Button badge production system

Abstract

Provided is a button badge production system that, even when a material runs out during continuous production of button badges, resumes button badge production without wasting the material of a button badge for which production has been interrupted. A button badge production system 300 comprises a printer 1, a crimping machine 100, and a controller 12. The crimping machine 100 includes a first stocker 2a capable of holding a plurality of shells SE, a first supply mechanism 2, and a first die M1. Upon receipt of instructions to produce two or more button badges, the controller 12 causes the first supply mechanism 2 to supply a first shell SE1 from the first stocker 2a to the first die M1. After the supply of the first shell SE1, the controller 12 causes the printer to start printing on a first base sheet WF1. After the printing on the first base sheet WF1, the controller 12 causes the printer 1 to supply the first base sheet WF1 to the crimping machine 100. If there is no second shell SE2 in the first stocker 2a, the controller 12 stops printing on a second base sheet WF2.

Description

Badge production system

[0001] The present disclosure relates to a can badge production system for producing can badges.

[0002] Patent Document 1 discloses a can badge manufacturing device that includes a printing unit that prints an image on a film, a covering unit that covers the front lid with the film, and a can product assembling unit that joins the front lid and the back lid covered with the film. The covering unit and the can product assembling unit crimp the material.

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

[0004] An apparatus has been devised that includes a printer that prints an image on a sheet and a crimping machine that performs crimping. In this apparatus, the sheet with the printed image is fed to the crimping machine, which crimps the sheet, the front member, and the back member together to complete a can badge. In this apparatus, printing of an image on a sheet and crimping can be performed in parallel. For example, while the crimping machine is crimping a previous sheet to the front member and the back member, the printer can print an image on the next sheet. This allows printing for the next can badge to be performed before the previous can badge is completed, thereby reducing the time required to continuously produce multiple can badges.

[0005] In the above-mentioned device, badge materials such as a sheet, a front member, and a back member, as well as color materials for printing an image on the sheet, are consumed to complete a badge. To continuously produce multiple badges, a user refills the device with multiple pieces of each material. When continuously producing multiple badges, if the badge material or color materials run out, the user cannot produce the next badge. Therefore, the user must replenish the material or color materials. When the user replenishes the material or color materials, the printer and crimping machine are stopped. However, stopping the printer and crimping machine means that the production of badges is interrupted. Some users remove the badge material (e.g., consisting of a sheet and a front member) from the device when the printer and crimping machine stop. The user then replenishes the material or color materials. However, if the material for the can badge being produced is removed from the device, the material for the can badge being produced will be wasted and production of the can badge using the material for the can badge being produced will not be able to be resumed.

[0006] The object of the present disclosure is to provide a can badge production system that, even if material runs out while can badges are being produced continuously, allows the production of can badges to continue without wasting material for can badges in the middle of being produced.

[0007] (1) The can badge production system according to the present disclosure is a can badge production system including a printer, a crimping machine, and a controller, wherein the crimping machine has a first stocker capable of holding a plurality of shells, a first supply mechanism, and a first mold, and the controller, on the condition that two or more can badge production instructions have been received, causes the first supply mechanism to supply a first shell from the first stocker to the first mold, and after supplying the first shell, causes the printer to start printing a first backing sheet, and after printing the first backing sheet, causes the printer to supply the first backing sheet to the crimping machine, causes the first supply mechanism to detect the presence or absence of a second shell in the first stocker, and executes or stops printing of the second backing sheet depending on the presence or absence of the second shell.

[0008] If the backing paper for the second badge is printed while the first badge is being produced, provided that a shell for the second badge is available, the production of the second badge can be completed quickly. If the shell for the second badge is not available, the second badge cannot be produced, and therefore printing the backing paper for the second badge would be wasted. With the above configuration, printing the backing paper for the second badge is stopped provided that a shell for the second badge is not available, thereby reducing backing paper waste.

[0009] (2) The controller may stop printing on the second mount if it detects that the second shell is absent.

[0010] (3) The crimping machine may have a conveying mechanism and a crimping mechanism, and the controller may cause the conveying mechanism to supply the printed first mount to the first mold, cause the printer to start printing the first medium, and after printing of the first medium is completed, cause the printer to supply the first medium to the crimping machine, and after supplying the first medium is completed, stop the printer, cause the conveying mechanism to supply the first medium supplied from the printer to the first mold, and cause the crimping mechanism to crimp the first shell, the first mount, and the first medium together to produce a first outer material.

[0011] (4) The crimping machine may have a second stocker capable of holding a plurality of back parts, a second supply mechanism, and a second mold, and the controller may cause the second supply mechanism to supply the first back part from the second stocker to the second mold after production of the first outer material is completed or in parallel with production of the first outer material, and after production of the first outer material is completed and after supplying the first back part, cause the crimping mechanism to crimp the first outer material and the first back part to produce a first can badge, and after production of the first can badge is completed, stop operation of the crimping machine.

[0012] (5) The crimping machine may have a conveying mechanism and a crimping mechanism, and the controller may cause the conveying mechanism to supply the first mount to the first mold, cause the printer to start printing the first medium, and after printing of the first medium is completed, cause the printer to supply the first medium to the crimping machine, cause the conveying mechanism to supply the first medium supplied from the printer to the first mold, and cause the crimping mechanism to crimp the first shell, the first mount, and the first medium together to produce a first surface material.

[0013] (6) The controller may cause the printer to stop printing on the second mount if it detects that there is no color material remaining in the printing on the first medium.

[0014] (7) The crimping machine may have a second stocker capable of holding a plurality of back parts, a second supply mechanism, and a second mold, and the controller may cause the second supply mechanism to supply the first back part from the second stocker to the second mold after production of the first outer material is completed or in parallel with production of the first outer material, and after production of the first outer material is completed and after supplying the first back part, cause the crimping mechanism to crimp the first outer material and the first back part to produce a first can badge.

[0015] (8) The printer may have a first tray capable of holding multiple backing sheets, and the controller may cause the printer to detect the presence or absence of a second backing sheet in the first tray after printing of the first medium is completed, and may stop printing of the second backing sheet if it detects that the second backing sheet is absent.

[0016] (9) The printer has a first tray capable of holding a plurality of backing sheets, and the controller, after completing printing of the first medium, causes the printer to detect the presence or absence of a second backing sheet in the first tray, and, if the presence of the second backing sheet is detected, causes the printer to start printing of the second backing sheet. After completing production of the first can badge, the controller causes the first supply mechanism to supply a second shell from the first stocker to the first mold, and after completing the supply of the second shell, causes the printer to supply the second backing sheet to the crimping machine.

[0017] (10) The printer may have a second tray capable of holding multiple media, and after printing of the second mount is completed, the controller may cause the printer to detect whether or not there is a second medium in the second tray, and may start printing of the second medium if it detects that the second medium is present.

[0018] (11) The printer may have a second tray capable of holding multiple media, and the controller may cause the printer to detect the presence or absence of second media in the second tray after printing of the second mount is completed, and may stop printing of the second media if it detects that the second media is absent.

[0019] (12) After the production of the first can badge is completed, the controller may cause the second supply mechanism to detect the presence or absence of a second back part in the second stocker, cause the first supply mechanism to supply the second shell from the first stocker to the first mold, cause the printer to supply the second backing and the second medium to the first mold, cause the crimping mechanism to crimp the second shell, the second backing, and the second medium together to produce a second outer material, and may stop operation of the crimping machine after the production of the second outer material is completed, provided that the absence of the second back part is detected.

[0020] (13) After the production of the first can badge is completed, the controller may cause the second supply mechanism to detect the presence or absence of a second back part in the second stocker, cause the first supply mechanism to supply a second shell from the first stocker to the first mold, cause the printer to supply the second backing and the second medium to the first mold, cause the crimping mechanism to crimp the second shell, the second backing, and the second medium together to produce a second outer material, and supply the second back part from the second stocker to the second mold, and, on the condition that the presence of the second back part is detected, cause the second outer material and the second back part to be crimped together to produce a second can badge after the production of the second outer material is completed.

[0021] According to the present disclosure, even if material runs out while can badges are being produced continuously, the material used in the process of producing the can badges is not wasted and production of the can badges can continue.

[0022] FIG. 1 is an external perspective view of the can badge production system 300. FIG. 2 is an external perspective view of the can badge production system 300 with the exterior body 101 removed. FIG. 3 is a top view of the can badge production system 300 with the exterior body 101 removed. FIG. 4 is a block diagram of the first control unit 11 of the crimping machine 100. FIG. 5 is a cross-sectional view showing the configuration of the can badge 200. FIG. 6(A) is a top view of the medium PF, and FIG. 6(B) is a top view of the backing sheet WF. FIG. 7 is a schematic diagram showing the main components of the printer 1. FIG. 8 is a block diagram showing the main components of the second control unit 50 of the printer 1. FIG. 9 is a block diagram showing the main components of the controller 12. FIG. 10 is a cross-sectional perspective view showing the configuration of the first supply mechanism 2. FIG. 11 is a timing chart showing the operation of the can badge production system 300. FIG. 12 is a timing chart following FIG. 11 showing the operation of the can badge production system 300. FIG. 13 is a timing chart following FIG. 12 showing the operation of the can badge production system 300. Fig. 14 is a timing chart illustrating the operation of the can badge production system 300, following Fig. 13. Fig. 15 is a sequence diagram illustrating the operation of the can badge production system 300 when the material for the can badge 200 runs out. Fig. 16 is a sequence diagram illustrating the operation of the can badge production system 300, following Fig. 15.

