Can badge production device and method

Abstract

Provided is a can badge production device that saves time and effort for a user when placing a medium on a mold, and that ensures the positional accuracy of the medium.　Conveying rollers Ro8 to Ro10 are rotationally driven by a conveying motor to convey white backing paper F toward a target position on a first lower mold M1. When a second conveying sensor 32 detects the white backing paper F, measurement of the drive amount of the conveying motor begins. When the drive amount of the conveying motor reaches a first drive amount, the rotational drive of the conveying motor is stopped. Next, by rotating the conveying motor in the reverse direction, the conveying rollers Ro9 and Ro10 are caused to rotate in the reverse direction, thereby conveying the white backing paper F toward the detection position of a first conveying sensor 31. A second drive amount is measured from when the conveying motor begins to rotate in the reverse direction until the first conveying sensor 31 detects the white backing paper. The first drive amount is corrected in proportion to an excess or shortfall in the second drive amount with respect to a reference drive amount.

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 has been printed, with the printed surface facing the surface of the front member, and then joins the 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 manufacture a can badge.

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

[0004] When coating a medium on the surface of a front member, the user must manually and accurately position the medium and place it in the mold. It is desirable to eliminate this hassle and improve user convenience. The present disclosure aims to eliminate the user's hassle when placing a medium in a mold in a can badge manufacturing device while ensuring positional accuracy.

[0005] (1) An image recording device according to the present disclosure is a can badge production device that uses a mold to connect a medium on which an image is recorded, a front member, and a back member to produce a can badge, the device comprising: a transport unit having a first transport path for transporting the medium to a target position on the mold, a second transport path for transporting at least a portion of the medium from the target position, and a transport mechanism that transports at least a portion of the medium along the first transport path and the second transport path, a first sensor that detects the medium transported along the second transport path, and a control unit. The control unit controls the transport mechanism to perform a first process of transporting the medium along the first transport path toward the target position at a first drive amount, a second process of transporting at least a portion of the medium from the target position along the second transport path, and a third process of correcting the first drive amount based on a second drive amount of the transport mechanism from the start of the second process to the time the first sensor detects at least a portion of the medium.

[0006] The system focuses on the fact that the starting position of transport along the second transport path, and therefore the second drive amount, changes depending on whether the transport distance (first drive amount) to the target position along the first transport path is excessive or insufficient, and corrects the first drive amount based on the second drive amount, thereby enabling the first drive amount to be automatically set with high accuracy.

[0007] (2) Preferably, the device further includes a memory that stores a reference drive amount for the transport mechanism to transport at least a portion of the medium from the target position to the detection position of the first sensor, and the control unit may, in the third process, perform a correction to increase the first drive amount on condition that the second drive amount is less than the reference drive amount, and perform a correction to decrease the first drive amount on condition that the second drive amount is greater than the reference drive amount.

[0008] (3) Preferably, in the third process, the control unit may set an amount proportional to the difference between the second drive amount and the reference drive amount as the correction amount for the first drive amount.

[0009] (4) Preferably, the control unit executes the second process on the condition that it receives a signal indicating that the medium is located at the target position, and stores in the memory as the reference drive amount the amount of drive of the transport mechanism from the start of the second process until the first sensor detects at least a portion of the medium.

[0010] (5) Preferably, the device further includes a second sensor that detects the medium being transported along the first transport path, and the control unit can execute the first process after the second sensor detects the medium.

[0011] (6) Preferably, the first conveying path has a common portion and a first individual portion, the second conveying path has the common portion and a second individual portion, the first sensor detects at least a portion of the medium conveyed along the second individual portion, and the second sensor detects the medium conveyed along the first individual portion.

[0012] (7) Preferably, the first transport path may be at least partially curved, and the second transport path may be linear.

[0013] (8) Preferably, the transport mechanism may include a drive source, a first transport mechanism to which the driving force of the drive source is transmitted to transport the medium along the first transport path, and a second transport mechanism to which the driving force of the drive source is transmitted to transport at least a portion of the medium along the second transport path.

[0014] (9) Furthermore, the method disclosed herein is a correction method for a can badge manufacturing device that uses a mold to connect a medium on which an image is recorded, a front member, and a back member to manufacture a can badge, and includes driving a conveying mechanism with a first drive amount to convey the medium along a first conveying path toward a target position on the mold, driving the conveying mechanism to convey at least a portion of the medium from the target position along a second conveying path, and correcting the first drive amount based on a second drive amount of the conveying mechanism from when at least a portion of the medium has been conveyed from the target position to when a first sensor detects at least a portion of the medium on the second conveying path.

