Tin badge production device and method

Abstract

Provided is a tin badge production device with which it is possible to automate the determination of a driving parameter for driving with an appropriate movement amount and output.　This tin badge production device comprises: a connection mechanism 6 for connecting a material of a tin badge to manufacture a tin badge; a connection motor 62 for driving the connection mechanism 6; a first loading mechanism 2, a transport mechanism 3, a peeling mechanism 4, a guide mechanism 5, a second loading mechanism 7, and a retrieval mechanism 8 that supply the material to the connection mechanism 6 or retrieve the tin badge; a first loading motor 22, a transport motor 35, a peeling motor 42, a guide motor 53, a second loading motor 72, and a retrieval motor 82 that drive the aforementioned mechanisms; and a controller 11. The controller 11 changes the output of the connection motor 62 to specify a first output at which a stationary state and a moving state of the connection mechanism 6 are switched, and determines output to the connection motor 62 on the basis of the first output.

Description

Can badge manufacturing device and method

[0001] The present disclosure relates to a can badge manufacturing device and method for manufacturing can badges.

[0002] There is a can badge manufacturing device that coats the surface of a front member with a medium on which an image is printed, and then joins a back member to the front member so that the peripheral portion of the medium that extends beyond the peripheral portion of the front member is sandwiched between the front and back members to produce a can badge.

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

[0004] A badge manufacturing device produces badges by moving and processing a material. To produce badges with precision, it is necessary to drive the structure for moving the material and the mold for processing the material with an appropriate movement amount and output. However, badge manufacturing devices are subject to individual differences due to manufacturing errors and other factors, as well as changes in device status due to the environment and usage conditions. To drive badge manufacturing devices with the appropriate movement amount and output, it is necessary to determine appropriate drive parameters for each device or depending on the device status.

[0005] The present disclosure aims to automate the determination of drive parameters for driving a can badge production device with an appropriate amount of movement and output.

[0006] (1) A can badge manufacturing device according to the present disclosure includes a first mechanism that manufactures can badges by connecting a material for the can badges, a first drive unit that drives the first mechanism, a second mechanism that supplies the material to the first mechanism or removes the can badges, a second drive unit that drives the second mechanism, and a controller. The controller changes the output of the first drive unit to identify a first output at which the first mechanism switches between a stationary state and a moving state, and determines an output to the first drive unit based on the first output.

[0007] With the above configuration, the output of the first drive unit can be automatically determined based on the minimum output required to move the first mechanism.

[0008] (2) The material includes a front member and a back member, the first mechanism has a first lower mold that supports the front member, a second lower mold that supports the back member, and a guide mechanism that guides the first lower mold and the second lower mold to a connection position, the first drive unit has a guide motor that drives the guide mechanism, and the controller may change the output of the guide motor as the first output to identify a guide output that switches the guide mechanism between a stationary state and a moving state, and determine the output to the guide motor based on the guide output.

[0009] The power to the guide motor can be automatically determined based on the minimum power required to move the guide mechanism.

[0010] (3) The first mechanism may be arranged at the connection position and have a connection mechanism that can be raised and lowered, the first drive unit may have a connection motor that drives the connection mechanism, and the controller may change the output of the connection motor to identify a first connection output at which the connection mechanism switches between a stationary state and a moving state, and may determine the output to the connection motor based on the first connection output.

[0011] The power to the connection motor can be automatically determined based on the minimum power required to move the connection mechanism.

[0012] (4) The controller may identify the first connection output when the connection mechanism is in contact with the first lower mold or the second lower mold.

[0013] (5) The controller may identify the first connection output when the connection mechanism is in contact with the second lower mold.

[0014] (6) The output to the connection motor may include a second output when the first lower mold and the connection mechanism come into contact with each other and a third output when the second lower mold and the connection mechanism come into contact with each other, and the controller may determine the output to the connection motor so that the third output is greater than the second output.

[0015] By making the third output greater than the second output, it is possible to increase the force required for connecting the back member more than that for connecting the front member.

[0016] (7) The controller may determine the travel distance of the first mechanism based on the drive amount for driving the first drive unit from a predetermined origin position to a stop position using the determined output to the first drive unit.

[0017] (8) The controller may control the second drive unit to determine the start and end points of the drive range of the second mechanism based on the drive amount for driving the second mechanism from the origin position to the stop position.

[0018] (9) The second mechanism has a first loading mechanism that loads the front member into the first lower mold and a second loading mechanism that loads the back member into the second lower mold, the second drive unit has a loading motor that drives the first loading mechanism and the second loading mechanism, the origin position is one end position of the movable range of each of the first loading mechanism and the second loading mechanism, and the controller may determine a position a predetermined distance from the origin position as the start point for each of the first loading mechanism and the second loading mechanism, and determine the other end position of the movable range relative to the origin position as the end point.

[0019] (10) The second mechanism may have a removal mechanism that removes the can badge produced by the first mechanism from the first mechanism, the second drive unit may have a removal motor that drives the removal mechanism, and the controller may determine a position that is a predetermined distance away from the origin position toward the stop position as the start point, and determine a position that is a predetermined distance away from the stop position toward the origin position as the end point.

[0020] (11) The controller may drive the removal mechanism from the origin position toward the stop position while the second lower mold is supporting the can badge, and determine the position where the drive of the removal mechanism stops as the stop position.

[0021] The position where the take-out mechanism collides with the can badge is set as the stop position, and the position where the take-out mechanism can adsorb the can badge without colliding with it is set as the end point.

[0022] (12) The second mechanism may have a peeling mechanism that peels off a specified area from a medium on which an image is recorded, the specified area including the image and to be supplied to the first mechanism, the second drive unit may have a peeling motor that drives the peeling mechanism, and the controller may determine a position that is a specified distance away from the origin position toward the stop position as the start point, and determine the stop position as the end point.

[0023] As a position a predetermined distance from the origin position to the stop position, for example, a position where the peeling mechanism does not reach one end of its movable range by inertia after driving stops is set as the start point, and the stop position is set as the end point.

[0024] (13) A device may include a first mechanism that produces a can badge by connecting material for the can badge, a first drive unit that drives the first mechanism, a second mechanism that supplies the material to the first mechanism or removes the can badge, a second drive unit that drives the second mechanism, and a controller, wherein the controller may control the second drive unit to determine a start point and an end point of a drive range of the second mechanism based on a drive amount for driving the second mechanism from a predetermined origin position to a stop position.

[0025] (14) A method according to the present disclosure is a method performed by a can badge manufacturing device that includes a first mechanism that produces a can badge by connecting material for the can badge, a first drive unit that drives the first mechanism, a second mechanism that supplies the material to the first mechanism or removes the can badge, and a second drive unit that drives the second mechanism, in which the output of the first drive unit is increased to identify a first output at which the first mechanism switches between a stationary state and a moving state, and the output to the first drive unit is determined based on the first output.

[0026] (15) The method disclosed herein is a method performed by a can badge manufacturing device that includes a first mechanism that produces a can badge by connecting material for the can badge, a first drive unit that drives the first mechanism, a second mechanism that supplies the material to the first mechanism or removes the can badge, and a second drive unit that drives the second mechanism, and includes controlling the second drive unit to start driving the second mechanism, which is located at a predetermined start position, and driving the second mechanism to a stop position where the second mechanism stops, and controlling the second drive unit to determine the start and end points of the driving range of the second mechanism based on the drive amount used to drive the second mechanism from a predetermined origin position to the stop position.

[0027] According to the present disclosure, it is possible to automate the determination of drive parameters for driving a can badge production device with an appropriate movement amount and output.

[0028] FIG. 1 is an external perspective view of the badge production apparatus 100. FIG. 2 is an external perspective view of the badge production apparatus 100 with the outer casing 101 removed. FIG. 3 is a top view of the badge production apparatus 100 with the outer casing 101 removed. FIG. 4 is a block diagram of the controller 11 of the badge production apparatus 100. FIG. 5 is a cross-sectional view of the badge. FIG. 6(A) is a plan view of the white backing F, and FIG. 6(B) is a plan view of the print medium W. FIG. 7 is a top view of the first loading mechanism 2. FIG. 8 is a side view of the transport mechanism 3. FIG. 9 is an external perspective view of the peeling mechanism 4. FIG. 10 is a top view of the guide mechanism 5. FIG. 11 is an external perspective view of the guide mechanism 5. FIG. 12 is a side view of the connection mechanism 6. FIG. 13 is a top view of the second loading mechanism 7. FIG. 14 is an external perspective view of the removal mechanism 8. FIG. 15 is a flowchart illustrating the automatic adjustment procedure of the badge production apparatus 100. FIG. 16 is a flowchart explaining the procedure for automatically adjusting the connection mechanism 6. FIG. 17(A) is a side view of the rotating cam 67 at the home position, FIG. 17(B) is a side view showing the state in which the upper mold M0 and the first lower mold M1 are in contact, and FIG. 17(C) is a side view showing the state in which connection is complete. FIG. 18 is a flowchart explaining the procedure for automatically adjusting the guide mechanism 5. FIG. 19(A) is a top view of the rotary support table 54 at the home position, and FIG. 19(B) is a top view of the rotary support table 54 with the second lower mold M2 in the connection position. FIG. 20 is a flowchart explaining the procedure for automatically adjusting the peeling mechanism 4. FIG. 21(A) is a side view of the peeling arm 45 at the home position, FIG. 21(B) is a side view showing the state in which the head main body 47b of the remaining portion pressing head 47 is in contact with the first lower mold M1, and FIG. 21(C) is a side view showing the state in which the peeling head 48 is pressed down and fixed. Figure 22 is a flowchart explaining the procedure for automatic adjustment of the take-out mechanism 8. Figure 23(A) is a side view of the take-out arm 83 in the home position (recovery position), and Figure 23(B) is a side view of the take-out arm 83 in the take-out position. Figure 24 is a flowchart explaining the procedure for automatic adjustment of the first loading mechanism 2. Figure 25(A) is a top view of the first loading slider 25 in the home position, and Figure 25(B) is a top view of the first loading slider 25 at the downstream end.

