Tin badge manufacturing system, tin badge manufacturing program, and tin badge manufacturing method

Abstract

Provided is a tin badge manufacturing system, a tin badge manufacturing program, and a tin badge manufacturing method capable of efficiently and highly accurately manufacturing tin badges.　The tin badge manufacturing system comprises: a printing unit that prints an image on a print target medium; a mold unit that has a lower mold in which an obverse member and a reverse member are to be loaded, and is for manufacturing a tin badge by combining the print target medium, the obverse member, and the reverse member; a conveyance unit that conveys the print target medium from the printing unit to the lower mold of the mold unit; and a control device. The control device receives image data, and generates rotated image data obtained by rotating an object image included in the image data by a prescribed angle. The printing unit prints the object image on the print target medium on the basis of the rotated image data.

Description

Badge production system, badge production program, and badge production method

[0001] The present disclosure relates to a can badge production system, a can badge production program, and a can badge production method.

[0002] Conventionally, there are known devices for producing can badges, such as can badges with a predetermined image applied thereto, and Patent Document 1 discloses a can badge production device that produces can badges by crimping a front cover to a back cover. In this can badge production device, an image to be printed is printed on the printing surface of a transparent film based on image data of the print image, which is a mirror image of the image, and the user manually places the printed film on the front cover. The printed film is placed so that the printed surface faces the surface of the front cover.

[0003] Japanese Patent Application Laid-Open No. 2019-136210

[0004] However, in the above-described conventional technology, the user must manually place the printed film on the cover, which is time-consuming and there is also a risk that the printed film will not be properly placed in the predetermined position on the cover.

[0005] Therefore, an object of the present disclosure is to provide a can badge production system, a can badge production program, and a can badge production method that are capable of producing can badges efficiently and with high precision.

[0006] The can badge production system disclosed herein comprises a printing unit that prints an image on a print medium, a mold unit that has a lower mold into which a front member and a back member are loaded and that combines the print medium, the front member, and the back member to produce a can badge, a transport unit that transports the print medium from the printing unit to the lower mold of the mold unit, and a control device, wherein the control device accepts image data and generates rotated image data by rotating an object image included in the image data by a predetermined angle, and the printing unit prints the object image on the print medium based on the rotated image data.

[0007] According to the present disclosure, the print medium is transported to the lower mold of the mold unit by the transport unit. This eliminates the need for the user to place the print medium, resulting in efficiency. Furthermore, rotated image data, which rotates the object image included in the image data by a predetermined angle, is generated by the control device, and the object image included in the rotated image data is printed on the print medium by the printing unit. This makes it possible to print the object image on the print medium with high precision, depending on the orientation of the safety pin attached to the backing member, for example, in the case of a can badge. As a result, it is possible to produce can badges efficiently and with high precision.

[0008] According to the present disclosure, it is possible to provide a can badge production system, a can badge production program, and a can badge production method that are capable of producing can badges efficiently and with high precision.

[0009] 1. A perspective view showing a can badge production system according to one embodiment. A plan view of the can badge production system of FIG. 1. A block diagram showing the configuration of a control system for the can badge production system of FIG. 1. A plan view of a print medium. A plan view of a backing sheet. A perspective view of a front member. A perspective view of a back member seen from the front side. A perspective view of a back member seen from the back side. A cross-sectional view of a can badge produced by connecting the front member and the back member. A perspective view showing the configuration of a front member supply unit. A perspective view showing the configuration of a back member supply unit. A cross-sectional view showing the configuration of a printing unit in the can badge production system of FIG. 1. A diagram showing an example of the display content on the display unit before processing. A diagram showing an example of the display content on the display unit during processing. An explanatory diagram showing the steps up to the rotation processing of an object image. A diagram showing the loading direction. A flowchart showing the flow of processing in the can badge production system. A flowchart following FIG. 13.

[0010] A badge production system according to an embodiment of the present disclosure will be described below with reference to the drawings. The badge production system described below is merely one embodiment of the present disclosure. Therefore, the present disclosure is not limited to the following embodiment, and additions, deletions, and modifications can be made without departing from the spirit of the present disclosure.

[0011] 1, a badge production system 100 according to an embodiment of the present disclosure includes a printing unit 1, a transport unit 2, a mold unit 3, a front member supply unit 4, a back member supply unit 5, a pressing unit 6, a removal unit 7, a collection container 8, a badge stocker 9, and a control device 110 (FIG. 3). The control device 110 may be built into the printing unit 1, the transport unit 2, or the mold unit 3.

[0012] The printing unit 1 has a housing 80, and the transport unit 2 is detachable from the housing 80. Hereinafter, the removal direction of the transport unit 2 from the housing 80 will be referred to as the "front," and the direction opposite to the "front" will be referred to as the "rear." Furthermore, directions that intersect (e.g., perpendicular to) the removal direction and intersect (e.g., perpendicular to) each other will be referred to as the "up-down direction" and the "left-right direction." However, the arrangement directions in the can badge production system 100 are not limited to the above directions.

[0013] First, we will explain the can badge 200 produced by the can badge production system 100. As shown in Fig. 5D, the can badge 200 is, for example, a metal badge. The mold unit 3 produces the can badge 200 by combining a print medium W, a backing sheet F, and a can member CE, which will be described later. The can member CE includes a front member SE and a back member BE.

[0014] 5A , the surface member SE has a surface member main body portion SEb that is, for example, circular in plan view, and a peripheral edge portion SEa that is provided on the periphery of the surface member main body portion SEb and protrudes downward. The surface member SE is made of a magnetic material such as a tin-plated steel sheet.

[0015] 5B , the backing member BE has a backing member main body portion BEb that is, for example, circular in plan view and a peripheral edge portion BEa that is provided on the periphery of the backing member main body portion BEb and protrudes upward. The backing member BE is formed of a magnetic material such as a tin-plated steel plate. The backing member main body portion BEb has two holes BEb1 that are spaced apart from each other in the radial direction.

