Packaging device

Abstract

The purpose of the present invention is to provide countermeasures for various issues to be improved in order to enhance the effectiveness of implementing a packaging device that performs a process all at once by bringing an entire welding spot in to contact with a heating part.　The problem of the present invention is solved by a packaging device that welds and packages an object to be packaged by using a pair of cutting dies, and that is characterized by comprising: a temperature measurement means for measuring the temperature of the cutting dies that have been heated; a determination means capable of determining whether or not the temperature measured by the temperature measurement means is an appropriate welding temperature for packaging; and a control means for restricting packaging control by a packaging means when the determination means determines that the measured temperature is not in a temperature range appropriate for welding.

Description

packaging equipment

[0001] The present invention relates to a packaging device that covers a tray on which an item to be packaged is placed with a film and heat-seals the film to the edge of the tray.

[0002] Conventional packaging devices have been designed to improve convenience by placing the packaged item on a loading platform and pushing it into the machine body, and then automatically pushing the loading platform out of the machine body after heat sealing (see, for example, Patent Document 1).

[0003] Japanese Patent Application Laid-Open No. 2003-261102

[0004] The packaging device described in Patent Document 1 has the drawback of taking a long time to complete one process because it uses a rotating heat-sealing roller. It is possible to eliminate the heat-sealing roller and process the entire welding area at once by contacting a cutting die as a heat-generating part, but when implementing a packaging device in this way, there are various points that need to be improved in order to increase its effectiveness.

[0005] The present invention addresses these problems and aims to address various points that need to be improved in order to increase the effectiveness of packaging equipment that processes the entire welding area at once by bringing it into contact with a heat-generating part.

[0006] The packaging device of the present invention has at least the following configuration: a packaging device that uses a pair of cutter dies to weld and package items to be packaged, characterized by comprising: a temperature measuring means for measuring the temperature of the heated cutter dies; a determining means for determining whether the temperature measured by the temperature measuring means is within an appropriate temperature range for welding for packaging; and a control means for limiting packaging control by the packaging means when the determining means determines that the measured temperature is outside the appropriate temperature range for welding. Here, the temperature measuring means includes both modes in which the temperature of the upper cutter die is calculated directly or indirectly.

[0007] According to the present invention, it is possible to provide a packaging device that can effectively prevent packaging defects.

[0008] 7A is a right perspective view showing the appearance of a packaging device according to an embodiment of the present invention; FIG. 7B is a left perspective view showing the appearance of a packaging device according to an embodiment of the present invention; FIG. 7C is a plan view showing the appearance of a packaging device according to an embodiment of the present invention; FIG. 7D is a right side view of a packaging device according to an embodiment of the present invention; FIG. 7E is a right side view of a measuring means and a packaging means (with a portion of the machine frame removed); FIG. 7F is a right perspective view of a measuring means and a packaging means (with a portion of the machine frame removed); FIG. 7G is a front cross-sectional view illustrating an upper cutter die and an upper cutter die folder, where FIG. 7A shows the upper cutter die folder when no upper cutter die is loaded, FIG. 7B shows the upper cutter die alone, and FIG. 7C shows the upper cutter die loaded in the upper cutter die folder. FIG. 8A is a plan view, FIG. 8B is a front view, FIG. 8C is a bottom view, FIG. 8D is an upper perspective view, and FIG. 8E is a lower perspective view showing an upper cutter die. 9(a) is a plan view, FIG. 9(b) is a front view, FIG. 9(c) is a bottom view, FIG. 9(d) is an upper perspective view, FIG. 9(e) is a right side view, and FIG. 9(f) is a conceptual diagram showing a heat transfer member. 10(a) is a plan view, FIG. 10(b) is a front view, FIG. 10(c) is a bottom view, FIG. 10(d) is an upper perspective view, FIG. 10(e) is a right side view, and FIG. 10(f) is an enlarged view of portion D in FIG. 10(d). 11(a) is a plan view, and FIG. 11(b) is a side cross-sectional view for explaining a lower die. 11(b) is a perspective view showing how a lower die is attached to and detached from a lower die folder. 11(c) is a partially enlarged side cross-sectional view of a lower die. FIG. 1 is a side cross-sectional view showing the change in state when the lower die is pushed up against the upper die. FIG. 2 is a diagram explaining another example of the upper die and the lower die. FIG. 3 is a diagram explaining the mechanism of action of determining the loading state. FIG. 4 is a flow chart showing the flow of various processes for the die. FIG. 5 is a diagram showing an example of the layout of the display screen. FIG. 6 is a diagram showing an example of the layout of the display screen. FIG. 7 is a diagram showing an example of the layout of the display screen. FIG. 8 is a diagram (table) showing setting items used to determine the packaging state and attachment conditions. FIG. 9 is a diagram (table) showing the priority order for PLU setting information, tray setting information, and die setting information. FIG. 10 is a diagram showing an example of the layout of the main menu. FIG. 11 is a diagram showing an example of the layout of a packaging mode screen.1 is a diagram showing an example of a pop-up menu displayed in response to a packaging start command. FIG. 1 is a diagram showing an example of the layout of a product master setting screen. FIG. 2 is a diagram showing an example of the layout of a PLU setting screen. FIG. 3 is a diagram showing an example of the layout of a tray selection screen. FIG. 4 is a diagram showing an example of the layout of a setting screen for each tray. FIG. 5 is a diagram showing an example of the layout of a setting screen for each cutter die. FIG. 6 is a diagram showing an example of the layout of a setting screen for each cutter die. FIG. 7 is a perspective view showing how upper cutter dies and lower cutter dies are stored in a cutter die storage means. FIG. 8 is a right side view showing how upper cutter dies and lower cutter dies are stored in a cutter die storage means. FIG. 9 is a diagram explaining an example of the electrical configuration of the packaging device 100. FIG. 10 is a flow chart showing the processing flow during normal operation of the packaging device. FIG. 11 is a diagram showing an example of the layout of an error display screen. FIG. 12 is a flow chart showing the processing flow during normal operation of the packaging device. FIG. 13 is a diagram showing the processing flow during normal operation of the packaging device. FIG. 14 is a flow chart showing the processing flow in another embodiment regarding cutter die replacement. FIG. 15 is a diagram showing an example of the layout of an error display screen. FIG. 16 is a flow chart showing the processing flow when an emergency stop button is pressed during packaging.

[0009] An example of an embodiment of a packaging device according to the present invention will be described below with reference to the drawings. However, the drawings below have been created for explanatory purposes, and for the sake of clarity, components not necessary for the explanation may be intentionally omitted. Furthermore, components may be intentionally enlarged or reduced in size for the purpose of explanation, and the drawings are not drawn to an accurate scale. In the following description, the same reference numerals in different drawings indicate parts with the same function, and duplicate explanations in each drawing will be omitted as appropriate.

[0010] (Overall Configuration) Figures 1 to 4 show the appearance of a packaging device according to an embodiment of the present invention, with Figure 1 being a right perspective view, Figure 2 being a left perspective view, Figure 3 being a plan view, and Figure 4 being a right side view. Figures 5 and 6 particularly show the weighing means and packaging means, with Figure 5 being a right side view (with part of the machine frame removed) and Figure 6 being a right perspective view (with part of the machine frame removed).

[0011] 1 to 3, the packaging device 100 according to the embodiment of the present invention weighs the packaged items (contents) placed on a tray T by tare weight, and while carrying the tray T with the packaged items inside the device, automatically performs a series of operations up to carrying out the device after top sealing and labeling, which involves a gas replacement process (processing the entire welded area at once) to extend the expiration date of the packaged items. In other words, the device can be said to have a packaging process between the process of weighing the packaged items and the process of labeling. More specifically, as shown by the arrow in FIG. 3, in the packaging device 100, when a tray T carrying an article to be packaged is placed on the weighing means 1, the weight of the article to be packaged is measured, and the tray T is carried forward into the machine frame having the packaging means 2 by the in-feed bar IB (see FIGS. 5 and 6). In the machine frame, the lower punch 25 (see FIG. 1) pushes the tray T upward, and first, the air existing in the space formed between the film, which is always stretched and held at both ends by the film holding means 211 and the surplus film winding means 212 (see FIG. 1), and the tray T is replaced with an inert gas, and then the film is wound around the tray T. While the edges are abutted and the film is clamped between the lower die 25 and the upper die 24 (see Figure 1), the film is heat-sealed at a predetermined heat seal temperature for a predetermined tray sealing time to seal and package it, and after the film is cut, the lower die 25 and the tray T descend and return to a predetermined height (fixed position), and the in-feed bar IB (see Figures 5 and 6) again advances the tray T in the carry-in direction to transport it to the subsequent area 3, and while moving it in the carry-out direction perpendicular to the carry-in direction, a label is attached by the label attachment means 7, and then the tray T is discharged onto the first discharge table 4, and then the tray T is moved in the opposite direction to the carry-in direction to be sent to the second discharge table 5.

[0012] As shown in Figure 5, the in-feed bar IB, which is the transport mechanism for the trays T, is suspended at four circumferential positions on two left and right chains that can rotate around the entire circumference from the front of the weighing means 1 to the rear of the packaging means 2, and is configured to transport the trays T from the weighing means 1 to the packaging means 2, and then from the packaging means 2 to the subsequent area 3 as the chains rotate.

[0013] In an embodiment of the present invention, three types of upper and lower die dies are provided and configured to be interchangeable to accommodate three different sizes of trays T: large, medium, and small. Furthermore, when the die dies are replaced, different packaging operation controls are executed, such as packaging with different heat-sealing temperatures, tray sealing times, and gas filling times. Specifically, when the emergency stop button 8 is pressed to replace the die, the die temperature is lowered by a cooling means (including reducing the heater output, natural cooling, or active cooling using a fan, etc.) until it reaches a temperature at which replacement is possible (e.g., 35°C). After the die replacement, the die temperature is raised by the heater means until it reaches a temperature suitable for the replaced die. However, this configuration is merely an example; there may be two sizes, large and small, or four or more sizes. Furthermore, there may be only one tray size, which is not intended to be interchangeable. On the other hand, even for trays of the same size, it may be preferable to perform different packaging operations for trays of different types, specifically, different materials. For example, a temperature suitable for a foam tray is 110°C, while a temperature suitable for a resin tray is 180°C. In an embodiment of the present invention, the heat sealing temperature is actually changed depending on the type of tray, and the packaging operation is performed. That is, when a tray type with a different set temperature is replaced, the die temperature is increased by a heater, or decreased by a cooling means (including reducing the output of the heater, natural cooling, or active cooling using a fan, etc.).

[0014] The weighing unit 1, packaging unit 2, and rear-stage area 3 are arranged vertically from the front toward the rear of the device. As shown in FIG. 1 , above the weighing unit 1 and upstream of the weighing unit 1 in the conveying direction, a console 6 is located. The console 6 has a front panel display, a numeric keypad, a touch panel, and an emergency stop button 8 (pressed to replace the die), and includes a speaker for emitting buzzers and various voice messages and a control unit. To explain this arrangement in more detail, the lower end of the console 6 case is located upstream of the weighing unit 1, and both the center of the console 6 and the center of the display are located in the weighing unit 1 area. Although the console 6 is tilted, the upper end of the console 6 case is also located upstream of the weighing unit 1. The upper portion of the rear-stage area 3 is a labeling unit 7 that prints and affixes product labels bearing information such as the weighed weight, unit price, and price. The lower die 25 is also equipped with a gas replacement mechanism (not shown in FIGS. 1 to 3 ). In this specification, "gas replacement" refers to "gas replacement" used in a broad sense (regardless of the specific process) of replacing the air inside a package with an inert gas to extend the shelf life, and includes both "gas replacement" used in the narrow sense of completely removing the air and then adding gas, and "gas flushing" in which gas is sprayed to expel the air. Gas replacement packaging in this broad sense is sometimes called MAP packaging.

[0015] In an embodiment of the present invention having such a configuration, the top seal is performed while gas is replaced between the packaged item and the film, so that the gas replacement process for extending the expiration date of the packaged item and the packaging process using the top seal can be performed approximately simultaneously, thereby making the work more efficient.

[0016] Furthermore, in this embodiment of the present invention, the tray T is inserted from the front, packaged, and then returned to the front, significantly contributing to the efficiency of work in the backroom, and this configuration is realized in a compact design. However, from the perspective of performing the gas replacement process to extend the expiration date of the packaged items and the packaging process using a top seal substantially simultaneously, the configuration in which the tray is inserted from the front and then returned to the front is not essential. It is also possible to realize a simple one-way transport from the front to the rear, or to first perform the packaging process and then the weighing process. Furthermore, it is also possible to eliminate the weighing process and labeling process and create an apparatus configuration specialized for the packaging process. Regarding the packaging process, gas replacement is not necessarily required from the perspective of packaging operations that take into account the appropriate welding temperature. In other words, even if the gas replacement process is not included, it is within the scope of the present invention.

[0017] The machine frame shown in FIG. 1 , particularly the upper portion, not only houses the packaging means 2 and other components, but also plays a vital role in isolating the interior from the outside. The lower portion of the machine frame is equipped with buffer tanks (BT1, BT2) for gas replacement (see FIG. 6 ). After weighing by the weighing means 1, the tray T is transported, and the upper and lower cutters are closed to seal the top. To prevent an operator from accidentally inserting their hand into the container and causing an accident, a shutter 11 is provided between the weighing means 1 and the packaging means 2, slightly including the area of ​​the weighing means 1 (see FIG. 6 ). When the tray T is transported to the packaging means 2 by the infeed bar IB (see FIGS. 5 and 6 ), the shutter 11 isolates the inside and outside of the housing. Because the transport means in this embodiment of the present invention is the infeed bar IB (see FIGS. 5 and 6 ), rather than a belt conveyor, the shutter is configured to close by lifting from bottom to top, avoiding the chain portion. However, the shutter may be configured to close by descending from top to bottom, or a shutter may not be provided and the device may be stopped when a sensor detects the intrusion of a hand, thereby ensuring safety.

[0018] To improve convenience during transportation, the first and second discharge trays 4 and 5 are detachable. After these trays are removed, the label application unit 7 is configured to slide fully to the left in FIG. 3 so that it fits within the machine frame's left-right range and does not get in the way during transportation. Conversely, in a "pricing mode" in which only pricing labels are issued without packaging, the label application unit 7 is slid fully to the right in FIG. 3 so that an operator manually applies pricing labels to products. To achieve this, the packaging device 100 according to the embodiment of the present invention is equipped with a label application unit slide rail 71 and anti-tip legs 72. The anti-tip legs 72 support the entire device to prevent the packaging device 100 from losing balance and tipping over when the label application unit 7 is moved all the way to the right.

