Fully automatic inspection system for gravure cylinders and inspection method for gravure cylinders

Abstract

Provided are a fully automatic inspection system for gravure cylinders and an inspection method for gravure cylinders that can save labor and reduce false detection in the inspection of the surface of rolls to be engraved and plates to be engraved, and that can operate unattended even at night.　The present invention includes: at least one non-traveling industrial robot; a processing device that performs processing on a roll to be engraved; a cylinder surface inspection device that inspects the surface of the processed roll to be engraved; a turntable-type roll stock device on which the roll to be engraved is placed before or after inspection by the cylinder surface inspection device; and a clean room in which are disposed at least the cylinder surface inspection device, the industrial robot that coveys the roll to be engraved to the cylinder surface inspection device, and the turntable-type roll stock device. Inspection of the surface of the processed roll to be engraved is performed within the clean room.

Description

Fully automatic inspection system for gravure cylinders and inspection method for gravure cylinders

[0001] The present invention relates to a fully automatic inspection system for gravure cylinders (also called gravure plate-making rolls), and more particularly to a fully automatic inspection system for gravure cylinders that is capable of unmanned operation even at night to inspect the surface condition of the roll to be plate-making when manufacturing gravure cylinders.

[0002] Conventionally, gravure platemaking factories that manufacture gravure cylinders (also called gravure platemaking rolls) include those described in Patent Documents 1 and 2. The fully automatic gravure platemaking processing systems described in Patent Documents 1 and 2 enable gravure cylinders to be manufactured more quickly than before, save space, enable unmanned operation even at night, and further reduce dust generation between processes.

[0003] Furthermore, in manufacturing a gravure cylinder, a surface inspection of the gravure cylinder (which is also called a roll to be plated) before plate-making (before cells are formed) is performed by an operator visually inspecting the surface using a magnifying glass or an optical microscope to check whether plating has been properly performed, and after plate-making, a plate surface inspection of the gravure cylinder is performed by an operator visually inspecting whether plate-making has been performed normally, or a proof print (trial print) is made and compared with the original (so-called proofreading work).

[0004] Therefore, for example, Patent Document 4 discloses an apparatus for automatically inspecting the smooth outer peripheral surface (copper plating layer) of a gravure cylinder (i.e., a roll to be plated) before platemaking (before cells are formed) for initial defects such as scratches and dents. Furthermore, Patent Documents 5 and 6 disclose apparatuses for inspecting the outer peripheral surface of a gravure cylinder after platemaking.

[0005] However, in the inspection devices for plate-making rolls described in Patent Documents 3 to 5, when the plate-making roll is set in the inspection device after the plating process or the paper polishing process, dust from the surrounding area or polishing residue from the polishing process adheres to the roll, which can result in false detection. As a result, it has become necessary for an operator to visually inspect using a magnifying glass or optical microscope to determine whether plating has been properly performed, or to visually inspect whether the plate has been properly made on the gravure cylinder after plate-making, or to perform a proof print (trial print) and compare it with the original (so-called proofreading work).

[0006] WO2011 / 125926WO2012 / 043515JP 05-93694A JP 2002-254590A JP 2006-194702A

[0007] The present invention has been made in consideration of the above-mentioned problems of the prior art, and has as its object to provide a fully automatic inspection system and method for gravure cylinders that can reduce the labor required for inspecting the surface and plate surface of plate-making rolls and reduce false detections, and that can be operated unmanned even at night.

[0008] In order to solve the above-mentioned problems, the fully automatic inspection system for gravure cylinders of the present invention is a fully automatic inspection system for gravure cylinders for manufacturing gravure cylinders, and includes at least one non-traveling industrial robot equipped with a robot arm having a handling area for chucking and handling a plate-making roll and transporting it to each processing device, at least one processing device arranged in the handling area for processing the transported plate-making roll, a cylinder surface inspection device for inspecting the surface of the processed plate-making roll, a rotary table type roll stock device on which the plate-making roll is placed before or after inspection by the cylinder surface inspection device, and a clean room in which at least the cylinder surface inspection device, the industrial robot that transports the plate-making roll to the cylinder surface inspection device, and the rotary table type roll stock device are arranged, and in which inspection of the surface of the processed plate-making roll is performed within the clean room.

[0009] It is preferable to configure the plate-making roll to wait in the rotary table type roll stock device while the surface of the plate-making roll is being inspected within the cylinder surface inspection device, thereby eliminating the backlog of the plate-making roll between the processing device and the cylinder surface inspection device.

[0010] Depending on the area of ​​the peripheral surface of the plate-making roll, the planned processing time of the plate-making roll in the processing device is compared with the planned inspection time of the plate-making roll processed in the processing device in the cylinder surface inspection device, and if the planned inspection time of the plate-making roll in the cylinder surface inspection device is longer, it is preferable to have the plate-making roll wait in the rotary table type roll stock device, thereby eliminating the backlog of the plate-making roll between the processing device and the cylinder surface inspection device.

[0011] It is preferable that the processing device is selected from the group consisting of a degreasing device, a strike plating device, a copper plating device, a grinding wheel polishing device, a photosensitive film coating device, a laser exposure device, a developing device, an etching device, an ultrasonic cleaning device, a resist stripping device, a surface hardening coating forming device, and a paper polishing device, and that the surface of the plate-making roll after processing in the processing device is inspected by the cylinder surface inspection device located in the clean room.

[0012] It is preferable that the processing device is a grinding stone polishing device, a paper polishing device, or a developing device, and that the surface of the plate-making roll after processing in the grinding stone polishing device, paper polishing device, or developing device is inspected by the cylinder surface inspection device located in the clean room.