[0015] According to the present disclosure, in a can badge manufacturing device, the user's effort in placing a medium on a mold can be reduced and positional accuracy can be ensured.

[0016] FIG. 1 is an external perspective view of the can badge manufacturing apparatus 100. FIG. 2 is an external perspective view of the can badge manufacturing apparatus 100 with the exterior body 101 removed. FIG. 3 is a top view of the can badge manufacturing apparatus 100 with the exterior body 101 removed. FIG. 4 is a block diagram of the control unit 11 of the can badge manufacturing apparatus 100. FIG. 5 is a cross-sectional view showing the configuration of a can badge. FIG. 6(A) is a plan view of a white backing sheet F, and FIG. 6(B) is a plan view of a print medium W. FIG. 7 is a side view of the conveyance unit 3. FIG. 8 is a flowchart showing the automatic adjustment operation of the control unit 11. FIG. 9(A) is a diagram showing the white backing sheet F at the detection position of the second conveyance sensor 32, FIG. 9(B) is a diagram showing the white backing sheet F at the target position, and FIG. 9(C) is a diagram showing the white backing sheet F at the detection position of the first conveyance sensor 31. FIG. 10(A) is a diagram showing the white backing sheet F with an insufficient first drive amount, and FIG. 10(B) is a diagram showing the white backing sheet F with an excessive first drive amount. Fig. 11 is a perspective view of the appearance of the peeling unit 4. Fig. 12(A) is a side view of the peeling arm 45 at the standby position, Fig. 12(B) is a side view showing a state in which the head main body 47b of the remaining portion pressing head 47 is in contact with the first lower die M1, and Fig. 12(C) is a side view showing the peeling head 48 at the pressing and fixing position.

[0017] 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.

[0018] 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 unit 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.

[0019] As shown in Figures 1 to 4, the can badge production device 100 is placed on the printing device 1. The can badge production device 100 includes a first loading unit 2, a conveying unit 3, a peeling unit 4, a guide unit 5, a connecting unit 6, a second loading unit 7, an unloading unit 8, and a control unit 11. The guide unit 5 and the connecting unit 6 connect the can badge materials to produce the can badge 200. The first loading unit 2, the conveying unit 3, the peeling unit 4, and the second loading unit 7 supply the can badge material to the guide unit 5. The unloading unit 8 unloads the can badge 200 from the guide unit 5 and stores it in the can badge container 10.

[0020] [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). Therefore, 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.

[0021] [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.

[0022] The first loading section 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").

[0023] When the first loading unit 2 has completed loading the front member SE, the control unit 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 unit 3. The transport unit 3 transports the white backing sheet F onto the front member SE loaded in the first lower mold M1. The peeling unit 4 uses the peeling head 48 to press and fix the connected portion Fb of the white backing sheet F on the front member SE.

[0024] With the peeling unit 4 pressing and fixing the connected portion Fb of the white mount F, the transport unit 3 transports the white mount F toward the collection box 9. This causes the connecting portion Fc and the linear weak portion Fd of the white mount F to break. The connected portion Fb is peeled off and remains on the front member SE. The remaining portion Fa of the white mount F is discarded in the collection box 9. After that, the peeling unit 4 releases the pressure on the connected portion Fb, and the control unit 11 inputs a signal indicating the release of the pressure to the external device 12. The external device 12 inputs a signal to the printing device 1 to supply the print medium W.

[0025] The printing device 1 prints a predetermined image on the back surface of the connected portion Wb of the print medium W and supplies it to the transport unit 3. The transport unit 3 transports the print medium W onto the connected portion Fb of the white mount F. When the peeling unit 4 presses and fixes the connected portion Wb of the print medium W, the transport unit 3 peels the connected portion Wb from the print medium W and discards the remaining portion Wa in a collection box 9. The peeling unit 4 then releases the pressure.

[0026] The guide unit 5 guides the first lower mold M1, which has the connection portion Wb of the print medium W, the connection portion Fb of the white mount F, and the front member SE loaded thereon, from the loading position P1 to the connection position P2. At the connection position P2, the connection unit 6 presses the upper mold M0 against the first lower mold M1 to connect 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 unit 6 then returns the upper mold M0 upward.