[0016] As shown in Figures 5B and 5C, a safety pin 150 is provided on the back side of the backing member main body BEb. The safety pin 150 has a pin main body 151, protrusions 151a connected to the pin main body 151 and spaced apart in the radial direction of the backing member main body BEb, and a connecting portion 152. The protrusions 151a of the safety pin 150 are inserted into the holes BEb1 so as to protrude toward the front side of the backing member main body BEb (the side where the connecting portion 152 is provided, the upper side in Figure 5B). The connecting portion 152 connects one protrusion 151a to the other protrusion 151a on the front side of the backing member main body BEb. With the above configuration, the safety pin 150 is attached to the backing member BE.

[0017] A fixing jig 155 is detachably provided on the backing member BE. The fixing jig 155 has supported portions 156, 157 that are spaced apart from each other in the radial direction. The supported portion 156 has wall portions 156a, 156b that are spaced apart from each other in the radial direction. The wall portion 156b is disposed closer to the supported portion 157 than the wall portion 156a. The height of the wall portion 156a is greater than the height of the wall portion 156b. The pin main body portion 151 is disposed between the wall portions 156a and 156b. The pin main body portion 151 is supported in an upright position by the wall portions 156a and 156b. When the backing members BE are stacked vertically in the backing member supply unit 5, the wall 156a and the supported portion 157 of the supported portion 156 are supported by the backing member main body portion BEb of the backing member BE located below the backing member BE on which the wall 156a and the supported portion 157 of the supported portion 156 are provided. This prevents interference between one stacked backing member BE and the other stacked backing member BE, thereby preventing damage caused by contact between the backing members BE. After the can badge 200 is produced, the user can release the support of the pin main body portion 151 by the supported portion 156 by gripping the supported portion 157 and rotating it upward. This allows the fixing jig 155 to be detached from the backing member BE.

[0018] As shown in FIG. 5D , the front member SE has a peripheral edge SEa that protrudes downward, and the back member BE has a peripheral edge BEa that protrudes upward. The can badge 200 is formed by connecting the front member SE, on which the covered portion Fb of the mount F and the covered portion Wb of the print medium W (described later) are arranged, and the back member BE, which are held apart by an upper mold 33 (described later). An example of the connection between the front member SE and the back member BE is crimping. The peripheral edge Fg of the covered portion Fb and the peripheral edge Wg of the covered portion Wb, which are arranged on the front member SE, are folded and sandwiched between the peripheral edge SEa and the peripheral edge BEa, and the peripheral edge SEa and the peripheral edge BEa are then crimped together. This produces the can badge 200.

[0019] As shown in FIG. 4A , the print medium W is a rectangular, transparent sheet. The print medium W includes, for example, a transparent resin film and an ink-receiving layer formed on one side of the resin film. The print medium W has a downstream end We1 and an upstream end We2 in the first transport direction Dc1 when transported by the transport unit 2 toward the mold unit 3. The print medium W includes a covered portion Wb covering the front member SE, a remaining portion Wa different from the covered portion Wb, a connecting portion Wec connecting the covered portion Wb and the remaining portion Wa, and a linear weakened portion Wd extending linearly from the downstream end of the connecting portion Wec to the downstream end We1. The covered portion Wb includes a front portion Wf1 covering the surface of the front member SE, a front portion Wf2 covering the edge of the front member SE, and the aforementioned peripheral portion Wg. The connecting portion Wec and the linear weakened portion Wd are weak portions, such as perforations, that are weaker than the covered portion Wb and the remaining portion Wa. The connecting portion Wc and the linear weakened portion Wd are cut by conveying the remaining portion Wa in a second conveying direction Dc2 opposite to the first conveying direction Dc1 by the conveying unit 2 while the covered portion Wb is pressed by the pressing unit 6 in the mold unit 3, thereby separating the covered portion Wb from the remaining portion Wa. Note that, according to the arrangement direction of the can badge production system 100 in Figure 1, the first conveying direction Dc1 is backward and the second conveying direction Dc2 is forward.

[0020] As shown in FIG. 4B , the backing sheet F is, for example, a rectangular white sheet. The backing sheet F has the same shape and size as the print medium W. The configuration of the backing sheet F is basically the same as the configuration of the print medium W, except for the material. The backing sheet F includes a downstream end Fe1 and an upstream end Fe2 in the first transport direction Dc1, a covered portion Fb, a remaining portion Fa, a connecting portion Fc, and a linear weak portion Fd. The covered portion Fb has a front portion Ff1, a front portion Ff2, and a peripheral portion Fg. The downstream end Fe1 corresponds to the downstream end We1, the upstream end Fe2 corresponds to the upstream end We2, the covered portion Fb corresponds to the covered portion Wb, the remaining portion Fa corresponds to the remaining portion Wa, the connecting portion Fc corresponds to the connecting portion Wec, and the linear weak portion Fd corresponds to the linear weak portion Wd. The front portion Ff1 corresponds to the front portion Wf1, the front portion Ff2 corresponds to the front portion Wf2, and the peripheral portion Fg corresponds to the peripheral portion Wg.

[0021] As shown in FIG. 3 , the control device 110 of the badge production system 100 is a computer that includes an interface 111 for transmitting and receiving various data, such as image data, to and from an external device 114, a calculation unit 112, such as a CPU, for processing the data, and a storage unit 113, such as a memory, for storing the data. The storage unit 113 stores a predetermined badge production program. The storage unit 113 is composed of, for example, RAM, ROM, flash memory, and / or a hard disk. The calculation unit 112 controls each unit by executing the badge production program stored in the storage unit 113, causing each unit to perform various operations, such as printing, conveying, and crimping, as described below. The calculation unit 52 corresponds to a generation means, a loading control means, a printing control means, a conveying control means, a production control means, a display control means, and an image data generation means.