[0013] It is preferable that the industrial robots include at least a first industrial robot and a second industrial robot, and the processing equipment is selected from a degreasing equipment, a strike plating equipment, a copper plating equipment, a grinding wheel polishing equipment, a photosensitive film coating equipment, a laser exposure equipment, a developing equipment, an etching equipment, an ultrasonic cleaning equipment, a resist stripping equipment, a surface hardening coating forming equipment, and a paper polishing equipment, and that at least one of the processing equipment is arranged in the handling area of ​​the first industrial robot, and at least one of the processing equipment that is not arranged in the handling area of ​​the first industrial robot is arranged in the handling area of ​​the second industrial robot, and that the plate-making process is sequentially carried out by transferring the plate-making rolls between the first industrial robot and the second industrial robot and transporting them sequentially to the processing equipment so that they can be processed in the processing equipment, and that the surface of the plate-making rolls after processing in the processing equipment is inspected by the cylinder surface inspection device in the clean room.

[0014] It is preferable that the grinding wheel polishing device, the ultrasonic cleaning device, the laser exposure device, the photosensitive film coating device, the paper polishing device, the cylinder surface inspection device, the rotary table type roll stock device, and the first industrial robot are arranged in a clean room, and the degreasing device, the strike plating device, the copper plating device, the developing device, the corrosion device, the resist stripping device, the surface hardening coating forming device, and the second industrial robot are arranged in a non-clean room, and the pressure in the clean room is made higher than the pressure in the non-clean room.

[0015] The gravure cylinder inspection method of the present invention is a gravure cylinder inspection method using the fully automatic gravure cylinder inspection system, and includes a process of transporting a plate-making roll using the industrial robot, a process of processing the plate-making roll in the processing device, and a process of inspecting the surface of the plate-making roll using the cylinder surface inspection device, with the inspection processes being performed in the clean room.

[0016] It is preferable to further include a step of having the plate-making roll wait in the rotary table type roll stock device while inspection of the surface of the plate-making roll is being carried out in the cylinder surface inspection device, thereby eliminating the backlog of the plate-making roll between the processing device and the cylinder surface inspection device.

[0017] It is preferable that the method further includes a step of comparing, depending on the area of ​​the peripheral surface of the plate-made roll, the planned processing time of the plate-made roll in the processing device with the planned inspection time of the plate-made roll processed in the processing device in the cylinder surface inspection device, and if the planned inspection time of the plate-made roll in the cylinder surface inspection device is longer, making the plate-made roll wait in the rotary table type roll stock device, thereby eliminating the backlog of the plate-made roll between the processing device and the cylinder surface inspection device.

[0018] The fully automatic gravure cylinder manufacturing system of the present invention is a fully automatic gravure cylinder manufacturing system incorporating the fully automatic gravure cylinder inspection system, and is a fully automatic gravure cylinder manufacturing system that manufactures gravure cylinders by performing platemaking processing with the processing device and inspecting the surface of the processed plate-making roll with the cylinder surface inspection device.

[0019] The method for manufacturing a gravure cylinder of the present invention is a method for manufacturing a gravure cylinder using the fully automated manufacturing system for gravure cylinders, and includes a process for transporting a plate-making roll using the industrial robot, a process for processing the plate-making roll in the processing device, and a process for inspecting the surface of the plate-making roll using the cylinder surface inspection device, with the inspection process being carried out in the clean room, thereby allowing the plate-making process to be carried out.

[0020] The present invention has the remarkable effect of providing a fully automatic inspection system and an inspection method for gravure cylinders that can reduce the labor required for inspecting the surface and plate surface of the plate-making roll and that can reduce false detections, and that can operate unmanned even at night.

[0021] 1 is a schematic plan view showing one embodiment of a fully automatic gravure cylinder manufacturing system according to the present invention, and FIG. 2 is a schematic plan view showing another embodiment of a fully automatic gravure cylinder manufacturing system according to the present invention.

[0022] The following describes embodiments of the present invention, but these embodiments are shown by way of example only, and it goes without saying that various modifications are possible without departing from the technical concept of the present invention.

[0023] The fully automatic inspection system for gravure cylinders according to the present invention will be described with reference to the accompanying drawings, in which: In Fig. 1, reference numeral 10A denotes a fully automatic inspection system for gravure cylinders according to the present invention.

[0024] The fully automatic gravure cylinder inspection system 10A is a fully automatic gravure cylinder inspection system for manufacturing gravure cylinders (also called gravure plate-making rolls). The fully automatic inspection system 10A includes robot arms 12, 14 having handling areas P, Q, at least one non-traveling industrial robot 40, 42 for chucking and handling a plate-making roll 16 and transporting it to each of the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, and 38, and at least one of the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, and 38, which is disposed in the handling areas P, Q and performs processing on the transported plate base material. The plate-making roll 16 may be a cylindrical hollow plate base material, such as an aluminum hollow roll, an iron hollow roll, or a CFRP (Carbon Fiber Reinforced Plastics) hollow roll.

[0025] The fully automatic inspection system 10A for gravure cylinders also includes a clean room A in which are located at least a cylinder surface inspection device 44 that inspects the surface of the processed plate-making roll 16, an industrial robot 40 that transports the plate-making roll, and a rotary table type roll stock device 46 on which the plate-making roll 16 is placed before or after inspection by the cylinder surface inspection device 44. The processing devices and other industrial robots 42 that are not located in clean room A are located in a non-clean room B that is not a clean room.

[0026] In the fully automatic inspection system 10A, the clean room A and the non-clean room B are connected to each other and separated by a wall 48. The cleanliness class of the clean room in the present invention is preferably a clean room that satisfies Class 1,000 to 100,000 of the US Federal Standard (Fed. Std. 209E).