[0029] The following describes in detail the can badge manufacturing apparatus 100 according to an embodiment of the present disclosure. Note that the following embodiment is merely an example of the present disclosure, and it goes without saying that the embodiment can be modified as appropriate without departing from the spirit and scope of the present disclosure.

[0030] 1 to 3, the up-down direction Dz is defined based on the state in which the badge production apparatus 100 is installed and ready for use. The front-rear direction Dx is defined with the side where the conveying mechanism 3 is provided as the near side. The left-right direction Dy is defined when the badge production apparatus 100 is viewed from the front.

[0031] As shown in Figures 1 to 4, the badge production device 100 is mounted on the printing device 1. The badge production device 100 includes a first loading mechanism 2, a transport mechanism 3, a peeling mechanism 4, a guide mechanism 5, a connection mechanism 6, a second loading mechanism 7, a removal mechanism 8, and a controller 11. The guide mechanism 5 and the connection mechanism 6 constitute a first mechanism. The first mechanism produces badges by connecting badge materials. The first mechanism includes a first drive unit that drives the first mechanism. The first loading mechanism 2, the transport mechanism 3, the peeling mechanism 4, the second loading mechanism 7, and the removal mechanism 8 constitute a second mechanism that supplies materials or removes badges from the first mechanism, and includes a second drive unit that drives the second mechanism.

[0032] [Outline of the Can Badge] As shown in FIG. 5 , the can badge in this embodiment has a structure in which four materials are stacked in order: a backing member BE, a front member SE, a white backing sheet F, and a print medium W. In this embodiment, a transparent film is used as the print medium W. A mirror image of a predetermined image is printed on the surface of the transparent film facing the white backing sheet F (e.g., the back side), and a normal image is displayed on the front side of the can badge. Note that the print medium W is not limited to a transparent film. The size of the white backing sheet F and the print medium W may be, for example, L size (89 mm × 127 mm) or another size. In this embodiment, the can badge is removed by magnetic attraction, as described below, so a magnetic material such as tin-plated steel sheet is used as the material for the front member SE.

[0033] [Operation of the Can Badge Production Apparatus 100] When the can badge production apparatus 100 receives a signal instructing production of a can badge from the external device 12, it produces the can badge as follows.

[0034] The first loading mechanism 2 loads the front member SE into a first loading mold (hereinafter referred to as the "first lower mold") located at a material loading position (hereinafter referred to as the "loading position"). In Figure 10, the first lower mold M1 is located at the loading position P1. Behind the loading position P1, at a connection position (hereinafter simply referred to as the "connection position") where the materials of the can badges are connected by crimping, a second loading mold (hereinafter referred to as the "second lower mold") is located below the connection mold (hereinafter referred to as the "upper mold").

[0035] When the first loading mechanism 2 has completed loading the front member SE, the controller 11 inputs a signal indicating the completion of loading to the external device 12. The external device 12 inputs a signal to the printing device 1 to supply a white backing sheet F. The printing device 1 supplies the white backing sheet F to the transport mechanism 3. The transport mechanism 3 transports the white backing sheet F onto the front member SE loaded on the first lower mold M1. The peeling mechanism 4 uses the peeling head 48 to press and fix the connection portion Fb of the white backing sheet F on the front member SE ( FIG. 9 ).

[0036] With the peeling mechanism 4 pressing and fixing the connected portion Fb of the white mount F, the transport mechanism 3 transports the white mount F toward the collection box 9 ( FIG. 8 ). This breaks the connecting portion Fc and the linear weakened portion Fd of the white mount F. The connected portion Fb is peeled off and remains on the front member SE. The remaining portion Fa is discarded in the collection box 9. After that, the peeling mechanism 4 releases the pressure on the connected portion Fb, and the controller 11 inputs a signal indicating release of fixation to the external device 12. The external device 12 inputs a signal to the printing device 1 to supply the print medium W.

[0037] The printing device 1 prints a predetermined image on the backside of the connected portion Wb of the print medium W and supplies it to the transport mechanism 3. The transport mechanism 3 transports the print medium W onto the connected portion Fb of the white mount F. When the peeling mechanism 4 presses and fixes the connected portion Wb of the print medium W ( FIG. 9 ), the transport mechanism 3 peels the connected portion Wb from the print medium W and discards the remaining portion Wa in a collection box 9. The peeling mechanism 4 then releases the pressure.

[0038] The guide mechanism 5 guides the first lower mold M1, which is loaded with the connection portion Wb of the print medium W, the connection portion Fb of the white mount F, and the front member SE, from the loading position P1 to the connection position P2 ( FIG. 10 ). The connection mechanism 6, which can raise and lower the upper mold M0, presses the upper mold M0 against the first lower mold M1 at the connection position P2, connecting the connection portion Wb of the print medium W, the connection portion Fb of the white mount F, and the front member SE by crimping. The connected connection portion Wb of the print medium W, the connection portion Fb of the white mount F, and the front member SE are held by the upper mold M0. The connection mechanism 6 then returns the upper mold M0 upward.

[0039] The second loading mechanism 7 loads the backing member BE into the second lower mold M2, which is located at the loading position P1. The guide mechanism 5 guides the second lower mold M2, with the backing member BE loaded, from the loading position P1 to the connecting position P2. The connecting mechanism 6 presses the upper mold M0 against the second lower mold M2, connecting the connecting portion Wb of the print medium W, the connecting portion Fb of the white mount F, the front member SE, and the backing member BE by crimping, to form the can badge 200. When the upper mold M0 rises, the can badge 200 remains on the second lower mold M2. The guide mechanism 5 guides the second lower mold M2 from the connecting position P2 to the loading position P1. The removal mechanism 8 removes the can badge 200 from the second lower mold M2 and stores it in the can badge container 10.

[0040] [White Mounting Sheet F and Printing Medium W] As shown in FIG. 6A, the white mounting sheet F has a remaining portion Fa, a connected portion Fb, a connecting portion Fc, and a linear weak portion Fd.

[0041] The remaining portion Fa is a lug portion along which the conveying mechanism 3 conveys the white backing sheet F. The connected portion Fb is used as material for the can badge. The connected portion Fb is a predetermined area that is to be supplied to the guide mechanism 5 and the connection mechanism 6. The connected portion Fb has a shape that matches the front member SE, for example, a circular shape in a plan view. The connected portion Fb is biased toward the leading edge of the white backing sheet F in the conveying direction when the white backing sheet F is conveyed onto the first lower mold M1. The connected portion Fb is surrounded by the remaining portion Fa. The connecting portion Fc is the boundary portion between the remaining portion Fa and the connected portion Fb. The linear weak portion Fd is a straight line portion that connects the leading edge Fe1 in the conveying direction Dc1 and the connecting portion Fc over the shortest distance when the white backing sheet F is conveyed toward the first lower mold M1.

[0042] The connecting portion Fc and the linear weak portion Fd are weaker than the remaining portion Fa and the connected portion Fb and are more susceptible to breakage. The connecting portion Fc and the linear weak portion Fd may be, for example, recesses thinner than the connected portion Fb and the remaining portion Fa. The connecting portion Fc and the linear weak portion Fd may be formed by perforations that are the same thickness as the connected portion Fb and the remaining portion Fa, but that partially cut the connecting portion Fc and the linear weak portion Fd. When the peeling mechanism 4 presses and fixes the connected portion Fb of the white backing sheet F and the transport mechanism 3 attempts to transport the white backing sheet F, the connecting portion Fc and the linear weak portion Fd break, and the connected portion Fb peels off from the white backing sheet F. The configuration of the print medium W is basically the same as that of the white backing sheet F, as shown in FIG. 6B . However, an image is recorded on the connected portion Wb of the print medium W.