[0022] The control device 110 is connected to the printing unit 1, the transport unit 2, the mold unit 3, the front member supply unit 4, the back member supply unit 5, the pressing unit 6, and the take-out unit 7 via drive circuits 115 to 121, and controls the operations of these units. The external device 114 is, for example, a mobile terminal such as a smartphone, a computer, a camera, a communication network, a recording medium reader, a display, or a printer.

[0023] The printing unit 1 is, for example, an inkjet printer and includes a head 92 and a movement motor 96a. The ejection operation of the head 92 and the movement motor 96a are controlled by a control device 110 to eject ink from the head 92 onto the print medium W and to move the print medium W relative to the head 92 by driving the movement motor 96a. As a result, an image is printed on the covered portion Wb of the print medium W using ink ejected from the head 92, and the print medium W moves to the transport unit 2. The printing unit 1 moves the mount F to the transport unit 2 without printing an image on the mount F. Note that the printing unit 1 is not limited to an inkjet printer and may be other printers such as a laser printer or thermal printer as long as it is capable of printing an image on the print medium W. Note that the detailed configuration of the printing unit 1 will be described later.

[0024] The transport unit 2 has a transport motor 23, multiple drive rollers Rk, and multiple driven rollers Ro. The drive roller Rk sandwiches the print medium W and the liner F between itself and the driven roller Ro, and rotates forward in response to the drive of the transport motor 23, thereby transporting the print medium W and the liner F above the front member SE of the first lower mold 30 along the first transport direction Dc1. Meanwhile, the drive roller Rk sandwiches the remaining portion Wa of the print medium W and the remaining portion Fa of the liner F between itself and the driven roller Ro, and rotates reverse in response to the drive of the transport motor 23, thereby transporting the remaining portions Wa, Fa to the collection container 8 along the second transport direction Dc2. The remaining portions Wa, Fa are collected in the collection container 8 as discarded portions. The drive of the transport motor 23 is controlled by the control device 110.

[0025] The pressing unit 6 has a pressing motor 60, a remaining portion pressing head 65, and a pressing head 66. The remaining portion pressing head 65 and the pressing head 66 press the print medium W against the front member SE when driven by the pressing motor 60. In this state, the remaining portion Wa of the print medium W is transported in the second transport direction Dc2 by the transport unit 2, whereby the connecting portion We and the linear weak portion Wd of the print medium W are cut, separating the covered portion Wb from the remaining portion Wa. This covered portion Wb remains on the front member SE, and the remaining portion Wa is transported to the collection container 8 for collection. Similarly to the print medium W, the backing sheet F is also separated into a covered portion Fb and a remaining portion Fa, with the covered portion Fb remaining on the front member SE and the remaining portion Fa being transported to the collection container 8 for collection. The pressing motor 60 is controlled by the control device 110.

[0026] The mold unit 3 has a first lower mold 30 that supports the front member SE, a second lower mold 31 that supports the back member BE, a rotary support table 32, an upper mold lifting motor 34, a lower mold moving motor 35, and an upper mold 33. The rotary support table 32 rotates the first lower mold 30 and the second lower mold 31 by driving the lower mold moving motor 35, and moves them to a second mold position P2 facing the upper mold 33, or to a first mold position P1 other than the second mold position P2. The upper mold 33 is raised and lowered by driving the upper mold lifting motor 34. The upper mold lifting motor 34 and the lower mold moving motor 35 are controlled by a control device 110.

[0027] The first lower mold 30 moves to the second mold position P2 below the upper mold 33 after the front member SE is supplied by the front member supply unit 4 at the first mold position P1 and the covering portions Wb, Fb are placed on the front member SE. The upper mold 33 then descends toward the first lower mold 30 to press the covering portions Wb, Fb against the front member SE, and then rises from the first lower mold 30 to separate the front member SE covered by the covering portions Wb, Fb from the first lower mold 30. The second lower mold 31 then descends toward the second lower mold 31 at the first mold position P1 and crimps the front member SE and the back member BE together so that the peripheral portions Wg, Fg of the covering portions Wb, Fb are sandwiched between them. This produces the can badge 200.

[0028] The take-out unit 7 has a take-out motor 70, a swing arm 71, a magnet member 72, and a seat 73. The swing arm 71 has a magnet member 72 attached to its tip, and is controlled by the take-out motor 70 so that the magnet member 72 rotates between the second lower mold 31 and the seat 73 at the first mold position P1. After the magnet member 72 attaches to the can badge 200 supported by the second lower mold 31, the swing arm 71 rotates to move the can badge 200 to the seat 73. The can badge 200 slides down the downwardly sloping seat 73 into the can badge stocker 9 and is stored in the can badge stocker 9. The take-out motor 70 is controlled by the control device 110.

[0029] Next, the front member supply unit 4 and the back member supply unit 5 will be described in detail.

[0030] The front member supply unit 4 is located above the printing unit 1 and to the right of the die unit 3. As shown in FIG. 6 , the front member supply unit 4 includes a front member stocker 40 and a loading mechanism 4s. The loading mechanism 4s slides and supplies the front member SE toward the first lower die 30 and includes a front member slider 43, a pusher 45, and a pusher motor 46. The front member stocker 40 stores multiple front members SE, each of which is, for example, circular in plan view, stacked vertically. The front member stocker 40 is cylindrical. The front member stocker 40 is erected with its axis oriented vertically, and a slit 40a extending vertically is formed near the first lower die 30. The slit 40a has a width smaller than the diameter of the front member SE and is formed from the top to the bottom of the front member stocker 40. A user can visually check the front members SE stored in the front member stocker 40 through the slit 40a of the front member stocker 40. In other words, the user can grasp the remaining number of surface members SE. When the remaining number becomes low, the user can replenish the surface members SE from the top end of the surface member stocker 40.

[0031] The front member slider 43 supplies the front member SE to the first lower die 30 along a predetermined loading direction D1. The loading direction D1 is a direction connecting the center of the first lower die 30 at the first die position P1 and the center of the front member stocker 40 in a plan view.