[0027] In the fully automatic inspection system for gravure cylinders 10A, the plate-making roll 16 is transferred between the first industrial robot 40 and the second industrial robot 42 by opening and closing the shutter 50, and moves back and forth between the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, and 38 in the clean room A and the non-clean room B to perform each plate-making process. In this way, the plate-making roll is transferred between the first industrial robot 40 and the second industrial robot 42, i.e., the industrial robots 40 and 42, and transported to each processing device in sequence, thereby performing the plate-making processes sequentially in the clean room A and the non-clean room B. In the fully automatic inspection system for gravure cylinders 10A, the surface of the processed plate-making roll 16 is inspected in the clean room A.

[0028] Furthermore, while the surface of the plate-making roll 16 is being inspected in the cylinder surface inspection device 44, the plate-making roll 16 is made to wait in the rotary table type roll stock device 46, thereby eliminating retention of the plate-making roll 16 between each of the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38 and the cylinder surface inspection device 44. This standby state is controlled by automatically calculating the scheduled time using a computer 52 or the like located outside the clean room A and the non-clean room B.

[0029] Preferably, while the surface of the plate-making roll 16 is being inspected within the cylinder surface inspection device 44, the plate-making roll 16 is made to wait in the rotary table type roll stock device 46, thereby preventing the plate-making roll from stagnating between the processing devices 24, 26, 28, namely the grinding stone polishing device 24, paper polishing device 26 or developing device 28, and the cylinder surface inspection device.

[0030] In addition, the fully automatic gravure cylinder inspection system 10A can also compare, for example, the planned processing time (i.e., the planned time for processing to be completed) of the plate-made roll 16 in the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, and 38 with the planned inspection time (i.e., the planned time for inspection to be completed) of the plate-made roll 16 processed in the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, and 38 in the cylinder surface inspection device 44. This comparison is made by automatically calculating the planned times using a computer 52 or the like located outside the clean room A and the non-clean room B. If the planned inspection time of the plate-made roll 16 in the cylinder surface inspection device 44 is longer than the planned processing time of the plate-made roll 16 in the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, the plate-made roll 16 can be made to wait in the rotary table type roll stock device 46, thereby eliminating the retention of the plate-made roll 16 between the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38 and the cylinder surface inspection device 44. The area of ​​the peripheral surface of the plate-made roll 16 is calculated by multiplying the circumference of the plate-made roll 16 by the longitudinal length of the plate-made roll 16, and this calculation is performed using an unprocessed plate base material.

[0031] For example, if the plate-making roll 16 is an aluminum hollow roll (plate base material) with a circumference of 600 mm and a face length of 1200 mm, the processing time for each of the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, and 38 is about 15 minutes, but the inspection of the cylinder surface in the cylinder surface inspection device 44 takes only about half that time. However, if the plate-making roll 16 is a plate base material with a circumference of 942 mm or a face length exceeding 1200 mm, the inspection of the cylinder surface in the cylinder surface inspection device 44 will be longer than the processing time for the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, and 38. In this case, the plate-making roll 16 cannot be set in the cylinder surface inspection device 44, and the plate-making roll 16 will be stuck between the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38 and the cylinder surface inspection device 44. In the present invention, this stuck state can be eliminated by adjusting the time that the plate-making roll 16 is kept waiting in the rotary table type roll stock device 46 depending on the area of ​​the peripheral surface of the plate-making roll 16.

[0032] The processing equipment is selected from the group consisting of a degreasing equipment 36, a strike plating equipment 114, a copper plating equipment 38, a grinding wheel polishing equipment 24, a photosensitive film coating equipment 18, a laser exposure equipment 20, a developing equipment 28, an etching equipment 30, an ultrasonic cleaning equipment 22, a resist stripping equipment 32, a surface hardening coating forming equipment 34, and a paper polishing equipment 26, and the surface of the plate-making roll 16 after processing in the processing equipment is inspected by the cylinder surface inspection equipment 44 located in the clean room A.

[0033] In the illustrated example, the photosensitive film coating device 18 is provided above the laser exposure device 20. Also, in the illustrated example, the paper polishing device 26 is provided above the grindstone polishing device 24. The strike plating device 114 is a device that performs strike plating using nickel plating or alkaline copper plating. The strike plating process is performed between the degreasing process in the degreasing device 36 and the copper plating process in the copper plating device 38.

[0034] In the illustrated example, a photosensitive film coating device 18 is installed and laser exposure is performed by a laser exposure device 20, but an electronic engraving device may be installed and electronic engraving may be performed.

[0035] The surface hardening film forming device 34 may be a chrome plating device, a DLC (Diamond-Like Carbon) film forming device, a silicon dioxide film forming device, or the like, but in the illustrated example, a chrome plating device is shown.

[0036] As the processing device, known processing devices can be used, such as those described in Patent Documents 1 and 2.

[0037] It is particularly preferable that the above-mentioned processing device is a grinding stone polishing device 24, a paper polishing device 26 or a developing device 28, and that the surface of the plate-making roll 16 after processing in the grinding stone polishing device 24, the paper polishing device 26 or the developing device 28 is inspected by the cylinder surface inspection device 44 located in the clean room.

[0038] 1, the grinding wheel polishing device 24, the ultrasonic cleaning device 22, the laser exposure device 20, the photosensitive film coating device 18, the paper polishing device 26, the cylinder surface inspection device 44, the rotary table type roll stock device 46, and the first industrial robot 40 are arranged in a clean room A. On the other hand, the degreasing device 36, the strike plating device 114, the copper plating device 38, the developing device 28, the etching device 30, the resist stripping device 32, the surface hardening coating forming device 34, and the second industrial robot 42 are arranged in a non-clean room B.