[0043] [Configuration of Controller 11] As shown in FIG. 4 , the controller 11 includes a control device 110, a first drive circuit 114, a second drive circuit 115, a third drive circuit 116, a fourth drive circuit 117, a fifth drive circuit 118, a sixth drive circuit 119, and a seventh drive circuit 120. The control device 110 includes a calculation unit 111, a memory unit 112, and an interface 113. The memory unit 112 is, for example, a read-only memory (ROM), a random access memory (RAM), a flash ROM, or a hard disk drive (HDD). The memory unit 112 stores firmware and parameters. The parameters include output values ​​and drive amounts for operating the badge production apparatus 100. The calculation unit 111 is, for example, a central processing unit (CPU) or a field programmable gate array (FPGA). By executing the firmware, the calculation unit 111 controls each component of the badge production apparatus 100 according to the parameters and automatically adjusts the parameters. The interface 113 connects the control device 110 and the external device 12. The external device 12 may be, for example, a personal computer or a mobile terminal such as a smartphone. The external device 12 has an application program for operating the badge production device 100. The external device 12 may use a GUI (Graphical User Interface) to accept user operations and display information related to the badge production device 100.

[0044] The first drive circuit 114 connects the first loading home sensor 21 and the first loading motor 22 of the first loading mechanism 2 to the control device 110. The second drive circuit 115 connects the first transport sensor 31, the second transport sensor 32, the third transport sensor 33, and the transport motor 35 of the transport mechanism 3 to the control device 110. The third drive circuit 116 connects the peeling home sensor 41 and the peeling motor 42 of the peeling mechanism 4 to the control device 110. The fourth drive circuit 117 connects the guide home sensor 51 and the guide motor 53 of the guide mechanism 5 to the control device 110. The fifth drive circuit 118 connects the connection home sensor 61 and the connection motor 62 of the connection mechanism 6 to the control device 110. The sixth drive circuit 119 connects the second loading home sensor 71 and the second loading motor 72 of the second loading mechanism 7 to the control device 110. The seventh drive circuit 120 connects the removal home sensor 81 and the removal motor 82 of the removal mechanism 8 to the control device 110. The first loading motor 22, the transport motor 35, the peeling motor 42, the guide motor 53, the connection motor 62, the second loading motor 72, and the removal motor 82 may be DC motors, or may be motors other than DC motors as long as the drive amount can be controlled. The first loading home sensor 21, the first transport sensor 31, the second transport sensor 32, the third transport sensor 33, the peeling home sensor 41, the guide home sensor 51, the connection home sensor 61, the second loading home sensor 71, and the removal home sensor 81 may be optical sensors that detect changes in light intensity due to the presence or absence of a detection target, or mechanical sensors that detect changes in the posture of a sensor member due to the presence or absence of a detection target. Alternatively, electrical sensors that detect the opening and closing of contacts due to the presence or absence of a detection target may be used.

[0045] [Configuration of First Loading Mechanism 2] The first loading mechanism 2 is disposed to the rear right of the loading position P1 ( FIG. 3 ). As shown in FIG. 7 , the first loading mechanism 2 includes a first loading home sensor 21, a first loading motor 22, a first loading stocker 23, a first loading slope 24, a first loading slider 25, and a first loading light shielding piece 26. The first loading home sensor 21 is an optical sensor. The side of the first loading slider 25 toward the loading position P1 in the movement direction D2 is referred to as the downstream side, and the other side is referred to as the upstream side. The rotation axis of the first loading motor 22 is perpendicular to the main surface of the first loading slider 25.

[0046] A pinion gear (not shown) is attached to the rotating shaft 22a of the first loading motor 22. The first loading stocker 23 is a cylindrical member whose longitudinal direction is the vertical direction Dz and accommodates front members SE. In FIG. 7 , front members SE that are generally circular in top view are stacked in the vertical direction Dz within the first loading stocker 23. Of the front members SE within the first loading stocker 23, the lowest front member SE is placed on the first loading slope 24.

[0047] The first loading slope 24 has a guide surface that guides the surface member SE and the first loading slider 25 along the D2 direction. The first loading slope 24 has an upstream first loading stopper and a downstream first loading stopper, both not shown. The upstream first loading stopper abuts against the upstream end of the first loading slider 25, thereby defining the upstream end (origin position) of the movable range of the first loading slider 25. The downstream first loading stopper abuts against the downstream end of the first loading slider 25, thereby defining the downstream end of the movable range of the first loading slider 25. A gap is provided between the guide surface of the first loading slope 24 and the lower end of the first loading stocker 23, allowing just one surface member SE to pass through.

[0048] The first loading slider 25 is a flat member and has a rack gear 25a on its side when viewed from above. The rack gear 25a meshes with the pinion gear of the first loading motor 22. When the controller 11 drives and rotates the first loading motor 22, the first loading slider 25 moves back and forth on the first loading slope 24 in the direction D2. The first loading slider 25 is provided with a first loading light blocking piece 26. When the first loading slider 25 is in the origin position, the first loading light blocking piece 26 blocks the detection light of the first loading home sensor 21. This allows the first loading slider 25 to be detected as being in the home position.

[0049] [Operation of the First Loading Mechanism 2] When the first loading light-shielding piece 26 blocks the detection light of the first loading home sensor 21, the first loading home sensor 21 outputs a detection signal indicating that the detection light has been blocked to the controller 11. Upon receiving this detection signal, the controller 11 determines that the first loading slider 25 is at the home position. When loading a face member SE, the controller 11 rotates the first loading motor 22 to move the first loading slider 25 from the home position toward the first lower mold M1. When the first loading slider 25 reaches the first loading stocker 23, it abuts against the lowest face member SE and transports it. When the controller 11 drives the first loading motor 22 by a predetermined drive amount, the first loading slider 25 abuts against the downstream first loading stopper, and the face member SE is loaded from the first loading slope 24 into the first lower mold M1. Thereafter, the first loading slider 25 returns to the original position.

[0050] [Printing Device 1] The printing device 1 supplies a white backing sheet F and a print medium W on which a predetermined image is printed as materials for the badges to the transport mechanism 3 of the badge production device 100. In this embodiment, the printing device 1 is an inkjet printer. The printing device 1 includes a sheet holder (not shown) that accommodates the white backing sheet F and the print medium W. As shown in FIG. 8 , the printing device 1 includes a paper feed roller 102, a platen 103, an ejection head 104, and an ejection roller 105. The paper feed roller 102 feeds the white backing sheet F or the print medium W from the sheet holder onto the platen 103. The ejection head 104 ejects ink according to image data to form an image on the connected portion Wb of the print medium W. The printing device 1 does not form an image on the white backing sheet F. The ejection roller 105 ejects the white backing sheet F and the print medium W toward the receiving port of the transport mechanism 3.

[0051] The inkjet printer used as the printing device 1 may have a serial head or a line head type ejection head for ejecting ink. Furthermore, the printing device 1 may be an inkjet printer or a printer other than an inkjet printer, such as a laser printer or a thermal printer. An application program installed on the external device 12 may send image data to the printing device 1 to be printed. Furthermore, the printing device 1 may acquire image data from an imaging device such as a camera that captures an image and generates image data, a reading device that reads an image from a document and generates image data, a storage medium that stores image data, or a computer having a storage device that stores image data. Furthermore, the printing device 1 may acquire image data from a remote device via a communication network and print a predetermined image on the printing medium W using the acquired image data.

[0052] [Configuration of Transport Mechanism 3] The transport mechanism 3 is disposed in front of the badge production apparatus 100, at a position where the printing device 1 supplies the white backing sheet F and the print medium W. As shown in FIG. 8 , the transport mechanism 3 includes a first transport sensor 31, a second transport sensor 32, a third transport sensor 33, a transport motor 35, transport rollers Ro1 to Ro12, a transport guide 36, a first transport guide piece 37, a second transport guide piece 38, a support plate 39, and a transport stopper S. The first transport sensor 31 detects the white backing sheet F and the print medium W at the receiving opening that receives the white backing sheet F and the print medium W from the printing device 1. The second transport sensor 32 detects the white backing sheet F and the print medium W at a position where the first transport guide piece 37 changes the transport direction of the white backing sheet F and the print medium W. The third transport sensor 33 detects the white backing sheet F and the print medium W between the transport rollers Ro9, Ro10 and the transport rollers Ro11, Ro12. The transport stopper S is disposed upright on the rotation shaft 54b of the rotary support table 54 of the guide mechanism 5. The transport stopper S also serves as a support for the connection support plate 68 of the connection mechanism 6.

[0053] A transport motor 35 drives and rotates the transport rollers Ro1 to Ro12. The rotation of the transport motor 35 is transmitted to the transport rollers Ro1 to Ro12 via a drive transmission mechanism such as gears and belts. The transport rollers Ro1 to Ro12 transport the white backing F and the print medium W. A transport guide 36, a first transport guide piece 37, and a second transport guide piece 38 guide the white backing F and the print medium W. The transport guide 36 has a pair of transport guide plates 36a and 36b. A support plate 39 supports the first transport sensor 31, the second transport sensor 32, the third transport sensor 33, the transport motor 35, the transport rollers Ro1 to Ro12, the transport guide 36, the first transport guide piece 37, and the second transport guide piece 38. A transport stopper S restricts the transport of the white backing F and the print medium W that are transported beyond the first lower mold M1.