[0027] The second loading unit 7 loads the backing member BE into the second lower mold M2, which is located at the loading position P1. The guide unit 5 guides the second lower mold M2, with the loaded backing member BE, from the loading position P1 to the connecting position P2. The connecting unit 6 produces the can badge 200 by crimping. Specifically, the connecting unit 6 presses the upper mold M0 against the second lower mold M2 to connect the connected portion Wb of the print medium W, the connected portion Fb of the white mount F, the front member SE, and the backing member BE. When the upper mold M0 rises, the can badge 200 remains on the second lower mold M2. The guide unit 5 guides the second lower mold M2 from the connecting position P2 to the loading position P1. The removal unit 8 removes the can badge 200 from the second lower mold M2 and stores it in the can badge container 10.

[0028] [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.

[0029] The remaining portion Fa is a tab used by the conveying unit 3 to convey the white backing sheet F. The connected portion Fb is used as material for the can badge. 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 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 in the shortest distance when the white backing sheet F is conveyed toward the first lower mold M1.

[0030] 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 likely to break. The connecting portion Fc and the linear weak portion Fd may be, for example, a recess 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. When the peeling unit 4 presses and fixes the connected portion Fb of the white backing F and the conveying unit 3 attempts to convey the white backing F, the connecting portion Fc and the linear weak portion Fd break, and the connected portion Fb peels off from the white backing F. The configuration of the print medium W is basically the same as the configuration of the white backing F, as shown in FIG. 6(B). However, an image is recorded on the connected portion Wb of the print medium W.

[0031] [Configuration of Control Unit 11] As shown in Figure 4, the control unit 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 is a memory that stores firmware and parameters. The parameters include output values ​​and drive amounts for operating the can badge production apparatus 100.

[0032] The calculation unit 111 is, for example, a central processing unit (CPU) or a field programmable gate array (FPGA). By executing firmware, the calculation unit 111 controls each component of the badge production apparatus 100 according to parameters and automatically adjusts the parameters. The interface 113 connects the control unit 11 to an 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 is equipped with an application program for operating the badge production apparatus 100. The application program may display a graphical user interface (GUI) screen on the external device 12 to accept user operations and display information related to the badge production apparatus 100.

[0033] The first drive circuit 114 connects the first loading home sensor 21 and the first loading motor 22 of the first loading unit 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 unit 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 unit 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 unit 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 unit 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 unit 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 unit 8 to the control device 110.

[0034] 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.

[0035] [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 material for a can badge to the transport unit 3 of the can badge production device 100. In this embodiment, the printing device 1 is an inkjet printer. The printing device 1 is equipped with a sheet holder (not shown) that accommodates the white backing sheet F and the print medium W. As shown in FIG. 7 , the printing device 1 is equipped with 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 forms an image on the connection portion Wb of the print medium W by ejecting ink according to image data. 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 opening of the transport unit 3.

[0036] The inkjet printer used as the printing device 1 may have a serial head or line head type ejection head for ejecting ink. The printing device 1 may also 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 be printed to the printing device 1. The printing device 1 may also 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 that has a storage device that stores image data. The printing device 1 may also acquire image data from a remote device via a communication network.

[0037] [Configuration of Transport Unit 3] The transport unit 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. 7 , the transport unit 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 third transport sensor 33 detects the white backing sheet F and the print medium W at an inlet 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 bends the transport path of the white backing sheet F and the print medium W and changes the transport direction. The first transport sensor 31 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 mounted upright on the rotation shaft 54b of the rotary support table 54 of the guide unit 5. The transport stopper S also serves as a support for the connection support plate 68 of the connection unit 6.

[0038] The 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 motor 35 has a rotary encoder. The rotary encoder of the transport motor 35 outputs a pulse signal to the second drive circuit 115 each time the transport motor 35 rotates a predetermined rotation angle. By counting these pulse signals, the control unit 11 detects the drive amount of the transport motor 35. The transport rollers Ro1 to Ro12 transport the white backing sheet F and the print medium W. The transport guide 36, a first transport guide piece 37, and a second transport guide piece 38 guide the white backing sheet F and the print medium W. The transport guide 36 has a pair of transport guide plates 36a and 36b. The support plate 39 supports the first conveying sensor 31, the second conveying sensor 32, the third conveying sensor 33, the conveying motor 35, the conveying rollers Ro1 to Ro12, the conveying guide 36, the first conveying guide piece 37, and the second conveying guide piece 38.