[0039] The pressure in the clean room A is set higher than the pressure in the non-clean room B. The difference in pressure between the clean room A and the non-clean room B is preferably 2 to 10 Pa, and more preferably 5 to 7 Pa. That is, the pressure in the clean room A is preferably 2 to 10 Pa higher than the pressure in the non-clean room B, and more preferably 5 to 7 Pa higher. In this way, by making the pressure in the clean room A higher than the pressure in the non-clean room B, air flows from the clean room A to the non-clean room B. For example, it is preferable to pressurize the clean room A to the above pressure and exhaust air in the non-clean room B.

[0040] When the processing device is a grindstone polishing device 24, the plate-making roll 16 on which a copper plating layer is formed by a copper plating process before the gravure cells are formed by the copper plating device 38 is inspected after being grinded by the grindstone polishing device 24. When inspecting the surface of the plate-making roll 16 on which a copper plating layer is formed by such a copper plating process and after being grinded by the grindstone polishing device 24, for example, techniques of an inspection device that detects defects by an imaging means such as those described in Patent Document 3 and Patent Document 4 can be applied.

[0041] When the processing device is a developing device 28, the surface of the plate-making roll 16 developed by the developing device 28 is inspected. When inspecting the surface of the plate-making roll 16 developed by such a developing device 28, for example, a technology of an inspection device such as that described in Patent Document 5 can be applied, which compares an imaging means with the original image used for plate-making to detect cell defects.

[0042] Furthermore, when the processing device is a paper polishing device 26, after gravure cells are formed on the plate-making roll 16 and the plate-making process is performed, the surface of the plate-making roll 16 that has been subjected to the paper polishing process is inspected. In inspecting the surface of the plate-making roll 16 that has been subjected to such paper polishing process, for example, a technology of an inspection device that detects cell defects by comparing an imaging means with the original image used in plate-making, as described in Patent Document 5, can be applied.

[0043] The cylinder surface inspection device 44 may be any device capable of inspecting the surface of the plate-making roll 16 after a copper plating layer has been formed by copper plating and grinded by the grinding device 24, or the surface of the plate-making roll 16 developed by the developing device 28, and / or the surface of the plate-making roll 16 after paper grinding, and in addition to the above-mentioned technologies, known cylinder surface inspection devices and cylinder surface inspection devices available on the market may be used. Also, cylinder surface inspection devices that use known AI (Artificial Intelligence) to improve inspection accuracy may be used.

[0044] The gravure cylinder inspection method according to the present invention can be carried out by using the above-described fully automatic gravure cylinder inspection system 10A. More specifically, the gravure cylinder inspection method according to the present invention includes a process of transporting the plate-making roll 16 by the industrial robots 40, 42, a process of processing the plate-making roll 16 in the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, and a process of inspecting the surface of the plate-making roll 16 by the cylinder surface inspection device 44, and the inspection processes are carried out in the clean room A.

[0045] The gravure cylinder inspection method of the present invention preferably further includes a step of making the plate-making roll 16 wait in the rotary table type roll stock device 46 while the surface of the plate-making roll 16 is being inspected in the cylinder surface inspection device 44, thereby eliminating the backlog of the plate-making roll between the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38 and the cylinder surface inspection device.

[0046] Furthermore, the method includes a step of comparing, depending on the area of ​​the peripheral surface of the plate-made roll 16, the planned processing time of the plate-made roll 16 in the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38 with the planned inspection time of the plate-made roll 16 processed in the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38 in the cylinder surface inspection device 44, and if the planned inspection time of the plate-made roll 16 in the cylinder surface inspection device 44 is longer, a step of making the plate-made roll 16 wait in the rotary table type roll stock device 46, thereby preferably eliminating the accumulation of the plate-made roll 16 between the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38 and the cylinder surface inspection device 44.

[0047] The processing device used in the above-mentioned gravure cylinder inspection method is preferably the grindstone polishing device 24, the paper polishing device 26, or the developing device 28, and the surface of the plate-made roll 16 after processing in the grindstone polishing device 24, the paper polishing device 26, or the developing device 28 is particularly preferably inspected by the cylinder surface inspection device 44 located in the clean room A. That is, the gravure cylinder inspection method according to the present invention further includes the step of making the plate-made roll wait in the rotary table type roll stock device 46 while the surface of the plate-made roll 16 is being inspected in the cylinder surface inspection device 44, so that it is preferable to eliminate retention of the plate-made roll between the processing device 24, 26, 28, i.e., the grindstone polishing device 24, the paper polishing device 26, or the developing device 28, and the cylinder surface inspection device.

[0048] Furthermore, as shown in FIG. 1, a fully automatic gravure cylinder manufacturing system 54A according to the present invention is a fully automatic gravure cylinder manufacturing system incorporating the fully automatic gravure cylinder inspection system 10A, and is a fully automatic gravure cylinder manufacturing system that manufactures gravure cylinders by performing platemaking processing using the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, and 38 and inspecting the surface of the processed plate-making roll 16 using the cylinder surface inspection device 44.

[0049] The method for manufacturing a gravure cylinder according to the present invention is a method for manufacturing a gravure cylinder using the fully automatic gravure cylinder manufacturing system 54A, and includes a process for transporting the plate-made roll 16 by the industrial robots 40, 42, a process for processing the plate-made roll 16 in the processing devices 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, and a process for inspecting the surface of the plate-made roll 16 by the cylinder surface inspection device 44, and the inspection process is carried out in the clean room A, thereby allowing the plate-making process to be carried out.

[0050] Referring now to FIG. 2, a fully automatic inspection system 10B for gravure cylinders according to the present invention is shown.

[0051] The fully automatic gravure cylinder inspection system 10B is a fully automatic gravure cylinder inspection system for manufacturing gravure cylinders (also called gravure platemaking rolls), similar to the above-mentioned fully automatic inspection system 10A. The fully automatic gravure cylinder inspection system 10A is a single-line system in which one processing device for each process is installed, whereas the fully automatic gravure cylinder inspection system 10B is a two-line system in which two processing devices for each process are installed.