[0023] The following describes in detail the can badge production system 300 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.

[0024] 1 to 3, the up-down direction is defined based on the state in which the can badge production system 300 is installed and ready for use. The front-rear direction is defined with the side where the conveying mechanism 3 is installed as the front side. The left-right direction is defined when looking at the can badge production system 300 from the front. The ordinal numbers assigned to the medium PF, mount WF, shell SE, and back part BE, which are the materials for the can badge 200, correspond to the order in which the can badge 200 is completed. For example, the materials for the first completed can badge 200 are represented as the first medium PF1, the first mount WF1, the first shell SE1, the first front material FM1, and the first back part BE1. The materials for the second completed can badge 200 are the second medium PF2, the second mount WF2, the second shell SE2, the second front material FM2, and the second back part BE2. The same applies to the ordinal numbers assigned to the can badges 200 themselves. That is, the first completed can badge 200 is referred to as the first can badge 200, and the second completed can badge 200 is referred to as the second can badge 200. When the printer 1 stops printing, it means that it is waiting to print. Printing also includes the medium PF and backing paper WF passing through the printer 1 without ink being ejected.

[0025] 1 to 5 , the can badge production system 300 includes a printer 1, a crimping machine 100, a controller 12, and an exterior body 101. The printer 1 supplies a medium PF and a backing paper WF to the crimping machine 100 as materials for the can badge 200. The crimping machine 100 produces the can badge 200. The controller 12 monitors and controls the operation of the printer 1 and the crimping machine 100. The exterior body provides a neat appearance for the can badge production system 300 and ensures the safety of the user.

[0026] [Overview of the Can Badge 200] As shown in Figure 5, the can badge 200 has a surface material FM and a back part BE. The surface material FM has, from the front side, a medium PF, a backing paper WF, and a shell SE. The can badge 200 is crimped by folding the peripheral portions of the medium PF and backing paper WF toward the back side of the shell SE and sandwiching them between the shell SE and the back part BE. As described below, the can badge 200 is removed by magnetic attraction, so a magnetic material such as tin-plated steel sheet is used as the material for at least one of the shell SE and the back part BE.

[0027] [Medium PF] Medium PF is a transparent film of L size (89 mm x 127 mm). One side of medium PF is the printing surface. The printing surface has an ink-receiving layer, and a mirror image (reversed image) of a predetermined image is printed on it. By facing the printing surface to the back of the can badge 200, a normal image of the predetermined image is displayed on the front side of the can badge 200. Note that medium PF may be a size other than L size. Medium PF may also be a translucent film.

[0028] As shown in FIG. 6A, the medium PF has a remaining medium portion PFa, a connected medium portion PFb, a connecting medium portion PFc, and a linear weak portion PFd. One short side of the medium PF is referred to as the medium edge portion PFe1. The remaining medium portion PFa is an ear portion that the transport mechanism 3 uses to transport the medium PF from the printer 1 to the first mold M1. A predetermined image is printed on the connected medium portion PFb. The connected medium portion PFb is surrounded by the remaining medium portion PFa. The connected medium portion PFb has a contour shape that corresponds to the shell SE and is larger in diameter than the shell SE. The connected medium portion PFb is biased toward the edge portion PFe1. The connecting medium portion PFc is the boundary between the remaining medium portion PFa and the connected medium portion PFb. The medium linear weak portion PFd is a straight portion that connects the medium edge portion PFe1 and the medium connecting portion PFc over the shortest distance. The medium connecting portion PFc and the medium linear weak portion PFd are weaker than the medium remaining portion PFa and the medium connected portion PFb and are more susceptible to breakage. The medium connecting portion PFc and the medium linear weak portion PFd may be, for example, a depression that is thinner than the medium remaining portion PFa and the medium connected portion PFb. The thickness of the medium connecting portion PFc and the medium linear weak portion PFd may be the same as the thickness of the medium remaining portion PFa and the medium connected portion PFb, and perforations that partially cut the medium connecting portion PFc and the medium linear weak portion PFd may be formed. Hereinafter, the medium connected portion PFb may be referred to as the medium PF for short.

[0029] [Backing Paper WF] The backing paper WF is a white film of L size. The backing paper WF may be a size other than L size. The size of the backing paper WF may be different from the size of the medium PF. The backing paper WF may be a color other than white. An image may be printed on the backing paper WF instead of the medium PF, or an image may be printed on both the medium PF and the backing paper WF. The can badge 200 does not need to have a backing paper WF. If the backing paper WF is omitted and the front side of the shell SE has a metallic luster, the front side of the can badge 200 can be given a metallic luster.

[0030] As shown in FIG. 6(B), the backing sheet WF has a backing sheet remaining portion WFa, a backing sheet connected portion WFb, a backing sheet connecting portion WFc, and a backing sheet linear weak portion WFd. One short side of the backing sheet WF is referred to as the backing sheet edge portion WFe1. The backing sheet remaining portion WFa is a lug portion used by the transport mechanism 3 to transport the backing sheet WF from the printer 1 to the first mold M1. The backing sheet connected portion WFb is surrounded by the backing sheet remaining portion WFa. The backing sheet connected portion WFb has a contour shape corresponding to the shell SE and is larger in diameter than the shell SE. The backing sheet connected portion WFb is biased toward the backing sheet edge portion WFe1. The backing sheet connecting portion WFc is the boundary portion between the backing sheet remaining portion WFa and the backing sheet connected portion WFb. The mount linear weak portion WFd is a straight line portion connecting the mount edge portion WFe1 and the mount connecting portion WFc over the shortest distance. The mount connecting portion WFc and the mount linear weak portion WFd are weaker than the mount remaining portion WFa and the mount connected portion WFb and are more likely to break. The mount connecting portion WFc and the mount linear weak portion WFd may be, for example, a depression thinner than the mount remaining portion WFa and the mount connected portion WFb. The thickness of the mount connecting portion WFc and the mount linear weak portion WFd may be the same as the thickness of the mount remaining portion WFa and the mount connected portion WFb, and perforations may be formed in the mount connecting portion WFc and the mount linear weak portion WFd, respectively. Hereinafter, the mount connected portion WFb may be referred to as the mount WF for short.

[0031] [Printer 1] The printer 1 is an inkjet printer. The printer 1 may have a serial head or a line head ejection head that ejects ink as a colorant. As shown in Figures 7 and 8, the printer 1 includes a first tray 20A, a second tray 20B, a first feeding unit 21A, a second feeding unit 21B, a transport roller unit 28, a recording unit 29, a discharge roller unit 32, a platen 40, a second control unit 50, a tray sensor 57, and a remaining amount sensor 58.

[0032] [First Tray 20A, Second Tray 20B] The first tray 20A and the second tray 20B are each detachably attached to the printer 1. The first tray 20A can hold a plurality of backing sheets WF. The second tray 20B can hold a plurality of media PF.

[0033] [First Feeder 21A, Second Feeder 21B] The first feeder 21A includes a shaft 22A, a feed arm 23A, and a feed roller 24A. The shaft 22A is supported by the frame of the printer 1. The feed arm 23A is rotatably supported on the shaft 22A. The feed arm 23A is biased downward by its own weight or the elastic force of a spring or the like. The feed roller 24A is rotatably supported at the rotating end of the feed arm 23A. The feed roller 24A is driven to rotate by the transport motor 55 and feeds the backing sheet WF held in the first tray 20A to the transport path 25. Similarly, the second feeder 21B includes a feed roller 24B, a feed arm 23B, and a shaft 22B, and feeds the medium PF supported in the second tray 20B to the transport path 25.

[0034] [Transport path 25] The transport path 25 starts at the rear ends of the first tray 20A and the second tray 20B, extends from bottom to top at the rear of the printer 1, makes a U-turn, passes through the recording unit 29, and reaches the receiving opening 3a of the transport mechanism 3. A portion of the transport path 25 is formed by an outer guide member 26 and an inner guide member 27 that face each other at a predetermined distance. Within the transport path 25, the backing sheet WF and the medium PF are transported in the transport direction indicated by the dashed arrow in Figure 7.

[0035] [Transport roller unit 28] The transport roller unit 28 is disposed upstream of the recording unit 29 in the transport direction. The transport roller unit 28 includes a transport roller 30 and a pinch roller 31. The pinch roller 31 is in pressure contact with the transport roller 30. When the transport roller 30 is driven to rotate by the transport motor 55, the pinch roller 31 rotates along with it. The backing sheet WF and the medium PF are sandwiched between the transport roller 30 and the pinch roller 31 and transported.