[0019] The weighing means 1 is configured to weigh the placed packaged items and trays T, and transmits information on the weighed weight to the control unit of the console 6. As shown in Fig. 5, rod-shaped in-feed bars IB are stretched across two left and right chains that can travel the entire circumference from the front of the weighing means 1 to the rear of the packaging means 2 at four circumferential positions, allowing the placed trays T to be carried into the machine frame that houses the packaging means 2 and then transported directly to the rear area 3. More specifically, as shown in Fig. 5, a total of eight in-feed bar support members IB1 for stretching the in-feed bars IB are provided on the two left and right chains at four circumferential positions on the two left and right chains, and four antibacterial treated metal rod-shaped in-feed bars IB are connected to the two left and right chains (see also Fig. 6). The spacing between the in-feed bars IB in the circumferential arrangement is set so that when the in-feed bar IB retreats temporarily to prevent contact with the ascending lower die 25, the in-feed bar IB will not interfere with the next packaged item placed on the weighing means 1. The height of the in-feed bar IB relative to the tray T placement surface is configured to be located midway between the height of the bottom surface and the height of the top surface of the tray T, but the height may be changed as appropriate as long as the tray T can be transported stably.

[0020] As mentioned above, three types of trays T are available: large, medium, and small. Interchangeable upper and lower die dies 24 and 25 are provided for packaging the trays T to accommodate each size. Specifically, in this embodiment, an upper die for a large tray (150 mm wide and 150 mm deep), an upper die for a medium tray (150 mm wide and 120 mm deep), and an upper die for a small tray (120 mm wide and 120 mm deep) are provided. However, the outer shapes of the die dies are all the same regardless of tray size. To properly center the three types of trays T (large, medium, and small) relative to the in-feed bar IB, the platform of the weighing unit 1 is provided with recesses of slightly different depths corresponding to the large, medium, and small tray sizes. That is, a deeper recess for the medium size is located inside the recess for the large size, and an even deeper recess for the small size is located inside the recess for the medium size. The difference in level caused by this recess is kept to a minimum so as not to create resistance when the in-feed bar IB transports the tray T. Additionally, guides 12 tapering toward the center are provided on both the left and right sides as a means for centering (see the partially enlarged view in FIG. 2). Furthermore, instead of recesses or guides, a visually identifiable indicator may also be used as a means for centering. Even if there is some left-right misalignment, the tray T is naturally guided to the correct position when pushed up by the lower die 25 because the sides of the tray T are inclined. While a detailed description will be omitted, the packaging device 100 according to an embodiment of the present invention is also provided with a detection and determination means capable of detecting compatibility between the upper and lower die sets and detecting non-loading.

[0021] As shown in FIG. 5 , the trays T that have been packaged by thermal welding are transferred from the packaging means 2 to the subsequent area 3. As shown in FIG. 6 , the subsequent area 3 is composed of a conveyor belt and functions as a discharge means for moving the trays T outside the machine frame. Above the subsequent area 3, a labeling means 7 is provided for printing and affixing product labels. Therefore, the subsequent area 3 can also be regarded as the labeling means 7. Thus, the trays T are transferred by the subsequent area 3 in an output direction perpendicular to the input direction and discharged toward the first output tray 4. The first output tray 4 shown in FIGS. 1 and 3 is equipped with a drive roller that moves the trays T in the opposite direction to the input direction to the second output tray 5. The second output tray 5 is inclined, and the trays T move under their own weight. Therefore, the rollers of the second output tray 5 are simply rollers without any driving force.

[0022] The packaging device 100 according to the embodiment of the present invention includes an upper die storage means 24H and a lower die storage means 25H as storage means capable of storing all types of unused die dies for the upper die 24 and the lower die 25. This eliminates the need to store unused die dies in a location separate from the packaging device body, thereby saving space. The upper die storage means 24H and the lower die storage means 25H are located in the vicinity of the film holding means 211 and the surplus film winding means 212. More specifically, in the packaging device 100 according to the embodiment of the present invention, the upper die storage means 24H and the lower die storage means 25H are located above the weighing means 1 and the packaging means 2 in a manner corresponding to the placement of the weighing means 1 and the packaging means 2. The lower die storage means 25H is located above the weighing means 1, near the console 6 having a display unit, and downstream of the console 6. Of course, this is just one example, and the upper die storage means 24H and the lower die storage means 25H may be configured so that their positions are reversed, or they may be configured so that they are separated into a storage space for upper and lower die dies of one size and a storage space for upper and lower die dies of another size.

[0023] To summarize the machine frame containing the packaging means 2, in Fig. 4 , a film holding means 211 for holding the film used to package the containers and a surplus film take-up means 212 for taking up excess film when sealing the containers are disposed in the upper part of the machine frame, corresponding to the front-to-rear arrangement of the weighing means 1 and packaging means 2, respectively, as shown by the dashed line areas. These components collectively constitute the film hanging means 21. The film holding means 211 is provided with a film set shaft lever 211L that can be raised or tilted, and the surplus film take-up means 212 is provided with a winding shaft lever 212L that can be raised or tilted. In Fig. 6 , the film set shaft lever 211L is tilted approximately perpendicular to the axial direction, while the winding shaft lever 212L, which does not have a roll loaded, is raised and extends axially. As can be seen from Fig. 6 , the roll film R cannot be inserted unless the lever is raised, but tilting the lever after inserting the roll film R prevents the roll film R from falling out. In addition, the setting shaft expands in conjunction with the tilting of the lever, tensioning the film's core from the inside, ensuring stable fixation of the roll film R to the setting shaft. The dimensions are also set so that the side panel SP cannot be closed unless the lever is tilted, ensuring the safety of the device.

[0024] In Figure 4, a first imaging means is provided at position A marked with a circle, and a second imaging means is provided at position B marked with a circle. The first imaging means captures an image of the tray T being carried into the machine casing from above by the in-feed bar IB (see Figures 5 and 6). Using the captured image information, the control unit of the packaging device 100 determines the tray size and the state of the packaged items. The second imaging means captures an image of the tray T from the side within the machine casing, and using the captured image information, the control unit of the packaging device 100 determines whether the tray T is securely fitted into the lower die 25 when pushed upward. These imaging means may also be configured to be used to determine the compatibility of the die and the type of tray. When determining the type of tray, the tray may be color-coded or may be labeled with appropriate identification information and the type may be determined based on the identification information.

[0025] As shown in Figures 1 and 4, the film hanging means 21 is arranged to fit within the upper part of the machine frame in which the weighing means 1 and packaging means 2 are arranged. The film is hung in the same direction as the weighing means 1, packaging means 2, and rear area 3, which are vertically aligned from the front to the back of the machine. In other words, the hanging direction of the film is the same as the conveyance direction of the tray T. In conventional packaging machines, the film hanging means is usually arranged to protrude significantly outside the machine frame in which the packaging means and other components are arranged. However, in this embodiment, the film holding means 211 and surplus film winding means 212 are arranged above and near the mounting means, which can mount multiple cutting dies, and the film is hung below and near the mounting means, greatly contributing to space savings. More specifically, in this embodiment, as shown in Figure 5, a mounting means (as an upper die holder 240 in which upper die dies 24 are loaded) is provided between the film hanging means 21 (comprised of film holding means 211 and surplus film winding means 212) and the transport space for tray T (by in-feed bar IB). Also, as shown in Figure 5, this embodiment employs an arrangement in which the film unwound from the film holding means 211 is given a constant tension by a dancer roller DR to stabilize the tension, and then the film is looped around two film feed shafts FS, FS so that it passes near the bottom of the mounting means, and then taken up by surplus film winding means 212.

[0026] The film suspending means 21, consisting of the film holding means 211 and the surplus film winding means 212, is configured to fit in the area above the weighing means 1 and the packaging means 2. However, the surplus film winding means 212 may be configured to extend into the rear area 3, or the console 6 may be located in a different position so that the film holding means 211 protrudes further forward. Even with such a configuration, it can be said that this is a technical concept for space saving that is clearly distinguishable from the conventional technology in which the film suspending means is located in a significantly protruding area outside the machine frame. Furthermore, even if the film holding means 211 and the surplus film winding means 212 are arranged in the opposite front-to-rear directions, this does not impair space saving, and the film holding means 211 may be arranged at the rear and the surplus film winding means 212 at the front.

[0027] In FIG. 1 , the side panel SP is pivotally supported on its right long side and configured to pivot rearward. This configuration allows the roll film R to be replaced from the right side, and the upper and lower die sets 24 and 25 to be replaced from the right side. Thus, the upper die set 24, film holding means 211, and surplus film winding means 212 can be attached and detached from the same orientation along the winding shaft during replacement. The lower die set 25 can also be attached and detached from the same orientation along the winding shaft. However, the lower die set 25 requires an additional replacement step of inserting it from the right side and then dropping it slightly downward. The label application means 7 can be tilted (rotated) rearward, facilitating replacement of the roll film R and replacement of the upper and lower die sets 24 and 25. The rotatable configuration also facilitates label replacement. The rotatable side panel SP may be located on the left side instead of the right side. In other words, the rotatable side panel SP does not have to be provided on the same side as the side on which the first discharge tray 4, etc. are arranged. However, in terms of space saving, it is advantageous to configure the side panel SP on the same side as the side on which the first discharge tray 4, etc. are arranged to be rotatable.

[0028] The top panel UP, front panel FP, and side panels SP of the machine frame are made of transparent material or have transparent plates fitted in them so that the state of the film suspended on the film suspension means 21 can be checked. In addition to visual check, the top panel UP is configured to be slidable rearward to a position where it does not come into contact with the label application means 7, so that any problems can be dealt with, and the front panel FP is also pivotally supported at its upper edge so that it can rotate. The front panel FP may also be pivotally supported at its lower edge, or it may be configured to be slidable.

[0029] As shown in Figures 5 and 6, an upper die holder 240, into which the upper die 24 is loaded, is provided between the film hanging means 21 and the transport space for the tray T (transported by the in-feed bar IB), and functions as a mounting means for replacing multiple die holders. The upper die holder 240 is provided with a locking mechanism that prevents the upper die 24 from being removed after it has been fully inserted and loaded. To remove the upper die 24, a lock release lever 24L must be operated (see Figure 9). The lock release lever 24L is configured to prevent the unlocking operation when it is inappropriate to remove the upper die, such as when the temperature is high, in conjunction with the die replacement process. The locking mechanism may be configured as an automatic locking mechanism. In this case, it is preferable to configure the locking operation and the unlocking prohibition operation to be linked to the temperature of the upper die 24 during the die replacement process.

[0030] The upper die holder 240 is provided with a heater means 241 (see FIG. 7( a)) for supplying heat for welding the film. The upper die 24 is provided with a metal plate 242 (as a top seal portion 242) (see FIG. 7( b)) for transmitting the heat supplied from the heater means 241, and a film cutting means 244 (see FIGS. 7( b) and 8) for cutting the film. The heater means 241 contacts the metal plate 242 of the upper die 24 loaded in the upper die holder 240. The metal plate 242 has a protrusion 242a whose size corresponds to the edge of the tray T and a central portion 242b surrounded by the protrusion 242a (see also FIG. 9( c)). The heat supplied from the heater means 241 is transmitted to the protrusion 242a, thereby heat-sealing the film in contact with the edge of the tray T at a predetermined heat-sealing temperature for a predetermined tray-sealing time.

[0031] In the embodiment of the present invention, aluminum, which has high thermal conductivity, is used as the material for the metal plate 242, but this does not prevent the use of silver, copper, gold, etc., which have higher thermal conductivity, and even if a material has a lower thermal conductivity than aluminum, it may also be used as long as there are no practical problems.

[0032] In the embodiment of the present invention, the metal plate 242 has a structure including a protrusion 242a corresponding to the edge of the tray T and an uneven shape, but the protrusion 242a and the central portion 242b are basically a single-piece structure composed of a single member. However, the metal plate may be configured by bonding two plates together and by extending a heat pipe between the two plates to conduct heat from the heater more quickly and more evenly over a wider area. Furthermore, because the protrusion 242a, which functions as a top seal, welds the film and the container, the central portion 242b, which is not located at the top seal, does not need to be hot. Rather, considering the risk of heat dissipation from the central portion 242b, it is preferable to configure the central portion 242b to have a heat-retaining material fixed thereto, and such a configuration may be used.

[0033] A temperature sensor (not shown) is provided near the upper die holder 240. The temperature sensor constitutes part of the die temperature calculation means. The temperature sensor may be provided near the heater means 241 or on a heat transfer member (described later). Essentially, the die temperature calculation means, upon receiving detection information from the temperature sensor, can determine the temperature of the metal plate 242 of the upper die 24 directly or indirectly by measuring current, voltage, thermography, or the like and performing appropriate calculations on the measured values. Specifically, the temperature of the upper die is directly detected by the temperature sensor, and the temperatures of the heater means and heat transfer member are also detected by the temperature sensor. Then, the temperature of the metal plate 242 of the upper die that contacts the edge of the tray T is calculated by a computer predictive calculation based on the temperature information and the thermal resistance and heat capacity of the heater means and heat transfer member. The calculated temperature information of the upper die 24 (metal plate 242) is used to execute various process controls for the die (described later) and packaging operation control that takes into account the optimum welding temperature. For this reason, the control unit of the packaging device 100 is provided with a means for determining whether or not the temperature measured by the temperature sensor is the appropriate welding temperature for packaging.

[0034] A lower die 25 is provided below the upper die holder 240, sandwiching the transport space for the trays T. The lower die 25 pushes up the trays T, and the film sequentially fed out from the roll film R loaded in the film hanging means 21 is clamped between the metal plate 242 of the upper die 24 and the lower die 25, and a packaging process (top sealing process) is performed at a predetermined heat sealing temperature for a predetermined tray sealing time. In this way, the film hanging means 21, the upper die 24, and the lower die 25 constitute the packaging means 2, which is disposed downstream of the weighing means 1 in the transport direction.

[0035] In this embodiment, the roll film R is supported by a shaft of the film holding means 211 passing through its center hole. The fed film is sealed with a metal plate 242 and cut to the size of the tray T by the film cutting means 244, leaving only the cut periphery, i.e., the film with the inside hollowed out. This film waste is then sequentially wound up by the surplus film winding means 212.

[0036] As shown in Figure 7(b), a metal plate 242 that functions as a top seal is disposed to face the fed film (see also Figure 8). When the tray T is moved upward by the lower die 25, the film is heat-sealed along the edge of the tray T at a predetermined heat-sealing temperature for a predetermined tray-sealing time, with the edge of the tray T and the film sandwiched between the lower die 25 and the metal plate 242 of the upper die 24. Before heat-sealing, a gas replacement process is performed in which an inert gas is injected into the space formed between the film and the tray T to extend the shelf life of the packaged goods, replacing the air with the inert gas.

[0037] (Conveying Operation by In-feed Bar) As shown in Figure 5, the in-feed bar IB, which is a conveying mechanism for trays T, is suspended at four circumferential positions on two left and right chains that can rotate around the entire circumference from the front of the weighing means 1 to the rear of the packaging means 2. As the chains rotate, trays T can be transported from the weighing means 1 to the packaging means 2, and then from the packaging means 2 to the rear area 3. Rollers 31 are placed in the space between the packaging means 2 and the rear area 3, allowing trays T to move smoothly from the packaging means 2 to the rear area 3. Since most of the items to be packaged are food, the metal in-feed bar IB is treated with antibacterial and anti-rust properties. The in-feed bar IB is connected to the chains via a total of eight in-feed bar support members IB1, which are provided at four circumferential positions on the two left and right chains.

