusions 3A and the second group of protrusions 3B are arranged in the axial direction X with a pitch P, and the space between the first group of protrusions 3A and the second group of protrusions 3B is a pitch P / 2 in the axial direction X.

[0055] The alternating staggered pattern shown in Figure 11(b) is arranged by alternating the first group of protrusions 3A and the second group of protrusions 3B in two rows (rows along the circumferential direction) in the axial direction X, and shifting the second group of protrusions 3B in two rows by 1 / 4 pitch in the circumferential direction Y relative to the first group of protrusions 3A in two rows.

[0056] Specifically, in the first group of protrusions 3A and the second group of protrusions 3B, the first and second rows are arranged with a pitch Z in the circumferential direction Y, and the next row is offset by half a pitch (Z / 2) in the circumferential direction Y relative to the first row. The space between the first row of the first group of protrusions 3A and the first row of the second group of protrusions 3B is a pitch of Z / 4 in the circumferential direction Y. In addition, each row (rows along the circumferential direction) of the first group of protrusions 3A and the second group of protrusions 3B is arranged with a pitch P in the axial direction X. Furthermore, the space between the first row and the next row of the first group of protrusions 3A and the second group of protrusions 3B is a pitch of P / 4 in the axial direction X. Furthermore, the space between the first row of the first group of protrusions 3A and the first row of the second group of protrusions 3B is a pitch of P / 2 in the axial direction X. By arranging the protrusions 30 in an alternating staggered pattern, the density of protrusions 30 can be increased compared to an alternating arrangement. The alternating staggered pattern can be formed by alternately forming the first group of protrusions 3A and the second group of protrusions 3B in the axial direction X (rows along the circumferential direction Y), shifting the second group of protrusions 3B by 1 / 4 pitch (Z / 4) in the circumferential direction Y relative to the first group of protrusions 3A, and then performing perforation on the entire circumference in the same manner as before, while relatively shifting the metal round bar 2 by 1 / 4 pitch (P / 4) in the axial direction X and shifting it by 1 / 2 pitch (Z / 2) in the circumferential direction Y.

[0057] (1) Calculation of control information L and S Figure 12 is a flowchart showing an example of the operation of the control device 120 up to the calculation of control information L and S.

[0058] First, the operator inputs the diameter d of the metal round bar 2, the number of circumferential protrusions, and the height h of the protrusions as basic information on the operation display unit 123. Furthermore, the operator selects the arrangement of the protrusions 30 from alternating arrangement or alternating staggered arrangement in one direction (only one of the protrusions 30A or 30B) (S1). Here, it is assumed that alternating arrangement is selected. Note that the diameter d, the height h of the protrusions 30, the number of circumferential protrusions, and all or part of the arrangement of the protrusions 30 may be predetermined.

[0059] Next, the operator inputs the apex angle α of the projection 30 to the operation display unit 123, and the control unit 121 accepts the apex angle α of the projection 30 (S2).

[0060] Next, the control unit 121 calculates the vertex angle β from the vertex angle α received in step S2 using equation (1) (S3), and calculates the sizes μ1, μ2, μ3 and the incident angle γ of each part (S4). Specifically, the control unit 121 calculates μ2 from the calculated β using equation (2), calculates μ3 from the received α using equation (3), calculates μ1 from the calculated μ2 and μ3 using equation (4), and calculates the incident angle γ from the received α based on the α-γ table 122c.

[0061] The control unit 121 determines an incident angle γ' that is closest to the previously calculated γ, such that the number of protrusions in L is an integer, in order to satisfy condition 1 included in the processing condition 122d (S5). For example, in the case shown in Figure 4, the arrangement pattern of the protrusions is the alternating arrangement shown in Figure 11(a), the number of circumferential protrusions is 12, the number of protrusions 30 visible from the axial direction X is 24, and the angular spacing θ (circumferential pitch Z / 2) shown in Figure 4 is 15°. On the other hand, even if the number of circumferential protrusions is the same 12, if the alternating staggered arrangement pattern shown in Figure 11(b) is selected, the number of protrusions 30 visible from the axial direction X becomes 48, and the angular spacing θ (circumferential pitch Z / 4) becomes 7.5°.