[0036] [Discharge Roller Unit 32] The discharge roller unit 32 is disposed downstream of the recording unit 29 in the transport direction. The discharge roller unit 32 includes a discharge roller 33 and a spur 34. The spur 34 is pressed against the discharge roller 33. When the discharge roller 33 is driven to rotate by the transport motor 55, the spur 34 rotates along with the discharge roller 33. The backing sheet WF and the medium PF are sandwiched between the discharge roller 33 and the spur 34 and transported.

[0037] [Third Sensor 35] The third sensor 35 is disposed upstream of the conveying roller unit 28 in the conveying direction. The third sensor 35 includes a support shaft 36 disposed outside the conveying path 25, an arm unit 37 that rotates around the support shaft 36, a light-shielding unit 38 that extends across the support shaft 36 to the opposite side of the arm unit 37, and an optical sensor 39. The optical sensor 39 is a so-called photointerrupter and includes a light-emitting unit and a light-receiving unit. The light-emitting unit is, for example, a light-emitting diode, and the light-receiving unit is, for example, a photodiode. The light-emitting unit irradiates light onto the light-receiving unit. The light-receiving unit outputs a signal corresponding to the amount of light received. The output signal from the light-receiving unit may be a voltage signal whose voltage changes depending on the amount of light received, or may be another signal. The arm unit 37 is pushed down and rotated when the backing sheet WF and the medium PF pass through the conveying path 25. The light-shielding portion 38 rotates together with the arm portion 37 to move forward and backward in the optical path of the light emitted by the light-emitting portion of the optical sensor 39, thereby changing the amount of light received by the light-receiving portion. Hereinafter, the output signal from the light-receiving portion of the optical sensor 39 will be referred to as the detection signal of the third sensor 35.

[0038] [Recording Unit 29] The recording unit 29 is located between the transport roller unit 28 and the discharge roller unit 32 in the transport direction. The recording unit 29 faces the platen 40 from above. The recording unit 29 includes a carriage 41 and a recording head 42. The carriage 41 is supported by guide rails 43 and 44. The guide rails 43 and 44 extend in the left-right direction and are spaced apart from each other in the front-to-rear direction. The carriage 41 moves back and forth along the guide rails 43 and 44. The recording head 42 is mounted on the carriage 41. A plurality of nozzles 45 are formed on the underside of the recording head 42. The recording head 42 ejects tiny ink droplets from the nozzles 45. As the carriage 41 moves, the recording head 42 ejects ink droplets onto the medium PF on the platen 40, thereby printing an image on the medium PF.

[0039] [Platen 40] The platen 40 is located between the transport roller unit 28 in the transport direction and the discharge roller unit 32. The platen 40 faces the recording unit 29 from below, and supports the backing sheet WF and medium PF transported by the transport roller unit 28 from below.

[0040] [Tray Sensor 57] The tray sensor 57 outputs a signal corresponding to the installation state of each of the first tray 20A and the second tray 20B. The installation state refers to whether the first tray 20A is installed in a state where the backing sheet WF can be fed, and whether the second tray 20B is installed in a state where the medium PF can be fed. The tray sensor 57 may be, for example, a mechanical sensor or an optical sensor.

[0041] [Remaining ink level sensor 58] The remaining ink level sensor 58 detects whether the ink level in the ink cartridge is above a predetermined level for each of the colors yellow (Y), magenta (M), cyan (C), and black (K). The printer 1 detects that there is ink if the ink level in the ink cartridge is above the predetermined level, and detects that there is no ink if the ink level in the ink cartridge is below the predetermined level. The remaining ink level sensor 58 may be, for example, a mechanical sensor or an optical sensor.

[0042] [Second Control Unit 50] The second control unit 50 includes a second calculation unit 51, a second storage unit 52, a second interface 53, and an ASIC (Application Specific Integrated Circuit) 54. The second calculation unit 51 is, for example, a central processing unit (CPU) or a field programmable gate array (FPGA). The second storage unit 52 is, for example, a read-only memory (ROM), a random access memory (RAM), an electrically erasable programmable read-only memory (EEPROM), a flash ROM, or a hard disk drive (HDD). The second interface 53 may be a wired interface such as a universal serial bus (USB) or a wireless interface such as Bluetooth (registered trademark). The second storage unit 52 stores programs and parameters. The second calculation unit 51 executes the programs in accordance with the parameters. The second interface 53 connects the second control unit 50 and the controller 12 to input and output signals. The ASIC 54 performs input / output processing for the second control unit 50. The ASIC 135 is connected to the carry motor 55, the carriage motor 56, the recording head 42, the third sensor 35, the tray sensor 57, and the remaining amount sensor 58. When a drive signal for the carry motor 55 is input from the second calculation unit 51, the ASIC 54 inputs a drive current corresponding to the drive signal to the carry motor 55. Similarly, when a drive signal for the carriage motor 56 is input from the second calculation unit 51, the ASIC 54 inputs a drive current corresponding to the drive signal to the carriage motor 56. When the carry motor 55 is driven to rotate in accordance with the drive current, the first feed unit 21A, the second feed unit 21B, the carry roller unit 28, the discharge roller unit 32, and the carriage 41 are driven. When the carriage motor 56 is driven to rotate in accordance with the drive current, the carriage 41 is driven.

[0043] The second control unit 50 detects that the liner WF is not present if the detection signal from the third sensor 35 does not change within a predetermined time after the second control unit 50 rotates the transport motor 55 and causes the first feed unit 21A to start feeding the liner WF. Furthermore, if the detection signal from the third sensor 35 changes within the predetermined time, the second control unit 50 detects that the liner WF is present. The second control unit 50 detects that the liner PF is not present if the detection signal from the third sensor 35 does not change within a predetermined time after the second control unit 50 rotates the transport motor 55 and causes the second feed unit 21B to start feeding the medium PF. Furthermore, if the detection signal from the third sensor 35 changes within the predetermined time, the second control unit 50 detects that the medium PF is present. The second control unit 50 and the second calculation unit 51 eject ink from the nozzles 45 of the recording head 42 in accordance with the image data. In this embodiment, ink is not ejected onto the liner WF. The second control unit 50 detects the installation state of each of the first tray 20A and the second tray 20B from the output signal of the tray sensor 57.

[0044] [Crimping Machine 100] The crimping machine 100 produces the can badges 200 using the backing paper WF and medium PF supplied by the printer 1. As shown in Figures 2 to 4, the crimping machine 100 includes a first supply mechanism 2, a conveying mechanism 3, a peeling mechanism 4, a rotation mechanism 5, a crimping mechanism 6, a second supply mechanism 7, a removal mechanism 8, a collection box 9, a can badge container 10, and a first control unit 11.

[0045] [First Supply Mechanism 2] As shown in FIG. 10, the first supply mechanism 2 includes a first stocker 2a, a first supply slope 2b, a first supply slider 2c, and a first sensor 2d. The first stocker 2a is a vertically elongated cylindrical member capable of holding multiple shells SE. The inside of the first stocker 2a in horizontal cross section is shaped to fit the outer shape of the shells SE. The first stocker 2a may be replaced to fit the outer shape of the shells SE. As shown in FIG. 2, the shells SE are stacked vertically in the first stocker 2a. Of the shells SE in the first stocker 2a, the lowest shell SE is placed on the first supply slope 2b.

[0046] The first supply slope 2b has a guide surface that guides the shell SE and the first supply slider 2c toward the first mold M1. A gap is provided between the guide surface of the first supply slope 2b and the lower end of the first stocker 2a, allowing just one shell SE to pass through. The first supply slider 2c is a flat member that reciprocates on the guide surface of the first supply slope 2b using a rack and pinion mechanism (not shown). The first supply slider 2c slides the lowest shell SE in the first stocker 2a along the guide surface of the first supply slope 2b and transports it to the first mold M1. This supplies the shell SE to the first mold M1. As described below, with the shell SE supplied to the first mold M1, the transport mechanism 3 sequentially transports the backing sheet WF and the medium PF onto the first mold M1.

[0047] The first sensor 2d has an arm 2d1, a spring 2d3, and a contact 2d4. The arm 2d1 is rotatably supported on a shaft 2d2. The spring 2d3 biases the rotating end of the arm 2d1 upward. When the weight of a shell SE in the first stocker 2a presses the tip of the arm 2d1 downward on the first stocker 2a, the contact 2d4 is opened. When there is no shell SE in the first stocker 2a, the rotating end of the arm 2d1 advances into the first stocker 2a, and the contact 2d4 becomes conductive. This allows the first supply mechanism to detect the presence or absence of a shell SE in the first stocker and output a signal according to the detection result.

[0048] [Transport mechanism 3] The transport mechanism 3 is disposed at the front of the badge production system 300, in a position covering the discharge port from the front through which the backing sheet WF and medium PF are discharged from the printer 1. The transport mechanism 3 has an acceptance port 3a, a fourth sensor 3b, a transport motor (not shown), and a group of transport rollers (not shown). The acceptance port 3a guides the backing sheet WF and medium PF discharged by the printer 1 to the fourth sensor 3b. The fourth sensor 3b detects the backing sheet WF and medium PF discharged by the printer 1. The transport motor rotates and drives the group of transport rollers. The group of transport rollers transports the backing sheet WF and medium PF from the acceptance port 3a to the first mold M1.