[0039] The "first transport path" refers to the path from the position where the second transport sensor 32 detects the white backing sheet F and the print medium W to the target position on the first lower mold M1 to which the white backing sheet F and the print medium W are transported. The "second transport path" refers to the path from the target position to the position where the first transport sensor 31 detects at least a portion of the white backing sheet F and the print medium W (e.g., the remaining portion Fa of the white backing sheet F and the remaining portion Wa of the print medium W). The second transport path is a linear transport path. The transport path between the target position and the transport rollers Ro9 and Ro10 is a common portion of the first transport path and the second transport path. The transport path between the detection position of the second transport sensor and the transport rollers Ro9 and Ro10 is an individual portion of the first transport path (referred to as the "first individual portion"). The transport path between the transport rollers Ro9 and Ro10 and the transport rollers Ro11 and Ro12 is an individual portion of the second transport path (referred to as the "second individual portion"). The second transport sensor 32 is located in the first individual portion, and the first transport sensor 31 is located in the second individual portion.

[0040] The transport motor 35, transport rollers Ro1 to Ro12, transport guide 36, first transport guide piece 37, second transport guide piece 38, and support plate 39 constitute a transport mechanism. The transport mechanism uses the transport motor 35 as a drive source to transmit driving force to the transport rollers Ro1 to Ro12, thereby transporting at least a portion of the white backing sheet F along the first transport path and the second transport path. On the first transport path, the transport motor 35 and transport rollers Ro7 to Ro10 function as a first transport mechanism to transport the white backing sheet F and the print medium W. On the second transport path, the transport motor 35 and transport rollers Ro9 to Ro12 function as a second transport mechanism to transport at least a portion of the white backing sheet F and the print medium W.

[0041] The guide unit 5 has a rotary support table 54. The rotary support table 54 rotates around a rotation shaft 54b while supporting the first lower mold M1 and the second lower mold M2. This causes the first lower mold M1 and the second lower mold M2 to rotate between the loading position P1 and the connection position P2. A transport stopper S is erected on the rotation shaft 54b. The transport stopper S restricts the movement of the white backing sheet F and the print medium W that have been transported backward beyond the target position. The distance from the transport nip of the transport rollers Ro9 and Ro10 to the transport stopper S is shorter than the overall length of the white backing sheet F and the print medium W in the transport direction ( FIG. 10B ).

[0042] [Operation of the Conveying Unit 3] When the printing device 1 supplies a white backing sheet F, the third conveying sensor 33 detects the white backing sheet F and outputs a detection signal to the second drive circuit 115. When the control unit 11 receives the detection signal from the third conveying sensor 33, it drives the conveying motor 35 to rotate the conveying rollers Ro1 to Ro12 and convey the white backing sheet F. The conveying guide 36 changes the traveling direction of the white backing sheet F, which is output from rear to front in the front-rear direction Dx, to downward to upward in the vertical direction Dz. The stiffness of the white backing sheet F varies depending on its material and environmental conditions. Therefore, the path along which the white backing sheet F passes is not always the same. To account for variations in the path along which the white backing sheet F passes, the distance between the pair of conveying guide plates 36a, 36b is set sufficiently wide relative to the thickness of the white backing sheet F or the print medium W. The conveying rollers Ro1 to Ro10 convey the white backing sheet F along the conveying guide 36 and the first conveying guide piece 37 to the first lower mold M1. The first transport guide piece 37 curves the transport path of the white backing sheet F. The second transport sensor 32 detects the white backing sheet F at the curved portion of the transport path.

[0043] The drive amount of the transport motor 35 is proportional to the transport distance from the white backing sheet F. When the drive amount of the transport motor 35 reaches a predetermined drive amount (referred to as the "first drive amount"), the control unit 11 stops the rotational drive of the transport motor 35. The control unit 11 stores the first drive amount in the memory unit 112 in order to determine the timing to stop the transport of the white backing sheet F. After the rotational drive of the transport motor 35 is stopped, the white backing sheet F is also transported by the inertial rotation of the transport motor 35 and the transport rollers Ro1 to Ro12.

[0044] The transport stopper S restricts the movement of the white liner F and the print medium W when the transport unit 3 has transported them too far. After that, when the peeling unit 4 presses and fixes the white liner F, the control unit 11 reverses the rotation direction of the transport motor 35 and drives it to rotate. The transport rollers Ro9 to Ro12 transport the remaining portion Fa of the white liner F along the second transport guide piece 38 to the collection box 9. The first transport sensor 31 detects the remaining portion Fa of the white liner F being transported toward the collection box 9. The third transport sensor 33 detects the leading edge of the white liner F. The first transport sensor 31 and the second transport sensor 32 may detect the leading edge or trailing edge of the white liner F in the transport direction. The operation of the transport unit 3 is similar to that described above when the printing device 1 supplies the print medium W.