[0054] [Operation of the Transport Mechanism 3] The printing device 1 supplies a white backing sheet F or print medium W to the transport mechanism 3. When the first transport sensor 31 detects the supplied white backing sheet F or print medium W, it outputs a detection signal to the second drive circuit 115. When the controller 11 receives the detection signal from the first transport sensor 31, it drives the transport motor 35 to rotate and causes the transport rollers Ro1 to Ro12 to transport the white backing sheet F or print medium W. The transport guide 36 changes the traveling direction of the white backing sheet F or print medium W, which is output from rear to front in the front-rear direction Dx, to from bottom to top in the up-down direction Dz. Because the stiffness of the white backing sheet F and the print medium W differ depending on the material and environmental conditions, they do not always travel the same path. To account for variations in the path, the distance between the pair of transport guide plates 36a, 36b is set sufficiently wide relative to the thickness of the white backing sheet F or print medium W. The transport rollers Ro1 to Ro10 transport the white backing sheet F and the print medium W to the first lower mold M1 along the transport guide 36 and the first transport guide piece 37. The first transport guide piece 37 curves the transport path of the white backing sheet F and the print medium W.

[0055] The second transport sensor 32 detects the white liner F and the print medium W at the curved portion of the transport path. The transport motor 35 has a rotary encoder. The rotary encoder of the transport motor 35 outputs a pulse signal each time the transport motor 35 rotates a predetermined rotation angle. By counting these pulse signals, the controller 11 detects the drive amount of the transport motor 35. The drive amount of the transport motor 35 is proportional to the transport distance between the white liner F and the print medium W. The controller 11 stops the rotation of the transport motor 35 when the drive amount of the transport motor 35 reaches a predetermined drive amount. This predetermined drive amount corresponds to the transport distance from the detection position of the first transport sensor 31 to the first lower mold M1. After that, when the peeling mechanism 4 presses and fixes the white liner F or the print medium W, the controller 11 reverses the rotation direction of the transport motor 35 and drives it to rotate. The transport rollers Ro9 to Ro12 transport the white liner F or the print medium W along the second transport guide piece 38 to the collection box 9.

[0056] [Configuration of Peeling Mechanism 4] The peeling mechanism 4 is disposed to the left front of the loading position P1 so as to face the first loading mechanism 2 across the loading position P1 ( FIG. 3 ). As shown in FIGS. 9 , 21(A), 21(B), and 21(C), the peeling mechanism 4 has a support wall 40, a peeling home sensor 41, a peeling motor 42, a speed reduction mechanism 43, a connecting shaft 44, a peeling arm 45, a support block 46, a remaining portion push-down head 47, a peeling head 48, and a peeling light-shielding piece 49.

[0057] The support wall 40 supports a peeling home sensor 41, a peeling motor 42, a speed reduction mechanism 43, a connecting shaft 44, a peeling arm 45, a support block 46, a residual portion pressing head 47, a peeling head 48, and a peeling light-shielding piece 49. The peeling home sensor 41 is an optical sensor. The peeling motor 42 is driven and controlled by the controller 11. The speed reduction mechanism 43 has a reduction gear and transmits the rotational driving force of the peeling motor 42 to the connecting shaft 44. The connecting shaft 44 is a rotation shaft of the peeling arm 45. When the connecting shaft 44 is rotationally driven, the peeling arm 45 rotates in a rotation direction D4 between a standby position and a pressing and fixing position in accordance with the rotational movement of the connecting shaft 44. The standby position is the position of the peeling arm 45 shown in FIG. 21(A). The pressing and fixing position is the position of the peeling arm 45 shown in FIG. 21(C).

[0058] A support block 46 is connected to the tip of the peeling arm 45. The support block 46 supports the peeling head 48. The remaining portion pressing head 47 has a support shaft 47a, a head main body 47b, and a spring 47c. The head main body 47b is connected to one end of the support shaft 47a. The other end of the support shaft 47a is connected to the spring 47c. When the peeling head 48 is in the pressing and fixing position, the support shaft 47a extends along the transport direction of the white backing sheet F and the print medium W. The spring 47c biases the head main body 47b toward the remaining portion Fa of the white backing sheet F and the remaining portion Wa of the print medium W. A peeling light shielding piece 49 is provided on the peeling arm 45. When the peeling arm 45 is in the home position, the peeling light shielding piece 49 blocks the detection light of the peeling home sensor 41. This allows the peeling home sensor 41 to detect that the peeling arm 45 is in the home position.

[0059] [Operation of Peeling Mechanism 4] When the peeling light-shielding piece 49 blocks the detection light of the peeling home sensor 41, the peeling home sensor 41 outputs a detection signal indicating that the detection light has been blocked to the third drive circuit 116. Upon receiving this detection signal, the controller 11 determines that the peeling arm 45 is at the home position. When the peeling arm 45 is at the home position, the peeling head 48 is at the standby position. When the controller 11 drives the peeling motor 42 to rotate, the peeling arm rotates from the home position, and the peeling head 48 moves from the standby position toward the pressing and fixing position.

[0060] When the white mount F is transported onto the front member SE, the head main body 47b comes into contact with the remaining portion Fa of the white mount F, preventing the head main body 47b from moving. The peeling head 48 reaches the connected portion Fb of the white mount F at the fixed pressure position while elastically deforming the spring 47c. In this way, the force with which the peeling head 48 collides with the white mount F and the front member SE can be reduced. After peeling of the connected portion Fb of the white mount F is complete, the controller 11 rotates the peeling motor 42 in the reverse direction to return the peeling arm 45 to the origin position.

[0061] When the print medium W is transported onto the front member SE and white mount F, the head main body 47b comes into contact with the remaining portion Wa of the print medium W, preventing the head main body 47b from moving. The peeling head 48 reaches the connected portion Wb of the print medium W at the fixed pressure position while elastically deforming the spring 47c. In this way, the force with which the peeling head 48 collides with the print medium W, the connected portion Fb of the white mount F, and the front member SE can be reduced. After peeling of the connected portion Wb of the print medium W is complete, the controller 11 rotates the peeling motor 42 in the reverse direction to return the peeling arm 45 to the origin position.

[0062] [Configuration of Guide Mechanism 5] The guide mechanism 5 rotates one of the first lower mold M1 and the second lower mold M2 between a loading position P1 and a connecting position P2, and in parallel with this rotation, rotates the other lower mold between the connecting position P2 and the loading position P1. The loading position P1 is a position sandwiched between the first loading slope 24 and the second loading slope of the first loading mechanism 2. The connecting position P2 is a position against which the upper mold M0 of the connecting mechanism 6, which will be described later, is pressed.

[0063] As shown in Figures 10 and 11, the guide mechanism 5 includes a first lower mold M1, a second lower mold M2, a guide home sensor 51, a guide motor 53 facing in the vertical direction Dz, a rotary support table 54, a guide stopper 55, and a guide light blocking piece 56. The rotary support table 54 rotates about a rotation axis 54b. In Figures 10 and 11, the rotary support table 54 is in its home position. In the home position, the first lower mold M1 is located at the loading position P1, and the second lower mold M2 is located at the connecting position P2.

[0064] The rotary support table 54 has a semicircular guide groove 54c. A rod-shaped guide stopper 55 is inserted into the guide groove 54c parallel to the rotary shaft 54b. In the home position, the guide stopper 55 abuts against the end of the guide groove 54c on the second lower mold M2 side. When the rotary support table 54 is rotated 180 degrees, the guide stopper 55 abuts against the end of the guide groove 54c on the first lower mold M1 side. In this way, the rotatable range of the rotary support table 54 is defined. The guide home sensor 51 is an optical sensor. A guide light blocking piece 56 is attached to the rotary support table 54. When the rotary support table 54 is in the home position, the guide light blocking piece 56 blocks the detection light of the guide home sensor 51. This allows the guide home sensor 51 to detect that the rotary support table is in the home position.

[0065] A rack gear 54a is provided on the outer circumferential side of the rotary support table 54. A pinion gear 53a is attached to the rotation shaft of the guide motor 53. The pinion gear 53a and the rack gear 54a mesh together to transmit the rotational driving force of the guide motor 53 to the rotary support table 54. The rotary support table 54 supports a first lower mold M1 and a second lower mold M2 via springs (not shown). The first lower mold M1 and the second lower mold M2 rotate together with the rotary support table 54 around a rotation shaft 54b.

[0066] The first lower mold M1 and the second lower mold M2 face each other across the rotation axis 54b. Both the first lower mold M1 and the second lower mold M2 are circular in plan view. When production of the can badge 200 begins, the first lower mold M1 is placed at the loading position P1 as its initial position. When the guide light-blocking piece 56 blocks the detection light of the guide home sensor 51, the guide home sensor 51 outputs a detection signal indicating that the detection light has been blocked to the fourth drive circuit 117. Upon receiving this detection signal, the controller 11 determines that the rotary support table 54 is in the home position.