[0052] The fully automatic inspection system 10B is equipped with robot arms 56, 58, 60, 62, and 64 having handling areas R, S, T, U, and V, which chuck and handle the plate-making roll 16, which is a cylindrical hollow plate base material, and transport it to each processing device 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, and 88b. and at least one processing device (68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, 88b) that is disposed in each of the handling areas (R, S, T, U, V) and processes the transported plate-making roll. As the plate-making roll (16), a hollow aluminum roll, a hollow iron roll, a hollow CFRP (Carbon Fiber Reinforced Plastics) roll, or the like can also be used.

[0053] The fully automatic inspection system 10B for gravure cylinders also includes a clean room C in which are located at least the cylinder surface inspection device 44 that inspects the surface of the processed plate-making roll 16, the industrial robots 90, 92, 94 that transport the plate-making roll 16, and the rotary table type roll stock devices 100a, 100b, 102a, 102b on which the plate-making roll 16 is placed before or after inspection by the cylinder surface inspection device 44. The processing devices and other industrial robots 96, 98 that are not located in the clean room C are located in a non-clean room D that is not a clean room.

[0054] In the fully automatic inspection system 10B, the clean room C and the non-clean room D are connected to each other and separated by a wall 104. The cleanliness class of the clean room in the present invention is preferably a clean room that satisfies the US Federal Standard (Fed. Std. 209E) class of 1,000 to 100,000.

[0055] In the fully automatic inspection system 10B, the first shutter 106 is opened and closed, and the plate-making roll 16 is handed over by the first industrial robot 90 and the second industrial robot 96, and moves back and forth between each of the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, and 88a in the clean room C and non-clean room D, where each plate-making process is carried out (this is the first plate-making process line).

[0056] In this way, the plate-making roll 16 is transferred between the first industrial robot 90 and the second industrial robot 96 and transported to each processing device in sequence, so that the plate-making process is carried out sequentially in the clean room C and non-clean room D. Then, the third industrial robot 92 chucks the plate-making roll 16 and transports it to the cylinder surface inspection device 44. In the fully automatic inspection system 10B, the surface of the processed plate-making roll 16 is inspected in the clean room C.

[0057] In addition, in the fully automatic inspection system for gravure cylinders 10B, by opening and closing the second shutter 108, the plate-making roll 16 is handed over by the fourth industrial robot 94 and the fifth industrial robot 98, and moves back and forth between each of the processing devices 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, and 88b in the clean room C and non-clean room D, where each plate-making process is carried out (this is the second plate-making process line).

[0058] In this way, the plate-making roll 16 is transferred between the fourth industrial robot 94 and the fifth industrial robot 98 and transported to each processing device in sequence, so that the plate-making process is carried out sequentially in the clean room C and non-clean room D. Then, the third industrial robot 92 chucks the plate-making roll 16 and transports it to the cylinder surface inspection device 44. In the fully automatic inspection system 10B, the surface of the processed plate-making roll 16 is inspected in the clean room C.

[0059] In the fully automatic inspection system 10B, for the two plate-making lines described above, at least one of the processing units of each of the plate-making lines is placed within the handling area S of the third industrial robot 92, and one cylinder surface inspection device 44 is installed, and the cylinder surface inspection device 44 functions as the inspection device for both of the two plate-making lines described above.

[0060] Furthermore, while the surface of the plate-making roll 16 is being inspected in the cylinder surface inspection device 44, the plate-making roll 16 is made to wait at the rotary table type roll stock devices 100a, 100b, 102a, 102b, thereby eliminating retention of the plate-making roll 16 between each of the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, 88b and the cylinder surface inspection device 44. This waiting state is controlled by computers 110, 112, etc., located outside the clean room C and non-clean room D, which automatically calculate and control a scheduled time.

[0061] Preferably, while the surface of the plate-made roll 16 is being inspected in the cylinder surface inspection device 44, the plate-made roll 16 is made to wait in the rotary table type roll stock devices 100a, 100b, 102a, 102b, thereby preventing the plate-made roll 16 from stagnation between the processing devices 74a, 74b, 78a, 78b, 76a, 76b, i.e., the grindstone polishing devices 74a, 74b, developing devices 78a, 78b or paper polishing devices 76a, 76b, and the cylinder surface inspection device 44. This waiting state is controlled by computers 110, 112, etc., located outside the clean room C and non-clean room D, which automatically calculate and control the scheduled time.

[0062] Furthermore, in the fully automatic inspection system 10B, similarly to the fully automatic inspection system 10A, the planned processing time (i.e., the time required for processing) of the plate-making roll 16 in the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, 88b is determined according to the area of ​​the peripheral surface of the plate-making roll 16. The inspection time (planned time for completing the inspection) can be compared with the planned inspection time (i.e., planned time for completing the inspection) in the cylinder surface inspection device 44 for the plate-making roll 16 processed by the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, 88b. This comparison can be configured so that the planned time is automatically calculated and compared by computers 110, 112, etc., located outside the clean room C.

[0063] In addition, when the planned inspection time of the plate-making roll 16 in the cylinder surface inspection device 44 is longer than the planned processing time of the plate-making roll 16 in the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, 88b, the rotary table type roll stock device 100a , 100b, 102a, 102b, the plate-making roll 16 is kept waiting at the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, 88b and the cylinder surface inspection device 44. The area of ​​the peripheral surface of the plate-making roll 16 is calculated by multiplying the circumference of the plate-making roll 16 by the length of the plate-making roll 16 in the longitudinal direction, and this calculation is performed using an unprocessed plate base material.