[0049] The transport mechanism 3 transports the backing sheet WF and medium PF from the printer 1 to the first mold M1. At this time, the backing sheet WF is transported in the first transport direction Dc1 with the backing sheet edge WFe1 at its leading edge, and the medium PF is transported in the first transport direction Dc1 with the medium edge PFe1 at its leading edge. The transport mechanism 3 also transports the backing sheet remaining portion WFa and the medium remaining portion PFa from the first mold M1 to the collection box 9. At this time, the backing sheet WF is transported in the second transport direction Dc2 with the backing sheet edge WFe2 at its leading edge, and the medium PF is transported in the second transport direction Dc2 with the medium edge PFe2 at its leading edge.

[0050] [Peeling Mechanism 4] The peeling mechanism 4 includes a peeling arm 4a and a peeling head 4b. The peeling arm 4a rotates around a rotation axis (not shown). The peeling head 4b is provided at the tip of the peeling arm 4a. Rotation of the peeling arm 4a causes the peeling head 4b to reciprocate between a standby position and a pressing and fixing position. At the pressing and fixing position, the peeling head 4b presses and fixes the mount WF on the first mold M1. With the peeling head 4b pressing and fixing the mount connected portion WFb on the first mold M1, the transport mechanism 3 transports the mount remaining portion WFa to the collection box 9. The mount connecting portion WFc and the mount linear weakened portion WFd are broken, and the mount connected portion WFb is peeled off from the mount remaining portion WFa. After the remaining portion WFa of the backing sheet is collected in the collection box 9, the peeling arm 4a rotates and the peeling head 4b moves to the standby position. Then, when the transport mechanism 3 supplies the medium PF onto the first mold M1, the connected portion PFb of the medium is peeled off from the remaining portion PFa of the medium in the same manner.

[0051] [Rotation Mechanism 5] The rotation mechanism 5 includes a rotary support table 5a, a first mold M1, and a second mold M2. The rotary support table 5a rotates around a rotation axis 5b whose axial direction is the vertical direction. The first mold M1 and the second mold M2 are supported on the upper surface of the rotary support table 5a. As the rotary support table 5a rotates, the first mold M1 and the second mold M2 reciprocate between a material supply position and a crimping position P2 where the cover material FM and the can badge 200 are crimped. Hereinafter, this material supply position will be referred to as the supply position P1. The first mold M1 and the second mold M2 face each other across the rotation axis. Therefore, when the first mold M1 is located at the supply position P1, the second mold M2 is located at the crimping position P2. Conversely, when the first mold M1 is located at the crimping position P2, the second mold M2 is located at the supply position P1.

[0052] [Crimping Mechanism 6] The crimping mechanism 6 has an elevator device 6a, an upper mold M0, and a crimping motor 62. By rotating the crimping motor 62, the crimping mechanism 6 causes the elevator device 6a to raise and lower the upper mold M0 at the crimping position P2, thereby pressing it against and separating it from the first mold M1 and the second mold M2. The rotation mechanism 5 moves the first mold M1 from the supply position P1 to the crimping position P2. The crimping mechanism 6 lowers the upper mold M0 and presses it against the first mold M1, crimping the shell SE, the backing sheet WF, and the medium PF together to produce the surface material FM. The crimping mechanism 6 raises the upper mold M0 while holding the surface material FM. The rotation mechanism 5 moves the second mold M2 from the supply position P1 to the crimping position P2. The crimping mechanism 6 lowers the upper mold M0 while holding the front material FM and presses it against the second mold M2, crimping the front material FM and the back part BE together to produce the can badge 200. When the crimping mechanism 6 raises the upper mold M0, the rotation mechanism 5 moves the second mold M2 to the supply position P1 with the can badge 200 placed on it.

[0053] [Second Supply Mechanism 7] The second supply mechanism 7 includes a second stocker 7a, a second supply slope 7b, a second supply slider 7c, and a second sensor 7d. The second stocker 7a is a vertically long, cylindrical member capable of holding multiple back parts BE. The inside of the horizontal cross section of the second stocker 7a is shaped to fit the outer shape of the back parts BE. The second stocker 7a may be replaced to fit the outer shape of the back parts BE. The back parts BE are stacked vertically in the second stocker 7a. Of the back parts BE in the second stocker 7a, the lowest back part BE is placed on the second supply slope 7b.

[0054] The second supply slope 7b has a second supply guide surface that guides the back parts BE and the second supply slider 7c toward the second mold M2. A gap is provided between the guide surface of the second supply slope 7b and the lower end of the second stocker 7a, allowing just one back part BE to pass through. The second supply slider 7c is a flat member that reciprocates on the guide surface of the second supply slope 7b by a rack and pinion mechanism (not shown). The second supply slider 7c slides the lowest back part BE in the second stocker 7a on the second supply guide surface of the second supply slope 7b and transports it to the second mold M2. This allows the back part BE to be supplied to the second mold M2.

[0055] The second sensor 7d has the same configuration as the first sensor 2d of the first supply mechanism 2. The second sensor 7d detects the presence or absence of back parts BE in the second stocker 7a and outputs a signal according to the detection result.

[0056] [Removal mechanism 8] The removal mechanism 8 comprises a removal arm 8a, a removal head 8b, and a seat 8c. The removal arm 8a rotates around a rotation axis (not shown). The removal head 8b is a magnetic member. The removal head 8b is provided at the tip of the removal arm 8a. Rotation of the removal arm 8a causes the removal head 8b to move back and forth between a collection position and a removal position. The seat 8c is provided at the collection position. The seat 8c has an upper surface and a groove. The upper surface of the seat 8c is an inclined surface that slopes downward toward the badge holder 10. The groove in the seat 8c has an opening shape that can accommodate only the tip portion of the removal arm 8a, including the removal head 8b. The groove has a depth that prevents the removal head 8b accommodated in the groove from magnetically adsorbing the badge 200 on the seat 8c.

[0057] At the removal position, the removal head 8b approaches the second mold M2 located at the supply position P1 and magnetically attracts the badge 200 placed on the second mold M2. The removal head 8b moves to the collection position as the removal arm 8a rotates, with the badge 200 still magnetically attracted to it. At the collection position, the tip of the removal arm 8a, including the removal head 8b, is housed in the groove of the seat 8c. The badge 200 abuts against the upper surface of the seat 8c and cannot enter the groove, so it detaches from the removal head 8b. Released from the magnetic attraction of the removal head 8b, the badge 200 slides down the upper surface of the seat 8c and falls into the badge container 10, where it is collected.

[0058] 4 , the first control unit 11 includes a first calculation unit 111, a first storage unit 112, a first interface 113, 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 first internal bus 110 connects the first calculation unit 111, the first storage unit 112, the first interface 113, the first drive circuit 114, the second drive circuit 115, the third drive circuit 116, the fourth drive circuit 117, the fifth drive circuit 118, the sixth drive circuit 119, and the seventh drive circuit 120. The first drive circuit 114 is connected to the first supply mechanism 2. The second drive circuit 115 is connected to the transport mechanism 3. The third drive circuit 116 is connected to the peeling mechanism 4. The fourth drive circuit 117 is connected to the rotation mechanism 5. The fifth drive circuit 118 is connected to the crimping mechanism 6. The sixth drive circuit 119 is connected to the second supply mechanism 7. The seventh drive circuit 120 is connected to the take-out mechanism 8.

[0059] The first calculation unit 111 is, for example, a CPU or FPGA. The first storage unit 112 is, for example, a ROM, RAM, flash ROM, HDD, etc. The first interface 113 may be a wired interface such as USB, or a wireless interface such as Bluetooth (registered trademark). The first storage unit 112 stores firmware and parameters. The parameters include output values ​​and drive amounts for operating the badge production system 300. The first calculation unit 111 executes the firmware to control each component of the badge production system 300 in accordance with the parameters. The first interface 113 connects the first control unit 11 and the controller 12 to input and output signals. The controller 12 may be, for example, a personal computer or a mobile terminal such as a smartphone.

[0060] [Controller 12] The controller 12 is equipped with an application program for operating the badge production system 300. The controller 12 may be, for example, a personal computer or a mobile terminal such as a tablet terminal or a smartphone. As shown in FIG. 9 , the controller 12 includes a third calculation unit 91, a third storage unit 92, and a third interface 93. A third internal bus 90 connects the third calculation unit 91, the third storage unit 92, and the third interface 93. The third calculation unit 91 is a CPU. The third storage unit 92 is, for example, a ROM, RAM, flash ROM, HDD, or SSD (Solid State Drive). The third interface 93 connects the controller 12 to the printer 1 and the crimping machine 100 and performs signal input and output. The third interface 93 may be a wired interface such as USB or a wireless interface such as Bluetooth (registered trademark). The third storage unit 92 stores an operating system, application programs, and setting parameters. The controller 12 executes the application programs to receive instructions for producing the badge 200 from a user of the badge production system 300, and then monitors and controls the operation of the printer 1 and the crimping machine 100 to produce the badge 200.