[0067] The guide motor 53 has a rotary encoder. The rotary encoder outputs a pulse signal each time the guide motor 53 rotates a predetermined rotation angle. By counting these pulse signals, the controller 11 obtains the position of the rotary support table 54. The guide home sensor 51 detects whether the rotary support table 54 is in its home position and outputs a detection signal. In this embodiment, when the first lower mold M1 is located at the loading position P1, the guide home sensor 51 outputs a detection signal indicating that the rotary support table 54 is in its home position.

[0068] [Operation of Guide Mechanism 5] The guide mechanism 5 starts the rotational movement of the rotary support table 54 from the origin position when the controller 11 sends a predetermined output to the guide motor 53. When the rotary support table 54 reaches a predetermined deceleration start position, the guide mechanism 5 lowers the target value of the rotational speed of the guide motor 53. Furthermore, when the rotary support table 54 reaches the distance for determining drive completion, the guide mechanism 5 determines that the operation is normal. As a result, the first lower mold M1 and the second lower mold M2 rotate and move to the loading position P1 and the connecting position P2.

[0069] 2, 3, and 12, the connection mechanism 6 includes a connection home sensor 61, a connection motor 62, a first gear 63, a second gear 64, a third gear 65, a fourth gear 66, and a rotating cam 67. The connection mechanism 6 further includes a connection support plate 68, a plate member 68a, and an upper mold M0. The upper mold M0 has an inner mold M0a, an outer mold M0b, and a pressed member M0c. The connection support plate 68 is erected behind the rotary support table 54. The connection motor 62 is attached to the right of the connection support plate 68 (FIG. 3).

[0070] The first gear 63 is attached to the rotary shaft of the connection motor 62. The second gear 64 meshes with the first gear 63. The third gear 65 is attached to the same rotary shaft as the second gear 64. The fourth gear 66 meshes with the third gear 65. A gear (not shown) is attached to the same rotary shaft as the fourth gear 66 and meshes with the rotary cam 67. This transmits the rotational driving force of the connection motor 62 to the rotary cam 67. The connection support plate 68 is provided with a plate member 68a. The plate member 68a extends from the connection support plate 68 in the front-rear direction Dx above the connection position P2. The plate member 68a supports the rotary shaft 67a of the rotary cam 67. The upper mold M0 is disposed below the plate member 68a. The connection support plate 68 has a first connection stopper and a second connection stopper (not shown) that define the rotatable range of the rotary cam 67.

[0071] Both the inner mold M0a and the outer mold M0b are circular in top view. The outer mold M0b is provided coaxially below the inner mold M0a. The inner diameter of the outer mold M0b is larger than the outer diameter of the inner mold M0a. A pair of pressed members M0c extending in the left-right direction Dy are attached to the inner mold M0a. A rotating cam 67 abuts against the pair of pressed members M0c from above. When the rotational driving force of the connection motor 62 is transmitted to the rotating cam 67, the rotating cam 67 presses the pair of pressed members M0c downward. As a result, the inner mold M0a slides relative to the outer mold M0b and descends to the first lower mold M1 or the second lower mold M2.

[0072] The inner die M0a is biased upward by a biasing member (not shown). When the connection motor 62 is rotated in the reverse direction to release the pressure applied by the rotating cam 67 to the pressed member M0c, the biasing member causes the inner die M0a to rise. A connection home sensor 61 is attached to the connection support plate 68. The connection home sensor 61 is an optical sensor. The rotating cam 67 has a light-blocking piece 67b. When the light-blocking piece 67b blocks the detection light of the connection home sensor 61, the connection home sensor 61 outputs a detection signal to the fifth drive circuit 118 indicating that the rotating cam 67 is in the home position. At this time, the upper die M0 is in the highest position.

[0073] [Operation of the connection mechanism 6] When the controller 11 provides a predetermined output to the connection motor 62, the rotating cam 67 starts rotating from the origin position. When the rotating cam 67 reaches a predetermined deceleration start position, the connection mechanism 6 reduces the target value of the rotation speed of the connection motor 62. Furthermore, when the rotating cam 67 reaches the distance for determining drive completion, the connection mechanism 6 determines that the operation is normal.

[0074] [Configuration of Second Loading Mechanism 7] The second loading mechanism 7 is disposed to the left and rear of the loading position P1 ( FIG. 3 ). The second loading mechanism 7 has a configuration similar to that of the first loading mechanism 2. As shown in FIG. 13 , the second loading mechanism 7 has a second loading home sensor 71, a second loading motor 72, a second loading stocker 73, a second loading slope 74, a second loading slider 75, and a second loading light blocking piece 76. The side of the second loading slider 75 toward the loading position P1 in the movement direction D7 is referred to as the downstream side, and the other side is referred to as the upstream side.

[0075] The second loading motor 72 has a rotation shaft perpendicular to the main surface of the second loading slider 75. A pinion gear (not shown) is attached to the rotation shaft 72a of the second loading motor 72. The second loading stocker 73 is a cylindrical member with its longitudinal direction in the vertical direction Dz, and stores back members BE. In FIG. 13 , back members BE, which are generally circular in top view, are stacked in the vertical direction Dz within the second loading stocker 73. Of the back members BE within the second loading stocker 73, the lowest back member BE is placed on the second loading slope 74.

[0076] The second loading slope 74 has a guide surface that guides the backing member BE and the second loading slider 75 along the D7 direction. The second loading slope 74 has an upstream second loading stopper and a downstream second loading stopper (not shown). The upstream second loading stopper abuts against the upstream end of the second loading slider 75, thereby defining the upstream end (origin position) of the movable range of the second loading slider 75. The downstream second loading stopper abuts against the downstream end of the second loading slider 75, thereby defining the downstream end of the movable range of the second loading slider 75. A gap is provided between the guide surface of the second loading slope 74 and the lower end of the second loading stocker 73, allowing just one backing member BE to pass through.

[0077] The second loading slider 75 is a flat member having a rack gear 75a on its side in a top view. The rack gear 75a meshes with the pinion gear of the second loading motor 72. When the controller 11 drives and rotates the second loading motor 72, the second loading slider 75 moves back and forth on the second loading slope 74 in the direction D7. The second loading slider 75 is provided with a second loading light blocking piece 76. When the second loading slider 75 is at the home position, the second loading light blocking piece 76 blocks the detection light of the second loading home sensor 71. This allows the second loading home sensor 71 to detect that the second loading slider 75 is at the home position.

[0078] [Operation of the Second Loading Mechanism 7] When the second loading light-shielding piece 76 blocks the detection light of the second loading home sensor 71, the second loading home sensor 71 outputs a detection signal indicating that the detection light has been blocked to the sixth drive circuit 119. Upon receiving this detection signal, the controller 11 determines that the second loading slider 75 is at the home position. When loading a back member BE, the controller 11 rotates the second loading motor 72 to move the second loading slider 75 from the home position toward the second lower mold M2. When the second loading slider 75 reaches the second loading stocker 73, it abuts against the lowest back member BE and transports it. When the controller 11 drives the second loading motor 72 by a predetermined drive amount, the second loading slider 75 abuts against the downstream second loading stopper, and the back member BE is loaded from the second loading slope 74 into the second lower mold M2. Thereafter, the second loading slider 75 returns to the original position.

[0079] [Configuration of the Ejection Mechanism 8] The ejection mechanism 8 is disposed to the right front of the loading position P1 (FIG. 3). As shown in FIG. 14, the ejection mechanism 8 includes an ejection home sensor 81, an ejection motor 82, an ejection arm 83, a magnet member 84, and a seat 85. The ejection arm 83 is rotatably supported on the main body of the ejection mechanism 8. The rotational driving force of the ejection motor 82 is transmitted to the rotation shaft of the ejection arm 83 via a transmission mechanism (not shown). The ejection arm 83 rotates between a collection position and an ejection position. The collection position is the position of the ejection arm 83 shown in FIG. 23(A), and the ejection position is the position of the ejection arm 83 shown in FIG. 23(B).

[0080] The take-out arm 83 is equipped with a light-blocking piece 83a. The take-out home sensor 81 is an optical sensor. When the take-out arm 83 is in the collection position, the light-blocking piece 83a blocks the detection light of the take-out home sensor 81. This allows the take-out home sensor 81 to detect that the take-out arm 83 is in the collection position. A magnetic member 84 is attached to the tip of the take-out arm 83. The magnetic member 84 magnetically attracts the can badge 200 when the take-out arm 83 is in the take-out position. The magnetic member 84 has a magnetic force sufficient to hold the can badge 200 while the take-out arm 83 rotates from the take-out position to the collection position.

[0081] The seat 85 extends from the collection position toward the badge holder 10. The seat 85 has a seat surface 85a and a groove 85b. The seat surface 85a is an inclined surface that slopes downward toward the badge holder 10. The seat surface 85a is provided with a groove 85b that accommodates the removal arm 83. The width of the groove 85b is smaller than the outer diameter of the badge 200. Therefore, when the removal arm 83 is accommodated in the groove 85b and the magnetic member 84 is completely immersed in the groove 85b, the badge 200 cannot follow the magnetic member 84 into the groove 85b and is therefore detached from the magnetic member 84. The badge 200 that has detached from the magnetic member 84 slides down the seat surface 85a and is accommodated in the badge holder 10.