[0064] For example, if the plate-making roll 16 is an aluminum hollow roll (plate base material) with a circumference of 600 mm and a face length of 1200 mm, the processing time for each of the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, and 88b is approximately 15 minutes, but inspection of the cylinder surface in the cylinder surface inspection device 44 takes only about half that time.

[0065] However, when the plate-making roll 16 is a plate base material with a circumference of 942 mm or a face length exceeding 1200 mm, the inspection of the cylinder surface in the cylinder surface inspection device 44 becomes longer than the processing time of the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, 88b. In this case, the plate-making roll 16 cannot be set in the cylinder surface inspection device 44, and the plate-making roll 16 will be stuck between the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, 88b and the cylinder surface inspection device 44. In the present invention, this sticking can be eliminated by adjusting the time that the plate-making roll 16 is kept waiting at the rotary table type roll stock devices 100a, 100b, 102a, 102b depending on the area of ​​the peripheral surface of the plate-making roll 16.

[0066] The processing equipment is selected from degreasing equipment 86a, 86b, strike plating equipment 116a, 116b, copper plating equipment 88a, 88b, grinding wheel polishing equipment 74a, 74b, photosensitive film coating equipment 68a, 68b, laser exposure equipment 70a, 70b, developing equipment 78a, 78b, corrosion equipment 80a, 80b, ultrasonic cleaning equipment 72a, 72b, resist stripping equipment 82a, 82b, surface hardening coating formation equipment 84a, 84b, and paper polishing equipment 76a, 76b, and the surface of the plate-making roll 16 after processing in the processing equipment is inspected by the cylinder surface inspection device 44 located in the clean room C.

[0067] In the illustrated example, photosensitive film coating devices 68a and 68b are provided above the laser exposure devices 70a and 70b, and paper polishing devices 76a and 76b are provided above the grindstone polishing devices 74a and 74b.

[0068] The strike plating devices 116a and 116b are devices for performing strike plating using nickel plating or alkaline copper plating. The strike plating process is performed between the degreasing process in the degreasing devices 86a and 86b and the copper plating process in the copper plating devices 88a and 88b.

[0069] In the illustrated example, photosensitive film coating devices 68a and 68b are installed and laser exposure devices 70a and 70b are used to perform laser exposure. However, an electronic engraving device may be installed to perform electronic engraving.

[0070] The surface hardening film forming devices 84a and 84b may be a chrome plating device, a DLC (Diamond-Like Carbon) film forming device, a silicon dioxide film forming device, or the like, but in the illustrated example, a chrome plating device is used.

[0071] As the processing device, known processing devices can be used, such as those described in Patent Documents 1 and 2.

[0072] It is particularly preferable that the above-mentioned processing device is a grindstone polishing device 74a, 74b, a developing device 78a, 78b or a paper polishing device 76a, 76b, and that the surface of the plate-making roll 16 after processing in the grindstone polishing device 74a, 74b or the paper polishing device 76a, 76b is inspected by the cylinder surface inspection device 44 located in the clean room C.

[0073] In the example of Figure 2, the grinding wheel polishing devices 74a, 74b, the ultrasonic cleaning devices 72a, 72b, the laser exposure devices 70a, 70b, the photosensitive film coating devices 68a, 68b, the paper polishing devices 76a, 76b, the cylinder surface inspection device 44, the rotary table type roll stock devices 100a, 100b, 102a, 102b, the first industrial robot 90, the second industrial robot 96, and the third industrial robot 92 are arranged in clean room C.

[0074] On the other hand, the degreasing devices 86a, 86b, strike plating devices 116a, 116b, copper plating devices 88a, 88b, developing devices 78a, 78b, corrosion devices 80a, 80b, resist stripping devices 82a, 82b, surface hardening coating forming devices 84a, 84b, fourth industrial robot 94, and fifth industrial robot 98 are located in non-clean room D.

[0075] The pressure in the clean room C is set higher than the pressure in the non-clean room D. The difference in pressure between the clean room C and the non-clean room D is preferably 2 to 10 Pa, and more preferably 5 to 7 Pa. That is, the pressure in the clean room C is preferably 2 to 10 Pa higher than the pressure in the non-clean room D, and more preferably 5 to 7 Pa higher. In this way, by making the pressure in the clean room C higher than the pressure in the non-clean room D, air flows from the clean room C to the non-clean room D. For example, it is preferable to pressurize the clean room C to the above pressure and exhaust air in the non-clean room D.

[0076] When the processing device is the grindstone polishing device 74a, 74b, the surface of the plate-making roll 16 on which a copper plated layer is formed by the copper plating process before the gravure cells are formed by the copper plating devices 88a, 88b is inspected. When inspecting the surface of the plate-making roll 16 on which a copper plated layer is formed by such a copper plating process and which has been grinded by the grindstone polishing devices 74a, 74b, for example, techniques of an inspection device that detects defects by an imaging means such as those described in Patent Document 3 and Patent Document 4 can be applied.

[0077] Furthermore, when the processing device is the developing device 78a, 78b, the surface of the plate-making roll 16 developed by the developing device 78a, 78b is inspected. When inspecting the surface of the plate-making roll 16 developed by such developing device 78a, 78b, for example, a technology of an inspection device that compares an imaging means with the original image used for plate-making to detect cell defects, as described in Patent Document 5, can be applied.

[0078] Furthermore, when the processing device is a paper polishing device 76a or 76b, after gravure cells are formed on the plate-making roll 16 and the plate-making process is performed, the surface of the plate-making roll 16 that has been subjected to the paper polishing process is inspected. In inspecting the surface of the plate-making roll 16 that has been subjected to such paper polishing process, for example, a technology of an inspection device that detects cell defects by comparing an imaging means with the original image used in plate-making, as described in Patent Document 5, can be applied.