[0032] A space equal to or slightly larger than the thickness of one front member SE is provided between the lower end of the front member stocker 40 and the upper surface of the front member slider 43. The pusher 45 pushes the front member SE on the front member slider 43 toward the first lower die 30. The pusher 45 is disposed on the opposite side of the front member stocker 40 from the first lower die 30. In other words, the front member stocker 40 is disposed between the first lower die 30 and the pusher 45. The pusher 45 includes, for example, a flat pusher body 45a and a rack gear 45b connected to the pusher body 45a and extending in the loading direction D1. The rack gear 45b is meshed with a pinion gear 47 connected to the rotation shaft of a pusher motor 46. When the pusher motor 46 is driven to rotate, the rack gear 45b moves in the loading direction D1 and the opposite direction, and as a result, the pusher body 45a moves on the front member slider 43 in the loading direction D1 and the opposite direction. In this case, when the pusher body 45a moves in the loading direction D1, the tip of the pusher body 45a passes below the front member stocker 40 and reaches the vicinity of the first lower die 30. As a result, one front member SE supplied from the front member stocker 40 onto the front member slider 43 is pushed out by the pusher body 45a and sent out in the loading direction D1 toward the first lower die 30. As a result, the first lower die 30 supports the front member SE. On the other hand, when the pusher body 45a moves in the opposite direction to the loading direction D1 and retreats, the tip of the pusher body 45a retreats from below the front member stocker 40 to the outside. As a result, one front member SE is supplied from the front member stocker 40 onto the front member slider 43.

[0033] The front member slider 43 is disposed below the front member stocker 40 and extends from a predetermined position adjacent to the first lower die 30 through below the front member stocker 40. The front member slider 43 has a pair of contact paths 42 with which the front member SE comes into contact, and guide portions 41 provided on the outer sides of each contact path 42 (i.e., on the outer sides in a direction perpendicular to the loading direction D1) to guide the front member SE pushed out by the pusher 45 to the first lower die 30. The front member slider 43 also has a groove 44 formed lower than the contact paths 42. This groove 44 is formed between one contact path 42 and the other contact path 42. When the front member SE is supplied from the front member stocker 40 to the front member slider 43, it is supported by the pair of contact paths 42, but not by the groove 44.

[0034] The front member slider 43 has a notch 43a at its downstream end in the loading direction D1. This notch 43a is arc-shaped and convex in the opposite direction to the loading direction D1. By providing the above-mentioned notch 43a in the front member slider 43, when the front member SE is supplied from the downstream end of the front member slider 43 to the first lower die 30, the upstream end of the front member SE (i.e., the end opposite to the side where the first lower die 30 is located) is less likely to get caught on the front member slider 43. Therefore, the front member SE can be supplied to a predetermined position in the first lower die 30 with high accuracy.

[0035] Next, the back material supply unit 5 supplies the back material BE to a second lower mold 31 that is different from the first lower mold 30. The method of supplying the back material BE by the back material supply unit 5 is basically the same as the method of supplying the front material SE by the front material supply unit 4.

[0036] The backing material supply unit 5 is located above the printing unit 1 and to the left of the mold unit 3. As shown in FIG. 7 , the backing material supply unit 5 includes a backing material stocker 50 and a loading mechanism 5s. The loading mechanism 5s slides and supplies backing materials BE toward the second lower mold 31, and includes a backing material slider 53, a pusher 55, and a pusher motor 56. The backing material stocker 50 stores multiple backing materials BE, each of which is, for example, circular in plan view, stacked vertically. The backing material stocker 50 is cylindrical. The backing material stocker 50 is erected with its axis oriented vertically, and a slit 50a extending vertically is formed near the second lower mold 31. The slit 50a has a width smaller than the diameter of the backing material BE and is formed from the top to the bottom of the backing material stocker 50. The user can visually check the back materials BE stored in the back material stocker 50 through the slits 50a of the back material stocker 50. In other words, the user can grasp the remaining number of back materials BE. When the remaining number becomes low, the user can replenish the back materials BE from the top end of the back material stocker 50.

[0037] The back material slider 53 supplies the back material BE along a predetermined loading direction D2 to the second lower mold 31. In a plan view, the loading direction D2 is a direction connecting the center of the second lower mold 31 at the first mold position P1 and the center of the back material stocker 50, and is a direction inclined at a predetermined angle θ with respect to an orthogonal direction D3 that is orthogonal to the first conveying direction Dc1 (or the second conveying direction Dc2) as shown in FIG.

[0038] Between the lower end of the back material stocker 50 and the upper surface of the back material slider 53, there is provided a space equal to or slightly larger than the thickness of one back material BE. The pusher 55 pushes the back material BE on the back material slider 53 toward the second lower mold 31. The pusher 55 is disposed on the opposite side of the back material stocker 50 from the second lower mold 31. In other words, the back material stocker 50 is disposed between the second lower mold 31 and the pusher 55. When the pusher motor 56 is driven to rotate, the pusher 55 moves on the back material slider 53 in the loading direction D2 and in the opposite direction via a rack gear and pinion gear (not shown) similar to those of the front material supply unit 4. In this case, when the pusher 55 moves in the loading direction D2, the tip of the pusher 55 passes below the back material stocker 50 and reaches the vicinity of the second lower mold 31. As a result, one back material BE supplied from the back material stocker 50 onto the back material slider 53 is pushed out by the pusher 55 and sent out in the loading direction D2 toward the second lower die 31. On the other hand, when the pusher 55 moves in the direction opposite to the loading direction D2 to retreat, the tip of the pusher 55 retreats from below the back material stocker 50 to the outside. As a result, one back material BE is supplied from the back material stocker 50 onto the back material slider 53.