[0082] [Operation of the removal mechanism 8] The removal arm 83 starts rotating with the collection position as the origin position, and rotates toward the removal position. When the controller 11 drives the removal motor 82 by a predetermined drive amount, the removal arm 83 reaches the removal position. As a result, the magnet member 84 magnetically attracts the can badge 200. Thereafter, when the controller 11 rotates the removal motor 82 in the reverse direction, the removal arm 83 rotates to the collection position.

[0083] [Automatic adjustment of the can badge manufacturing device 100] In Figure 15, the shaded flowchart symbols represent processes related to the external device 12, and the unshaded flowchart symbols represent processes related to the controller 11 of the can badge manufacturing device 100.

[0084] As shown in Figure 15, when a button requesting automatic adjustment is pressed (S1) and the external device 12 receives the settings for the automatic adjustment (S2), it transmits the received settings to the controller 11 of the can badge manufacturing device 100 (S3).

[0085] The controller 11 performs the adjustment drive in accordance with the instruction received by the external device 12 (S4), and returns the obtained adjustment result to the external device 12 (S5). The external device 12 displays the adjustment result returned by the controller 11 (S6), and the process ends.

[0086] Next, the automatic adjustment of each mechanism constituting the badge production apparatus 100 will be described, focusing on the process corresponding to step S4 in Figure 15. Hereinafter, the duty ratio of the PWM (Pulse Width Modulation) signal output by the controller 11 to drive the motor will be referred to as "output." The number of rotations of the motor will be referred to as "drive amount." The number of rotations of the motor can be represented, for example, by the pulse count of a rotary encoder attached to the motor.

[0087] [Automatic Adjustment of Connection Mechanism 6] Automatic adjustment of the connection mechanism 6 involves adjusting the startup output power for starting the upper mold M0 to rise and fall, and the post-start output power_2nd after the upper mold M0 has started to rise and fall. The automatic adjustment also involves adjusting the target stop position target of the upper mold M0 and the deceleration start position down_vel_pos for slowing down the upper mold M0's rise and fall speed. Furthermore, the automatic adjustment also involves adjusting the deceleration rate down_vel_rate, which is the amount of deceleration of the upper mold M0 at the deceleration start position, and the drive completion determination distance retry_pulse_max, which is the criterion for determining whether the upper mold M0 has risen and fallen the intended distance. To adjust these parameters, the badge manufacturing apparatus 100 performs the following operations (see FIG. 16 ).

[0088] (1) The controller 11 outputs a PWM signal to the connecting motor 62 so as to move the stopped upper mold M0 in the movable direction (S11). When the rotating cam 67 is in the home position as shown in Figure 17 (A), the movable direction is the downward direction. (2) If the rotary encoder of the connecting motor 62 does not output a pulse signal (No in S12), the upper mold M0 is not moving, so the controller 11 increases the output to the connecting motor 62 (S13). If the output to the connecting motor 62 exceeds a predetermined upper limit, it is considered an error and the adjustment operation is terminated.

[0089] (3) When the rotary encoder of the connecting motor 62 outputs a pulse signal (Yes in S12), the upper mold M0 switches from a stationary state to a moving state. The controller 11 identifies the output to the connecting motor 62 at the start as the first connecting output. The controller 11 determines a value obtained by increasing the first connecting output by a predetermined percentage as the starting output power required to drive the connecting motor 62 and stores this value in the memory unit 112 (S14). The controller 11 stores a value obtained by decreasing the starting output power by a predetermined percentage as the post-start output power_2nd in the memory unit 112. In this way, identifying the first connecting output refers to referencing the output to the connecting motor 62 when the upper mold M0 switches from a stationary state to a moving state (e.g., the duty ratio of the PWM signal). Furthermore, determining the starting output power refers to performing a calculation to increase the first connecting output by a predetermined percentage. (4) The controller 11 returns the upper mold M0 to the origin position (S15). (5) The controller 11 changes the output to the connection motor 62 within a predetermined range from the starting output power to perform the connection operation.

[0090] (6) The controller 11 searches for an output that is a boundary value determining whether the upper mold M0 will descend the distance required for the connection operation. In this search, the controller 11 inputs a PWM signal to the connection motor 62 (S16) to lower the upper mold M0. If the number of pulses output by the rotary encoder does not reach a predetermined value (No in S17), the output to the connection motor 62 is insufficient. The predetermined value is, for example, the number of pulses required for the upper mold M0 to descend the distance required for the connection operation. If the output to the connection motor 62 is insufficient, as shown in FIG. 17(B), the upper mold M0 remains in contact with the lower mold and is unable to descend, so the controller 11 increases the duty ratio (S18). Thereafter, the controller 11 returns to step S15 and repeats the above process. If the number of pulses reaches the predetermined value (Yes in S17), the controller 11 determines the duty ratio at that time to be the minimum output required to lower the upper mold M0 the distance required for the connection operation (S19). Note that a binary search method can be used to reduce the number of trials to determine the minimum output.

[0091] (7) The controller 11 stores in the memory unit 112, as the output required for the connection operation, an output obtained by increasing the minimum output required for the connection operation by a predetermined ratio, the minimum output required for the connection operation. The output required for the connection operation includes an output (second output) when the upper mold M0 contacts the first lower mold M1 and an output (third output) when the upper mold M0 contacts the second lower mold M2, and the controller 11 determines the third output to be greater than the second output. In this embodiment, the controller 11 determines the predetermined ratio so that the third output is greater than the second output.

[0092] (8) The controller 11 lowers the upper mold M0 from the origin position to the first lower mold M1 using the second output, and acquires the drive amount of the connecting motor 62. Furthermore, the controller 11 lowers the upper mold M0 from the origin position to the second lower mold M2 using the third output, and acquires the drive amount of the connecting motor 62 ( FIG. 17(C) ). In other words, the controller 11 returns the upper mold M0 to the origin position (S20), inputs a PWM signal to the connecting motor 62 (S21), lowers the upper mold M0, and when the increase in the number of pulses stops (Yes in S22), the upper mold M0 has been driven to the stop position, so the drive amount at that time is acquired (S23), and the movement distance of the upper mold M0 is determined and stored in the memory unit 112.

[0093] (9) The controller 11 determines the target stop position "target" based on the acquired drive amount and stores it in the memory unit 112 (S24). In this way, the controller 11 determines the start and end points of the drive range of the upper mold M0. The deceleration start position "down_vel_pos" and the drive completion determination distance "retry_pulse_max" are set to positions that are predetermined percentages of the target stop position "target". The deceleration rate "down_vel_rate" may be set to, for example, a fixed value. (10) After completing the adjustment, the controller 11 reduces the speed using the searched parameters and returns to the origin position (S25). Note that the upper mold M0's lifting speed is reduced to prevent damage to the stopper that prevents the upper mold M0 from lifting and lowering.

[0094] The controller 11 changes the output to the connecting motor 62 to specify a first output (e.g., activation output power) at which the upper mold M0 switches between a stationary state and a moving state. The controller 11 determines a first connecting output to the connecting motor 62 based on the first output. Note that the first connecting output is preferably specified when the upper mold M0 is in contact with the first lower mold M1 or the second lower mold M2. In particular, it is preferable to specify the first connecting output when the upper mold M0 is in contact with the second lower mold M2.

[0095] The elastic compression of the spring supporting the lower mold and the crimping deformation of the can badge alleviate collisions between the upper mold M0 and the first lower mold M1 and second lower mold M2. Furthermore, in order to alleviate collisions between the rotating cam 67 that drives the upper mold M0 and the first or second connection stopper, it is desirable to set a target stop position "target" taking into consideration that the cam will rotate due to inertia after driving is stopped.

[0096] [Automatic Adjustment of Guide Mechanism 5] In automatic adjustment of the guide mechanism 5, the controller 11 adjusts the startup output power and the target stop position target of the rotary support table 54. The controller 11 also adjusts the deceleration start position down_vel_pos, the deceleration rate down_vel_rate, and the distance retry_pulse_max used to determine drive completion. As shown in FIG. 18 , in order to adjust these parameters, the badge production apparatus 100 performs the following adjustment operations.

[0097] (1) The controller 11 outputs a PWM signal to the guide motor 53 so that the rotary support table 54 rotates in the movable direction (S31). When the rotary support table 54 is in the home position as shown in FIG. 19A, the operating direction is clockwise when viewed from above. (2) If the rotary encoder of the guide motor 53 does not output a pulse signal (No in S32), the rotary support table 54 remains stationary and does not rotate. The controller 11 increases the output to the guide motor 53 (S33). If the output to the guide motor 53 exceeds a predetermined upper limit, the controller 11 determines this to be an error and terminates the adjustment operation. (3) If the rotary encoder of the guide motor 53 outputs a pulse signal (Yes in S32), the rotary support table 54 switches from a stationary state to a moving state. The controller 11 identifies the output to the guide motor 53 at this time as the guidance output, determines a value obtained by increasing the guidance output by a predetermined rate as the starting output power to the guide motor 53, and stores the value in the memory unit 112 (S34). In this way, identifying the guidance output means referring to the output to the guide motor 53 when the rotary support table 54 switches from a stationary state to a moving state (for example, the duty ratio of the PWM signal). Also, determining the starting output power means performing a calculation to increase the guidance output by a predetermined rate. (4) The controller 11 returns the rotary support table 54 to the origin (home position) (S35).