[0079] The cylinder surface inspection device 44 is similar to that installed in the fully automatic inspection system 10A described above, and is capable of inspecting the surface of the plate-making roll 16 on which a copper plating layer has been formed by copper plating and which has been grinded by the grinding devices 74a and 74b, the surface of the plate-making roll 16 which has been developed by the developing devices 78a and 78b, and / or the surface of the plate-making roll 16 which has been subjected to a paper grinding process.In addition to the above-mentioned technologies, known cylinder surface inspection devices and cylinder surface inspection devices available on the market can be used.Also, cylinder surface inspection devices which use known AI (artificial intelligence) to improve inspection accuracy can be used.

[0080] The gravure cylinder inspection method according to the present invention can be carried out using the fully automatic gravure cylinder inspection system 10B described above. More specifically, the gravure cylinder inspection method according to the present invention using the fully automatic inspection system 10B includes the steps of transporting the plate-making roll 16 by the industrial robots 90, 92, 94, 96, and 98, processing the plate-making roll 16 in the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, and 88b, and inspecting the surface of the plate-making roll 16 by the cylinder surface inspection device 44, with the inspection steps being carried out in the clean room C.

[0081] The gravure cylinder inspection method of the present invention preferably further includes a step of making the plate-making roll 16 wait at the rotary table type roll stock device 100a, 100b, 102a, 102b while inspection of the surface of the plate-making roll 16 is being carried out in the cylinder surface inspection device 44, thereby eliminating the retention of the plate-making roll between the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, 88b and the cylinder surface inspection device.

[0082] The gravure cylinder inspection method according to the present invention further includes: determining a scheduled processing time of the plate-making roll 16 in the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, 88b; and determining the cylinder surface area of ​​the plate-making roll 16 processed in the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, 88b. and if the planned inspection time of the plate-making roll 16 in the cylinder surface inspection device 44 is longer, making the plate-making roll 16 wait at the rotary table type roll stock device 100a, 100b, 102a, 102b, it is preferable to eliminate the backlog of the plate-making roll 16 between the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, 88b and the cylinder surface inspection device 44.

[0083] The processing devices used in the above-mentioned gravure cylinder inspection method are grindstone polishing devices 74a, 74b, developing devices 78a, 78b, or paper polishing devices 76a, 76b, and in the inspection process, an inspection method in which the surface of the plate-making roll 16 after processing in the grindstone polishing devices 74a, 74b, developing devices 78a, 78b, or paper polishing devices 76a, 76b is inspected by the cylinder surface inspection device 44 located in the clean room is particularly preferred. In other words, the gravure cylinder inspection method of the present invention further includes a step of making the plate-making roll 16 wait at the rotary table type roll stock device 100a, 100b, 102a, 102b while inspection of the surface of the plate-making roll 16 is being carried out in the cylinder surface inspection device 44, and it is preferable to eliminate the stagnation of the plate-making roll 16 between the processing devices 74a, 74b, 78a, 78b, 76a, 76b, namely the grindstone polishing devices 74a, 74b, paper polishing devices 76a, 76b or developing devices 78a, 78b, and the cylinder surface inspection device 44.

[0084] Furthermore, as shown in FIG. 2, a fully automatic gravure cylinder manufacturing system 54B according to the present invention is a fully automatic gravure cylinder manufacturing system incorporating the fully automatic gravure cylinder inspection system 10B, and is a fully automatic gravure cylinder manufacturing system that manufactures gravure cylinders by performing platemaking processing using the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, and 88b and inspecting the surface of the processed plate-making roll 16 using the cylinder surface inspection device 44.

[0085] The method for manufacturing a gravure cylinder according to the present invention is a method for manufacturing a gravure cylinder using the fully automatic gravure cylinder manufacturing system 54B, and includes a process of transporting the plate-made roll 16 by the industrial robots 90, 92, 94, 96, and 98, a process of treating the plate-made roll 16 in the processing devices 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 76b, 78b, 80b, 82b, 84b, 86b, and 88b, and a process of inspecting the surface of the plate-made roll 16 by the cylinder surface inspection device 44, and the transport process, processing process, and inspection process are performed in the clean room C, thereby making the plate-making process a method for manufacturing a gravure cylinder.

[0086] 10A, 10B: Fully automatic inspection system for gravure cylinders, 12, 14, 56, 58, 60, 62, 64: Robot arm, 16: Plate-making roll, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 68a, 70a, 72a, 74a, 76a, 78a, 80a, 82a, 84a, 86a, 88a, 68b, 70b, 72b, 74b, 7 6b, 78b, 80b, 82b, 84b, 86b, 88b: processing equipment, 18, 68a, 68b: photosensitive film coating equipment, 20, 70a, 70b: laser exposure equipment, 22, 72a, 72b: ultrasonic cleaning equipment, 24, 74a, 74b: grinding stone polishing equipment, 26, 76a, 76b: paper polishing equipment, 28, 78a, 78b: developing equipment, 30, 80a, 80b: etching equipment, 3 2, 82a, 82b: resist stripping equipment, 34, 84a, 84b: surface hardening coating forming equipment, 36, 86a, 86b: degreasing equipment, 38, 88a, 88b: copper plating equipment, 40, 42, 90, 92, 94, 96, 98: industrial robot, 44: cylinder surface inspection equipment, 46, 100a, 100b, 102a, 102b: rotary table type roll stock equipment, 48, 104: wall, 50: shutter, 52, 110, 112: computer, 54A, 54B: fully automatic gravure cylinder manufacturing system, 106: first shutter, 108: second shutter, 114, 116a, 116b: strike plating equipment, A, C: clean room, B, D: non-clean room, P, Q, R, S, T, U, V: handling area.