[0061] [Operation of the Can Badge Production System 300] When all materials for the can badge 200 are available, the can badge production system 300 operates as shown in the timing charts of FIGS. 11 to 14. "All materials for the can badge 200 are available" means that when a user instructs the can badge production system 300 to produce two or more can badges 200, all materials constituting the can badges 200 are available in the number of the can badges 200 instructed to be produced. In the timing charts of FIGS. 11 to 14, the top row indicates the operation related to the job. The first job is a job for producing the first can badge 200, and the second job is a job for producing the second can badge 200. The second row from the top indicates the operation of the controller 12. The third to sixth rows indicate the operation of the printer 1. The seventh to sixteenth rows indicate the operation of the crimping machine 100. Of these rows, the seventh row indicates the names of the operations performed by the crimping machine 100. Rows eight to sixteen describe the names of each part of the crimping machine 100, including the conveying mechanism 3, the conveying mechanism 3 as a peeling mechanism, the conveying mechanism 3 as a discharge mechanism, the first supply mechanism 2 that supplies the shell, the second supply mechanism 7 that supplies the back part BE, the peeling mechanism 4, the rotation mechanism 5, the crimping mechanism 6, and the removal mechanism 8. Each row describes the operation of each part. In FIGS. 11 to 14 , arrows indicate the order of operations between the controller 12, the printer 1, and the crimping machine 100. The base of the arrow indicates the completion timing of the preceding process, and the tip of the arrow indicates the start timing of the subsequent process.

[0062] 11 , when the controller 12 receives a user instruction to produce n (n is an integer greater than or equal to 2) can badges 200, the controller 12 outputs a signal to the crimping machine 100 instructing the crimping machine 100 to produce n can badges 200. In the first job, when the signal instructing the crimping machine 100 to produce n can badges 200 is input from the controller 12, the first control unit 11 of the crimping machine 100 causes the first sensor 2d of the first supply mechanism 2 to detect the presence or absence of a first shell SE1 in the first stocker 2a. The crimping machine 100 also causes the second sensor 7d of the second supply mechanism 7 to detect the presence or absence of a first back part BE1 in the second stocker 7a. When the presence of the first shell SE1 and the first back part BE1 is detected, the crimping machine 100 causes the first supply mechanism 2 to supply the first shell SE1 to the first mold M1 in step #1, which is the SE1 supply step. The crimping machine 100 outputs a signal indicating that the first shell SE1 has been supplied to the first mold M1 to the controller 12. After outputting this signal, the crimping machine 100 waits until the first mount WF1 is supplied from the printer 1 as a WF1 waiting process.

[0063] When the controller 12 receives a signal from the crimping machine 100 indicating that the first shell SE1 has been supplied to the first mold M1, it outputs a signal to the printer 1 instructing it to print the first liner WF1. When the printer 1 receives the signal instructing it to print the first liner WF1, it begins feeding the first liner WF1 from the first tray 20A. If the third sensor 35 detects the first liner WF1 within a predetermined time after starting to feed the first liner WF1, the printer 1 executes printing on the first liner WF1. Note that printing the liner WF1 involves printing blank data that does not require ink ejection, and does not involve printing an image that requires ink ejection. After printing the first liner WF1 and supplying it to the crimping machine 100, the printer 1 causes the remaining ink sensor 58 to detect the presence or absence of each color of ink. In the example of FIG. 11 , all colors of ink are detected to be present.

[0064] When the fourth sensor 3b of the transport mechanism 3 detects the first liner WF1 supplied from the printer 1, the crimping machine 100 executes the WF1 transport process. As the WF1 transport process, the crimping machine 100 causes the transport mechanism 3 to transport the first liner WF1 to the first mold M1 in process #2. In process #3, the crimping machine 100 causes the transport mechanism 3 and the peeling mechanism 4 to peel the liner connected portion WFb of the first liner WF1 from the liner remaining portion WFa. In process #4, the crimping machine 100 causes the transport mechanism 3 to eject the liner remaining portion WFa into the collection box 9. Note that in the WF1 transport process, the crimping machine 100 causes the first sensor 2d of the first supply mechanism 2 to detect the presence or absence of the second shell SE2. When the first sensor 1d detects the presence of the second shell SE2, the controller 12 does not need to execute the operation of Case 4 (C3) shown in Figures 15 and 16, and therefore the crimping machine 100 does not output a signal indicating the presence of the second shell SE2. After completing step #4, the crimping machine 100 outputs a signal to the controller 12 indicating that peeling of the first backing sheet WF1 is complete. Furthermore, the crimping machine 100 waits for the first medium PF1 to be supplied from the printer 1 as a WF1 waiting step.

[0065] When the controller 12 receives a signal indicating that peeling of the first backing sheet WF1 is complete, it outputs a signal to the printer 1 instructing it to print on the first medium PF1. When the printer 1 receives the signal instructing it to print on the first medium PF1, it starts feeding the first medium PF1 from the second tray 20B. If the third sensor 35 detects the first medium PF1 within a predetermined time after starting to feed the first medium PF1, the printer 1 executes printing on the first medium PF1. After printing on the first medium PF1 is complete, the printer 1 supplies the first medium PF1 to the crimping machine 100 and then causes the remaining ink sensor 58 to detect the presence or absence of ink of each color. In the example of FIG. 11 , it is detected that all colors of ink are present.

[0066] When the fourth sensor 3b of the transport mechanism 3 detects the first medium PF1 supplied from the printer 1, the crimping machine 100 executes a PF1 transport process. As part of the PF1 transport process, the crimping machine 100 outputs a signal to the controller 12 indicating that the first medium PF1 has been detected. When the controller 12 receives the signal indicating that the first medium PF1 has been detected, it outputs a signal to the printer 1 instructing it to print on the second backing sheet WF2. In process #5, the crimping machine 100 causes the transport mechanism 3 to transport the first medium PF1 to the first mold M1. In process #6, the crimping machine 100 causes the transport mechanism 3 and the peeling mechanism 4 to peel the connected portion PFb of the medium from the remaining portion PFa of the medium. In process #7 (see FIG. 12 ), the crimping machine 100 causes the transport mechanism 3 to eject the remaining portion PFa of the medium into the collection box 9.

[0067] When a signal instructing printing on the second liner WF2 is input, the printer 1 executes printing on the second liner WF2. The printer 1 starts feeding the second liner WF2 from the first tray 20A, and when the third sensor 35 detects the second liner WF2 within a predetermined time, the printer 1 executes printing on the second liner WF2. After printing on the second liner WF2 is complete, the printer 1 holds the second liner WF2. The second liner WF2 is held in a state where it can be detected by the fourth sensor 3b.

[0068] Next, in step #8, the crimping machine 100 causes the rotation mechanism 5 to move the first mold M1 to the crimping position P2 as the SE1 crimping step. In step #9, the crimping machine 100 causes the crimping mechanism 6 to crimp the first shell SE1, the first mount WF1, and the first medium PF1 together to produce the first front material FM1. In step #10, the crimping machine 100 causes the second supply mechanism 7 to supply the first back part BE1 to the second mold M2 as the BE1 supply step. In step #11, the crimping machine 100 causes the rotation mechanism 5 to move the second mold M2 to the crimping position P2 as the BE1 crimping step. In step #12, the crimping machine 100 crimps the first front material FM1 and the first back part BE1 together using the crimping mechanism 6 to produce the first can badge 200.

[0069] In step #13, the crimping machine 100 causes the rotation mechanism 5 to move the second mold M2 to the supply position P1 as a product removal process. After moving the second mold M2 to the supply position P1, the crimping machine 100 causes the second sensor 7d of the second supply mechanism 7 to detect the presence or absence of the second back part BE2. In the example of FIG. 12 , the presence of the second back part BE2 is detected. Then, in step #14, the crimping machine 100 causes the removal mechanism 8 to remove the first badge 200 from the second mold M2 and store the removed first badge 200 in the badge holder 10. In step #15, the crimping machine 100 causes the rotation mechanism 5 to move the first mold M1 to the supply position P1 as an initialization process. This completes the first job.

[0070] In the second job, when the fourth sensor 3b of the transport mechanism 3 detects the second backing sheet WF2 supplied from the printer 1, the crimping machine 100 starts executing the WF2 transport process before the completion of the first job, as shown in Fig. 12. As the WF2 transport process, in step #2, the crimping machine 100 causes the transport mechanism 3 to stop transporting the second backing sheet WF2 until the first supply mechanism 2 has completed supplying the second shell SE2 to the first mold M1.

[0071] After completing the initialization step of the first job, the crimping machine 100 causes the first supply mechanism 2 to supply the second shell SE2 to the first mold M1 in step #1 as the SE2 supply step. After completing the supply of the second shell SE2, the crimping machine 100 causes the transport mechanism 3 to start transporting the second liner WF2 to the first mold M1 as a continuation of step #2 of the WF2 transport step. In step #3, the crimping machine 100 causes the transport mechanism 3 and the peeling mechanism 4 to peel the liner connected portion WFb from the liner remaining portion WFa. In step #4, the crimping machine 100 causes the transport mechanism 3 to discharge the liner remaining portion WFa into the collection box 9.