[0098] (5) The controller 11 uses the activation output power to the guide motor 53 to rotate the rotary support table 54 clockwise and counterclockwise as viewed from above, searching for an operable stroke (drive amount). That is, the controller 11 outputs a PWM signal to the guide motor 53 (S36) to rotate the rotary support table 54 clockwise. When the number of pulses from the rotary encoder stops increasing (Yes in S37), the guide stopper 55 has relatively moved through the operable range from one end to the other end of the guide groove 54c. The controller 11 acquires the drive amount from the start to the end of the clockwise rotation (S38). Next, the controller 11 outputs a PWM signal to the guide motor 53 (S39) to rotate the rotary support table 54 counterclockwise. When the number of pulses from the rotary encoder stops increasing (Yes in S40), the guide stopper 55 has relatively moved through the operable range from the other end to the one end of the guide groove 54c. The controller 11 acquires the drive amount from the start to the end of the counterclockwise rotation and stores it in the storage unit 112 (S41). (6) The controller 11 calculates the average value of the stroke (drive amount) that can be operated in the clockwise and counterclockwise directions and stores this in the storage unit 112 as the stop target position "target" (S42). The controller 11 stores in the storage unit 112 positions where the deceleration start position "down_vel_pos" and the distance "retry_pulse_max" for determining drive completion are each a predetermined ratio to the stop target position "target". The controller 11 may store a fixed value, for example, as the deceleration rate "down_vel_rate" in the storage unit 112.

[0099] In this way, the controller 11 changes the output to the guide motor 53 and specifies the output at which the rotary support table 54 switches between a stationary state and a moving state as the first output (guidance output). The controller 11 determines the output (starting output power) to the guide motor 53 based on the guidance output.

[0100] [Automatic Adjustment of Peeling Mechanism 4] In automatic adjustment of the peeling mechanism 4, the controller 11 adjusts the origin position (position from which rotation starts) and the target stop position (target) of the peeling arm 45. To adjust these parameters, the badge manufacturing apparatus 100 performs the following operations (see FIG. 20 ).

[0101] (1) The controller 11 rotates the peeling arm 45 from the home position shown in FIG. 21A to one-quarter of the maximum rotation range (S51). Thereafter, the controller 11 returns the peeling arm 45 at the maximum speed until the peeling home sensor 41 detects the peeling arm 45 (S52). This causes the controller 11 to search for the position (drive amount) at which the peeling home sensor 41 detects the peeling arm 45 (S53). (2) The controller 11 determines the drive amount, obtained by subtracting a predetermined drive amount from the position (drive amount) at which the peeling home sensor 41 detects the peeling arm 45, as the starting point (S54). When the peeling motor 42 is stopped after the peeling home sensor 41 detects the peeling arm 45, the peeling arm 45 moves a certain distance between the time the peeling motor 42 is stopped and the time the peeling arm 45 decelerates and stops. However, because the peeling home sensor 41 is close to the stopper, the peeling arm 45 cannot decelerate sufficiently and collides with the stopper. When the peeling arm 45 collides with the stopper, it bounces back and moves away from the stopper. After the peeling motor 42 stops rotating, the relationship between the drive amount (number of pulses) of the peeling motor 42 and the position of the peeling arm 45 changes. This causes the position control of the peeling arm 45 to become unstable. As described above, by setting the start point to a position that is a predetermined distance away from the origin position toward the stop position, it is possible to prevent the control of the peeling arm 45 from becoming unstable. This is because the start point can be set to a position where the peeling arm 45 will not collide with the stopper even if the peeling home sensor 41 detects the peeling arm 45 after the peeling motor 42 stops driving.

[0102] (3) The controller 11 rotates the peeling arm 45 in the forward direction from the origin position (S55) until the pulse count of the peeling motor 42 stops increasing (Yes in S56), and searches for the distance (drive amount) at which the peeling arm 45 contacts the first lower mold M1 (S57). (4) The controller 11 rotates the peeling arm 45 from the origin position, and increases the drive amount by a predetermined drive amount until the pulse count of the peeling motor 42 stops increasing, and stores this drive amount, which is the end point, in the memory unit 112 (S58). The head main body 47b presses the remaining portion Fa of the white backing sheet F or the remaining portion Wa of the print medium W at a height L4a above the rotary support table 54 as shown in FIG. 21(B), and then the peeling head 48 reaches the pressing and fixing position while elastically deforming the spring 47c (FIG. 21(C)). The pressing and fixing position is at a height L4b from the rotary support table 54, which is lower than the height L4a at which the head main body 47b presses down on the white backing F, etc. In this way, the head main body 47b presses and fixes the connection portion Fb of the white backing F and the connection portion Wb of the print medium W. The increase in the predetermined drive amount takes into account the drive amount required to elastically deform the spring 47c. (5) The controller 11 returns the peeling arm 45 to the origin position. (6) As a test operation, the controller 11 drives the peeling arm 45 to the target stop position "target," maintains the excited state of the peeling motor 42 for one second, and then returns it to the origin position.

[0103] [Automatic Adjustment of Take-Out Mechanism 8] In the automatic adjustment of the take-out mechanism 8, the controller 11 adjusts the start point, which is the starting point of the rotation of the take-out arm 83, and the target stop position, which is the end point. To adjust these parameters, the badge production apparatus 100 performs the following operation (see FIG. 22 ).

[0104] (1) First, the controller 11 rotates the take-out arm 83 from the home position shown in FIG. 23A to half of its maximum rotation range (S61). Then, the controller 11 returns the take-out arm 83 at maximum speed until the take-out home sensor 81 detects the take-out light shielding piece 83a of the take-out arm 83 (S62), thereby searching for the position (drive amount) at which the take-out home sensor 81 detects the take-out light shielding piece 83a (Yes in S63). This position corresponds to a position a predetermined distance away from the origin position toward the stop position. The controller 11 determines this position as the start point (S64). (2) The controller 11 waits until a badge is loaded into the second lower mold M2. For example, when the operator loads a badge into the second lower mold M2 and notifies the application program of the external device 12, a guide screen is displayed. The adjustment operation may resume when the operator presses a button on the guide screen indicating the resumption of the adjustment operation. (3) When a can badge is loaded into the second lower mold M2 (Yes in S65), the controller 11 rotates the removal arm 83 forward from the origin position toward the stop position shown in Figure 23 (B) until the pulse count of the removal motor 82 stops increasing, and searches for the drive stroke distance (drive amount) while the second lower mold M2 is supporting the can badge (S66).

[0105] (4) When the pulse count of the take-out motor 82 stops increasing (Yes in S67), the controller 11 acquires the pulse count as the drive amount (S68) and stores in the memory unit 112 a position a predetermined drive amount before the position (drive amount) where the pulse count of the take-out motor 82 stops increasing as the stop target position (Target) (S69). The controller 11 sets a distance at which the magnetic member 84 can magnetically attract the can badge without colliding with it, because a collision of the magnetic member 84 leaves a collision mark on the can badge. The stop target position (Target) corresponds to the end point. (5) The controller 11 returns the take-out arm 83 to the origin position. (6) The controller 11 waits until a can badge is loaded into the second lower mold M2. As in (2), the external device 12 may be used. (7) As a test operation, the controller 11 drives the take-out arm 83 to the stop target position (Target) and then returns it to the origin position.

[0106] [Automatic adjustment of first loading mechanism 2 and second loading mechanism 7] The automatic adjustment of the second loading mechanism 7 is similar to the automatic adjustment of the first loading mechanism 2, so below we will only explain the automatic adjustment of the first loading mechanism 2, and this explanation will also serve as an explanation of the automatic adjustment of the second loading mechanism 7.

[0107] The automatic adjustment of the first loading mechanism 2 involves adjusting the origin position, which is the starting point for the movement of the first loading slider 25, and the target stop position, "Target." To adjust these parameters, the badge manufacturing apparatus 100 performs the following operations (see FIG. 24).

[0108] (1) The controller 11 moves the first loading slider 25 to one-quarter of its maximum movement range (S71). The controller 11 then moves the first loading slider 25 toward the origin, searches for the distance at which the first loading slider 25 reaches its maximum speed before colliding with the stopper, and moves the slider to that distance. (2) The controller 11 moves the first loading slider 25 toward the origin at maximum speed until it collides with the stopper (S72), and moves the slider to the stopper stop position (Yes in S73). (3) The controller 11 sets a position a predetermined distance back from the stopper position as the starting point (S74). Because the first loading slider 25 hitting the stopper too forcefully can cause rebound or damage, the starting point of control is determined separately. (4) The controller 11 moves the first loading slider 25 to the origin position shown in FIG. 25(A) (S75). (5) The controller 11 moves the first loading slider 25 downstream until it hits the stopper (S76). To load the front member SE into the first lower mold M1, the first loading slider 25 must hit the stopper. Therefore, the controller 11 searches for the distance at which the first loading slider 25 hits the stopper (S77). The controller 11 stores the position at that distance from the origin position as the target stop position, i.e., the end point, in the memory unit 112 (S78). As shown in FIG. 25(B), the end point is the other end position of the movable range of the first loading slider 25 relative to the origin position.