[0039] The back material slider 53 guides the back material BE pushed out by the pusher 55 toward the second lower mold 31 in the loading direction D2. The back material slider 53 is disposed below the back material stocker 50 and extends from a predetermined position adjacent to the lower mold 3 through below the back material stocker 50. The back material slider 53 has a pair of contact paths 51 provided downstream thereof and guide portions 52 provided on the outer sides of each contact path 51 (i.e., on the outer sides in a direction perpendicular to the loading direction D2) to guide the back material BE pushed out by the pusher 55 to the second lower mold 31. The contact paths 51 are spaced apart from each other in a direction perpendicular to the loading direction D2. Only both end portions of the back material BE supplied from the back material stocker 50 in a direction perpendicular to the loading direction D2 are supported from below by the contact paths 51 of the back material slider 53. This prevents interference with the safety pin 150 provided on the back material BE.

[0040] Next, the printing unit 1 will be described in detail.

[0041] The housing 80 of the printing unit 1 has a main body 84 and an openable / closable cover (not shown) provided on the main body 84. As shown in Figure 8, the main body 84 is formed, for example, in a substantially rectangular parallelepiped shape and has a bottom surface 80b, a front surface 80c, and a back surface 80d, as well as a top surface, left side surface, and right side surface (not shown). For example, the mold unit 3, front member supply unit 4, back member supply unit 5, pressing unit 6, and removal unit 7 are arranged on the top surface of the main body 84, the control device 110 (Figure 3) is housed within the main body 84, and the collection container 8 and can badge stocker 9 are arranged forward of the main body 84. The transport unit 2 is detached from the housing 80 toward the front.

[0042] The main body 84 of the housing 80 has a first storage chamber 81 and a second storage chamber 86. The second storage chamber 86 is located above the first storage chamber 81. The first storage chamber 81 is a space that stores a cassette 90 for the print medium W. The cassette 90 is formed in a box shape with an open top and includes a lower plate 90a that supports the print medium W, a rear plate 90b, and a front plate 90c that opens and closes a first opening 82a provided on the front surface 80c of the housing 80. The lower plate 90a is a flat plate that intersects the vertical direction, and the print medium W is placed on it. The rear plate 90b slopes upward from the rear end of the lower plate 90a toward the rear. The front plate 90c rises from the front end of the lower plate 90a and covers the first opening 82a when the cassette 90 is stored in the first storage chamber 81. When the cassette 90 is pulled out of the first storage chamber 81, the first opening 82a is opened.

[0043] The user moves the cassette 90 forward from the first storage chamber 81 and pulls it out of the first storage chamber 81. The user then stacks multiple print media W vertically and places them on the lower plate 90a of the cassette 90, storing them in the cassette 90. The user then moves the cassette 90, which now contains the multiple print media W, backward and positions it in the first storage chamber 81. This causes the cassette 90 to be stored in the first storage chamber 81.

[0044] A second opening 86a, which is an opening to the second storage chamber 86, is provided on the top surface of the main body 84. The second storage chamber 86 is a space that houses the head 92. The second storage chamber 86 is in communication with the first storage chamber 81. The print medium W is supplied to the second storage chamber 86 from the cassette 90 housed in the first storage chamber 81, and a predetermined image is printed on the print medium W by the head 92 in the second storage chamber 86. In addition, an outlet 86b is provided on the front surface 80c of the main body 84, through which the print medium W printed by the head 92 is discharged from the second storage chamber 86. The outlet 86b is located above the first opening 82a on the front surface 80c of the main body 84. The second storage chamber 86 is in communication with the outside of the main body 84 via the outlet 86b.

[0045] The first storage chamber 81 is provided with a first supply roller 93 and a curved wall 94, while the second storage chamber 86 is provided with a platen 95, an upstream movable roller 96, and a downstream movable roller 96. The first supply roller 93, the upstream movable roller 96, the downstream movable roller 96, and a second supply roller 98 (described later) each comprise a roller pair. The first supply roller 93 is rotated about an axis extending in the left-right direction by the drive of a first supply motor 93a (FIG. 3). The upstream movable roller 96 and the downstream movable roller 96 are rotated about an axis extending in the left-right direction by the drive of a movement motor 96a (FIG. 3). The drive of the first supply motor 93a and the movement motor 96a is controlled by a control device 110.

[0046] The first supply roller 93 is disposed above the cassette 90 and abuts from above on the uppermost print medium W among the print media W stored in the cassette 90. As the first supply roller 93 rotates, the uppermost print medium W moves upward and rearward along the rear plate 90b of the cassette 90, and then moves from the cassette 90 to the curved wall 94. The curved wall 94 is disposed rearward of the upstream moving roller 96, above the cassette 90, and below the upstream moving roller 96, and is curved convexly rearward. The print medium W moves upward and rearward along the curved wall 94, and then moves forward to the upstream moving roller 96.

[0047] The upstream moving roller 96 rotates behind the platen 95 while sandwiching the print medium W, thereby moving the print medium W onto the platen 95 located in front of it. The platen 95 is located above the cassette 90. The upper surface of the platen 95 faces the lower surface of the head 92 and supports the print medium W supplied from the cassette 90 from below. Ink is ejected from the head 92 onto the print medium W on the platen 95, and an image is printed thereon. The downstream moving roller 96 is located in front of the platen 95 and rotates while sandwiching the print medium W, thereby moving the print medium W toward the discharge opening 86b. The print medium W is then discharged from the discharge opening 86b toward the transport unit 2.

[0048] Furthermore, the printing unit 1 has a tray 97 that stores the mount F. The tray 97 is a rectangular flat plate that is disposed at the rear of the main body 84 and is inclined upward from the rear surface 80d of the main body 84. The mount F is disposed on the tray 97.

[0049] A supply port 88 is provided on the rear surface 80d of the main body 84. The lower end of the tray 97 is connected to the part of the rear surface 80d that forms the supply port 88. The tray 97 communicates with the second storage chamber 86 of the main body 84 via the supply port 88. A support base 97a and a second supply roller 98 are provided in the second storage chamber 86. The support base 97a is disposed so as to extend the tray 97 forward, and supports the backing sheet F supplied from the tray 97 from below.