[0062] Next, the control unit 121 calculates the values ​​of L and S in the control information from the predetermined d, h and number of circumferential protrusions, the obtained μ1, L number of internal protrusions and incidence angle γ', so as to satisfy conditions 2 and 3 included in the machining conditions 122d, and displays the values ​​of L and S on the operation display unit 123 (S6).

[0063] (2) Machining based on control information L and S The operator adjusts the spacing L between the punching members 52A and 52B so that it matches the value of L displayed on the operation display unit 123, and positions the metal round bar 2 on the V block 102 when the punching unit 50 has risen and is at its top dead center.

[0064] Next, the control unit 121 rotates the stepping motor 108 to position the processing location of the metal round bar 2, controls the press machine 114 to lower the perforation unit 50 from the top dead center, and controls the cutting stroke S of the perforation unit 50 to cause the perforation cutting blades 52a of each perforation member 52A, 52B to cut into the circumferential surface 2a of the metal round bar 2. This cutting creates protrusions 30A, 30B in opposite directions.

[0065] Next, the control unit 121 forms two rows of protrusions 30A and 30B, and then the press machine 114 raises the perforation unit 50 to its top dead center. Next, the control unit 121 rotates the drive gear 109 by a certain angle using the stepping motor 108, and similarly rotates the assignment gear 107 meshed with the drive gear 109 by a certain angle, thereby changing the rotational support position of the metal round bar 2.

[0066] Next, after the rotational position of the metal rod 2 is determined, the control unit 121 lowers the perforation unit 50 and makes cuts with the perforation members 52A and 52B, forming similar protrusions 30A and 30B in the rows adjacent to the previously formed protrusions 30A and 30B in each row. By repeating this process, multiple first groups of protrusions 3A and second groups of protrusions 3B are formed in one region 3a of the metal rod 2. Then, by moving the metal rod 2 in the axial direction and forming the protrusions 30A and 30B as described above, multiple first groups of protrusions 3A and second groups of protrusions 3B are formed in the other two regions 3b and 3c, thereby manufacturing the sheet feed shaft 1 shown in Figures 1 and 2.

[0067] (Effects and benefits of this embodiment) According to this embodiment, the following actions and effects are achieved. (a) Since protrusions 30 having apex angles α and β within a preferred range depending on the characteristics of the sheet 12 can be formed, uneven feeding of the sheet can be reduced. Furthermore, protrusions 30 that are highly durable and cause less damage to the sheet 12 can be formed. (b) The control device 120 can determine a preferred apex angle β according to the apex angle α of the projection 30, so that the optimal projection can be stably formed without relying on the experience or intuition of the worker.

[0068] (Variation 1) Figure 13 shows an example of the α-β table 122e according to Modification 1. The memory unit 122 may further store the α-β table 122e. The α-β table 122e has the following items: "Protrusion classification", "Level", "α", "β", "μ1", "μ2", and "μ3".

[0069] The "Projection Classification" records "Large Projection," indicating a relatively large α; "Medium Projection," indicating a moderate α; and "Small Projection," indicating a relatively small α. The "Level" records the magnitude of α in stages: +4, +3, +2, +1, 0, -1, -2, -3, -4, -5.

[0070] In "α", α is recorded in degrees. In "β", the preferred β corresponding to α is recorded in degrees. In "μ1", "μ2", and "μ3", μ1, μ2, and μ3 shown in Figures 8(b), (c), and 9 are recorded in millimeters, respectively.

[0071] The values ​​of α, β, μ1, μ2, and μ3 correspond to Examples 1 to 10 described later. Here, large protrusion, medium protrusion, and small protrusion are examples of size information that show the size of α in steps. Note that the α-β table 122e shows the case where the height h of the protrusion 30 is 0.07 mm, but an α-β table 122e may be provided for each different h. Also, the α-β table 122e may include L and S.