Claims

1. A fully automatic inspection system for gravure cylinders used in manufacturing gravure cylinders, comprising: at least one non-traveling industrial robot equipped with a robot arm having a handling area for chucking and handling a plate-made roll and transporting it to each processing device; at least one processing device arranged in the handling area for processing the transported plate-made roll; a cylinder surface inspection device for inspecting the surface of the processed plate-made roll; a rotating table type roll stock device on which the plate-made roll is placed before or after inspection by the cylinder surface inspection device; and a clean room in which at least the cylinder surface inspection device, the industrial robot that transports the plate-made roll to the cylinder surface inspection device, and the rotating table type roll stock device are arranged, and in which inspection of the surface of the processed plate-made roll is performed within the clean room.

2. A fully automatic inspection system for gravure cylinders as described in claim 1, wherein the plate-making roll is made to wait in the rotary table type roll stock device while inspection of the surface of the plate-making roll is being carried out in the cylinder surface inspection device, thereby eliminating the backlog of the plate-making roll between the processing device and the cylinder surface inspection device.

3. A fully automatic inspection system for gravure cylinders as described in claim 1, which compares the planned processing time of the plate-made roll in the processing device with the planned inspection time of the plate-made roll processed in the processing device in the cylinder surface inspection device depending on the area of ​​the peripheral surface of the plate-made roll, and if the planned inspection time of the plate-made roll in the cylinder surface inspection device is longer, the plate-made roll is made to wait in the rotating table type roll stock device, thereby eliminating the backlog of the plate-made roll between the processing device and the cylinder surface inspection device.

4. A fully automatic inspection system for gravure cylinders as described in claim 1, wherein the processing equipment is selected from the group consisting of a degreasing equipment, a strike plating equipment, a copper plating equipment, a grinding wheel polishing equipment, a photosensitive film coating equipment, a laser exposure equipment, a developing equipment, an etching equipment, an ultrasonic cleaning equipment, a resist stripping equipment, a surface hardening film forming equipment, and a paper polishing equipment, and the surface of the plate-making roll after processing in the processing equipment is inspected by the cylinder surface inspection equipment arranged in the clean room.

5. A fully automatic inspection system for gravure cylinders as described in claim 1, wherein the processing device is a grindstone polishing device, a paper polishing device or a developing device, and the surface of the plate-making roll after processing in the grindstone polishing device, the paper polishing device or the developing device is inspected by the cylinder surface inspection device arranged in the clean room.

6. A fully automatic inspection system for gravure cylinders as described in claim 1, wherein the industrial robots include at least a first industrial robot and a second industrial robot, the processing equipment is selected from the group consisting of a degreasing equipment, a strike plating equipment, a copper plating equipment, a grinding wheel polishing equipment, a photosensitive film coating equipment, a laser exposure equipment, a developing equipment, an etching equipment, an ultrasonic cleaning equipment, a resist stripping equipment, a surface hardening coating forming equipment, and a paper polishing equipment, at least one of the processing equipment is arranged in a handling area of ​​the first industrial robot, and at least one of the processing equipment not arranged in the handling area of ​​the first industrial robot is arranged in the handling area of ​​the second industrial robot, the plate-making process is sequentially performed by transferring the plate-making roll between the first industrial robot and the second industrial robot and transporting it sequentially to the processing equipment so that the processing in the processing equipment is performed, and the surface of the plate-making roll after processing in the processing equipment is inspected by the cylinder surface inspection device in the clean room.

7. A fully automatic inspection system for gravure cylinders as described in claim 6, wherein the grindstone polishing device, the ultrasonic cleaning device, the laser exposure device, the photosensitive film coating device, the paper polishing device, the cylinder surface inspection device, the rotary table type roll stock device, and the first industrial robot are arranged in a clean room, and the degreasing device, strike plating device, copper plating device, developing device, etching device, resist stripping device, surface hardening film forming device, and the second industrial robot are arranged in a non-clean room, and the pressure in the clean room is made higher than the pressure in the non-clean room.

8. A method for inspecting gravure cylinders using the fully automatic inspection system for gravure cylinders described in claim 1, comprising the steps of: transporting a plate-made roll by the industrial robot; processing the plate-made roll in the processing device; and inspecting the surface of the plate-made roll by the cylinder surface inspection device, wherein the inspection steps are performed within the clean room.

9. A gravure cylinder inspection method as described in claim 8, further comprising a step of making the plate-making roll wait in the rotary table type roll stock device while inspection of the surface of the plate-making roll is being carried out in the cylinder surface inspection device, thereby eliminating the retention of the plate-making roll between the processing device and the cylinder surface inspection device.

10. An inspection method for gravure cylinders as described in claim 8, further comprising the steps of: comparing, depending on the area of ​​the peripheral surface of the plate-made roll, the planned processing time of the plate-made roll in the processing device with the planned inspection time of the plate-made roll processed in the processing device in the cylinder surface inspection device; and if the planned inspection time of the plate-made roll in the cylinder surface inspection device is longer, making the plate-made roll wait in the rotary table type roll stock device, thereby eliminating the stagnation of the plate-made roll between the processing device and the cylinder surface inspection device.

11. A fully automatic gravure cylinder manufacturing system incorporating the fully automatic gravure cylinder inspection system of claim 1, which manufactures gravure cylinders by carrying out plate making processing with the processing device and inspecting the surface of the processed plate-making roll with the cylinder surface inspection device.

12. A method for manufacturing a gravure cylinder using the fully automated manufacturing system for gravure cylinders described in claim 11, comprising: a process for transporting a plate-made roll by the industrial robot; a process for processing the plate-made roll in the processing device; and a process for inspecting the surface of the plate-made roll by the cylinder surface inspection device, wherein the inspection process is carried out in the clean room, thereby enabling the plate-making process to be carried out.

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