[0050] The second supply roller 98 is rotated about an axis extending in the left-right direction by the drive of a second supply motor 98a (FIG. 3). The drive of the second supply motor 98a is controlled by a control device 110 (FIG. 3). The second supply roller 98 is disposed above the support base 97a and contacts from above the uppermost backing sheet F among the backing sheets F disposed on the tray 97 and the support base 97a. As the second supply roller 98 rotates, the backing sheet F is transported to the upstream movable roller 96 located in front, passed over the platen 95 by the upstream movable roller 96, and then discharged to the transport unit 2 through the discharge port 86b by the downstream movable roller 96.

[0051] In this configuration, the printing unit 1 does not print an image on the backing sheet F, and sends the backing sheet F to the transport unit 2 ahead of the print medium W. The transport unit 2 transports the backing sheet F onto the front member SE. As a result, the backing sheet F is transported onto the front member SE loaded in the first lower mold 30.

[0052] The printing unit 1 prints an object image Gb (FIGS. 10 and 11) described below on the covered portion Wb of the print medium W based on rotated image data described below, and sends the print medium W to the transport unit 2. In this case, the printing unit 1 prints an inverted image as the object image Gb on the covered portion Wb of the print medium W, which is a normal image when viewed from the front side of the print medium W. The object image Gb is, for example, an image of a character or mark. The transport unit 2 then transports the print medium W onto a backing sheet F placed on a front member SE. This causes the print medium W to be transported onto the backing sheet F on the front member SE.

[0053] Next, the rotated image data generated by the control device 110 will be described. In this embodiment, as described above, the loading direction D2 of the backing member BE is tilted at a predetermined angle θ with respect to the orthogonal direction D3. As shown in FIG. 12 , the safety pin 150 is aligned along the loading direction D2 when loaded. That is, when loaded, the safety pin 150 is tilted at an angle θ with respect to the orthogonal direction D3 in a plan view. Here, the head 92 performs a printing operation while moving left and right parallel to the orthogonal direction D3. Therefore, if the printing operation were performed without rotating the input image data, the image corresponding to the image data would be printed on the print medium W at an angle with respect to the extension direction of the safety pin 150. As a result, when a user attaches the can badge 200 to a bag or the like via the safety pin 150, the image may be tilted.

[0054] Therefore, the control device 110 generates rotated image data using the input image data. As shown in FIG. 9 , the control device 110 first displays an image selection button 131, a creation start button 132, a preview frame 133, a file folder selection button 134, and an operation status display section 135 on the display section 130 of the external device 114, which is, for example, a mobile terminal such as a smartphone. The user can use the file folder selection button 134 and the image selection button 131 to select desired image data (i.e., image data to be printed) from the input image data. After selecting the image data, the user can start creating the rotated image data by pressing the creation start button 132. The control device 110 may also be provided with a display section.

[0055] When the creation start button 132 is pressed, the control device 110 causes the display unit 130 to display a preview frame 133, an operating status display area 135, and a cancel button 136, as shown in Fig. 10. The object image Gb displayed in the preview frame 133 will be described later. The user can cancel the creation process midway by pressing the cancel button 136.

[0056] Furthermore, when the start creation button 132 is pressed, the control device 110 performs preprocessing on the image data selected by the user as needed, in addition to the above-mentioned display processing on the display unit 130. Preprocessing is a process of converting the image data into a data format supported by the badge production system 100, and of adjusting the image size of the image data to the size of the badge 200 (i.e., the size of the front member SE). Note that if the image data selected by the user does not require preprocessing, preprocessing is not required.

[0057] The image data described below has resolution information indicating how many dots are arranged per inch and pixel count information indicating the size of the image. Consider a case where the diameter of the covered portion Wb of the print medium W arranged on the surface member SE is, for example, 56 mm. Converting 56 mm to inches gives 2.20472 inches. If the printing resolution of the printing unit 1 is, for example, 600 dpi, then the required number of dots in each direction is 600 x 2.20472 = 1322. The image data described below is based on the assumption that the image related to the image data (i.e., the object image Gb) is expressed in 1322 dots x 1322 dots, i.e., the original size that can be used as is without scaling the dots of the image data.

[0058] The preprocessing performed by the control device 110 is, for example, as follows. For example, if the image data is in a user-specific template format, the user uses specified software to convert the image data to, for example, PNG data. The control device 110 then performs a preprocessing step of cropping the converted image data to crop out a necessary area. If the image data has a user-specific file extension, the control device 110 converts the image data to, for example, PNG data and performs a preprocessing step of cropping out the necessary area. Even if the image data is PNG data, if the original data is paired with data to which a circle indicating the printing position is added, the control device 110 performs a preprocessing step of detecting the circle and cropping out the data. As shown in FIG. 11 , the image data Da1 generated by the preprocessing is image data having a square outline, and the center of the square area coincides with the center of the object image Gb1. The image data Da1 generated by the preprocessing is an example of adjustment data. Therefore, the adjustment data may be the image data Da1, or the image data Da2 and Da3 described below.

[0059] When the preprocessing is completed, the control device 110 converts the resolution of the image data Da1 to the print resolution as needed. Note that if the image data selected by the user has a predetermined print resolution, the resolution conversion process is not required.

[0060] Next, the control device 110 processes the image data Da1 into a circle as needed to match the outer shape of the surface member SE. As a result, image data Da2 is generated in which the area including the object image Gb2 is circular. Note that if the image data selected by the user has a circular outer shape, the above processing is not required.

[0061] Next, the control device 110 creates a base image, for example, of L size, as needed, and generates image data Da3 by combining the created base image with the object image Gb2. In Figure 11, the object image of the image data Da3 is designated Gb3 to distinguish it from the previous and next object images, and the outline of the L size is indicated by a two-dot chain line for ease of understanding. Note that if the image data selected by the user is L size image data, the above generation process is not required.

[0062] The control device 110 generates image data Da4, which is rotated image data obtained by rotating the object image Gb3 of the image data Da3 by a predetermined angle. The predetermined angle corresponds to the angle θ shown in FIG. 12. In FIG. 11, the object image of the image data Da4 is designated Gb4 in order to distinguish it from the previous and next object images. The printing unit 1 prints the object image Gb on the print medium W based on the image data Da4.