[0072] In the above embodiment, the control unit 121 accepts α arbitrarily, but the operation display unit 123 may display a list of α shown in Figure 13 and allow the operator to select α. In this case, the control unit 121 obtains β, μ1, μ2, and μ3 from the α-β table 122e without using equations (1) to (4). Otherwise, as in the above embodiment, L and S are calculated from d, h, number of circumferential protrusions, μ1, number of internal protrusions of L, and γ' to satisfy the processing conditions 122d.

[0073] Alternatively, instead of the operator selecting α, they may select a level from the levels (+4 to -5) shown in Figure 13 displayed on the operation display unit 123, or select a protrusion category shown in Figure 13 displayed on the operation display unit 123. In this case, the level of the median value of the selected protrusion category may be selected. For example, if small protrusion is selected, it may be considered that level +2 or +3 has been selected; if medium protrusion is selected, it may be considered that level -1 has been selected; and if large protrusion is selected, it may be considered that level -4 has been selected. Alternatively, instead of selecting a protrusion category, the sheet type of the sheet 12 to be processed (Type 1 sheet, Type 2 sheet, or Type 3 sheet) may be selected.

[0074] (Examples) Next, embodiments of the present invention will be described with reference to Figures 14 and 15 and Table 1.

[0075] Figure 14 shows a photograph of a longitudinal section around the protrusion, where (a) shows Example 5 (described later) and (b) shows Comparative Example 1. Figure 15(a) shows a photograph of Example 5, where h=70μm, α=81.9°, and β=53.03°. Figure 15(b) shows a photograph of Comparative Example 1, where h and α are the same as in Example 5, but β is smaller than in Example 5, at β=40.0°. Therefore, Example 5 fell within the usable range, while Comparative Example 1 fell outside the usable range.

[0076] [Table 1] Table 1 shows the results of experiments conducted earlier, where the diameter d of the metal rod 2 was 12 mm and the height h of the projection 30 was 0.07 mm. Based on the experimental results, 10 examples were selected from 10 examples within the usable range, and the corresponding values ​​were recorded. The values ​​of μ1, μ2, and μ3 in Table 1 are measured values. The value of α in Table 1 was calculated from μ3 and h using the following formula (5). The value of β in Table 1 was calculated from μ1 and h using the following formula (6).

[0077] α = 2 × tan -1 (μ³ / 2h) ···(5) β = k·tan -1 (μ² / h) ···(6) However, k in equation (6) is a correction factor determined to match several β values ​​actually measured, and in this embodiment it was set to 1.12. In equation (5) above, a correction factor is not used because the α calculated by equation (5) is in close agreement with the α value actually measured. However, a correction factor may be used to bring the measured value closer to the actual measured value.

[0078] Figure 15 shows a preferred combination of α and β according to the embodiment. The range of α is set to 30 degrees or more and 110 degrees or less, and the range of α is divided into three ranges depending on the characteristics of the sheet used, for example, a first range E1 of 30 degrees ≤ α ≤ 64 degrees, a second range E2 of 64 degrees < α ≤ 89 degrees, and a third range E3 of 89 degrees < α ≤ 110 degrees. It is preferable to use a first type sheet in the first range E1, a second type sheet in the second range E2, and a third type sheet in the third range E3.

[0079] As shown in Figure 15, the reference line 40 approximated from Examples 1 to 10 can be expressed by the aforementioned equation (a). The upper limit line 41 can be expressed as β = β0 × 1.15, and the lower limit line 42 can be expressed as β = β0 × 0.85. The area between the upper limit line 41 and the lower limit line 42 is the region where the combination of α and β is within the usable range. Note that the reference line 40 may also be approximated by straight lines for multiple ranges with different values ​​of α.