[0038] The conveying operation of the infeed bar IB, which is connected to the chain serving as the drive unit and rotates as described above, will now be described. First, the tray T placed on the weighing means 1 is pushed by the infeed bar IB and transported to the packaging means 2, where the infeed bar IB stops. If this were to continue, the infeed bar IB would interfere with the infeed bar IB when the lower punching die 25 (described below) ascends, so the infeed bar IB temporarily retreats to the area where the weighing means 1 is located. As mentioned above, the spacing between the infeed bars IB in the circumferential direction is set so that when the infeed bar IB retreats, it will not interfere with the next packaged item placed on the weighing means 1. Once the infeed bar IB retreats, a shutter descends from above the front part of the machine frame, isolating the inside from the outside and ensuring safety. At this time, the infeed bar IB is located within the shutter. In other words, the shutter is not positioned exactly at the boundary between the weighing means 1 and the packaging means 2, but is located slightly within the area of ​​the weighing means 1. Because the in-feed bars IB are arranged intermittently in the circumferential direction, a shutter configuration that rises from below is also possible, as long as the chain portions arranged continuously in the circumferential direction are avoided. After the top of the tray T is sealed by the packaging means 2, the in-feed bar IB moves forward again and transports the tray T to the subsequent area 3. At this time, the rollers 31 ensure that the tray T is smoothly transported without falling between the packaging means 2 and the subsequent area 3. The height of the in-feed bar IB relative to the tray T placement surface is configured to be centered between the height of the bottom and top of the tray T, but the height may be changed as long as the tray T can be transported stably. This embodiment, configured as described above, allows packaged items to be transported from the weighing means through the packaging means to the subsequent area using a single transport means, significantly contributing to space and cost savings.

[0039] (Gas replacement and packaging operation by upper and lower die) Figure 7 is a front cross-sectional view illustrating the upper die and the upper die folder, where Figure 7(a) shows the upper die folder when the upper die is not loaded, Figure 7(b) shows the upper die alone, and Figure 7(c) shows the state in which the upper die is loaded into the upper die folder. Figure 8 is a diagram illustrating the upper die, where Figure 8(a) is a plan view, Figure 8(b) is a front view, Figure 8(c) is a bottom view, Figure 8(d) is an upper oblique view, and Figure 8(e) is a lower oblique view. Figure 11 is a diagram illustrating the lower die, where Figure 11(a) is a plan view, and Figure 11(b) is a side cross-sectional view. Figure 13 is an enlarged view of part A in Figure 11(b), rotated 90 degrees to show the state in which the lower die is horizontally positioned. FIG. 14 is a side cross-sectional view showing the change in state when the lower die is pushed up relative to the upper die.

[0040] As can be seen from comparing the front cross-sectional views of Figures 7(a) and 7(c), the upper cutting die 24 is loaded into the upper cutting die holder 240 by entering from the right side. That is, as described above, the upper cutting die 24, like the film holding means 211 and the surplus film winding means 212, is detachable from the right side of Figure 1, which is the same direction along the winding shaft. Also, as shown in Figure 7(b), the upper cutting die has a metal plate 242 that functions as a top seal when heat supplied from the heater means 241 is transferred, and a film cutting means 244 for cutting the film. As shown in Figure 8, the metal plate 242 has a chamfered rectangular shape to correspond to the edge of the tray T, and the film cutting means 244 is disposed on its periphery. The metal plate 242 also has a protrusion 242a sized to correspond to the edge of the tray T and a central portion 242b surrounded by the protrusion 242a (see also Figure 9(c)). The film cutting means 244 can cut the welded film to the size of the tray T. Although the heat from the heater means 241 is transferred only to the metal plate 242, a structure in which the heat is transferred to other metal parts is not excluded.

[0041] As shown in Fig. 7(a), when the upper die 24 is not loaded, the heater means 241 for supplying heat for film welding is positioned upward by a biasing means (not shown) (see also Figs. 10(b) and 10(d)). When the upper die 24 shown in Fig. 7(b) is inserted from the right side in the figure, the abutment portion at the tip of the upper die 24 abuts against the roller 2431 at the tip of the heater link 243, and the heater link 243 presses the heater means 241 downward as shown in Fig. 7(c) (see also Figs. 9(b) and 9(d)). The heater means 241 then comes into contact with the metal plate 242 of the upper die 24, enabling it to transmit heat for welding to the metal plate 242.

[0042] In this embodiment of the present invention, the heater means 241 is formed by drilling holes in an aluminum material and inserting cartridge heaters into the holes (see also FIG. 10(d)). However, it is also possible to use a silicon rubber heater, a plate heater, a plug-type heater, a sheathed heater, or the like. Furthermore, in addition to a heat conduction type heater, the heater type may be a convection type or a radiation type (radiation type), and is not limited to a heat conduction type.

[0043] The heater means may be configured to directly contact the metal plate 242 of the upper die 24, or may be configured to indirectly contact the heater means and the metal plate 242 by adding a heat transfer member with good thermal conductivity, such as gold, silver, copper, or aluminum, to the metal plate 242. For example, if the heater means has a small area relative to the size of the rectangular portion of the metal plate 242, heat transfer will be limited to the central area, resulting in poor efficiency. Therefore, as shown in FIG. 9( f), a heat transfer member HTM with good thermal conductivity and a size comparable to the area of ​​the metal plate 242 can be interposed between the heater means 241 and the metal plate 242 to effectively expand the area through which heat is transferred. If a heat transfer member HTM is provided, the thermal resistance and heat capacity of the heat transfer member HTM are taken into account when the upper die temperature calculation means calculates the temperature.

[0044] To package trays T of three different sizes (for example, large, medium, and small) by selecting and installing one die from among multiple die sizes, it is common to imagine providing a heater for each die. However, this requires the work of disconnecting and reconnecting the heat source connector each time the die is replaced, which is time-consuming. However, the packaging device 100 according to an embodiment of the present invention has the advantage that it does not require reconnecting the heater wires and does not require additional work to establish an electrical connection when replacing the upper die, making the replacement process simple and efficient.

[0045] As described above, the upper cutting die 24 is provided with a chamfered rectangular metal plate 242 whose size and shape correspond to the edge of the tray T, and the metal plate 242 is composed of a protruding portion 242a whose size corresponds to the edge of the tray T and a central portion 242b surrounded by the protruding portion 242a. In this embodiment, an upper cutting die for a large tray having a width of 150 mm and a depth of 150 mm, an upper cutting die for a medium-sized tray having a width of 150 mm and a depth of 120 mm, and an upper cutting die for a small tray having a width of 120 mm and a depth of 120 mm are prepared. Figure 8 shows an upper cutting die for a "medium" size tray. Meanwhile, Figure 9 shows an upper cutting die for a "large" size tray.

[0046] The metal plate 242 transfers heat supplied from a heater means 241 disposed inside the upper cutting die holder 240 to the film to perform top sealing. A cutting blade serving as a film cutting means 244 for cutting the film after top sealing is provided around the outer periphery of the chamfered rectangular metal plate 242. As shown in Figures 8 to 10, the film cutting means 244 is fixed to the main body of the upper cutting die 24. The metal plate 242 and the peripheral bottom plate 247 are connected to the main body of the upper cutting die 24 via a biasing means, and the biasing force of the former is set to be stronger than the biasing force of the latter. Therefore, when the edge of the tray T is abutted against the tray edge support portion 254 of the lower die 25 shown in Figure 11 and the lower die 25 is pushed upward, first the lower die 25 contacts the peripheral bottom plate 247 of the upper die 24, then the edge of the tray T contacts the metal plate 242, and finally the film pushed up by the tray T contacts the film cutting means 244.

[0047] The upper die 24 has three upper die holes 245 for detecting the die size, and one of these holes is filled in accordance with the size. The unfilled hole serves as a light-transmitting portion, and the filled hole functions as a light-shielding portion or a reflective portion.

[0048] If the side of the upper die 24 is gripped when the upper die 24 is removed from the upper die folder 240, the film cutting means 244 could fly out from the bottom of the upper die 24, which is dangerous. Therefore, the upper die 24 is provided with a gripping portion 246 for transportation, as shown in Figure 8. The presence of the gripping portion 246 for transportation causes the film cutting means 244 to fly out relatively downward when pressing to perform heat sealing, i.e., when the lower die 25 is pushed up, but when the upper die 24 is removed and held in the hand, the film cutting means 244 does not fly out relatively. The gripping portion 246 for transportation also contributes to preventing burns when the upper die 24 is held before it has fully cooled.

[0049] When attaching the upper cutting die 24 to the upper cutting die folder 240, the cutout portions 248 (see FIG. 8(d)) provided at the left and right lower ends of the upper cutting die 24 are first placed on rails 2401 on the left and right inner surfaces of the upper cutting die folder 240, and then the upper cutting die 24 can be easily loaded by sliding it (see also FIGS. 10(d) and 10(f)). When removing the upper cutting die 24 from the upper cutting die folder 240, the lock release lever 24L shown in FIG. 9 is pressed downward to release the lock, and then the drawer grip portion 24G is grasped and slid, and when most of the upper cutting die 24 protrudes, the transport grip portion 246 is grasped again to pull out the upper cutting die 24, thereby easily removing the upper cutting die 24.

[0050] 9 and 10 show the state in which an upper die is loaded into the upper die folder and the state in which an upper die is not loaded into the upper die folder. Figure 9 shows the state in which an upper die is loaded into the upper die folder, where Figure 9(a) is a plan view, Figure 9(b) is a front view, Figure 9(c) is a bottom view, Figure 9(d) is an upper oblique view, Figure 9(e) is a right side view, and Figure 9(f) is a conceptual diagram showing a heat transfer member. Figure 10 shows the state in which an upper die is not loaded into the upper die folder, where Figure 10(a) is a plan view, Figure 10(b) is a front view, Figure 10(c) is a bottom view, Figure 10(d) is an upper oblique view, Figure 10(e) is a right side view, and Figure 10(f) is an enlarged view of portion D in Figure 10(d). Unlike Figure 8, Figure 9 shows the state in which an upper die corresponding to a "large" size tray is loaded.

[0051] As can be seen by comparing Figures 9(b) and 10(b), or by comparing Figures 9(d) and 10(d), when the upper die 24 is loaded, the heater link 243 presses the heater means 241 downward, as shown in Figures 9(b) and 9(d), whereas when the upper die 24 is not loaded, as shown in Figures 10(b) and 10(d), the heater means 241 is positioned upward by a biasing means (not shown), and the heater link 243 also jumps upward along with it.

[0052] Figure 9(c) shows that the metal plate 242 is composed of a protrusion 242a having a size corresponding to the edge of the tray T and a central portion 242b surrounded by the protrusion 242a. Figure 10(d) shows that the heater means 241 is positioned upward by a biasing means (not shown), and a hole for inserting a cartridge heater can be seen.

[0053] 9(c) and 10(c), the extent of the heater means 241 is smaller than the size of the rectangular portion representing the extent of the metal plate 242. Therefore, as shown in Fig. 9(f), a heat transfer member HTM with good thermal conductivity and a size comparable to the extent of the metal plate 242 is interposed between the heater means 241 and the metal plate 242, thereby effectively expanding the area over which heat is transferred.

[0054] As shown in FIGS. 11( a) and 11(b), the lower die 25 includes a gas inlet 251 for gas replacement (gas flushing), a gas diffusion step 2510 connected to the gas inlet 251, and an air outlet 252. Because the area including the gas inlet 251 and the gas diffusion step 2510 is covered with a cover, the gas inlet 251 and the gas diffusion step 2510 are depicted by dashed lines in FIG. 11(a). The gas diffusion step 2510 has a triangular shape in top view, which provides gas with diffusibility that easily spreads laterally across the tray, as indicated by the hollow arrows in the figure. In FIG. 13, the dashed line F represents a film and also indicates the film support surface. However, because a cover covering the gas diffusion step 2510 and other components is located at the left end of the dashed line, only that area is depicted by a solid line. 13, the gas is diffused by the gas diffusion step 2510, enters the tray T, and is sent rearward, after which it finally turns downward and is discharged through the multiple air outlets 252. Note that the gas inlet 251 is located at the front (corresponding to the long side of the tray), while the air outlet 252 is located at the rear (corresponding to the opposing long side of the tray), but they may also be configured to be located on either side (either on both sides or on one side) corresponding to the short sides of the tray. Also, although the air outlet 252 is configured to communicate downward, it may also be configured to communicate rearward.

[0055] As shown in FIG. 11( a), the lower die 25 has three lower die holes 253 for detecting the die size, one of which is filled depending on the size. The unfilled holes function as light-transmitting portions, while the filled holes function as light-shielding or reflective portions. The tray T is raised by its edge being supported by a tray edge support portion 254 provided inside the lower die 25. The center of the lower die 25 is perforated vertically, and a tray bottom support means 26 is fixedly provided at this position on the housing (see FIG. 14). The tray bottom support means is configured to accommodate the size of the tray being used. For example, it may be configured to be interchangeable depending on the tray size being used, or it may be a sliding type whose depth can be adjusted depending on the tray size.

[0056] A method for attaching and detaching the lower die will be described using Figure 12. Figure 12 is a perspective view showing how the lower die is attached to and detached from the lower die folder. As shown in the figure, with the lower die 25 loaded in the lower die folder 250, the lower die 25 can be easily attached and detached to and from the lower die folder 250 by gripping the hole into which the tray falls inside the tray edge support portion 254 of the lower die 25, that is, by gripping the surrounding areas, i.e., the upper, lower, and inner surfaces.

[0057] The upper die 24, the upper die folder 240, and the lower die 25 cooperate to push up the tray T, perform a gas replacement process to extend the expiration date of the packaged items, and then perform the packaging process. This operation will be described. Figure 14 is a side cross-sectional view showing the change in state when the lower die is pushed up relative to the upper die. Figure 14(a) shows a state in which the lower die 25 has risen slightly from the lowest position, Figure 14(b) shows a state in which the lower die 25 has risen significantly and is in contact with the film F to form a closed space, and Figure 14(c) shows a state in which the lower die 25 continues to rise, contacts the metal plate 242, and then rises further, and the film F has been cut (cut out) by the film cutting means 244. Note that Figures 14(b) and 14(c) also show partial enlargements of parts B and C, respectively.