[0045] [Adjusting the First Drive Amount of the Conveying Unit 3] As described above, in the curved portion of the conveying path defined by the first conveying guide piece 37, the way in which the white backing F itself curves varies depending on the stiffness of the white backing F. For this reason, the timing at which the second conveying sensor 32 detects the leading edge of the white backing F can vary. Therefore, in order to accurately convey the connected portion Fb of the white backing F and the connected portion Wb of the print medium W to the desired position on the first lower mold, it is necessary to appropriately adjust the first drive amount, which is the number of pulses of the rotary encoder that determines the drive amount (conveyance distance) of the white backing F and the print medium W after the second conveying sensor 32 detects the white backing F and the print medium W.

[0046] In the conveying section 3, the first conveying guide piece 37 curves the conveying path of the white backing sheet F. The stiffness of the white backing sheet F can vary depending on the material and environmental conditions such as temperature and humidity. If the stiffness of the white backing sheet F varies, the curved state that the white backing sheet F can assume at the curved section will also vary. For this reason, the first drive amount required to accurately convey the white backing sheet F may also vary, making it necessary to adjust the first drive amount.

[0047] Fig. 8 is a flowchart showing the procedure for adjusting the conveyance unit 3. In Fig. 8, the shaded flowchart symbols represent processes in which the external device 12 executes an application program, while the unshaded flowchart symbols represent processes in which the control unit 11 executes firmware.

[0048] 8 , external device 12 first receives an input from an operator who adjusts conveyance unit 3 requesting adjustment of badge production apparatus 100 (S1). This process may be performed by receiving a button operation on a GUI screen displayed by an application program on external device 12. Next, upon receiving an adjustment request for badge production apparatus 100 from the operator (S2), external device 12 transmits the adjustment instruction to control unit 11 of badge production apparatus 100 (S3).

[0049] When the control unit 11 receives the adjustment instruction, it checks whether the adjustment is manual or not. If the instruction is automatic adjustment (N in S4), the control unit 11 requests printing from the external device 12 (S5). The external device 12 requests printing from the printing device 1 (S6). The printing device 1 supplies a white backing sheet to the transport unit 3. Note that the printing device 1 may supply a print medium W instead of the white backing sheet F. The printing device 1 may also supply the print medium W with an image printed on it, or may supply the print medium W without an image printed on it.

[0050] As the adjustment drive, the control unit 11 first executes a first process to transport the white backing sheet F, which is the medium, along the first transport path toward the target position at a first drive amount (S7). When the third transport sensor 33 detects the white backing sheet F, the control unit 11 starts rotational driving of the transport motor 35 to rotate the transport rollers Ro1 to Ro12. The transport rollers Ro1 to Ro12 transport the white backing sheet F along the transport path.

[0051] 9A, when the edge Fe1 of the white backing sheet F reaches the detection position of the second conveyance sensor 32, the second conveyance sensor 32 detects the edge Fe1 of the white backing sheet F. Upon receiving the detection signal from the second conveyance sensor 32, the control unit 11 starts counting the number of output pulses of the rotary encoder of the conveyance motor 35.

[0052] When the count value of the number of pulses reaches the first drive amount, the control unit 11 stops driving the conveyance motor 35. As shown in Figure 9(B) , if the first drive amount is appropriate, the white backing sheet F stops at the target position. In Figure 9(B) , the white backing sheet F stops when the edge Fe1 of the white backing sheet F just abuts against the conveyance stopper S.

[0053] Next, the control unit 11 executes a second process to transport at least a portion of the white backing sheet F, which is the medium, from the target position along the second transport path. The control unit 11 starts driving the transport motor 35 to rotate in the reverse direction and newly starts counting the number of pulses of the rotary encoder. This causes the transport rollers Ro1 to Ro12 to rotate in the reverse direction, transporting the white backing sheet F along the second transport path. The white backing sheet F is guided to the first transport sensor 31 by the second transport guide piece 38.

[0054] As shown in Figure 9 (C), when the white backing sheet F reaches the detection position of the first conveyance sensor 31, the first conveyance sensor 31 detects the edge Fe2 of the white backing sheet F. The control unit 11 sets the pulse count value of the rotary encoder at that time as the second drive amount. As shown in Figure 9 (B), if the first drive amount is appropriate, the drive amount required to move the edge Fe2 of the white backing sheet F from the position where the edge Fe1 of the white backing sheet F just abuts the conveyance stopper S to the position detected by the first conveyance sensor 31 becomes the second drive amount. The white backing sheet F is then conveyed to the collection box 9.

