Binding machine

Abstract

A binding machine according to the present disclosure comprises: a driver unit that moves in a first direction and presses a staple to bind the staple to an object; a motor unit; a control unit; a speed acquisition unit; and a position acquisition unit. The control unit acquires a deceleration start position of the driver unit during movement on the basis of a stop target position set for each binding machine and a movement speed acquired by the speed acquisition unit, and controls the motor unit such that the driver unit decelerates when a position detection unit determines that the driver unit has reached the deceleration start position.

Description

Binder

[0001] The present disclosure relates to a binder.

[0002] Staples for holding stems, vines, branches, etc. of plants, trees, etc. on guide elements such as wires, beams, strings, rods, pipes, tree branches, etc. are known.

[0003] Patent Documents 1 to 3 disclose such staples and a binder for binding using such staples. The binder described in Patent Document 3 includes a driver that presses and moves the staple forward, and a displacement portion that engages with a guide element (sometimes called an "object") by curving or bending the legs of the staple that moves forward.

[0004] Japanese Patent Application Laid-Open No. 2022-74007, Japanese Patent Application Laid-Open No. 2023-13307, Japanese Patent Application Laid-Open No. 2023-13317

[0005] In order to surely perform binding in such a binder, it is necessary to secure the moving distance of the driver. However, if a margin is provided in the dimensions so as not to collide with other parts of the binder such as a guide plate, the binder will be enlarged. On the other hand, if the driver is moved at a low speed for accurate positioning, the working efficiency will be reduced.

[0006] Therefore, an object of the present disclosure is to provide a binder that enables highly accurate positioning of a driver while suppressing a decrease in working efficiency.

[0007] This application relates to a fastening machine comprising: a driver unit for fastening staples to an object by moving in a first direction and pressing the staples; a motor unit for moving the driver unit; a control unit for controlling the motor unit; a speed acquisition unit for acquiring the speed of the driver unit in the first direction; and a position acquisition unit for acquiring the position of the driver unit in the first direction. In such a fastening machine, the control unit acquires the deceleration start position of the moving driver unit based on a stop target position set for each fastening machine and the speed acquired by the speed acquisition unit, and when it determines that the driver unit has reached the deceleration start position based on the position information of the driver unit acquired from the position acquisition unit, it controls the motor unit to decelerate the driver unit.

[0008] Here, staples (sometimes called "linear fasteners") are made from flexible wires that are plastically deformable and include components (including those with a plated surface or coated with resin, etc.) that engage with an object by deforming. Staples are also sometimes called wires, clips, wires, or fasteners.

[0009] The staple may be composed of any shape including two legs and a connecting part (sometimes called a crown) that connects the two legs. The two legs may be formed as parallel line segments, as non-parallel line segments, curves, or a combination thereof. The crown may be formed in a straight line or as a curve. For example, the staple may have an asymmetrical shape, as illustrated in this embodiment. Binding includes using staples to restrain the relative movement of one object and another object. For example, one object (sometimes called a "second object," such as a stem, vine, or branch of a plant or tree) may be surrounded by staples, and the two ends of the staples (the two tips) may be engaged with the other object (sometimes called a "first object," "guide," or "guide element," such as a wire, beam, string, rod, pipe, or tree branch) to achieve binding.

[0010] Figure 1A is a plan view (top view) showing staples before deformation, fastened by a fastening machine according to one embodiment. Figure 1B is a perspective view showing staples after deformation, fastened by a fastening machine according to one embodiment. Figure 2 is a perspective view of the fastening machine according to one embodiment. Figure 3 is a top view of the fastening machine according to one embodiment. Figure 4 is a side view of the fastening machine according to one embodiment. Figure 5 is a side view of the fastening machine according to one embodiment. Figure 6 is a block diagram of the fastening machine according to one embodiment. Figure 7A is a flowchart of the operating modes of the fastening machine according to one embodiment. Figure 7B is a schematic diagram illustrating the position of the driver of the fastening machine according to one embodiment. Figure 8 is a flowchart of the operating modes of the fastening machine according to one embodiment. Figure 9A is a graph showing the rotational speed of the motor of the fastening machine according to one embodiment. Figure 9B is a graph showing the rotational speed of the motor of the fastening machine according to one embodiment. Figure 10A is a graph showing the motor current of the fastening machine according to one embodiment. Figure 10B is a graph showing the motor current of the fastening machine according to one embodiment.

[0011] The following describes the configuration of the stapling machine 100 and the staples S used by this stapling machine 100 according to this embodiment. However, as will be understood by those skilled in the art, this disclosure is broadly applicable to stapling machines comprising a driver unit for fastening staples to an object by pressing the staples in a predetermined direction, a drive unit for driving the driver unit in a predetermined direction and in the opposite direction, and a control unit for controlling the drive unit, and is not limited to the staples S and stapling machine 100 shown in this embodiment. The following describes the configuration of the staples S according to this embodiment first.

[0012] [Structure of Staple S] First, the structure of staple S according to this embodiment will be described. Staple S is made of a wire that is plastically deformable. Staple S may be called a wire or a clip. Staple S includes, for example, a metal wire or wire (including those whose surface is plated or coated with resin, etc.).