[0058] The tray T transported by the infeed bar IB from the weighing means 1 is initially supported at its bottom by the tray bottom support means 26. Thereafter, when the lower die 25 rises, support of the bottom of the tray T by the tray bottom support means 26 is taken over by support of the edge of the tray T by the tray edge support portion 254 of the lower die 25, as shown in FIG. 14( a). Thereafter, when the lower die 25 rises to the position shown in FIG. 14( b), a closed space is formed by the lower die 25 and the film F, and an inert gas is injected through the gas inlet 251 and the gas diffusion step 2510 to replace the air present in the space formed between the film F and the tray T. Instead, the air is discharged from the air outlet 252. This performs a gas replacement process (gas flush) to extend the shelf life of the packaged products. The lower die 25 continues to rise, and the edge of the tray T comes into contact with the metal plate 242 of the upper die 24 (this state is not shown; the lower die 25 is positioned at a height between Figures 14(b) and 14(c)). In this state, top sealing begins, and after heat sealing is performed at a predetermined heat sealing temperature for a predetermined tray sealing time, the lower die 25 rises further, and the excess film around the top-sealed film is cut off by the film cutting means 244. The settings of the heat sealing temperature and tray sealing time are basically linked to the PLU, as will be described later. Figure 14(c) shows that the edges of the film F and the tray T are sandwiched between the metal plate 242 of the upper die 24 and the tray edge support portion 254 of the lower die 25, with the cutting edge of the film cutting means 244 positioned below. The mechanism by which the edge of the tray T first comes into contact with the metal plate 242 and then with the film cutting means 244 is achieved by setting the downward biasing force of the metal plate 242 to be weaker than the biasing force of the film cutting means 244, and by configuring the metal plate 242 to retreat upward relative to the film cutting means 244.Although not shown in the figure, when the lower die 25 descends, support of the edge of the tray T by the tray edge support portion 254 of the lower die 25 is taken over by support of the bottom of the tray T by the tray bottom support means 26, and the tray T is then transported to the subsequent area 3 by the infeed bar IB.

[0059] (Regarding Detection of Compatibility of Upper and Lower Die) As described above, in the embodiment of the present invention, three types of upper and lower die dies are provided to accommodate three different sizes of trays T: large, medium, and small. The upper die 24 can be replaced by simply inserting it from the right side of the side panel SP, and the lower die 25 can be replaced by inserting it from the right side of the side panel SP and then dropping it down. Here, whether or not the correct size die has been loaded is an issue. Therefore, in the embodiment of the present invention, a device is provided to detect whether the correct upper die 24 and the correct lower die 25 have been loaded. That is, the upper die 24 has three upper die holes 245 as shown in FIG. 8, and the lower die 25 has three lower die holes 253 as shown in FIG. 11. One of these holes is filled in for each size. In the portions corresponding to both ends of the three holes, a light-emitting element is provided below the lower die 25, and a light-receiving element is provided above the upper die 24. In the portion corresponding to the center, a light-emitting element is provided above the upper die 24, and a light-receiving element is provided below the lower die 25. Normally, two lights should be received, but if the upper die 24 and the lower die 25 do not correspond, the light will be blocked by one of them, meaning that the upper and lower die do not match, and this can be detected. Based on this premise, the sizes of the die dies that are loaded together above and below can also be detected and determined according to the position of the holes, and if necessary, a notification is made by a display means, audio guidance, or notification means such as communication with another external device.

[0060] In this embodiment, the light travels in opposite directions at the ends and the center to reduce interference between adjacent beams. However, if there is no risk of light interference, the three beams may be aligned. Although only one of three holes is filled depending on the size, two may be filled. Filling one hole and detecting two holes is preferable because it increases the possibility of determining various situations. Furthermore, a reflective sensor may be used instead of a combination of a light-emitting element and a light-receiving element. In this case, the filled hole would be a reflective portion rather than a light-blocking portion. Instead of an optical sensor, other optical means, such as an image sensor, may be used to capture the characteristics of the upper and lower die sets and perform image analysis to determine the fit. In this case, even if the upper and lower die sets are not aligned, the upper and lower die sets can be separately determined. This embodiment, configured as described above, provides a highly effective packaging device without stopping the line due to mismatched upper and lower die sets.

[0061] Problems can also occur due to errors other than misalignment of the upper and lower die dies. During busy periods, other tasks besides packaging may interrupt the work, forcing workers to perform other tasks. Or, due to inexperienced workers operating the machine, they may forget to load the die itself. Even when they have forgotten to load the die, they may mistakenly assume that the die has been replaced and attempt to resume work. However, in embodiments of the present invention, if both the upper and lower die dies are not loaded, the light is not blocked from all three holes, and the light emitted from the three light-emitting elements is detected by all three light-receiving elements. By determining that the upper and lower die dies are loaded when all three sensors are on and providing a warning, further operational errors due to forgetting to load the upper and lower die dies can be prevented.

[0062] As described above, the three holes can detect misalignment of the upper and lower die dies and failure to load the upper and lower die dies, but there are cases where other types of mistakes can occur. If an interruption occurs during the replacement work, it is possible that the upper die dies have been replaced but the lower die dies have not been replaced and are not loaded, or vice versa. Another example of detecting compatibility of the upper and lower die dies that takes into account such cases of mistakes will be described below.

[0063] FIG. 15 shows an example in which holes are provided in five different positions for the upper die hole 245 and the lower die hole 253 (one hole is filled in the illustration, so it appears as four holes). The three-hole configuration, including the upper die hole 2451 for matching determination and the lower die hole 2531 for matching determination, and the mechanism of operation, such as determining a match when two sensors are turned on, are the same as those in the example described above. In addition, in another example, as shown in FIG. 15, the upper die 24 is provided with a hole 2452 for determining whether a lower die is not loaded, and the lower die 25 is provided with a hole 2532 for determining whether an upper die is not loaded. In another example of detecting compatibility between the upper and lower die, the hole 2452 for determining whether a lower die is not loaded and the hole 2532 for determining whether an upper die is not loaded are provided, so that the control means of the packaging device can determine whether the lower die is not loaded or the upper die is not loaded. Of course, it is also possible to determine if both the upper and lower dies are not loaded.

[0064] The mechanism of action of the determination will be explained using Figure 16. Here, the numbers 2 to 4 with circles (hereinafter referred to as O2 to O4, etc.) are the upper die hole for match determination 2451 or the lower die hole for match determination 2531. Also, O1 is the lower die non-loading determination hole 2452, and O5 is the upper die non-loading determination hole 2532. Note that the lower die hole opposite the lower die non-loading determination hole 2452 of the upper die 24 is filled, but it may also be configured so that no hole is drilled originally. The same applies to the upper die hole opposite the upper die non-loading determination hole 2532 of the lower die 25.

[0065] As shown in FIG. 16( a), if the sensor output at the corresponding positions of O2 and O3 is on, it is determined that a large-size die is loaded. Also, as shown in FIG. 16( b), if the sensor output at the corresponding positions of O2 and O4 is on, it is determined that a medium-size die is loaded. Also, as shown in FIG. 16( c), if the sensor output at the corresponding positions of O3 and O4 is on, it is determined that a small-size die is loaded. Although not shown, if only one sensor output is on, it means that the sizes of the upper and lower die dies do not match. In contrast, if three sensor outputs are on, it means that neither the upper nor lower die dies are loaded. The determination method of the other example described above has the same mechanism of action even in the example described above where only three holes are provided.

[0066] If only one of the upper and lower die dies is left unloaded, three sensors alone cannot detect this. However, five sensors can properly detect this. That is, as can be seen from FIG. 16(d), if the sensor output of O1 is on, this means that the upper die is loaded but the lower die is not. On the other hand, as can be seen from FIG. 16(e), if the sensor output of O5 is on, this means that the lower die is loaded but the upper die is not. If neither the upper nor lower die dies are loaded, as explained above, the sensor outputs of O2 to O4 are on. In addition, the sensor outputs of O1 and O5 are also on, meaning that all five sensor outputs are on. Note that other methods may also be used to determine this. For example, although the tray size of the upper die is determined by sensors O2 to O4, whether the upper die is loaded or not can be determined by providing a physical sensor for inserting the upper die 24 into the upper die folder 240 shown in Figure 9, and the tray size of the lower die can be determined by sensors O2 to O4, and whether the lower die is loaded or not can be determined by sensor O1. With this configuration, sensor O5 can be omitted.

[0067] In both the example with three holes and the example with five holes, the size information of the container linked to the product information is stored in an appropriate storage means, and it is possible to detect a difference between the determined sizes of the upper and lower cutters and the size of the container linked to the called-up product information, and to issue a notification using the notification means as necessary.In contrast to this, it is also possible to control the system so that a product that does not correspond to the set cutter is not called up, and to make the user aware that the cutter is not compatible by not being able to call up the product.

[0068] The means for determining the suitability of the die does not have to use holes, but may be other detection means. For example, a more intelligent method using the first and second imaging means C1 and C2 to capture images of the tray T, or conversely, a more primitive method, may be used. For example, the weight of the die may be measured, or marks or numbers may be written on the die so that the die number can be visually identified. Even if an imaging element is used, the die may be determined by reading a barcode displayed on the die rather than the physical characteristics of the die itself. However, in a system using optical means or other physical quantities, a sensor that can identify which upper and lower die are loaded can be provided, making it possible to determine which size die is loaded in each of the upper and lower die folders, which would be advantageous for display screen guidance, as described below. Specific examples of sensors include the first and second imaging means C1 and C2 described above. That is, the first imaging means C1 may be configured as a wide-angle camera so that it can image the upper die 24 at the same time as the tray T being carried into the machine frame, or may be configured as a camera that can swivel, so that it can capture the upper die 24. Of course, a dedicated imaging means for the upper die 24 may be prepared. Alternatively, a physical sensor or the like according to the size of each die may be used as appropriate.

[0069] (Regarding Various Processing for Cutting Dies) In this embodiment, the packaging device is devised to perform effective processing for the upper and lower cutting dies while taking into consideration the device characteristics of the packaging device. Specifically, the device is configured to be able to perform processing that contributes to appropriate packaging operations by utilizing temperature information obtained from the cutting die temperature measuring means and, depending on the situation, also utilizing compatibility detection information for the upper and lower cutting dies. This will be described using Figures 17 to 22.

[0070] Fig. 17 is a flow diagram showing the flow of various processes for the cutting die, and Figs. 18 to 22 are examples of screen layouts displayed on the display unit of the console 6. The processes performed for the cutting die will be described with reference to the flow diagram of Fig. 17.

[0071] When changing the upper and lower cutting dies, the "emergency stop" button is pressed to stop the packaging machine and then the die and film are replaced. However, in step 1, the "emergency stop" button 8 is pressed first (ST1). The "emergency stop" button 8 is a mechanical button (see FIGS. 1 and 5) located on the machine frame, but it does not necessarily have to be a mechanical button. Figure 18(a) shows the screen layout immediately after the "emergency stop" button 8 is pressed. The type of cutting die currently set is determined and displayed. In Figure 18(a), the fact that upper cutting die 24A and lower cutting die 25A for large trays are set is displayed along with size information that the die is 150 mm wide and 150 mm deep.

[0072] In step 2, it is determined whether or not the cutting die is to be replaced (ST2). That is, if the "Film Change" button is pressed on the screen of FIG. 18(a), this indicates that the operator has input his / her intention to replace the film, not the cutting die, and the determination in step 2 is NO. In step 3, film replacement or other work is performed (ST3). Examples of other work include work in a "pricing mode" in which only pricing labels are issued without packaging. To switch to the pricing mode, the "Manual Pricing" button is pressed, and then the display screen transitions to the "Weighing Screen (Packaging Pricing / Packaging / Price Screen)." Another example of work is cleaning the packaging machine.

[0073] On the other hand, when the "Replace Cutting Die" button is pressed on the screen of FIG. 18( a) to replace the cutting die, a button prompting "Start Cooling" is displayed, as shown in the screen layout of FIG. 18( b). In this embodiment, "Start Cooling" refers to stopping the heat supply from the heater means 241 and allowing natural cooling. Of course, if the device is equipped with a cooling means to protect the device body when the entire device is slightly overheated, this may be used to actively cool the device, or a special cooling means dedicated to the cutting die may be provided. Furthermore, as for the operation mode, for example, pressing the "Replace Cutting Die" button may be skipped so that cooling (natural cooling) begins immediately. The display of the operation screen is merely an example.

[0074] Returning to the flow chart, when the "Start Cooling" button is pressed in step 4, the natural cooling state is entered (ST4), and the display unit displays the screen layout shown in FIG. 19(a). As shown in FIG. 19(a), first, the information "Cooling" is displayed. In addition to the tray size information corresponding to the current cutting die, the current temperature calculated by the cutting die temperature calculation means is also displayed, that is, "90°C," and the optimum temperature for replacement is "35°C." Furthermore, the estimated time until the optimum temperature is reached is also displayed. The estimated time may be a time required for the temperature to reach the optimum temperature from the current temperature, which may be set in advance, or may be a required time calculated using a predetermined algorithm based on the current temperature, the outside air temperature (room temperature), etc.; this is merely a guideline.

[0075] If the "emergency stop" button 8 is released during cooling, a message will be displayed informing the user that "replacement has not yet been carried out," or asking whether it is necessary to resume packaging with the die currently being loaded without replacement, and then a confirmation screen will be displayed to confirm whether "reheating is necessary" or whether heating should be carried out to the appropriate welding temperature, making it possible to reheat the die.

[0076] Monitoring continues until the current temperature calculated by the die temperature calculation means reaches the optimum replacement temperature of 35°C (ST5). Once the optimum replacement temperature is reached, the screen layout shown in FIG. 19(b) is displayed. After confirming the messages "Cooling Complete" and "Now Replacing," the operator presses the "Cutting Die Change" button in step 6 to change the upper and lower die sets to those corresponding to the desired tray size (ST6). When the "Cutting Die Change" button is pressed, the packaging device 100 according to an embodiment of the present invention executes control to loosen the film by rotating the film support shaft or the winding side in a loosening direction, thereby facilitating die replacement. This is because the film and the upper die set 24 are very close to each other, and there is a risk that the upper die set 24 may get caught on the film when inserted or removed (see FIG. 4). The operator then performs die replacement and, upon completion of the operation, presses the "Replacement Complete" button (not shown). In step 7, the loading status of the upper and lower die sets is determined (ST7).

[0077] If the determination reveals a problem with the loading status of the die, a prominent error message is displayed, along with the details of the error. For example, as shown in FIG. 20( a), a message indicating that the upper die is not loaded is displayed with a "die match error" highlighted. The "start heating" button is not activated and cannot be pressed. After an operator viewing the screen shown in FIG. 20( a) loads an unloaded upper die and presses the "die replacement complete" button, the die loaded in each of the upper and lower dies is displayed. As a result, if the wrong size upper die is loaded, for example, a message indicating that the upper die is large and the lower die is medium, indicating a size mismatch, is displayed with a "die match error" highlighted, and the "start heating" button is not activated and cannot be pressed. However, this display mode applies only when a sensor capable of individually determining the upper and lower die is installed. If a different sensor is installed, the message simply indicates that the upper and lower die do not match.

[0078] On the other hand, if the determination result indicates that the sizes of the upper and lower cutting dies are consistent, for example, as shown in FIG. 20( b), the guidance screen displays that both the upper and lower cutting dies are medium size, and the "Start Heating" button is activated and displayed as being pressable. The size information display for the separate upper and lower cutting dies may then transition to a single size information display, such as "Medium (2) Tray 150w x 120D," as shown in FIG. 20. Alternatively, heating may be started together with the display of "Start Heating" without requiring a button press.