[0109] [Effects of the embodiment] If the mechanisms of the can badge production apparatus 100 can be automatically adjusted as described above, it is possible to reduce the time and effort required to adjust the can badge production apparatus 100. Furthermore, since adjustments can be made without removing the exterior body 101 from the can badge production apparatus 100, the safety of the operator who instructs the can badge production apparatus 100 to perform automatic adjustments can be ensured.

[0110] [Modifications] (1) In the above embodiment, step S2 of the flowchart in FIG. 15 was described as an example in which the automatic adjustment settings are accepted. However, it goes without saying that the present disclosure is not limited to this. Step S2 may be omitted, and all automatic adjustments may always be performed. It is not always easy for an operator who instructs the badge production device 100 to perform automatic adjustments to appropriately specify the automatic adjustment settings. Furthermore, because the need for automatic adjustments of the badge production device 100 is not high, all automatic adjustments may always be performed. This reduces the workload on the operator and improves the convenience of the badge production device 100.

[0111] (2) In the above embodiment, the output at which the rotary support table 54 of the guide mechanism 5 switches between a stationary state and a moving state is defined as the first output (guidance output), and the output at which the rotary support table 54 switches from a stationary state to a moving state is specified. Also, the output at which the upper mold M0 switches from a stationary state to a moving state is specified as the first output (activation output power) at which the upper mold M0 of the connection mechanism 6 switches between a stationary state and a moving state. However, it goes without saying that the present disclosure is not limited to these, and the output at which the rotary support table 54 switches from a moving state to a stationary state may be specified as the first output, or the output at which the upper mold M0 switches from a moving state to a stationary state may be specified as the first output.

[0112] (3) In the automatic adjustment of the connection mechanism 6, instead of increasing the first connection output by a predetermined rate, a value obtained by adding a predetermined positive value to the first connection output may be determined as the start output power. Instead of decreasing the start output power by a predetermined rate, a value obtained by subtracting a predetermined positive value from the start output power may be determined as the post-start output power_2nd. As long as the increase in the start output power and the decrease in the post-start output power_2nd are the same, the calculation method is not limited. Similarly, instead of increasing the minimum output by a predetermined rate, an output obtained by adding a predetermined positive value to the minimum output may be determined as the output required for the connection operation. As long as the increase in the output is the same, the calculation method is not limited. In the automatic adjustment of the guidance mechanism 5, instead of increasing the guidance output by a predetermined rate, the start output power may be determined by adding a predetermined positive value to the guidance output. As long as the increase in the guidance output is the same, the calculation method is not limited.

[0113] (4) The present disclosure may also be a method executed by the badge manufacturing device 100.

[0114] DESCRIPTION OF SYMBOLS 1...Printing device 2...First loading mechanism 3...Conveying mechanism 4...Peeling mechanism 5...Guiding mechanism 6...Connection mechanism 7...Second loading mechanism 8...Removing mechanism 9...Collection box 10...Pot badge holder 11...Controller 12...External device 21...First loading home sensor 22...First loading motor 31...First conveying sensor 32...Second conveying sensor 33...Third conveying sensor 35...Conveying motor 41...Peeling home sensor 42...Peeling motor 51...Guiding home sensor 53...Guiding motor 55...Guiding stopper 61...Connection home sensor 62...Connection motor 71...Second loading home sensor 72...Second loading motor 81...Removal home sensor 82...Removal motor 100...Pot badge manufacturing device 110...Controller 200...Pot badge BE...Backing member F...White backing M0...Upper die M1...First lower die M2...Second lower die SE...Front member W...Printing medium

Claims

1. A can badge manufacturing device comprising: a first mechanism that manufactures can badges by connecting material for the can badges; a first drive unit that drives the first mechanism; a second mechanism that supplies the material to the first mechanism or removes the can badges; a second drive unit that drives the second mechanism; and a controller, wherein the controller changes the output of the first drive unit to identify a first output at which the first mechanism switches between a stationary state and a moving state, and determines the output to the first drive unit based on the first output.

2. A can badge manufacturing device as described in claim 1, wherein the material includes a front member and a back member, the first mechanism has a first lower mold that supports the front member, a second lower mold that supports the back member, and a guide mechanism that guides the first lower mold and the second lower mold to a connection position, the first drive unit has a guide motor that drives the guide mechanism, and the controller changes the output of the guide motor as the first output to identify a guide output that switches the guide mechanism between a stationary state and a moving state, and determines the output to the guide motor based on the guide output.

3. A can badge manufacturing device as described in claim 2, wherein the first mechanism is arranged at the connection position and has a connection mechanism that can be raised and lowered, the first drive unit has a connection motor that drives the connection mechanism, and the controller changes the output of the connection motor to identify a first connection output at which the connection mechanism switches between a stationary state and a moving state, and determines the output to the connection motor based on the first connection output.

4. A can badge manufacturing device as described in claim 3, wherein the controller identifies the first connection output when the connection mechanism is in contact with the first lower mold or the second lower mold.

5. A can badge manufacturing device as described in claim 4, wherein the controller identifies the first connection output when the connection mechanism is in contact with the second lower die.

6. A can badge manufacturing device as described in claim 3, wherein the output to the connection motor includes a second output when the first lower mold and the connection mechanism come into contact and a third output when the second lower mold and the connection mechanism come into contact, and the controller determines the output to the connection motor so that the third output is greater than the second output.

7. A can badge manufacturing device as described in claim 1, wherein the controller determines the distance of movement of the first mechanism based on the drive amount required to drive the first drive unit from the origin position to the stop position using the determined output to the first drive unit.

8. A can badge manufacturing device as described in any one of claims 2 to 6, wherein the controller controls the second drive unit to determine the start and end points of the drive range of the second mechanism based on the drive amount for driving the second mechanism from the origin position to the stop position.

9. A can badge manufacturing device as described in claim 8, wherein the second mechanism has a first loading mechanism that loads the front member into the first lower mold and a second loading mechanism that loads the back member into the second lower mold, the second drive unit has a loading motor that drives the first loading mechanism and the second loading mechanism, the origin position is a position at one end of the movable range of each of the first loading mechanism and the second loading mechanism, and the controller determines, for each of the first loading mechanism and the second loading mechanism, a position that is a predetermined distance from the origin position as the start point, and determines the position at the other end of the movable range relative to the origin position as the end point.

10. A can badge manufacturing device as described in claim 8, wherein the second mechanism has a removal mechanism that removes the can badge produced by the first mechanism from the first mechanism, the second drive unit has a removal motor that drives the removal mechanism, and the controller determines a position that is a predetermined distance away from the origin position toward the stop position as the start point, and determines a position that is a predetermined distance away from the stop position toward the origin position as the end point.

11. A can badge manufacturing device as described in claim 10, wherein the controller drives the removal mechanism from the origin position toward the stop position while the second lower mold is supporting the can badge, and determines the position where the drive of the removal mechanism stops as the stop position.

12. A can badge manufacturing device as described in claim 8, wherein the second mechanism has a peeling mechanism that peels off a specified area containing the image from a medium on which the image is recorded and that is to be supplied to the first mechanism, the second drive unit has a peeling motor that drives the peeling mechanism, and the controller determines a position that is a specified distance away from the origin position toward the stop position as the start point, and determines the stop position as the end point.

13. A can badge manufacturing device comprising: a first mechanism that manufactures can badges by connecting material for the can badges; a first drive unit that drives the first mechanism; a second mechanism that supplies the material to the first mechanism or removes the can badges; a second drive unit that drives the second mechanism; and a controller, wherein the controller controls the second drive unit to determine the start and end points of the drive range of the second mechanism based on the drive amount used to drive the second mechanism from a predetermined origin position to a stop position.

14. A method performed by a can badge manufacturing device comprising: a first mechanism that manufactures can badges by connecting the material for the can badges; a first drive unit that drives the first mechanism; a second mechanism that supplies the material to the first mechanism or removes the can badges; and a second drive unit that drives the second mechanism, the method comprising: changing the output of the first drive unit to identify a first output at which the first mechanism switches between a stationary state and a moving state; and determining the output to the first drive unit based on the first output.

15. A method performed by a can badge manufacturing device comprising: a first mechanism that manufactures can badges by connecting material for the can badges; a first drive unit that drives the first mechanism; a second mechanism that supplies the material to the first mechanism or removes the can badges; and a second drive unit that drives the second mechanism, the method comprising controlling the second drive unit to start driving the second mechanism from a predetermined start position and drive it to a stop position where the second mechanism stops; and controlling the second drive unit to determine the start and end points of the drive range of the second mechanism based on the drive amount used to drive the second mechanism from a predetermined origin position to the stop position.

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