[0055] The memory unit 112 stores a reference drive amount for the transport unit 3 to transport at least a portion of the white backing sheet F and print medium W, which are media, from the target position to the detection position of the first transport sensor 31. The control unit 11 compares the second drive amount with the reference drive amount, and if the difference between them is not within a predetermined range (for example, within ±1% of the reference drive amount) (N in S8), corrects the parameters (S9). For example, the first drive amount is corrected by adding the difference between the second drive amount and the reference drive amount as shown in the following equation.

[0056] (corrected first drive amount) = (uncorrected first drive amount) + {(reference drive amount) - (second drive amount)} The above is the third process that corrects the first drive amount based on the second drive amount from the start of the second process to the time when the first conveyance sensor 31 detects at least a portion of the medium. The badge production apparatus 100 executes the first process, the second process, and the third process.

[0057] 10A, when the first drive amount is insufficient, the second drive amount becomes less than the reference drive amount by that amount. Therefore, by using the above formula to increase the first drive amount by the amount of the second drive amount that is insufficient, the white backing sheet F can be transported to the appropriate position. That is, in the third process, the control unit 11 performs a correction to increase the first drive amount, provided that the second drive amount is less than the reference drive amount.

[0058] On the other hand, as shown in FIG. 10B , when the first drive amount is excessive, the second drive amount becomes greater than the reference drive amount by the excess amount. Therefore, by using the above formula to reduce the first drive amount by the excess amount of the second drive amount, the white backing sheet F can be transported to the appropriate position. That is, in the third process, the control unit 11 performs a correction to reduce the first drive amount, provided that the second drive amount is greater than the reference drive amount. The number of times the first drive amount is corrected as described above is set as the number of retries. If the number of retries is one (N in S10), the control unit 11 proceeds to step S5 and repeats the above process.

[0059] If the error of the second drive amount relative to the reference drive amount is within the allowable range, the control unit 11 sets the current first drive amount as the parameter (S11). After the processing of step S11, or after two retries (Y in S10), the control unit 11 responds to the external device 12 with the adjustment result (S12). That is, if the parameter is set in step S11, the control unit 11 responds that the adjustment was successful. On the other hand, if two retries have been performed, the parameter cannot be set, so the control unit 11 responds that the adjustment failed. The external device 12 displays the adjustment result received from the control unit 11 and ends the processing.

[0060] On the other hand, if the adjustment instruction is not for automatic adjustment but for manual adjustment (Y in S4), the control unit 11 also requests printing from the external device 12 (S15). The external device 12 that has received the printing request causes the printing device 1 to execute printing in the same manner as in the case of automatic adjustment (S16). The operator then manually executes the adjustment drive (S17). In step S17, when the third transport sensor 33 detects the white backing sheet F or the print medium W, the control unit 11 starts driving the transport motor 35 to rotate the transport rollers Ro1 to Ro12 and transport the white backing sheet F or the print medium W along the first transport path.

[0061] When the second transport sensor 32 detects the leading edge of the white backing F or print medium W, the control unit 11 begins counting the number of pulses output by the rotary encoder. When the counted value of the number of pulses reaches the first drive amount, the control unit 11 stops driving the transport motor 35. The operator performing manual adjustment visually checks the position of the white backing F or print medium W and inputs any excess or deficiency in the transport distance of the white backing F or print medium W into the external device 12 as a correction value. The external device 12 sends the correction value to the control unit 11 (S18). If the correction value is not 0 (N in S19), the control unit 11 corrects the first drive amount by an amount equivalent to the correction value and proceeds to step S17.

[0062] On the other hand, if the correction value is 0 (Y in S19), the control unit 11 sets the current first drive amount as a parameter (S20) and responds with the adjustment result to the external device 12 (S21). The external device 12 displays the adjustment result received from the control unit 11 and ends the process. Note that the control unit 11 may store in the memory unit 112 the drive amount of the transport motor 35 from the start of the second process until the first transport sensor 31 detects at least a portion of the white backing F or the print medium W, as a reference drive amount, on the condition that it receives a signal indicating that the white backing F or the print medium W is positioned at the target position, indicating that the correction value is 0. In this way, the reference drive amount can be set with high accuracy.

[0063] [Configuration of Peeling Unit 4] The peeling unit 4 is disposed to the left front of the loading position P1 so as to face the first loading unit 2 across the loading position P1 ( FIG. 3 ). As shown in FIGS. 11 and 12 , the peeling unit 4 includes a peeling home sensor 41, a peeling motor 42, a speed reducing mechanism 43, a connecting shaft 44, a peeling arm 45, a support block 46, a remaining portion pressing head 47, a peeling head 48, and a peeling light blocking piece 49.