[0079] Alternatively, the button display may not even indicate the start of heating, but heating may be started if the upper and lower die match, and not started if they do not. However, it is desirable to configure the system so that the fact that heating is in progress can be recognized by a screen display, audio notification, signpost, etc. Furthermore, if it is detected that the upper die has been reattached during replacement, heating may be restarted, or heating may be restarted under certain conditions, such as a gradual restart. By implementing these controls, the time required to reach the appropriate welding temperature can be shortened.

[0080] Thereafter, monitoring continues until the current temperature calculated by the die temperature calculation means reaches 160°C, the optimum welding temperature (ST8). At this time, the guidance screen on the display unit indicates that both the upper die and the lower die are medium-sized, as shown in FIG. 17(a), and also indicates that the die is "heating." The heating status may be indicated by flashing a pilot lamp provided on the device housing or a sign pole located outside the housing. The current temperature calculated by the die temperature calculation means is also displayed as "38°C" and the welding temperature as "160°C." In addition, an estimated time until the welding temperature is reached may be displayed.

[0081] If the "emergency stop" button 8 is pressed to cancel the emergency stop state during heating, a warning such as "Possible packaging defects" is issued, and the packaging device 100 is prevented from switching to the "packaging mode" or "packaging pricing mode" among the multiple processing modes available for various operations until the heating temperature reaches the appropriate temperature. On the other hand, the "pricing mode," which performs weighing and pricing without packaging or issues only pricing labels, can be performed even during heating, so the "manual pricing" button is available on the screen in FIG. 17(a). Thus, the packaging device 100 according to an embodiment of the present invention includes a mode switching means capable of switching between a first processing mode, in which both the packaging means and the pricing means perform processing, and a second processing mode, in which only the pricing means performs processing. However, the mode switching means is configured to restrict switching to modes other than the second processing mode if the upper die is not within the appropriate temperature range for welding. In addition, the operation screen for the "pricing mode" may be configured to prohibit changing the processing mode when the temperature is not appropriate for welding, or may be configured to simply notify the user that the temperature is not appropriate without prohibiting the change.

[0082] Furthermore, in addition to manual pricing, which is a completely independent task from packaging, it is also possible to configure the system so that some of the weighing work related to packaging can be started in advance. That is, even if packaging is not yet at a stage where it is possible to properly perform packaging, the weighing work, which is a preliminary process, can be performed. For example, if the welding temperature is 160°C, it is possible to configure the system so that switching to the weighing screen is permitted when the welding temperature reaches 120°C.

[0083] In step 8, when it is determined that the welding temperature has been reached, i.e., that heating is complete (ST8), the screen layout shown in Figure 17(b) is displayed. After confirming the messages "Heating complete" and "Please release the emergency stop button," the operator presses the "Heating complete" button for confirmation, and then releases the "Emergency Stop" button 8, allowing the operator to start the packaging and pricing process. Note that the operation may be configured so that pressing the "Heating complete" button is omitted and the "Emergency Stop" button 8 is directly released.

[0084] Additional configurations and modifications relating to various processes for the cutting die will be described. The welding temperature range setting may vary depending on the materials and compatibility of the tray, film, etc., and is configured to be configurable for storage and retrieval. In this case, it is preferable to configure the welding temperature to be changed by changing the "tray" or "film" settings on the weighing screen. It is also possible to set a master that combines the types of tray and film, and change the temperature by specifying it from that master. It is also preferable to configure the system so that if the combination of tray and film is not appropriate, a warning message is displayed or a warning or attention-call sound such as a buzzer sounds.

[0085] Furthermore, for notifications during cooling and heating, in addition to the screen display on the display unit, a sign pole may be provided that lights up blue during cooling, flashes blue when the appropriate replacement temperature is reached, lights up red during heating, and flashes red when the appropriate welding temperature is reached. The degree to which the appropriate welding temperature has been reached during heating and the appropriate replacement temperature has been reached during cooling can be grasped by changing the notification mode, which has the advantage of allowing the operator to grasp the temperature status while performing other tasks even if the waiting time is relatively long, or to grasp the situation from a location far from the packaging device. Notifications regarding the appropriate welding temperature and the appropriate replacement temperature may be made in multiple stages, for example, by flashing until the temperature is reached and then turning on once the temperature is reached, and gradually increasing the flashing cycle until the temperature is reached.

[0086] When replacing the cutting dies, if the temperature is not appropriate for replacement, a message or voice may be issued to advise the user to wear insulated gloves when replacing. Furthermore, if a sensor for detecting the loading state of the cutting dies is provided, a notification that the temperature is not appropriate for replacement can be issued if the cutting dies are replaced when the temperature is not appropriate for replacement. Furthermore, if a locking mechanism is provided when the cutting dies are loaded, the lock may be inhibited from being released until the temperature reaches the appropriate temperature for replacement, or a special authority may be set for unlocking the lock so that it can be released by a special operation such as a password.

[0087] (Display example of judgment results on the weighing screen) Figure 22 is a diagram showing an example of the display of judgment results on the weighing screen. For the product name "Gauda Cheese," "Large (1)" is displayed in the "Tray type selection" field, and "Width 150 x Depth 150" is displayed in the tray dimensions field. "Width 150 x Depth 150" is set in the tray dimensions field for "Gauda Cheese," and in this case, the cutting die is "Large (1)," so the combination is correct. If a "Medium (2)" or "Small (3)" cutting die is loaded, the target tray dimensions will be "Width 150 x Depth 120" or "Width 120 x Depth 120," which would be a combination that results in a size error for "Gauda Cheese." Therefore, if the judgment result for the loading status of the upper and lower cutting dies is medium or small, a notification of a size error is issued. For example, to make it easier to recognize that a size error has occurred, the display may be changed from the usual display format to make it more noticeable, or a more straightforward message such as "Size error" may be displayed. Furthermore, the error may be notified by audio. Furthermore, if the combination is correct, the tray dimensions may not be changed. However, depending on the operation at the site, changing the tray dimensions to match the cutter, such as changing the "Gauda Cheese" tray dimensions of "150W x 150D" to "150W x 120D" or "120W x 120D," may be permitted. In such cases, the tray dimensions may be changed as an exception. In other words, if the corresponding tray is not available, the product may be packaged using another tray. Furthermore, if the operator has a vague memory of the product number and wants to try entering it several times, being notified of a size error each time can be a bit annoying, so the notification timing may be configured to be a little later, for example, when the operator actually weighs the product without noticing the size error.In addition, it also displays that the current processing mode is "packaging pricing mode" and that the "heat seal temperature" is "160°C".As for this temperature display, it may be made more noticeable by changing the display mode unless the temperature is at the appropriate temperature.For example, while it is still necessary to wait for heating, the display may be red, and when the appropriate temperature is reached, the display may change to green. Note that when the "pricing mode" is selected as the "packaging mode," no packaging work is performed, so the system is configured not to determine whether the die size associated with the called product matches the loaded die size and notify the user of the match. Of course, the system may be configured to perform the determination and notification for packaging work to be performed later.

[0088] (Regarding Packaging Operation Control Taking into Account the Optimal Welding Temperature) The packaging device 100 according to an embodiment of the present invention is designed to execute optimal packaging operation control that takes into account the optimal welding temperature by utilizing PLU setting information, tray setting information, and die setting information. In summary, an optimal welding temperature is set for each die, and in some cases, for each tray, and packaging operations are performed at the appropriate temperature. Therefore, if the die temperature is not at the appropriate setting, control is performed to prevent the packaging operation from starting by prohibiting packaging or by having packaging wait until the appropriate setting temperature is reached. Control is also performed to notify the user that the temperature is not appropriate and to notify the user of the time required to reach the appropriate temperature. These controls are executed according to the setting items used for the PLU setting, tray setting, and die setting, as shown in FIG. 23 .

[0089] The PLU setting information is essentially a set of setting information stored in a product information storage unit, including the product name, a PLU (Price Look Up) code that identifies the product, a thumbnail image showing the product design, whether the product is a fixed weight or variable weight, and the price of the corresponding product (expressed as (unit price x quantity) or (unit price x weight)). In addition, in the packaging device 100 according to an embodiment of the present invention, specifications related to packaging operation control are also stored in association with the PLU code. Specifically, the type of tray, type of gas, gas filling time, and gas injection speed are set for each PLU. The product information storage unit may be configured to be included in the packaging device 100 or an external device. In either configuration, the control unit of the packaging device 100 executes a control process to store information to be set and stored in association with the product in the product information storage unit.

[0090] The tray setting information includes the heat sealing temperature, tray sealing time, gas filling time, and gas injection speed set for each tray. The reason for the heat sealing temperature setting in the tray setting is that even if the same cutting die is used, the temperature suitable for heat sealing varies depending on the type of tray used, specifically, the material. For example, the temperature suitable for foam trays is 110°C, while the temperature suitable for resin trays is 180°C.

[0091] The die setting information includes the heat sealing temperature, tray sealing time, and gas filling time set for each die. The reason for the heat sealing temperature setting in the die setting is that the temperature suitable for heat sealing varies depending on the heat capacity of the die size.

[0092] Priorities are assigned to the PLU setting information, tray setting information, and cutter setting information. That is, as shown in ascending order in the table of Fig. 24, packaging operation control is determined in the order of priority: PLU setting information, tray setting information, and cutter setting information.

[0093] For example, for the PLU product number "0001," a gas fill time of 300 msec and a tray to be used of "000001" are set, so these gas fill time and tray to be used are determined as the control content. However, for the PLU product number "0002," although a tray to be used of "000002" is set, the gas fill time is set to automatic and no specific value is set, so the tray setting, which is the next priority, is referenced. And for the tray number "000002," a gas fill time of 250 msec is set, so this gas fill time is determined as the control content.

[0094] For the PLU product number "0003," the gas fill time is set to automatic in the PLU setting information, with no specific value set. Similarly, for the tray "000003" used, which is set for the PLU product number "0003," the gas fill time is also set to automatic in the tray settings, with no specific value set. Therefore, the die setting, which has the lowest priority, is referenced. Since "Tray Mold 3" is set for the tray "000003" used, and a gas fill time of 1800 msec is set for "Tray Mold 3," this gas fill time is determined as the control content.

[0095] The heat-sealing temperature is determined without reference to the PLU setting information. The packaging operation control is determined based on the tray setting information and then the cutter setting information, in that order. In the example shown in Figure 24, specific temperatures are set for the heat-sealing temperature of tray "000001," such as 160°C, and for tray "000002," such as 157°C. Meanwhile, the heat-sealing temperature of tray "000003" is set to automatic. In this way, when a specific value is not set and the automatic setting is used, the cutter setting is referenced. For tray "000003," "tray mold 3" is set, and a heat-sealing temperature of 180°C is set for "tray mold 3," so this heat-sealing temperature is determined as the control content.

[0096] As described above, packaging operation control refers to various controls for performing packaging operations at an appropriate temperature. More specifically, packaging operation control may include prohibiting packaging operations, delaying the start of packaging, cooling the die as a heat-generating member (basically natural cooling, but cooling by a cooling fan or Peltier element may also be used), heating the die as a heat-generating member, providing a notification regarding the appropriate welding temperature, and performing appropriate packaging operations or restricting or prohibiting inappropriate packaging operations. This will be described using Figures 25 to 33.

[0097] 25 is a diagram showing an example of the layout of the main menu that is displayed after the packaging device 100 according to the embodiment of the present invention is powered on and initialization processing is performed, or in response to a call operation. The example of the screen layout shown here is set at the time of product shipment, but the button allocation position, size, etc. can be changed by customizing the settings by a technician or sales representative.

[0098] In the screen layout shown in Figure 25, the A1 button is operated to execute the "packaging mode" which performs the top sealing process and label affixing process, while the A2 button is operated to execute the "pricing mode" which prints only pricing labels without packaging, assuming that the worker will manually affix the pricing labels to the products.

[0099] In the screen layout shown in Fig. 25, the A3 button is a button operated to call up a "setting mode" screen for selecting and confirming each of the items of PLU setting, tray setting, and cutter setting. The A4 button is a "training mode" button operated to call up a training menu for the operator to master the operation of the packaging device. In addition, the screen layout shown in Fig. 25 also has a "setup" button for setting up the entire packaging device.

[0100] The main menu shown in FIG. 25 may be configured to display the temperature status of the die, specifically, whether the die temperature is at the appropriate temperature, and if not, whether the die is cooling or heating. It may also be configured to display an approximate time until the die temperature reaches the appropriate temperature. Instead of or in addition to the display means, an audio output means for providing audio notification may be used. In addition to the screen display on the display unit, a sign pole may be provided to notify the user during cooling or heating. The sign pole may illuminate blue during cooling, flash blue when the appropriate replacement temperature is reached, illuminate red during heating, and flash red when the appropriate welding temperature is reached. The degree to which the appropriate welding temperature or the appropriate replacement temperature during cooling has been reached can be grasped by changing the notification mode. This has the advantage of allowing the user to grasp the temperature status while performing other tasks, even during relatively long standby times, or to grasp the situation from a location far from the packaging machine. The notification of the optimum welding temperature and optimum replacement temperature may be made in multiple stages, for example by flashing the light until the temperature is reached, and then turning on the light when the temperature is reached, and by gradually increasing the flashing cycle until the temperature is reached. This configuration can alert the operator and enable the operator to forecast future work.

[0101] On the screen shown in Fig. 25, touching A1 "wrapping mode" switches to the wrapping mode, and the screen transitions to the screen shown in Fig. 26. Fig. 26 is a diagram showing an example of the layout of the wrapping mode screen. The example of the screen layout shown here is set at the time of product shipment, but the button allocation position, size, etc. can be changed as desired by customizing the screen.

[0102] In the screen layout shown in FIG. 26 , B1 is a display area showing the temperature status of the cutting die. Specifically, it displays whether the temperature of the cutting die is at an appropriate temperature, or if not, whether it is cooling or heating. As mentioned above, the welding temperature suitable for heat sealing varies depending on the type of tray and cutting die used, and simply being warm is not sufficient. Therefore, cooling or heating is performed to ensure that the cutting die is at the appropriate temperature. In this embodiment, cooling is performed by natural cooling. However, if the device is equipped with a cooling means for protecting the device body when the entire device is slightly overheated, this may be used to actively cool the device, or a special cooling means dedicated to the cutting die, such as a fan or Peltier element, may be provided.

[0103] In the screen layout shown in Fig. 26, B2 is a button operated to call up a menu screen for setting packaging machine PLU data. B3 is a button operated to call up a menu screen for setting trays. B4 is a display area showing the current die temperature and the currently set temperature that is set as appropriate. In the example shown in Fig. 26, the current die temperature is displayed as 142°C and the set temperature is displayed as 157°C. Therefore, the display area B1 shows that the die is being heated.