[0072] The controller 12 acquires the printing time for the first medium PF1 in the first job and instructs the printer 1 to print on the second medium PF2 at a timing that precedes the completion of the WF2 transport process by the printing time for the first medium PF1. In FIG. 16 (described later), this is the operation of counting backwards from the timing of C10 to print. As a result, immediately after the WF transport process is completed, the crimping machine 100 detects the second medium PF2 supplied from the printer 1 using the transport mechanism 3 without delay and executes the transport process for the second medium PF2.

[0073] In step #5, the crimping machine 100 causes the transport mechanism 3 to transport the second medium PF2 to the first mold M1 as a PF2 transport step. In step #6, the crimping machine 100 causes the transport mechanism 3 and the peeling mechanism 4 to peel the connected portion PFb of the medium from the remaining portion PFa of the medium. In step #7, the crimping machine 100 causes the transport mechanism 3 to eject the remaining portion PFa of the medium into the collection box 9.

[0074] In step #8, the crimping machine 100 causes the rotation mechanism 5 to move the first mold M1 to the crimping position P2 as the SE2 crimping step. In step #9, the crimping machine 100 causes the crimping mechanism 6 to crimp the second shell SE2, the second backing WF2, and the second medium PF2 together to produce the second front material FM2. In step #10, the crimping machine 100 causes the second supply mechanism 7 to supply the second back part BE2 to the second mold M2 as the BE2 crimping step. In step #11, the crimping machine 100 causes the rotation mechanism 5 to move the second mold M2 to the crimping position P2. In process #12, the crimping machine 100 uses the crimping mechanism 6 to crimp the second front material FM2 and the second back part BE2 together to produce the second badge 200. As shown in FIG. 14 , in process #13, the crimping machine 100 causes the rotation mechanism 5 to move the second mold to the supply position P1 as a product removal process. In process #14, the crimping machine 100 causes the removal mechanism 8 to remove the second badge 200 from the second mold M2 and store it in the badge holder 10. Thereafter, in process #15, the crimping machine 100 causes the rotation mechanism 5 to move the first mold M1 to the supply position P1 as an initialization process. Completion of process #15 completes the second job. Jobs 3 and beyond are similar to the second job.

[0075] [Operation When Can Badge 200 Material Runs Out] Next, six cases of operation of the can badge production system 300 when the can badge 200 material runs out are described. FIGS. 15 and 16 are sequence diagrams explaining the operation of the crimping machine 100, the printer 1, sensors, and the controller 12. The sensors are the first sensor 2d of the first supply mechanism 2, the second sensor 7d of the second supply mechanism 7, the third sensor 35 of the printer 1, and the fourth sensor 3b of the conveyance mechanism 3. Hereinafter, of two or more can badges 200 to be produced, the first can badge 200 will be referred to as the first can badge 200, and the second can badge 200 will be referred to as the second can badge 200. The material of the first can badge 200 will be referred to as the first medium PF1, the first mount WF1, the first shell SE1, the first back part BE1, and the first front material FM1. Similarly, the materials for the second can badge 200 are referred to as the second medium PF2, the second mount WF2, the second shell SE2, the second back part BE2, and the second front material FM2. Note that the operations following the crimping operation (K20) for producing the second can badge 200 are the same as the operations following the crimping operation (K9) for producing the first can badge 200. Furthermore, the operations for producing the third and subsequent can badges 200 are the same as the operations for producing the second can badge 200.

[0076] 15 , when the controller 12 receives a user instruction to produce n (n is an integer greater than or equal to 2) can badges 200, the controller 12 outputs a signal to the crimping machine 100 instructing the crimping machine 100 to produce n can badges 200 (C1). The crimping machine 100 causes the first sensor 2d of the first supply mechanism 2 to detect the presence or absence of the first shell SE1 in the first stocker 2a. The crimping machine 100 also causes the second sensor 7d of the second supply mechanism 7 to detect the presence or absence of the first back part BE1 in the second stocker 7a (S1). If the absence of the first shell SE1 or the first back part BE1 is detected, the first control unit 11 of the crimping machine 100 outputs a signal to the controller 12 indicating that the first shell SE1 or the first back part BE1 is absent. When the controller 12 receives a signal indicating that the first shell SE1 or the first back part BE1 is not present, it outputs a signal to the crimping machine 100 instructing it to stop the start of production of the first can badge 200 (C2). When the controller 12 receives a signal instructing it to stop the start of production of the first can badge 200, it stops the start of production of the first can badge 200 (K1).

[0077] [Case 2 (When the Second Liner WF2 is Absent)] After the first supply mechanism 2 supplies the first shell SE1 (K2), the controller 12 causes the printer 1 to detect the presence or absence of the first liner WF1 in the first tray 20A (S3). When a signal instructing printing on the first liner WF1 is input, the printer 1 begins feeding the first liner WF1 from the first tray 20A (J1). If the third sensor 35 does not detect the first liner WF1 within a predetermined time after starting feeding of the first liner WF1 (S3), the printer 1 outputs a signal to the controller 12 indicating that the first liner WF1 is absent. Upon receiving the signal indicating the absence of the first liner WF1, the controller 12 outputs a signal to the printer 1 instructing it to stop, thereby stopping the printer 1 (C5). When the printer 1 stops printing on the first liner WF1, the first mold M1 has the first shell SE1 supplied to it.

[0078] [Case 3 (When Ink or First Medium PF1 Is Absent)] When the printer 1 is printing on the first liner WF1 (P1), the controller 12 causes the printer 1 to detect the presence or absence of ink (S4). After the printer 1 supplies the first liner WF1 to the crimping machine 100, the printer 1 causes the remaining ink sensor 58 to detect the presence or absence of ink for each color (S4). If it detects that any color of ink is absent, the printer 1 outputs a signal to the controller 12 indicating that there is no ink. The controller 12 also causes the printer 1 to detect the presence or absence of the first medium PF1 in the second tray 20B (S6). After starting to feed the first medium PF1, if the third sensor 35 does not detect the first liner WF1 within a predetermined time (S6), the printer 1 outputs a signal to the controller 12 indicating that there is no first medium PF1. When the controller 12 receives a signal indicating that there is no ink or that there is no first liner WF1, it outputs a signal to stop the printer 1, thereby stopping the printer 1 (C6). When the printer 1 stops printing on the first medium PF1, the first mold M1 has been supplied with the first shell SE1 and the first liner WF1.

[0079] [Case 4 (No Second Shell SE2, Ink, or Second Backing Sheet WF2)] When the controller 12 receives an instruction to produce n (n is an integer greater than or equal to 2) can badges 200, it outputs a signal to the crimping machine 100 instructing it to produce n can badges 200. When the signal instructing it to produce n can badges 200 is input from the controller 12, the crimping machine 100 causes the first supply mechanism 2 to supply the first shell SE1 from the first stocker 2a to the first mold M1 (K1). After supplying the first shell SE1, the controller 12 causes the printer 1 to start printing the first backing sheet WF1 (C4). After printing the first backing sheet WF1, the printer 1 supplies the first backing sheet WF1 to the crimping machine 100 (J1) and causes the first sensor 2d of the first supply mechanism 2 to detect the presence or absence of the second shell SE2 in the first stocker 2a. The first sensor 2d may detect the presence or absence of the second shell SE2 after the first shell SE1 is supplied (K2) (S2), or may detect it when the first liner WF1 is peeled off (K3) (S5). If the absence of the second shell SE2 is detected, the crimping machine 100 outputs a signal indicating the absence of the second shell SE2 to the controller 12. When the signal indicating the absence of the second shell SE2 is input, the controller 12 outputs a signal to the printer 1 instructing it to stop printing the second liner WF2, thereby stopping printing of the second liner WF2 (J3).

[0080] The controller 12 causes the transport mechanism 3 to supply the printed first mount WF1 to the first mold M1 (C4). The controller 12 causes the printer 1 to start printing on the first medium PF1 (C7). After printing on the first medium PF1 is complete, the controller 12 causes the printer 1 to supply the first medium PF1 to the crimping machine 100 (J2). After supplying the first medium PF1 is complete, the controller 12 stops the printer 1 (C3) and causes the transport mechanism 3 to supply the first medium PF1 supplied from the printer 1 to the first mold M1 (K4). The controller 12 causes the crimping mechanism 6 to crimp the first shell SE1, the first mount WF1, and the first medium PF1 together to produce the first surface material FM1 (K6). Furthermore, after the production of the first front material FM1 is completed, or in parallel with the crimping of the first front material FM1, the controller 12 causes the second supply mechanism 7 to supply the first back part BE1 from the second stocker 7a to the second mold M2. After the production of the first front material FM1 is completed and the first back part BE1 is supplied, the controller 12 causes the crimping mechanism 6 to crimp the first front material FM1 and the first back part BE1 together to produce the first can badge 200. After the production of the first can badge 200 is completed, the controller 12 stops the operation of the crimping machine 100.