[0063] The following describes the processing flow in the badge production system 100 with reference to a flowchart. Note that the following flowchart also includes a case where multiple types of object images Gb are printed.

[0064] As shown in FIG. 13 , the control device 110 first designates image data selected by the user through operation of the image selection button 131 (step S1). The control device 110 then receives information indicating that the user has pressed the creation start button 132 (step S2). Next, the control device 110 determines whether any of the image data for the multiple object images Gb requires preprocessing (e.g., conversion to a specific format, such as PNG data supported by the badge production system 100) (step S3). In this case, the control device 110 determines that the image data requires preprocessing if the image data format (file extension) is user-specific, or if the image data is in PNG format and forms a pair of master data and data with a circle indicating the printing position. If there is image data requiring preprocessing (Yes in step S3), the control device 110 performs preprocessing, such as conversion to a supported format (step S4).

[0065] If there is no image data to be preprocessed (No in step S3) or after the processing of step S4, the control device 110 converts the resolution of the image data selected by the user into the print resolution (step S5). Next, the control device 110 processes the outer shape of the image data into a circle to match the outer shape of the surface member SE (step S6).

[0066] Next, the control device 110 creates an L-size base image (step S7), and generates image data by combining the created base image with the object image Gb (step S8). Subsequently, the control device 110 displays the object image Gb of the generated image data (image data before generating the rotated image data) on the display unit 130 of the external device 114, as shown in Figure 10 (step S9). That is, the control device 110 displays a preview of the non-rotated object image Gb on the display unit 130.

[0067] Next, the control device 110 determines whether position correction of the image data is necessary (step S10). In this case, the determination is made based on the deviation of the object image Gb from the base image when the object image Gb is combined with the base image. If position correction is necessary (Yes in step S10), the control device 110 executes the position correction (step S11).

[0068] If position correction is not required (No in step S10) or after the process of step S11, the control device 110 generates rotated image data by rotating the object image Gb of the image data by a predetermined angle (step S12).

[0069] The control device 110 then issues an instruction to produce the can badge 200 (step S13). In this case, the control device 110 drives the pusher motor 46 of the front portion supply unit 4 so that the front member SE is loaded into the first lower die 30. After the loading of the front member SE is complete, the printing unit 1 sends the backing sheet F to the transport unit 2 ahead of the print medium W, and the transport unit 2 transports the backing sheet F onto the front member SE.

[0070] The control device 110 then determines whether it is time to print on the print medium W (step S14). If it is time to print (Yes in step S14), the control device 110 causes the printing unit 1 to execute printing (step S15). The printing unit 1 then sends the print medium W to the transport unit 2, which transports the print medium W onto the backing sheet F of the front member SE. The first lower mold 30 then moves from the first mold position P1 to the second mold position P2, and the upper mold 33 descends to hold the front member SE on which the covering portions Fb and Wb are arranged. As the first lower mold 30 moves from the first mold position P1 to the second mold position P2, the second lower mold 31 moves from the second mold position P2 to the first mold position P1. Therefore, after the upper mold 33 holds the front member SE as described above, the second lower mold 31 moves from the second mold position P2 to the first mold position P1. Thereafter, the backing member BE is loaded into the second lower mold 31, and the second lower mold 31 moves from the first mold position P1 to the second mold position P2. Next, the upper mold 33, which holds the front member SE on which the covering portions Fb and Wb are arranged, moves down, thereby crimping the covering portions Fb and Wb, the front member SE, and the backing member BE to produce the can badge 200. The second lower mold 31, which holds the produced can badge 200, moves from the second mold position P1 to the first mold position P1, and the can badge 200 is removed by the removal unit 7 at the first mold position P1 and stored in the can badge stocker 9. Note that if it is not time to print (No in step S14), the control device 110 waits until it is time to print.

[0071] Next, the control device 110 updates the job list (step S16) and then determines whether or not to produce a can badge 200 using the same image data (step S17). If the can badge 200 is to be produced using the same image data (Yes in step S17), the control device 110 returns to the process of step S13 described above and repeats the subsequent processes. On the other hand, if the can badge 200 is not to be produced using the same image data (No in step S17), the control device 110 determines whether or not all jobs have been completed (step S18). If all jobs have not been completed (No in step S18), the control device 110 specifies the next job (step S19), and then returns to the process of step S5 described above and repeats the subsequent processes. On the other hand, if all jobs have been completed (Yes in step S18), the control device 110 ends the can badge production process.

[0072] As described above, according to the can badge production system 100 of this embodiment, the print medium W is transported by the transport unit 2 to the first lower mold 30 of the mold unit 3. This eliminates the need for the user to place the print medium W, making it efficient. In addition, the control device 110 generates rotated image data by rotating the object image Gb included in the image data by a predetermined angle, and the printing unit 1 prints the object image Gb included in the rotated image data on the print medium W. This makes it possible to print the object image Gb on the print medium W with high precision according to the orientation of the safety pin 150 provided on the backing member BE. As a result, the can badges 200 can be produced efficiently and with high precision.

[0073] Furthermore, in this embodiment, the safety pin 150 of the can badge 200 is positioned along the loading direction D2 when loaded. That is, when loaded, the safety pin 150 is positioned at an angle θ with respect to the orthogonal direction D3 in a plan view. In this regard, by positioning the backing material supply unit 5 so that the loading direction D2 is inclined with respect to the orthogonal direction D3, the device as a whole is made more compact than when the backing material supply unit 5 is positioned so that the loading direction D2 is parallel to the orthogonal direction D3. Even when the safety pin 150 is positioned at an angle to achieve compactness in this way, printing is performed based on rotated image data generated by the control device 110, so the object image Gb is positioned on the covered portion Wb of the print medium W at an appropriate angle with respect to the safety pin 150.