[0104] In the screen layout shown in Figure 26, B5 is a display area showing the type of cutting die currently loaded. B6 is a display area showing the currently set tray sealing time. The tray sealing time changes depending on the type of cutting die and tray loaded.

[0105] In the screen layout shown in Fig. 26, B7 is a display area showing whether the product corresponding to the current PLU is a product that requires gas filling. B8 is a display area showing the type of gas to be used. In other words, when the PLU is changed, the display in B8 changes.

[0106] For example, if the heater status display area B1 on the screen shown in FIG. 26 displays "suitable temperature," the packaging operation begins when an operation to start top sealing is performed. That is, the packaging device 100 is equipped with a start means for starting top sealing. In this embodiment of the present invention, placing the packaged items on the weighing section automatically starts the weighing and packaging operations. That is, the weighing section doubles as the start means. Alternatively, the packaging operation may not begin simply by placing the packaged items on the weighing section, but may begin upon pressing a separately provided start button. In this case, the start button would be the start means. Regardless of the type of start means, when the start means is activated, a notification is provided by voice guidance or a screen display, making the operator aware that packaging is about to begin. On the other hand, a notification is also provided even if the start means is not activated. This notification is preferably made conspicuous, such as by using a pop-up menu. Below, an explanation is given using FIG. 27, which shows an example of a pop-up menu displayed in response to a packaging start command.

[0107] In reality, the heater status display area B1 on the screen shown in FIG. 26 displays "Heating," so even if an operation to start top sealing is performed, the packaging operation does not begin. In an embodiment of the present invention, when an item to be packaged is placed on the weighing section, a pop-up menu C1, as shown in FIG. 27, displays a message stating, "Packaging will be possible once the heater reaches a usable temperature. Please pick up the item and wait." The message may also include a message indicating the approximate time required for the die temperature to reach the appropriate setting. Thus, the packaging operation control in this embodiment prohibits the packaging operation from starting if the die temperature has not reached the appropriate set temperature. After the prohibition on packaging is lifted, the operator must place the packaged item removed in accordance with the notification on the weighing section again, i.e., perform the operation to start top sealing again. This configuration prevents situations in which heat sealing is not performed properly.

[0108] As a modified example, a pop-up menu may display a message stating, "Packaging will begin once the heater reaches a usable temperature. Please wait.", and the packaging operation control may be set to standby control. In this case, the message may include a display indicating the approximate time required for the die temperature to reach the appropriate setting. In this manner, the packaging operation control in this modified example prevents the packaging operation from starting if the die temperature has not reached the appropriate setting by waiting until the appropriate setting is reached. Once the prohibition on the packaging operation is lifted, the packaging operation is automatically started. This configuration also prevents situations where heat sealing is not performed properly.

[0109] (Packaging Operation Specifications in PLU Settings, Tray Settings, and Cutter Settings) As explained above, the packaging device 100 according to an embodiment of the present invention controls the packaging operation not to start if the temperature of the cutter die is not at the appropriate set temperature, for example by prohibiting packaging or by waiting until the temperature reaches the appropriate set temperature, and also controls the device to notify the user that the temperature is not appropriate and the time required to reach the appropriate temperature, but this is based on the assumption that the packaging operation specifications have also been set in the PLU settings, tray settings, and cutter die settings, as will be explained below.

[0110] Figure 28 is a diagram showing an example of the layout of a product master setting screen, Figure 29 is a diagram showing an example of the layout of a PLU setting screen, Figure 30 is a diagram showing an example of the layout of a tray setting screen, Figure 31 is a diagram showing an example of the layout of a setting screen for each tray, Figure 32 is a diagram showing an example of the layout of a setting screen for each cutting die, and Figure 33 is a diagram showing an example of the layout of a setting screen for each cutting die.

[0111] The information stored in the product information storage means, the so-called product master, includes the product name, price, multi-image showing the product design, and place of origin for each PLU (Price Look Up) code, which is a product identifier. However, a characteristic item of the present invention is the packaging operation specifications. Touching the button D1, "Packaging Machine PLU Data," on the product master setting screen shown in Figure 28 will transition to the screen shown in Figure 29.

[0112] The PLU setting screen shown in FIG. 29 allows the setting of label application control parameters associated with the PLU, and also allows the setting of packaging operation parameters, a characteristic feature of the present invention. Specifically, when the E1 gas filling time button shown in FIG. 29 is touched, a pull-down menu of fill time options is displayed, and the fill time can be set by touching the confirm button. In the example shown in FIG. 29, "automatic" is specified as the fill time. As mentioned above, specifying "automatic" means that control is performed according to the fill time specified in the tray setting, which is the next highest priority. If "automatic" is also specified in the tray setting, control is performed according to the fill time specified in the die setting, which is the next highest priority.

[0113] Furthermore, touching the E2 gas selection button shown in FIG. 29 displays a pull-down menu of gas types to be used, and touching the confirm button allows the user to select the gas type. In the example shown in FIG. 29, "Gas 1" is selected as the gas type. Thus, the device is configured to memorize the type of gas used for packaging, linked to the PLU. The packaging device 100 according to an embodiment of the present invention replaces air with an inert gas to extend the shelf life of the packaged items. It is desirable to use different gases depending on the type of packaged item. For example, beef will darken if it does not contain approximately 30% oxygen, so an inert gas containing a mixture of three gases—nitrogen, carbon dioxide, and oxygen—is used. However, chicken and pork do not darken, so an inert gas containing only two gases—nitrogen and carbon dioxide—is used.

[0114] Touching the "Tray" button D2 on the product master setting screen shown in Fig. 28 transitions to the tray selection screen shown in Fig. 30. The tray selection screen shown in Fig. 30 is a screen for selecting the tray to be set from Trays 1 to 5 shown in F1 and confirming the tray for which information is to be set by pressing the Confirm button F2 in order to set the heat seal temperature, tray sealing time, and gas filling time for each tray type. Here, selecting Tray 1, which has the identification number "000001," and operating the Confirm button transitions to the tray-specific setting screen shown in Fig. 31. Unlike the display in Fig. 28, if a tray has already been set in the product master, the tray number will be displayed, and in this case, the tray setting information will be referenced.

[0115] 31 is a diagram showing an example of the layout of a setting screen for each tray. Here, as shown in the tray identification number display area G1, the setting screen for tray "000001" is displayed. As shown in the display area G2, the heat seal temperature is set to 160°C, as shown in the display area G3, the tray seal time is set to 500 msec, and as shown in the display area G4, the gas filling time is set to 300 msec. By touching these display areas, a predetermined change menu is displayed in a pull-down menu, allowing the values ​​to be changed.

[0116] FIG. 32 is a diagram showing an example of the layout of a setting screen for each cutting die, in which the setting screen for "Cutting Die 1" is displayed. However, on the screen, "Cutting Die 1" is displayed as "Tray Die 1" as shown in the tab H1. As shown in the display area H2, the heat sealing temperature is set to 160°C, as shown in the display area H3, the tray sealing time is set to 1000 msec, and as shown in the display area H4, the gas filling time is set to 300 msec. By touching any of the display areas, a predetermined change menu is displayed in a pull-down menu, allowing the values ​​to be changed.

[0117] FIG. 33 is a diagram showing another display screen of an example layout of the setting screen for each cutting die, in which the setting screen for "Cutting Die 2" is displayed. However, on the screen, "Cutting Die 2" is displayed as "Tray Die 2" as shown in the tab I1. As shown in the display area I2, the heat sealing temperature is set to 157°C, as shown in the display area I3, the tray sealing time is set to 500 msec, and as shown in the display area I4, the gas filling time is set to 250 msec. By touching any of the display areas, a predetermined change menu is displayed in a pull-down menu, allowing the values ​​to be changed.

[0118] (Regarding Gas Replacement Processing) Gas replacement processing, which extends the shelf life of packaged products, is performed by replacing air with an inert gas. Inert gas is used to extend the shelf life of food products by adjusting the ratio of three gases: nitrogen, carbon dioxide, and oxygen. While oxygen may seem unnecessary, it is actually necessary to maintain the redness of meat. As mentioned above, gas can be efficiently delivered by injecting gas between the film and the container while the upper and lower die-cutting dies are closed. That is, gas injection time can be shortened by injecting gas through the gas inlet 251 while evacuating the air inside the die-cutting dies through the air outlet 252. Furthermore, since the gas inlet 251 is located on the side of the weighing means 1, gas can be injected from the same position even with die-cutting dies of different sizes. Furthermore, since the gas inlet 251 and air outlet 252 are located in the film conveyance direction, the film can be reliably covered without shifting left or right. Here, only one type of film is used to eliminate the need to change film for each tray size. The same is true for the trays T, which are all the same width and have different depths (however, multiple heights may be prepared, and as already mentioned, the materials may also be different), allowing for efficient use of film. Conventionally, most gas replacement packaging involves injecting gas into the bag during bag production. The present embodiment is highly significant in that it injects gas while the film is sandwiched between the bags, thereby achieving an efficient gas replacement process at the top seal.

[0119] The gas replacement time can be changed automatically or manually depending on the size of the tray T (large, medium, and small). Alternatively, the gas replacement time can be changed depending on the expiration date. The expiration date can be selected directly on the console 6, or a recommended expiration date can be linked to product information, and the gas replacement time can be automatically changed depending on the product selection. Furthermore, multiple gas inlets, for example, three dedicated gas inlets for nitrogen, carbon dioxide, and oxygen, can be provided, allowing the optimal gas ratio to be adjusted by setting or automatic control.

[0120] (Gas Switching Process Corresponding to Product Information) As described above, the packaging device 100 according to an embodiment of the present invention is configured to be able to switch the type of gas depending on the product. For example, when packaging beef, an inert gas mixture of three types of gases, nitrogen, carbon dioxide, and oxygen, is used, while when packaging chicken or pork, an inert gas mixture of two types of gases, nitrogen and carbon dioxide, is used. However, if the operator simply switches the gas selection, there is a risk that the packaging will not be performed properly, such as not extending the expiration date or causing discoloration of the product. Therefore, the packaging device 100 according to an embodiment of the present invention is designed to reliably use the optimal type of gas for each food being packaged.

[0121] The packaging device 100 according to an embodiment of the present invention is configured to associate the type of gas used for packaging with each product and store the associated information in a product information storage unit. The packaging device 100 according to an embodiment of the present invention is configured to set and store the type of gas used for packaging, and to automatically change the gas to be enclosed at a predetermined timing, for example, when the product is retrieved. The product information storage unit may be provided within the packaging device 100 or an external device. In either configuration, the control unit of the packaging device 100 executes a storage control process to set and store the type of gas used for packaging in the product information storage unit, corresponding to the product. Furthermore, the packaging device 100 according to an embodiment of the present invention is also capable of setting and storing not only the type of gas used for each product, but also the amount (force) of gas spray. For example, foods containing many small pieces, such as whitebait, rather than large solids like meat or fish, can be easily sprayed with gas, resulting in the particles scattering and getting into the gap between the film and the edge of the tray before sealing. For such products, it is preferable to reduce the amount of gas spray to perform gas replacement.

[0122] (Regarding the Cutting Die Storage Means) As described above, the packaging device 100 according to the embodiment of the present invention includes an upper cutting die storage means 24H and a lower cutting die storage means 25H as storage means capable of storing all types of cutting dies that are not loaded, eliminating the need to store unused cutting dies in a location separate from the packaging device itself. In this embodiment, the storage means is configured to store two unused cutting dies out of the three types of cutting dies. However, if the device can be made larger so that all three types of cutting dies can be stored without being loaded when the packaging device is not in use, this configuration is more efficient when it is likely that the device will start with any size cutting die.

[0123] Fig. 34 is a perspective view showing the state in which the upper and lower cutting dies are accommodated in the die accommodating means, and Fig. 35 is a right side view showing the state in which the upper and lower cutting dies are accommodated in the die accommodating means. Figs. 34(a) and 35(a) show the state in which the upper and lower cutting dies are accommodated, and Figs. 34(b) and 35(b) show the state in which the upper and lower cutting dies are not accommodated. Fig. 35(c) is an enlarged view of the lower right corner of the upper die accommodating means 24H in Fig. 35(a).

[0124] In Figures 34 and 35, upper die 24B for medium-sized trays and lower die 25B for medium-sized trays are loaded in a folder and are in use (not shown), upper die 24A for large trays and upper die 24C for small trays that are not loaded in a folder are stored in upper die storage means 24H, and lower die 25A for large trays and lower die 25C for small trays that are not loaded in a folder are stored in lower die storage means 25H.

[0125] Because the upper die holder 24H and the lower die holder 25H are disposed near the film, they are covered with protective members to prevent the heat from affecting the film. That is, they are covered with covers to prevent inadvertent heat transfer to the film. For these protective members, heat insulating or cooling materials can be appropriately used to reduce the heat effect. Alternatively, a cooling fan may be provided in addition to the protective members.

[0126] The upper die storage means 24H is configured to allow the upper die to be slidably attached and detached so that two upper die dies can be stored vertically and spaced apart. As shown in Figure 35 (c), the right and left ends of the lower part of the upper die 24 are L-shaped or inverted L-like, and the upper die storage means 24H is shaped like a rail that rises up in an inverted L-shaped or inverted L-like shape, and the lower part of the upper die 24 fits into the rail shape to slide. Note that this rail shape relationship is the same for the upper die 24 and the upper die folder 240, so that loading into the folder and storing into the die storage means can be performed by a similar sliding operation.

[0127] The lower die storage means 25H is configured to allow the lower die to be slidably attached and detached so that two lower die sets can be stored upright and spaced apart. The relationship between the ends of the die sets and the rail shape of the storage means is substantially the same as that for the upper die sets. In addition, to make it easier to remove the two lower die sets lined up side by side, one of the left and right sides of the housing of the storage means is shorter than the other.

[0128] (Electrical Configuration of Packaging Apparatus) The electrical configuration of the packaging apparatus 100, which controls the mechanical components and various processes described above, will now be described. FIG. 36 is a diagram illustrating an example of the electrical configuration of the packaging apparatus 100 according to an embodiment of the present invention. As shown in FIG. 36, the packaging apparatus 100 includes a control unit CU that acquires information from each component and performs various controls, such as monitoring and controlling the operation of each component's mechanical components and controlling the electrical circuits of each component. The components controlled by the control unit CU include the weighing unit 1, the in-feed bar IB as a conveying unit, the console 6 as an input / output unit or operating unit, the label application unit 7, the label issuing unit 73 associated with the label application unit, the shutter 11, the film hanging unit 21 for conveying the film, the upper and lower cutters 24 and 25, the top seal unit 242, the conveyor belt 31 as a discharge unit, and the buffer tank BT for gas replacement. The control unit CU and each component are electrically connected to each other via communication interface circuits, signal lines, and the like.

[0129] The control unit CU comprehensively controls each component of the packaging device 100. The control unit CU executes a control program, for example, to cause a computer to execute the functions of the present invention. The control unit CU has a CPU as an arithmetic and control circuit, and storage devices such as RAM and ROM as a memory unit, and other storage devices. The memory unit stores the control program and the like, as well as the characteristics of the trays, gas, etc.