[0081] The controller 12 then causes the transport mechanism 3 to supply the first mount WF1 to the first mold M1. The controller 12 then causes the printer 1 to start printing on the first medium PF1 (C7). After printing on the first medium PF1 is complete, the controller 12 causes the printer 1 to supply the first medium PF1 to the crimping machine 100 (J2). The controller 12 then causes the transport mechanism 3 to supply the first medium PF1 supplied from the printer 1 to the first mold M1 (K4). The controller 12 then causes the crimping mechanism 6 to crimp the first shell SE1, the first mount WF1, and the first medium PF1 together to produce the first front material FM1 (K6). After printing on the first medium PF1 is complete (J2), the crimping machine 100 then causes the remaining ink sensor 58 to detect the presence or absence of ink for each color (S7). If the printer 1 detects that any color of ink is out, it outputs a signal indicating that there is no ink to the controller 12. When the controller 12 receives the signal indicating that there is no ink, it outputs a signal to the printer 1 instructing it to stop printing the second mount WF2. This causes the printer 1 to stop printing the second mount WF2 (J3). After the production of the first surface material FM1 (K6) is completed, or in parallel with the production of the first surface material FM1 (K6), the controller 12 causes the second supply mechanism 7 to supply the first back part BE1 from the second stocker 7a to the second mold M2 (K7). After the production of the first surface material FM1 (K6) is completed and the first back part BE1 is supplied (K7), the controller 12 causes the crimping mechanism 6 to crimp the first surface material FM1 and the first back part BE1 together to produce the first can badge 200 (K9).

[0082] After completing printing of the first medium PF1 (J2), the controller 12 causes the printer 1 to detect the presence or absence of the second liner WF2 in the first tray 20A. The printer 1 begins feeding the second liner WF2 from the first tray 20A, and if the third sensor 35 does not detect the second liner WF2 within a predetermined time, it detects that the second liner WF2 is absent (S8). When the printer 1 detects that the second liner WF2 is absent, it outputs a signal to the controller 12 indicating that the second liner WF2 is absent. When the controller 12 receives the signal indicating that the second liner WF2 is absent, it restarts the printer 1 (C3). The printer 1 stops printing the second liner WF2.

[0083] After completing printing of the first medium PF1 (J2), the controller 12 causes the printer 1 to detect the presence or absence of the second liner WF2 in the first tray 20A. The printer 1 begins feeding the second liner WF2 from the first tray 20A, and if the third sensor 35 detects the second liner WF2 within a predetermined time, it detects the presence of the second liner WF2 (S8). When the printer 1 detects the presence of the second liner WF2, it outputs a signal to the controller 12 indicating the presence of the second liner WF2. When the signal indicating the presence of the second liner WF2 is input, the controller 12 starts printing of the second liner WF2 (J3). After completing production of the first can badge 200 (K9), the controller 12 causes the first supply mechanism 2 to supply the second shell SE2 from the first stocker 2a to the first mold M1 (K13). After the supply of the second shell (K13) is completed, the controller 12 causes the printer 1 to supply the second backing sheet WF2 to the crimping machine 100.

[0084] [Case 5 (When Second Medium PF2 Is Not Present)] After completing printing of the second mount WF2 (J3), the controller 12 causes the printer 1 to detect the presence or absence of the second medium PF2 in the second tray 20B (S11). The printer 1 starts feeding the second medium PF2 (J5). If the third sensor 35 detects the second medium PF2 within a predetermined time after the start of feeding, the printer 1 detects that the second medium PF2 is present (S11). When the printer 1 detects the presence of the second medium PF2, it outputs a signal to the controller 12 indicating the presence of the second medium PF2. When the signal indicating the presence of the second medium PF2 is input, the controller 12 starts printing of the second medium PF2 (J5).

[0085] After completing printing on the second mount WF2 (J3), the controller 12 causes the printer 1 to detect the presence or absence of the second medium PF2 in the second tray 20B (S11). The printer 1 then starts feeding the second medium PF2 (J5). If the third sensor 35 does not detect the second medium PF2 within a predetermined time after the start of feeding, the printer 1 detects that the second medium PF2 is not present (S11). When the printer 1 detects that the second medium PF2 is not present, it outputs a signal to the controller 12 indicating that the second medium PF2 is not present. When the controller 12 receives the signal indicating that the second medium PF2 is not present, it outputs a signal to the printer 1 instructing it to stop printing the second medium PF2. The printer 1 then stops printing on the second medium PF2 (J5).

[0086] [Case 6 (When the Second Back Part BE2 is Absent)] After completing production of the first can badge 200 (K9), the controller 12 causes the second sensor 7d of the second supply mechanism 7 to detect the presence or absence of the second back part BE2 in the second stocker 7a (S10). If the absence of the second back part BE2 is detected, the crimping machine 100 outputs a signal to the controller 12 indicating that the second back part BE2 is absent. The controller 12 then causes the first supply mechanism 2 to supply the second shell SE2 from the first stocker 2a to the first mold M1 (K13). The controller 12 then causes the printer 1 to supply the second mount WF2 and the second medium PF2 to the first mold M1 (J3, J5). The controller 12 causes the crimping mechanism 6 to crimp the second shell SE2, the second mount WF2, and the second medium PF2 together to produce the second front material FM2 (K17). When the controller 12 receives a signal indicating that the second back part BE2 is not present, it outputs a signal to the crimping machine 100 to instruct it to stop supplying the second back part BE2, and stops the operation of the crimping machine 100 after completing the production of the second front material FM2 (K17).

[0087] Meanwhile, after completing the production of the first can badge 200 (K9), the controller 12 causes the second sensor 7d of the second supply mechanism 7 to detect the presence or absence of the second back part BE2 in the second stocker 7a (S10). If the second sensor 7d detects the presence of the second back part BE2, the crimping machine 100 outputs a signal to the controller 12 indicating the presence of the second back part BE2. The controller 12 then causes the first supply mechanism 2 to supply the second shell SE2 from the first stocker 2a to the first mold M1 (K13). The controller 12 then causes the printer 1 to supply the second mount WF2 and the second medium PF2 to the first mold M1 (J3, J5). The controller 12 then causes the crimping mechanism 6 to crimp the second shell, the second mount, and the second medium together to produce a second cover material (K17). The controller 12 supplies the second back part BE2 from the second stocker 7a to the second mold M2 (K18). Furthermore, when a signal indicating the presence of the second back part BE2 is input, the controller 12, after completing the production of the second front material FM2 (K17), causes the second front material FM2 and the second back part BE2 to be crimped together to produce the second can badge 200 (K20).

[0088] [Operation and Effects of the Embodiment] (1) If the printer 1 prints the second backing sheet WF2 on the condition that the first sensor 2d detects the presence of the second shell SE2 during production of the first can badge 200, the crimping device 100 can quickly complete production of the second can badge 200. If the second shell SE2 is not present, the crimping device 100 cannot produce the second can badge 200, and therefore even if the printer 1 prints the second backing sheet WF2, it is wasted. To address this problem, as in Case 4 above, if the first sensor 2d detects the absence of the second shell SE2, the controller 12 stops the printer 1 from printing the second backing sheet WF2, thereby preventing waste of the second backing sheet WF2.

[0089] (2) As in Case 4 above, when printer 1 stops printing second mount WF2, there is a risk that a user of badge production system 300 will notice that printer 1 has stopped, check the status of crimping machine 100, and remove the material that makes up first front material FM1. If the material that makes up first front material FM1 is removed, crimping machine 100 will be unable to produce first badge 200. To address this issue, crimping machine 100 produces first front material FM1 and holds it in upper mold M0, thereby preventing the material from being removed and enabling first badge 200 to be produced.

[0090] (3) As in case 4 above, if the first sensor 2d detects that the second shell SE2 is not present, the controller 12 stops the printer 1 and, after the first can badge 200 is produced, stops the crimping machine 100, thereby preventing material from being wasted within the can badge production system 300.

[0091] (4) When the printer 1 prints the second backing sheet WF2 in parallel with the production of the first can badge 200 by the crimping machine 100, if the production of the first can badge 200 is not completed by the time the printer 1 finishes printing the second backing sheet WF2, there is a risk that the printer 1 will supply the second backing sheet WF2 to the first mold M1 before the second shell SE2 has been supplied to the first mold M1. To address this issue, the controller 12 causes the printer 1 to supply the second backing sheet WF2 to the crimping machine 100 after the supply of the second shell SE2 is completed, thereby ensuring the production of the second can badge 200.

[0092] (5) Even if a shell SE is present in the first stocker 2a, if the lowest shell SE gets caught midway and does not descend to the first supply slope 2b, the tip of the arm 2d1 of the first sensor 2d cannot push the shell SE downward into the first stocker 2a. As a result, the first sensor 2d erroneously detects that a shell SE is absent. To address this problem, in Case 4 above, the controller 12 causes the first sensor 2d of the first supply mechanism 2 to detect the presence or absence of the second shell SE2 in the first stocker 2a when the first backing sheet WF1 is peeled off (K3). If the timing for detecting the presence or absence of the second shell SE2 is set later than the timing when the first shell SE1 is supplied (K2), the lowest shell SE may fall to the first supply slope 2b due to vibrations generated by the can badge production system 300 itself or external impacts before the first sensor 2d detects the second shell SE2. Therefore, the likelihood that the crimping machine 100 will be able to successfully produce the second can badge 200 can be increased.