[0064] The peeling home sensor 41 is an optical sensor. The peeling motor 42 is driven and controlled by the control unit 11. The reduction gear 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 the standby position and the 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. 12(A), and the pressing and fixing position is the position of the peeling arm 45 shown in FIG. 12(C).

[0065] 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.

[0066] [Operation of Peeling Unit 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 control unit 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 ( FIG. 12(A) ). When the control unit 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.

[0067] When the head main body 47b comes into contact with the remaining portion Fa of the white mount F, movement of the head main body 47b is prevented (FIG. 12(B)). The peeling head 48 reaches the connected portion Fb of the white mount F at the pressing and fixing position while elastically deforming the spring 47c, and presses and fixes it (FIG. 12(C)). In this way, the force with which the peeling head 48 collides with the connected portion Fb of the white mount F and the front member SE is reduced. After peeling of the connected portion Fb of the white mount F is completed, the control unit 11 rotates the peeling motor 42 in the reverse direction to return the peeling arm 45 to the origin position.

[0068] [Effects of the Embodiment] Using the transport unit 3 described above, the white backing sheet F and the print medium W can be placed on the first lower mold M1 with high positional accuracy without manual operation. When multiple pairs of transport rollers are arranged in the first transport path, slippage between the white backing sheet F and the print medium W and the transport rollers due to differences in transport speed between the transport rollers can prevent the white backing sheet F and the print medium W from being transported to the target position even when the transport motor 35 is driven by the first drive amount. To address this issue, as in the present embodiment, by providing only one pair of transport rollers Ro9 and Ro10 in the first transport path, problems caused by differences in transport speed between the transport rollers can be avoided, allowing the white backing sheet F and the print medium W to be transported to the target position with high positional accuracy. The position of the white backing sheet F and the print medium W on the first lower mold M1 can be accurately adjusted without relying on an operator skilled in adjusting the badge production device 100, thereby improving user convenience of the badge production device 100. The conveying unit 3 can be adjusted while the outer casing 101 is attached to the can badge manufacturing device 100, without the user having to approach moving parts or electrically conducting parts of the can badge manufacturing device 100, thereby ensuring the safety of the user.

[0069] [Modifications] (1) Although not specifically mentioned in the above embodiment, when the white mount F or the print medium W is transported via the second transport path, it is desirable not to use the peeling head 48 of the peeling unit 4 to press and fix the connected portion Fb of the white mount F or the connected portion Wb of the print medium W. Depending on conditions such as paper quality and temperature and humidity, the connecting portion Fc and linear weak portion Fd of the white mount F or the connecting portion Wc and linear weak portion Wd of the print medium W may be difficult to break. Even if the connected portion Fb of the white mount F or the connected portion Wb of the print medium W is pressed and fixed, if the white mount F and the print medium W are difficult to break, there is a risk of slippage occurring between the remaining portion Fa of the white mount F or the remaining portion Wa of the print medium W and the transport rollers Ro9, Ro10.

[0070] In such a case, the transport motor 35 rotates and the number of pulses of the rotary encoder increases, making it impossible to measure the second drive amount accurately, even though the remaining portion Fa of the white mount F or the remaining portion Wa of the print medium W has not moved. To address this problem, if the white mount F or the print medium W is transported without using the peeling head 48 to press and fix the connected portion Fb of the white mount F or the connected portion Wb of the print medium W, the second drive amount can be measured accurately.

[0071] (2) In the above embodiment, the case where the difference between the second drive amount and the reference drive amount is used as the correction amount for the first drive amount in the third process has been described as an example, but the present disclosure is not limited to this. For example, the correction amount for the first drive amount may be an amount proportional to the difference between the second drive amount and the reference drive amount.

[0072] (3) The transport path from the transport rollers Ro11 and Ro12 to the collection box 9 may be linear or may have a curved portion. Because the transport rollers Ro11 and Ro12 are disposed between the transport path from the transport rollers Ro11 and Ro12 to the collection box 9 and the second transport path, the transport state of the white backing sheet F and print medium W on the transport path from the transport rollers Ro11 and Ro12 to the collection box 9 is blocked by the transport rollers Ro11 and Ro12 and is unlikely to be transmitted to the second transport path. Therefore, the shape of the transport path from the transport rollers Ro11 and Ro12 to the collection box 9 can be set without affecting the second drive amount.