[0130] The weighing means 1 measures the weight of the packaged items when a tray T carrying the packaged items is placed on it, and once the scale interval stabilizes, it transmits the weight information to the control unit CU. The control unit CU receives a signal from the weighing means 1 and starts the packaging process. Therefore, the weighing means 1 also serves as a start-up means for the packaging device.

[0131] After the control unit CU receives the weight information, the in-feed bar IB receives a drive command from the control unit CU to start operating, moves the tray T to a position within the machine casing where the top sealing process will be performed, and then stops temporarily. After the control unit CU receives information that the top sealing process has been completed, the in-feed bar IB receives a drive command from the control unit CU to resume operation, and the tray T is transported to the subsequent area 3. In this way, the in-feed bar IB functions as a transport means within the packaging device 100.

[0132] The console 6 has a display unit, speaker, numeric keypad, and touch panel, and functions as input / output means or operation means operated by an operator. The label pasting means 7 pastes product labels onto the trays T that have been weighed and packaged, and the label pasting means 7 is accompanied by a label issuing unit 73 that prints and issues product labels containing information such as the weighed weight, unit price, and price. The control unit CU also commands and controls the operation timing of the label pasting means 7 and the label issuing unit 73.

[0133] The shutter 11 receives an operation command from the control unit CU and functions to separate the inside and outside of the housing, ensuring safety. The film hanging means 21 transports the film using a film holding means 211 and an excess film winding means 212. The upper and lower die sets 24, 25 sandwich the film between them; specifically, the lower die set 25 pushes up the tray T to perform the packaging process. A top seal unit 242 is provided in association with the upper die set 24. The control unit CU commands and monitors the operation timing of these components.

[0134] The conveyor belt 31 starts operating upon receiving a drive command from the control unit CU, and functions as a discharge means for transporting the trays T transported to the subsequent area 3 laterally to discharge them outside the machine. The buffer tank BT is connected to a gas cylinder or the like installed outside the packaging device 100, and temporarily stores gas for gas replacement. The amount of gas remaining in the buffer tank BT is monitored by the control unit CU.

[0135] (Processing Flow During Normal Operation of the Packaging Device) An example of a processing flow when the packaging device 100 starts up (powered on) and performs packaging and labeling processes will be described with reference to FIGS. 37 to 41. In the start step shown in FIG. 37, the packaging device 100 starts operation when the power is turned on. In step S101, compatibility of the upper and lower die dies is detected. If it is determined that the upper and lower die dies are mismatched or that no die dies are loaded, heating of the die dies is stopped in step S102. At this stage, the initial screen is not yet displayed, so no error message is displayed. However, a special screen display may be activated to display an error message or an audio alert (such as a buzzer). In step S103, heating of the die dies begins, and then in step S104, a standby screen is displayed until the device starts up. The standby screen is configured to confirm the date, but this may be replaced with other information, or other information may be displayed, or no information may be displayed at all.

[0136] Just before the standby screen ends, a screen prompting the operator to press the reset button is displayed, and in step S105, the operator presses the reset button. Of course, the system may be configured so that the prompt screen is not displayed, assuming the operator is familiar with the operation method. When the reset button is pressed, in step S106, the packaging device 100 begins an empty run to verify whether the multiple components serving as operating units are properly operating. Specifically, the components performing the empty run are the infeed bar IB as a conveying means, the conveyor belt 31 as a discharging means, and the lower die 25, which moves up and down. The order of these empty runs can be set as appropriate, or they may be operated substantially simultaneously. Empty runs of other operating units (e.g., the label application means 7) may also be performed. Although not shown, if an empty run is not performed for any component due to some unforeseen event, the control unit CU, which monitors the situation, issues an error notification.

[0137] In step S107, because the reset button has been pressed, compatibility detection of the upper and lower cutting dies is performed again. If it is determined that the upper and lower cutting dies do not match, heating of the cutting dies is stopped in step S108. At this stage, the menu screen is already displayed on the display unit of the console 6, so an error message such as mismatch of the upper and lower cutting dies is displayed. On the other hand, if it is determined that the upper and lower cutting dies match, heating of the cutting dies continues (step S109). In step S110, it is determined whether film remains in the film holding means 211. A specific method for this determination is to slightly operate the film hanging means 21. If the dancer roller DR moves up and down and the sensor reacts, it is determined that film is present; if the dancer roller DR does not move up and down and the sensor does not react, it is determined that film is not present. If it is determined that no film remains, an error message is displayed in step S111. However, because film refilling or replacement can be performed in a location other than the cutting dies, heating of the cutting dies continues without being stopped. Figure 38 shows examples of error display screens, with Figure 38(a) showing the error screen in step S108 and Figure 38(b) showing the error screen in step S111. On the screen of Figure 38(a), a pop-up window PW1 displays a message saying, "The tray type and setting information do not match. Please check the settings and tray type." On the screen of Figure 38(b), a pop-up window PW2 displays a message saying, "There is no film left. Please replace with new film."

[0138] The processing order from step S106 to step S110 described so far is merely an example, and this order can be rearranged. For example, it may be possible to first determine whether film remains, then check the alignment of the upper and lower cutting dies, or finally perform an idle run to check whether the operation can be performed. Furthermore, other confirmation processes may be added. If steps S106 to S110 are performed normally, a weighing screen is displayed (step S112).

[0139] 39, with the weighing screen displayed in step S112, the operator operates the display (touch panel) of the console 6 to call up the product using the PLU code (step S113). Next, the operator places the product on the weighing means 1 (step S114). In step S115, when the scale interval of the weighing means 1 stabilizes, weight information is sent from the weighing means 1 to the control unit CU.

[0140] Prior to starting the packaging process, the control unit CU performs the confirmation process shown in steps S116 to S126. In step S116, it is determined whether the temperature of the die is at the appropriate sealing temperature. If it is not at the appropriate temperature, an error message is displayed in step S117. In step S118, it is determined whether the inserted die matches the die associated with the product. If they do not match, an error message is displayed in step S119, and the operator takes appropriate action. In step S120, it is determined whether the gas associated with the product matches the gas connected to the packaging machine. Examples of this include a case where gas 1 is selected even though no gas is associated with the product, or a case where gas 1 is selected even though gas 2 is associated with the product. If they do not match, an error message is displayed in step S121, and the operator takes appropriate action. In step S122, it is determined whether the remaining gas level is equal to or greater than a specified value. If it is not equal to or greater than the specified value, an error message is displayed in step S123, and the operator takes appropriate action. In step S124, it is determined whether the upper and lower cutting dies match. If they do not match, an error message is displayed in step S125, and the operator takes appropriate action. In step S126, it is determined whether there are sufficient labels remaining. If there are not enough labels, an error message is displayed in step S127, and the operator takes appropriate action.

[0141] Figure 40 shows examples of error display screens, with Figure 40(a) showing the error screen in step S117 and Figure 40(b) showing the error screen in step S119. In the screen of Figure 40(a), a pop-up window PW3 displays a message conveying the error, saying, "Wrapping will be possible once the heater reaches a usable temperature. Please remove the product and wait." In the screen of Figure 40(b), a pop-up window PW4 displays a message conveying the error, saying, "The tray type and setting information do not match," and a message conveying what the operator should do, saying, "Please check the settings and tray type." Seeing this, the operator will take the appropriate action, which is to check the settings and tray type.

[0142] The processing order from step S116 to step S126 described above is merely an example, and this order can be rearranged. Other confirmation processes may also be added. If steps S116 to S126 are executed normally, a command is received from the control unit CU to open the shutter (step S128).

[0143] 41, after the shutter is opened in step S128, in the next step S129, a tray T (a container containing products) is carried into the device by the in-feed bar IB. Although not shown, if the in-feed bar IB fails to operate due to some unforeseen event, the control unit CU, which monitors the situation, issues an error notification. In step S130, the film suspending means 21 feeds the film. As with step S129, although not shown, if the film feed fails due to some unforeseen event, the control unit CU, which monitors the situation, issues an error notification. In step S131, a label is issued by the label issuing unit 73 in preparation for the completion of the packaging process. The error notification in the event of an unforeseen event is the same as described above. In step S132, the lower punching die 25 pushes the tray T upward. The error notification in the event of an unforeseen event is the same as described above. In step S133, the air present in the space formed between the tray T and the film, which is always stretched and held at both ends by the film holding means 211 and the surplus film take-up means 212, is replaced with an inert gas. If an unexpected event occurs, an error notification is issued, as described above. In step S134, the film is heat-sealed and sealed at a predetermined heat-sealing temperature for a predetermined tray sealing time, and a top sealing process is performed until the film is cut. If an unexpected event occurs, an error notification is issued, as described above. In step S135, the in-feed bar IB again advances the tray T to the subsequent area 3. If an unexpected event occurs, an error notification is issued, as described above. In step S136, the conveyor belt 31 transports the tray T to a position where a label can be attached. If an unexpected event occurs, an error notification is issued, as described above. In step S137, the label attachment means 7 attaches a label to the tray T. In the event of an unexpected event, an error notification is made in the same manner as described above.

[0144] (Processing Flow for Another Example of Cutting Die Replacement Processing) The process of cutting die replacement that is not a process performed during normal operation of the packaging device has already been described using Figure 17, but other examples are also possible and will be described below. In the processing flow shown in Figure 17, after pressing the emergency stop button 8, a declaration is made that a "cutting die replacement" will be performed, i.e., the "cutting die replacement" button is pressed, and then the replacement process is performed. A similar declaration is made for "film replacement." However, while these cutting die and film replacements can be performed without any special declaration operation, another example is a mode in which cutting dies are replaced without a declaration.

[0145] 42 is a flow chart showing the process flow for die replacement in another embodiment. In step S201, the emergency stop button 8 is pressed. The emergency stop button 8 is not a dedicated button for die replacement, but is a button that is widely used for safely maintaining the packaging device 100. Therefore, step S202 does not indicate any special process by the device, but rather indicates that the operator intends to start die replacement.

[0146] When the reset button is pressed in step S203, it is determined in step S204 whether the upper and lower cutting dies match. If they do not match, an error message is displayed in step S205, and heating of the cutting dies is stopped and natural cooling is performed so that the cutting dies can be replaced. Alternatively, active cooling may be performed. Figure 43 shows an error screen displayed in step S205. The screen in Figure 43 displays information indicating an error that a mismatch between the upper and lower cutting dies has been detected, as well as a message indicating the action to be taken by the operator: "Press the [Emergency Stop] button and replace with a matching tray mold." On the other hand, if it is determined in step S204 that the upper and lower cutting dies match, heating of the cutting dies continues (step S206).

[0147] (Processing flow when the emergency stop button is pressed during packaging) The processing flow shown in Fig. 42 shows the case where the emergency stop button is pressed when packaging processing is not being performed, for example, in pricing mode, but it is also possible that the emergency stop button will be pressed during packaging, so the processing in that case will be explained below. Fig. 44 is a flow chart showing the flow of processing when the emergency stop button is pressed during packaging.

[0148] In step S301, the emergency stop button 8 is pressed, and at this time, the control unit CU determines that the packaging device 100 is actually in use in packaging mode and that a tray T has been carried into the packaging device 100. In step S302, it is determined whether or not a product is present in the packaging area. This determination can be made using a pair of optical sensors or imaging means arranged diagonally with respect to the packaging area. If it is determined that no product is present in the packaging area, the packaging device continues to overheat, but the operating mechanism remains stopped (step S303).

[0149] On the other hand, if it is determined that a product is present in the packaging area, step S304 waits for a predetermined time (e.g., 30 seconds) to pass. Until this time has passed, the packaging device continues to heat, but the operating mechanism remains stopped (step S305). However, once the predetermined time has passed, heating of the die is stopped (step S306). By performing this process, even if the emergency stop button 8 is pressed accidentally during packaging, heating of the die continues as long as it is within 30 seconds, allowing for a smooth return to packaging. Conversely, if 30 seconds have passed, it is assumed that the intention to replace the die has been confirmed, and heating is stopped to allow the die to cool naturally in preparation for replacement.

[0150] (Alternative Embodiments) While the embodiments described so far have been directed to weighing, packaging, and labeling, a dedicated packaging mode may be provided for packaging only. The dedicated packaging mode is suitable for fixed-price products that do not require weighing. Because there is no need to transport the products to a downstream area for labeling, the dedicated packaging mode may be configured such that the in-feed bar IB rotates in the reverse direction after packaging and ejects the tray to the front. Alternatively, the device may be configured as a dedicated device for packaging only. Even in this case, the technical concept of substantially simultaneously performing a gas replacement process to extend the expiration date of the packaged items and a top-seal packaging process is still included. Furthermore, the present invention also includes a device configuration that is specialized for packaging, rather than a mode switch to the dedicated packaging mode. In other words, the device may be configured without a weighing unit, a console for the weighing unit, a labeling unit, etc., as separate devices, and communicate with these separate devices to form a dedicated device for packaging only.

[0151] In the embodiment described above, the weighing means 1 is provided in the upstream stage of the packaging means 2, but the weighing function may also be provided at the position of the tray bottom support means 26 (see FIG. 14) or in the downstream area 3 (see FIG. 5). If the weighing function is provided in the downstream area 3, weighing and labeling will be performed after packaging. In addition, the weight to be measured at this time will include the tray weight, film weight, and gas weight, so it is preferable to tare and print the weight including these. Note that if the weighing function is provided in the tray bottom support means 26 or the downstream area 3, the area indicated by the dashed line "1" in FIG. 4 will simply be a loading area for transporting the packaged items into the device.

[0152] It is also possible to provide the packaging means at the front stage. That is, upper and lower die sets may be arranged in the area indicated by the dashed line "1" in Fig. 4, and the tray may be placed directly on the lower die set, after which weighing and labeling may be performed. In this case, the weighing function is provided in the tray bottom support means 26 or the rear stage area 3 described above. When this configuration is adopted, it is preferable to provide a shutter at the front of the front stage, which closes as soon as the tray is placed thereon, to ensure safety.

[0153] In the described embodiment, the inert gas is filled by a gas flush, which sprays gas to expel air. However, a gas replacement (in the narrow sense) approach may be used, in which the air is removed and then the gas is introduced. While this takes longer than a gas flush, it is advantageous in terms of gas diffusibility and the ability of the gas to reach every corner. In this case, the air outlet is initially configured as a suction port for removing air. In addition, in the described embodiment, the film is suspended in the same direction as the weighing unit 1, packaging unit 2, and downstream area 3 are vertically aligned from the front to the back of the device, and the tray width is set to a single size. However, the film may be suspended in a direction perpendicular to the weighing unit 1 and packaging unit 2, allowing the tray width to be changed for each tray size.

[0154] (Additional Note) The embodiments described in this specification can be considered as a highly effective packaging device that reduces the time the line is stopped even if an inappropriate condition such as forgetting to load a cutting die occurs, and the invention of this packaging device will be described below.