[0080] Although embodiments of the present invention have been described above, the embodiments of the present invention are not limited to those described above, and various modifications and implementations are possible. Furthermore, some of the components of the above embodiments may be omitted or modified. In addition, steps may be added, deleted, modified, or rearranged in the flow of the above embodiments. [Explanation of symbols]

[0081] 1...Sheet feed shaft, 2...Metal round bar, 2a...Circumferential surface, 3A...First group of protrusions, 3B...Second group of protrusions, 3a~3c...Region, 10...Sheet feeding device, 11...Feed roller, 12...sheet, 12a...printed side, 12b...back side, 30, 30A, 30B...protrusions, 30a...cutting surface, 30b...rising surface, 31...cutting recess, 40...reference line, 41... Upper limit line, 42... Lower limit line, 50... Punching unit, 51... Holding member, 52A, 52B... Punching member, 52a... Punching blade, 53... Fastener, 100... Processing equipment, 101... Base, 102... V-block, 103... Lifter 106... Retaining bush, 107... Alignment gear, 108... Stepping motor 109...Drive gear, 114...Press machine, 120...Control device, 121...Control unit, 122...Memory unit, 122a...Program, 122b...Calculation formula information, 122c…α-γ table, 122d…Processing conditions, 122e…α-β table, 123...Operation display section, C...center, CL...centerline, d...diameter, h...height, L...spacing, P...pressure S...cutting stroke, X...axial direction, α...apex angle of the projection as viewed from the circumferential direction of the metal rod. β...Angle of the projection as viewed from the axial direction of the metal rod, γ...Angle of incidence, Y...Circumferential direction, θ...Angle

Claims

1. A support base for supporting a metal rod, A holding member driven by a processing device in a reciprocating direction opposite to the support base, A perforating member is attached to the holding member and forms a projection on the circumferential surface of the metal round bar by plastic processing so as to rise in the circumferential direction, When the apex angle of the projection as viewed from the circumferential direction of the metal round bar is α, and the apex angle of the projection as viewed from the axial direction of the metal round bar is β, a control unit calculates β from a relationship between α and β based on the input information about α, obtains control information for forming the projection having the desired α and β, and controls the processing apparatus to form the projection having the desired α and β at multiple locations on the circumferential surface of the metal round bar based on the control information, Equipped with, The control information is the distance from the center line passing through the center of the metal rod to the path along which the perforating member travels back and forth, and the cutting stroke of the perforating member relative to the circumferential surface of the metal rod. Manufacturing equipment for sheet feed shafts.

2. The manufacturing apparatus for a sheet feed shaft according to Claim 1, wherein the relationship between α and β is expressed by the following formulas (a) and (b) in the range where α is 30 degrees or more and 110 degrees or less. (a) β 0 =-0.002α 2 +0.854α-3.72 (b) 0.85β 0 ≦β≦1.15β 0

3. A method for manufacturing a sheet feed shaft, in which protrusions are formed on the circumferential surface of a metal round bar by plastic deformation using a perforated member so as to rise in the circumferential direction, When the apex angle of the projection viewed from the circumferential direction of the metal rod is α, and the apex angle of the projection viewed from the axial direction of the metal rod is β, the process of calculating β from a relationship between α and β based on the input information about α, and obtaining control information for forming the projection having the desired α and β, The process includes forming the projections having the target α and β at multiple locations in the circumferential and axial directions of the metal rod based on the control information, The control information is the distance from the center line passing through the center of the metal rod to the path along which the perforating member travels back and forth, and the cutting stroke of the perforating member relative to the circumferential surface of the metal rod. A method for manufacturing a sheet feed shaft.

4. The method for manufacturing a sheet feed shaft according to Claim 3, wherein the relationship between α and β is expressed by the following formulas (a) and (b) in the range where α is 30 degrees or more and 110 degrees or less. (a) β 0 =-0.002α 2 +0.854α-3.72 (b) 0.85b 0 ≦b≦1.15b 0

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