[0093] (6) Even if a back part BE is present in the second stocker 7a, if the bottom back part BE gets caught midway and does not descend to the second supply slope 7b, the second sensor 7d erroneously detects that no back part BE is present. To address this problem, in Case 4 above, the controller 12 causes the second supply mechanism 7 to detect the presence or absence of the second back part BE2 in the second stocker 7a when the rotary support table 5a rotates (K8). If the timing for detecting the presence or absence of the back part BE is set later than the timing for supplying the first back part BE1 (K7), the bottom back part BE may fall to the second supply slope 7b due to vibrations generated by the can badge production system 300 itself or external impacts before the second sensor 7d detects the second back part BE2. This increases the likelihood that the crimping machine 100 can successfully produce the second can badges 200.

[0094] (7) In the above case 1, it is possible to prevent the first shell SE1 from being wasted when the first back part BE1 is missing and the first can badge 200 cannot be produced. When the first shell SE1 is missing, the first can badge 200 cannot be produced, so it is appropriate to stop the start of production of the first can badge 200.

[0095] (8) By using the method described in the second example above, the production of the first badges 200 can be continued after the first mount WF1 is supplied to the first tray 20A of the printer 1. Therefore, the first shell SE1 supplied to the first mold M1 is not wasted.

[0096] (9) By using the method described in Case 3 above, production of the first badges 200 can be continued after the first medium PF1 is supplied to the second tray 20B of the printer 1. Therefore, the first shell SE1 and the first mount WF1 supplied to the first mold M1 are not wasted.

[0097] (10) By following the procedure of Case 6 above, after the second back part BE2 is supplied to the second stocker 7a of the second supply mechanism 7 of the crimping machine 100, production of the second badges 200 can be continued. Therefore, the second front material FM2 held in the first mold M1 is not wasted.

[0098] [Modifications] (1) In the above embodiment, the printer 1 is an inkjet printer, but the present disclosure is not limited to this. The printer 1 may be a printer other than an inkjet printer. Furthermore, the coloring material used to print on the backing sheet WF and the medium PF may be a material other than ink. Even if the coloring material is a material other than ink, the printer 1 includes a sensor that detects the remaining amount of coloring material.

[0099] 12 illustrates an example in which the second supply mechanism 7 supplies the first back part BE1 from the second stocker 7a to the second mold M2 after the production of the first front material FM1 is completed, but the present disclosure is not limited to this example, and the second supply mechanism 7 may supply the first back part BE1 from the second stocker 7a to the second mold M2 in parallel with the production of the first front material FM1. In this way, the production of the first can badge 200 can be completed quickly.

[0100] (3) In the above embodiment, the printer 1 has the first tray 20A and the second tray 20B, but the number of trays may be three or more. Also, a manual feed tray may be used.

[0101] (4) In the above embodiment, an example was described in which the third sensor 35 detects both the presence or absence of the backing sheet WF in the first tray 20A and the presence or absence of the medium PF in the second tray 20B, but the sensor that detects the presence or absence of the backing sheet WF in the first tray 20A and the sensor that detects the presence or absence of the medium PF in the second tray 20B may be separate sensors. Also, the third sensor 35 may be a mechanical sensor or an optical sensor.

[0102] (5) In the above embodiment, an example has been described in which the first sensor 2d of the first supply mechanism 2 and the second sensor 7d of the second supply mechanism 7 are both mechanical sensors, but the present disclosure is not limited to this. The first sensor 2d and the second sensor 7d may be sensors other than mechanical sensors, such as optical sensors. Furthermore, the first sensor 2d and the second sensor 7d may be sensors of different types.

[0103] DESCRIPTION OF SYMBOLS 1...Printer 2...First supply mechanism 2a...First stocker 2d...First sensor 3...Conveying mechanism 3b...Fourth sensor 4...Peeling mechanism 5...Rotation mechanism 6...Crimping mechanism 7...Second supply mechanism 7a...Second stocker 7d...Second sensor 8...Removal mechanism 10...Pot badge holder 11...First control unit 12...Controller 20A...First tray 20B...Second tray 35...Third sensor 50...Second control unit 100...Crimping machine 200...Pot badge 300...Pot badge production system BE...Back part FM...Surface material M0...Upper mold M1...First mold M2...Second mold PF...Medium SE...Shell WF...Backing paper

Claims

1. A can badge production system comprising a printer, a crimping machine, and a controller, wherein the crimping machine has a first stocker capable of holding a plurality of shells, a first supply mechanism, and a first mold, and the controller, on the condition that two or more can badge production instructions have been received, causes the first supply mechanism to supply a first shell from the first stocker to the first mold, after supplying the first shell, causes the printer to start printing on a first backing sheet, after printing on the first backing sheet, causes the printer to supply the first backing sheet to the crimping machine, causes the first supply mechanism to detect the presence or absence of a second shell in the first stocker, and executes or stops printing on the second backing sheet depending on the presence or absence of the second shell.

2. A can badge production system as described in claim 1, wherein the controller stops printing of the second mount when it detects that the second shell is absent.

3. The can badge production system of claim 2, wherein the crimping machine has a conveying mechanism and a crimping mechanism, and the controller: causes the conveying mechanism to supply the printed first mount to the first mold; causes the printer to start printing the first medium; after printing of the first medium is completed, causes the printer to supply the first medium to the crimping machine; after supplying the first medium is completed, stops the printer; causes the conveying mechanism to supply the first medium supplied from the printer to the first mold; and causes the crimping mechanism to crimp the first shell, the first mount, and the first medium together to produce a first outer material.

4. The can badge production system described in claim 3, wherein the crimping machine has a second stocker capable of holding a plurality of back parts, a second supply mechanism, and a second mold; and the controller causes the second supply mechanism to supply the first back part from the second stocker to the second mold after production of the first outer material is completed or in parallel with production of the first outer material, causes the crimping mechanism to crimp the first outer material and the first back part together to produce a first can badge after production of the first can badge is completed.

5. The can badge production system described in claim 1, wherein the crimping machine has a conveying mechanism and a crimping mechanism, and the controller causes the conveying mechanism to supply the first backing to the first mold, causes the printer to start printing the first medium, and after printing of the first medium is completed, causes the printer to supply the first medium to the crimping machine, causes the conveying mechanism to supply the first medium supplied from the printer to the first mold, and causes the crimping mechanism to crimp the first shell, the first backing, and the first medium together to produce a first outer material.

6. A can badge production system as described in claim 5, wherein the controller causes the printer to stop printing on the second backing sheet when it detects that there is no color material when printing on the first medium.

7. The can badge production system described in claim 5, wherein the crimping machine has a second stocker capable of holding a plurality of back parts, a second supply mechanism, and a second mold, and the controller causes the second supply mechanism to supply the first back part from the second stocker to the second mold after production of the first outer material is completed or in parallel with production of the first outer material, and after production of the first outer material is completed and after supplying the first back part, causes the crimping mechanism to crimp the first outer material and the first back part together to produce a first can badge.

8. A can badge production system as claimed in claim 5, wherein the printer has a first tray capable of holding a plurality of backing sheets, and the controller causes the printer to detect the presence or absence of a second backing sheet in the first tray after printing of the first medium is completed, and stops printing of the second backing sheet if it detects that the second backing sheet is absent.

9. The can badge production system described in claim 7, wherein the printer has a first tray capable of holding a plurality of backing sheets, and the controller, after completing printing of the first medium, causes the printer to detect the presence or absence of a second backing sheet in the first tray, and starts printing of the second backing sheet on the condition that it detects that the second backing sheet is present, after completing production of the first can badge, causes the first supply mechanism to supply a second shell from the first stocker to the first mold, and after completing supply of the second shell, causes the printer to supply the second backing sheet to the crimping machine.

10. A can badge production system as described in claim 9, wherein the printer has a second tray capable of holding multiple media, and the controller, after completing printing of the second mount, causes the printer to detect whether or not there is a second medium in the second tray, and starts printing of the second medium on the condition that it detects that the second medium is present.

11. A can badge production system as described in claim 9, wherein the printer has a second tray capable of holding multiple media, and the controller causes the printer to detect the presence or absence of the second media in the second tray after printing of the second backing sheet is completed, and stops printing of the second media if it detects that the second media is absent.

12. The can badge production system described in claim 10, wherein the controller: after completing production of the first can badge, causes the second supply mechanism to detect the presence or absence of a second back part in the second stocker; causes the first supply mechanism to supply the second shell from the first stocker to the first mold; causes the printer to supply the second backing and the second medium to the first mold; causes the crimping mechanism to crimp the second shell, the second backing and the second medium together to produce a second outer material; and stops operation of the crimping machine after completing production of the second outer material, on the condition that it detects that the second back part is absent.

13. The can badge production system described in claim 10, wherein the controller: after completion of production of the first can badge, causes the second supply mechanism to detect the presence or absence of a second back part in the second stocker; causes the first supply mechanism to supply a second shell from the first stocker to the first mold; causes the printer to supply the second backing and the second medium to the first mold; causes the crimping mechanism to produce a second outer material comprising the second shell, the second backing and the second medium by crimping them together; causes the second back part to be supplied from the second stocker to the second mold; and, on the condition that the presence of the second back part is detected, causes the second outer material and the second back part to be crimped together to produce a second can badge after completion of production of the second outer material.

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