[0155] <Appendix 1> Packaging device A is a packaging device capable of replacing multiple cutters to seal film onto containers of multiple sizes, and is characterized by comprising upper and lower cutters corresponding to the multiple sizes of containers, and a determination means provided in the device body for determining the loading status of the cutters.

[0156] <Note 2> In the packaging device A, the determining means determines the sizes of the upper and lower cutting dies and whether they match.

[0157] <Appendix 3> In the packaging device A, the upper and lower cutting dies each have a plurality of translucent portions and / or reflective portions arranged in different ways depending on the type, the device main body has a plurality of optical sensors, and the determination means determines whether the upper and lower cutting dies match depending on the light detection status of the plurality of optical sensors.

[0158] <Supplementary Note 4> In the packaging device A, the determination means determines the loading status of the upper and lower cutters between the time the device is turned on and the time the product call screen is displayed, and includes a notification means that issues a notification in accordance with the determination result of the determination means.

[0159] <Appendix 5> In packaging device A, the determination means determines the loading status of the upper and lower cutters between the time the device is turned on and the time the product call screen is displayed, and includes a notification means that issues a notification in accordance with the determination result of the determination means, and a storage means that stores size information of containers linked to product information, and if the size of the cutter determined by the determination means differs from the size of the container linked to the called product information, the notification means issues a notification.

[0160] Furthermore, in the embodiment described in this specification, if the temperature setting is not appropriate for the object to be welded that is to be brought into contact with the cutting die, heat sealing will not be performed properly, and there are various problems in improving the effectiveness of the packaging device, but it can be thought of as a packaging device that can perform optimal packaging operations, as shown below.

[0161] <Supplementary Note 6> A packaging device B that uses a die to perform a top seal on an item to be packaged, comprising: a heating means for heating the die, a temperature measuring means for measuring the temperature of the die, a determining means for determining whether the temperature measured by the temperature measuring means is an appropriate welding temperature for packaging, a packaging means for welding and packaging the item to be packaged using the die, and a packaging operation control means for controlling the packaging operation in accordance with the result determined by the determining means. With the above configuration, it is possible to provide a packaging device that can perform packaging operations that take into account the appropriate welding temperature.

[0162] <Supplementary Note 7> In the packaging device B, the packaging operation control means does not start packaging until the temperature reaches the appropriate welding temperature. With the above configuration, it is possible to prevent the occurrence of a situation where the heat sealing is not performed appropriately.

[0163] The packaging device C is the packaging device B, further comprising an alarm means, and the packaging operation control means causes the alarm means to notify whether the measured temperature is the appropriate welding temperature for packaging. With the above configuration, it is possible to provide a packaging device that can alert an operator.

[0164] The packaging device C further includes a start means for starting the top sealing, and the notification means issues a notification when the start means is activated. With the above configuration, it is possible to provide a packaging device that can make the operator aware that packaging is about to begin.

[0165] In the packaging device C, the notification means notifies the operator of the time until the measured temperature reaches the optimum welding temperature for packaging. According to the above configuration, a packaging device can be provided that allows the operator to forecast future work.

[0166] The packaging device B is a packaging device D that refers to the heat-sealing temperature stored in tray setting information in which the specifications of packaging operation control are set for each tray as the optimum welding temperature. With the above configuration, it is possible to appropriately deal with situations in which the optimum temperature for heat sealing varies depending on the type of tray used, for example, tray size, or tray material even if the tray size is the same.

[0167] The packaging device B is a packaging device E that refers to the heat-sealing temperature stored in cutter setting information in which the specifications for packaging operation control are set for each cutter as the optimum welding temperature. With the above configuration, it is possible to appropriately deal with a situation in which the optimum temperature for heat sealing varies depending on the heat capacity of the cutter size.

[0168] In the packaging device D or E, the appropriate heat-sealing temperature to be referenced is prioritized in the order of tray setting information and cutter setting information. This configuration allows for more precise setting of the appropriate welding temperature. For example, even if the appropriate temperature is set according to the tray size at the very least, it is also possible to set more precise control according to the tray type.

[0169] <Summary of the Embodiments> [Technical Field] The present invention relates to a packaging device that covers a tray containing packaged items with a film and heat-seals the film to the edges of the tray. [Background Art] A conventional packaging device has been improved in convenience by configuring the packaged items to be placed on a loading platform and pushed into the device, and then automatically pushing the loading platform out of the device by a discharge mechanism after heat sealing (see, for example, Patent Document 1). [Prior Art Literature] [Patent Document] [Patent Document 1] JP 2003-261102 A [Summary of the Invention] [Problem to be Solved by the Invention] The packaging device described in Patent Document 1 has a drawback in that it requires a long time for one process because it heat-seals by rotating a heated roller. It is possible to eliminate the heated roller and bring the entire welding area into contact with the heated part and process it all at once, but implementing a packaging device in this manner leaves various areas that need improvement to improve its effectiveness. [Means for Solving the Problem] (1) As described above, one aspect of this embodiment is a packaging device (100) comprising an upper die (24), a lower die (25), a heating means for heating the upper die, a temperature measuring means for measuring the temperature of the upper die, a determining means for determining whether the temperature measured by the temperature measuring means is within an appropriate welding temperature range for packaging, and a packaging means (2) for welding and packaging an item to be packaged using the upper die and the lower die, wherein the determining means limits packaging control by the packaging means when it determines that the measured temperature is outside the appropriate welding temperature range. With the above configuration, it is possible to provide a packaging device that can effectively prevent packaging defects.

[0170] (2) One aspect of this embodiment is the packaging device (100) described in (1), further comprising a match determination means for determining that the upper die and the lower die are the same size, and the heating means controls heating when the match determination means determines that the upper die and the lower die do not match. With this configuration, the time required to reach the appropriate welding temperature can be shortened.

[0171] (3) One aspect of this embodiment is the packaging device (100) described in (1), further comprising a heating status notification means that, after the match determination means determines that the upper die and the lower die are matched, notifies the user in different ways until the heat source of the upper die reaches an appropriate welding temperature by the heating means and after the appropriate welding temperature has been reached. With this configuration, even if the waiting time is relatively long, the user can keep track of the temperature while performing other tasks.

[0172] (4) One aspect of this embodiment is the packaging device (100) described in (1), including a packaging control stop means (8) that stops packaging control, and a reception means that receives a request to replace the upper die that becomes effective when the packaging control stop means is executed, and the determination means is capable of determining whether the temperature measured by the temperature measurement means is an appropriate temperature for replacing the upper die, and upon reception by the reception means, determines whether the measured temperature is an appropriate temperature for replacing the upper die, and outputs a result of the determination indicating whether the temperature is appropriate for replacement or not. With the above configuration, it is possible to appropriately determine whether the temperature is appropriate for replacement, thereby enabling safe replacement of the die.

[0173] (5) One aspect of this embodiment is the packaging device (100) described in (1), comprising the packaging means (2), a pricing means (7) that prices the packaged items based on the printed information, and a mode switching means that can switch between at least a first processing mode in which processing is performed by the packaging means and the pricing means, and a second processing mode in which processing is performed by only the pricing means, and the mode switching means restricts switching to modes other than the second processing mode if the upper die is not within a temperature range appropriate for welding.With the above configuration, it is possible to provide a packaging device that can effectively prevent packaging defects while still being able to perform a "pricing mode" operation in which only pricing labels are issued without packaging.

[0174] (6) One aspect of this embodiment is a packaging device comprising: a heating means for heating a cutting die; a temperature measuring means for measuring the temperature of the cutting die; a packaging control stopping means for stopping packaging control; a determining means for determining whether the temperature measured by the temperature measuring means is an appropriate temperature for replacing the cutting die; and a receiving means for receiving a cutting die replacement operation that becomes effective upon execution of the packaging control stopping means, and an output means for outputting, upon receipt by the receiving means, whether the temperature is appropriate for replacement or not, depending on the determination result of the determining means. With the above configuration, it is possible to appropriately determine whether the temperature is appropriate for replacement, thereby enabling cutting dies to be replaced safely.

[0175] (7) One aspect of this embodiment is a packaging device that packages packaged items by heat sealing using a pair of cutter dies, the packaging device comprising: temperature measuring means for measuring the temperature of the pair of cutter dies; determining means for determining whether the pair of cutter dies are at a temperature suitable for heat sealing using the temperature measuring means; and control means for controlling the packaging of the packaged items in accordance with the determination result of the determining means. With the above configuration, it is possible to provide a packaging device that can effectively prevent packaging defects.

[0176] The packaging machine 100 according to an embodiment of the present invention has been described above in detail with reference to the drawings. However, the specific configuration is not limited to these embodiments, and design changes within the spirit and scope of the present invention are also encompassed within the scope of the present invention. For example, although the embodiment describes two gas systems, a configuration with three or more gas systems is also possible. Furthermore, instead of preparing gases for each food type, a gas supply system may be configured with three gas cylinders (nitrogen, carbon dioxide, and oxygen) prepared and with different mixture ratios of these gases. Furthermore, for example, in the embodiment, natural cooling is described as starting after the "Start Cooling" button is pressed. However, if a cooling device is provided to protect the device body, cooling can be considered to begin when the cooling device begins to operate. This aspect is also encompassed within the present invention. Similarly, with regard to heating, if the heat from the packaging operation prior to the die change is still higher than room temperature even after cooling, the metal plate will be heated when it comes into contact with the heater device before the heater device begins reheating after the die change is completed. This aspect is also encompassed within the present invention. As an add-on configuration, an automatic locking mechanism can be provided to secure the die in the installed state, and the locking mechanism can be configured so that it will not be released until the die has cooled to the appropriate temperature for replacement. While this configuration improves the safety of the packaging device, it does not constitute a separate inventive concept and is still included in the present invention. Furthermore, the invention disclosed in this specification is not limited to the overall configuration of the packaging device 100 according to the embodiment. In other words, it is not limited to the conveying flow shown in FIG. 3 or the sealing configuration shown in FIG. 14 , but should be considered as an invention of a broader concept of measuring the temperature of the die and then performing effective control. Furthermore, the object to be heated and the object to be measured for temperature can be the lower die instead of, or in addition to, the upper die.When the lower die is heated, for example, a tray with a welding layer on the edge of the tray may be used, and the lower die may heat the edge from behind the tray edge, melting the welding layer and welding the film pressed against the edge of the tray to form a top seal. Other configurations may also be employed. Furthermore, in the embodiments, the heat-sealing temperature is stored in the tray setting information, and a priority order is set in the order of PLU setting information, tray setting information, and die setting information, based on the premise that even with the same die, the optimum heat-sealing temperature varies depending on the type and material of the tray used. However, in a required specification where only a single type of tray is used, the heat-sealing temperature may not be stored in the tray setting information, but may be automatically set, i.e., by referring to other setting information, or the priority order may be set differently depending on the situation. Furthermore, although the embodiments have been described as a packaging device that performs a gas replacement process to extend the shelf life of packaged products, the fact that the optimum welding temperature varies depending on the die size and tray type remains the same even in packaging devices that do not perform a gas replacement process. In the embodiment, when the cutting die is replaced, packaging operation control is performed by changing the heat sealing temperature, tray sealing time, and gas filling time, but in a packaging device that does not involve gas replacement processing, the specifications for packaging operation control are solely related to heat sealing, such as the heat sealing temperature and tray sealing time. In this way, the object of the present invention to provide a packaging device that can perform optimal packaging operations should be understood in a broad sense, and at the same time, it should be understood that the present specification also presents the object in a narrow sense.

[0177] 100 Packaging device 1 Weighing means 2 Packaging means 21 Film hanging means 211 Film holding means 211L Film set shaft lever 212 Surplus film winding means 212L Winding shaft lever 24 Upper cutting die 24G Pull-out grip portion 24H Upper cutting die storage means 24L Lock release lever 240 Upper cutting die folder (mounting means) 2401 Rail 241 Heater means (heating means) 242 Metal plate (top seal portion) 242a Convex portion 242b Central portion 243 Heater link 244 Film cutting means 245 Upper cutting die hole 246 Grip portion during transportation 248 Notch portion 25 Lower cutting die (gas replacement means) 25H Lower cutting die storage means 251 Gas injection port 2510 Gas diffusion step portion 252 Air exhaust port 253 Lower die hole 26 Tray bottom support means 3 Rear area 4 First discharge table 5 Second discharge table 6 Console 7 Label application means 71 Label application means slide rail 72 Anti-tip leg 8 Emergency stop button IB Infeed bar HTM Heat transfer member BT1 Buffer tank 1 BT2 Buffer tank 2 T Tray R Roll film FS Film feed shaft DR Dancer roller A1 Packaging mode button A2 Price marking mode button A3 Setting mode button A4 Training mode button B1 Die temperature display area B2 PLU setting menu call button B3 Tray setting menu call button B4 Heat seal temperature display area B5 Die type display area B6 Tray sealing time display area B7 Gas filling presence / absence display area B8 Gas used display area C1 Pop-up menu D1 Packaging machine PLU data setting button D2 Tray setting button E1 Gas filling time setting button E2 Gas selection buttonF1 Tray type selection setting button F2 Confirm button G1 Tray identification number display area G2 Heat seal temperature display area G3 Tray sealing time display area G4 Gas filling time display area H1 Cutting die 1 tab H2 Heat seal temperature display area H3 Tray sealing time display area H4 Gas filling time display area I1 Cutting die 2 tab I2 Heat seal temperature display area I3 Tray sealing time display area I4 Gas filling time display area

Claims

1. A packaging device that uses a pair of die cutters to weld and package items, comprising: a temperature measuring means for measuring the temperature of the heated die cutters; a determining means for determining whether the temperature measured by said temperature measuring means is within an appropriate welding temperature range for packaging; and a control means for restricting packaging control by said packaging means when said determining means determines that the measured temperature is outside the appropriate temperature range for welding.

2. The packaging device according to claim 1, characterized in that the pair of die sets are composed of an upper die and a lower die, and are provided with a match determination means for determining that the upper die and the lower die are the same size, and the control means controls heating when the match determination means determines that the upper die and the lower die do not match in size.

3. A packaging device as described in claim 2, characterized in that it is provided with a heating status notification means that, after the match determination means determines that the upper die and the lower die are matched, issues a notification in different manners until the temperature of the heated die reaches the appropriate welding temperature and after the appropriate welding temperature has been reached.

4. A packaging device as described in claim 2 or 3, characterized in that the matching determination means determines the loading status of the upper and lower die sets between the time the packaging device is turned on and the time the product call screen is displayed, and is equipped with a notification means that issues a notification in accordance with the determination result of the matching determination means.

5. A packaging device as described in claim 1, comprising: a pricing means for pricing the packaged items based on the printed information of the packaged items; and a mode switching means for switching between at least a first processing mode in which the packaged items are welded and packaged and processing by the pricing means is performed, and a second processing mode in which processing is performed only by the pricing means, wherein the mode switching means restricts mode switching to modes other than the second processing mode when the upper cutting die is not within the temperature range appropriate for welding.

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