[0074] Furthermore, in this embodiment, a preview of the object image Gb before rotation (non-rotated object image Gb) is displayed on the display unit 130. In this case, the non-rotated object image Gb is previewed, which makes it easier for the user to imagine the appearance of the completed can badge 200.

[0075] Furthermore, in this embodiment, rotated image data is generated using image data (adjustment data) generated by pre-processing performed as needed, making it possible to flexibly respond to the format of image data provided by the user.

[0076] The present disclosure is not limited to the above-described embodiment, and modifications can be made without departing from the spirit of the present disclosure. For example, the following modifications are possible.

[0077] In the above embodiment, the control device 110 is built into the printing unit 1, the transport unit 2, or the mold unit 3, but this is not limiting. The control device 110 may be provided in a terminal (for example, a personal computer or a mobile terminal) separate from the printing unit 1, the transport unit 2, and the mold unit 3. In this case, the display unit of the terminal corresponds to the display device. Alternatively, the control device 110 may be implemented by cooperation between a control device provided in each of the above units and a control device in one or more of the above terminals.

[0078] In addition, in the above embodiment, the object image Gb before rotation (non-rotated object image Gb) is previewed on the display unit 130, but this is not limited to this. The non-rotated object image Gb may be previewed on the display unit 130 after the rotation process is executed.

[0079] In the above embodiment, the object image Gb included in the image data is rotated by a predetermined angle to generate the rotated image data, but this is not limiting. As shown in FIG. 12 in the above embodiment, if the backing material BE provided with the safety pin 150 is symmetrical in one direction in a planar view, the backing material BE may be rotated 180° in a planar view and stored in the backing material stocker 50. In this case, the control device 110 generates the rotated image data by rotating the object image Gb included in the image data by an angle obtained by adding 180° to the predetermined angle.

[0080] In addition, in the above embodiment, the printing medium W is stored in the cassette 90 and the backing paper F is stored in the tray 97, but this is not limited to this, and the backing paper F may be stored in the cassette 90 and the printing medium W may be stored in the tray 97.

[0081] In the above embodiment, the printing unit 1 prints an inverted image on the print medium W, which is a normal image when viewed from the front side of the print medium W. However, this is not limited to this, and the printing unit 1 may print a non-inverted image. In this case, care is taken to prevent the front and back sides of the print medium W from being reversed when the print medium W is transported from the printing unit 1 toward the first lower mold 30.

[0082] Furthermore, in the above embodiment, the printing unit 1 is provided with both the tray 97 that stores the backing sheets F and the cassette 90 that stores the print media W. However, this is not limiting, and the printing unit 1 may be provided with only one storage section, and the backing sheets F and the print media W may be stored alternately in this storage section.

[0083] REFERENCE SIGNS LIST 1 Printing unit 2 Conveying unit 3 Mold unit 5s Loading mechanism 30 First lower mold 100 Badge production system 110 Control device 200 Badge BE Backing member D2 Loading direction Dc1, Dc2 Conveying direction Gb Object image SE Front member W Printing medium

Claims

1. A badge production system comprising: a printing unit which prints an image on a print medium; a mold unit which has a lower mold into which a front member and a back member are loaded, and which combines the print medium, the front member, and the back member to produce a badge; a transport unit which transports the print medium from the printing unit to the lower mold of the mold unit; and a control device, wherein the control device receives image data and generates rotated image data by rotating an object image included in the image data by a predetermined angle, and the printing unit prints the object image on the print medium based on the rotated image data.

2. A badge production system as described in claim 1, further comprising a loading mechanism which loads the backing material in a predetermined loading direction toward the lower mold, wherein the transport unit transports the printed medium in a predetermined transport direction toward the lower mold, the loading direction being a direction inclined at the predetermined angle with respect to a perpendicular direction perpendicular to the transport direction in a planar view, and the control device rotates the object image included in the image data by the predetermined angle or an angle equal to or greater than 180° to generate the rotated image data.

3. The can badge production system according to claim 1, wherein the control device causes a display device to display the non-rotated object image.

4. A can badge production system as described in claim 3, wherein the control device generates adjustment data by performing a predetermined processing on the image data, and causes the display device to preview the object image contained in the adjustment data.

5. A badge production system as described in claim 4, wherein the control device rotates the object image included in the adjustment data by the specified angle to generate the rotated image data.

6. A can badge production program to be executed by a computer in a can badge production system that produces can badges, causing the computer to function as: a generation means that accepts image data and generates rotated image data by rotating an object image included in the image data by a predetermined angle; a loading control means that controls a loading mechanism to load a front member and a back member into a lower mold of a mold unit having a lower mold into which the front member and the back member are loaded; a printing control means that controls a printing unit to print the object image on a print medium based on the rotated image data; a transport control means that controls a transport unit to transport the print medium from the printing unit to the lower mold of the mold unit; and a production control means that controls the mold unit to produce the can badge by combining the print medium, the front member, and the back member.

7. A can badge production program as described in claim 6, which causes the transport control means to control the transport unit to transport the printing medium in a predetermined transport direction toward the lower mold, and causes the loading control means to control the loading mechanism to load the backing material toward the lower mold in a loading direction that is inclined at the predetermined angle with respect to a perpendicular direction perpendicular to the transport direction in a planar view.

8. The can badge production program according to claim 6, further causing the computer to function as a display control means for displaying a preview of the object image included in the image data and not rotated on a display device.

9. A can badge production program as described in claim 8, further causing the computer to function as an adjustment data generating means for generating adjustment data by performing a predetermined processing on the image data, and previewing the object image contained in the adjustment data on the display device.

10. The can badge production program according to claim 9, which causes the generating means to generate the rotated image data by rotating the object image included in the adjustment data by the predetermined angle.

11. A method for making can badges, comprising: receiving image data, and generating rotated image data by rotating an object image contained in the image data by a predetermined angle; loading a front member and a back member into a lower mold of a mold unit; printing the object image on a print medium based on the rotated image data; transporting the print medium to the lower mold of the mold unit; and combining the print medium, the front member, and the back member to produce the can badge.

Images