[0073] (4) In the above embodiment, the second drive amount is compared with the reference drive amount, and if the difference between them is not within a predetermined range (for example, within ±1% of the reference drive amount) (N in S8), the parameter is corrected (S9). However, the present disclosure is not limited to this. For example, an allowable range of the reference drive amount may be stored in advance. In this case, if the second drive amount is not within the allowable range of the previously stored reference drive amount, the parameter is corrected. This also achieves the same effects as the above embodiment.

[0074] (5) The present disclosure may be a method for correcting a first driving amount in the conveying unit 3 executed by the badge production device 100.

[0075] LIST OF SYMBOLS 1...Printing device 2...First loading section 3...Conveying section 4...Removing section 5...Guiding section 6...Connection section 7...Second loading section 8...Removing section 9...Collection box 10...Pot badge holder 11...Control section 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...Removing home sensor 42...Removing motor 51...Guiding home sensor 53...Guiding motor 61...Connection home sensor 62...Connection motor 71...Second loading home sensor 72...Second loading motor 81...Removing home sensor 82...Removing motor 100...Pot badge manufacturing device 110...Controlling device 200...Pot badge BE...Backing member F...White backing Fa...Remaining portion of white backing F M0...Upper mold M1...First lower mold M2...Second lower die SE...Front member W...Print medium Wa...Remaining portion of print medium W

Claims

1. A can badge manufacturing device that uses a mold to connect a medium having an image recorded thereon to a front member and a back member to manufacture a can badge, the can badge manufacturing device comprising: a transport unit having a first transport path for transporting the medium to a target position on the mold, a second transport path for transporting at least a portion of the medium from the target position, and a transport mechanism for transporting at least a portion of the medium along the first transport path and the second transport path; a first sensor for detecting the medium transported along the second transport path; and a control unit, wherein the control unit controls the transport mechanism to perform the following: a first process for transporting the medium along the first transport path toward the target position at a first drive amount; a second process for transporting at least a portion of the medium from the target position along the second transport path; and a third process for correcting the first drive amount based on the second drive amount of the transport mechanism from the start of the second process to the time when the first sensor detects at least a portion of the medium.

2. A can badge manufacturing device as described in claim 1, further comprising a memory that stores a reference drive amount for the conveying mechanism to convey at least a portion of the medium from the target position to the detection position of the first sensor, and in the third process, the control unit performs a correction to increase the first drive amount on condition that the second drive amount is less than the reference drive amount, and performs a correction to decrease the first drive amount on condition that the second drive amount is greater than the reference drive amount.

3. A can badge manufacturing device as described in claim 2, wherein the control unit, in the third processing, sets an amount proportional to the difference between the second drive amount and the reference drive amount as the correction amount for the first drive amount.

4. A can badge manufacturing device as described in claim 2 or 3, wherein the control unit executes the second process on the condition that it receives a signal indicating that the medium is located at the target position, and stores in the memory the drive amount of the conveying mechanism from the start of the second process until the first sensor detects at least a portion of the medium as the reference drive amount.

5. A can badge manufacturing device as described in claim 1, further comprising a second sensor that detects the medium being transported along the first transport path, and the control unit executes the first process after the second sensor detects the medium.

6. A can badge manufacturing device as described in claim 5, wherein the first conveying path has a common portion and a first individual portion, the second conveying path has the common portion and a second individual portion, the first sensor detects at least a portion of the medium conveyed along the second individual portion, and the second sensor detects the medium conveyed along the first individual portion.

7. The can badge manufacturing device according to claim 1, wherein the first conveying path is at least partially curved, and the second conveying path is linear.

8. The can badge manufacturing apparatus described in claim 1, wherein the conveying mechanism comprises: a drive source; a first conveying mechanism to which the driving force of the drive source is transmitted to convey the medium along the first conveying path; and a second conveying mechanism to which the driving force of the drive source is transmitted to convey at least a portion of the medium along the second conveying path.

9. A correction method for a can badge manufacturing device that uses a mold to connect a medium on which an image is recorded, a front member, and a back member to manufacture a can badge, the correction method comprising: driving a conveying mechanism at a first drive amount to convey the medium along a first conveying path toward a target position on the mold; driving the conveying mechanism to convey at least a portion of the medium from the target position along a second conveying path; and correcting the first drive amount based on a second drive amount of the conveying mechanism from when at least a portion of the medium has been conveyed from the target position to when a first sensor detects at least a portion of the medium on the second conveying path.

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