[0013] Figure 1A is a top view plan of the staple S in the state before fastening (sometimes referred to as "before deformation"; the same applies hereafter) according to this embodiment. Figure 1B is a perspective view of the staple S in the state after fastening (sometimes referred to as "after deformation," or "when engaged," etc.; the same applies hereafter) according to this embodiment.

[0014] First, let's describe the structure of the staple S before fastening. This staple S has a first leg portion S1, a second leg portion S2, and a main body portion S3 that connects the first leg portion S1 and the second leg portion S2. In the state before fastening, the first leg portion S1 and the second leg portion S2 of the staple S are spaced apart, so an opening is provided between the first leg portion S1 and the second leg portion S2. In this embodiment, the direction from the main body portion S3, which is the closed portion, toward the opening (to the left in Figure 1A) is sometimes called the opening direction DR1 (of the staple S). Also, the direction that is perpendicular to the extension direction of the staple S (for example, the opening direction DR1 for the second leg portion S2 of the staple S in this embodiment) and perpendicular to the stacking direction, which will be described later, is sometimes called the lateral direction (of the part of the staple S), and the surface of the staple S facing the lateral direction is sometimes called the side of the staple S. Furthermore, the direction perpendicular to the lateral direction, in which multiple staples S are connected, is called the stacking direction or connecting direction. In particular, the direction perpendicular to the plane of the paper in Figure 1A is sometimes called the stacking direction upward (of the staples S), and the depth direction perpendicular to the plane of the paper in Figure 1A is sometimes called the stacking direction downward.

[0015] More specifically, the staple S comprises a main body S3 that connects a first leg S1 and a second leg S2 and surrounds a second object P such as a stem; a first leg S1 connected to one end of the main body S3 and having a first part S11 that bends and extends outward and a second part S12 that bends further from the first part S11 and extends in the opening direction DR1; and a second leg S2 connected to the other end of the main body S3 and having a third part S23 that extends in the opening direction DR1 and a fourth part S24 that is bent outward from the tip of the third part S23. As shown in the figure, the main body S3 is formed in a curved shape, from C-shape to semicircular arc shape. The first part S11 that connects the main body S3 and the second part S12 may be called a crank part, and the second part S12 that connects to the first part S11 and extends linearly in the opening direction DR1 may be called a straight part. Furthermore, the fourth part S24, which corresponds to the other end of the staple S and is bent at an acute angle relative to the third part S23, is sometimes called the hook part.

[0016] As shown in Figure 1B, which illustrates the deformed state, the hook portion S24, which corresponds to the tip of the second leg portion S2, engages with the first object G when the second leg portion S2 is bent in a direction approaching the first object G by the fastening machine 100 described later and hooked onto the first object G. At this time, the opening that was provided between the two legs in the state before deformation is closed when viewed from above, so that the second object P can be surrounded using staples S.

[0017] When the hook portion S24 is engaged with the first object G, the third portion S23 exerts an elastic force in the direction that widens the opening and returns it to its original position. As a result, the hook portion S24 can apply tension to the first object G in the direction that widens the opening, that is, in the direction that separates it from the first leg portion S1 and returns it to its original position. This makes it possible to prevent the first object G from bending and the encirclement of the second object P by the staples S from being released.

[0018] [Configuration of the Binding Machine] Below, an example of the configuration of a binding machine 100 for bending staples S shown in Figure 1A as shown in Figure 1B will be described. However, the binding machine may have other known configurations.

[0019] Except for some aspects where the configuration is reversed left to right (i.e., the first and second displacement parts of the binding machine disclosed in Patent Document 3, etc. are reversed left to right), the basic configuration of the binding machine 100 of this embodiment is the same as that of the binding machine disclosed in the said document, etc. Therefore, the configurations of the binding machine 100 will be described in an appropriate manner, with omissions and simplifications, so that it can be implemented by a person skilled in the art based on the said document, the description in this specification, and the state of the art at the time of filing this application.

[0020] Furthermore, in order to explain the relative directional relationships, for convenience, the direction to the right of the paper in Figure 4 (described later) is sometimes called the front X1, the opposite direction to the left of the paper is called the rear X2, and both directions are collectively referred to as the front-rear direction X. As described above, the front X1 corresponds to the direction in which the connected upper end staple S supported by the magazine 140 separates from the other staples S and moves, and also coincides with the opening direction DR1 of the staple S (Figure 1A).

[0021] Furthermore, in Figure 4, the direction upwards on the paper is sometimes called upward Z1, and the opposite direction downwards on the paper is sometimes called downward Z2, and both directions are sometimes collectively referred to as the up-down direction Z. In this embodiment, the up-down direction Z corresponds to the extension direction of the magazine 140 and also coincides with the connection direction DR2 (stacking direction) of the connected staples S supported by the magazine 140. Furthermore, in the same figure, the depth direction perpendicular to the paper is sometimes called leftward Y1, and the opposite direction perpendicular to the paper towards the front is sometimes called rightward Y2, and both directions are sometimes collectively referred to as the left-right direction Y. Furthermore, a top view (bottom view) refers to the viewpoint when the strapping machine 100, etc. is viewed from an upward Z1 (downward Z2) position looking downward Z2 (upward Z1), a front view (rear view) refers to the viewpoint when the strapping machine 100, etc. is viewed from a forward X1 (rearward X2) position looking rearward X2 (forward X1), and a right side view (left side view) refers to the viewpoint when the strapping machine 100, etc. is viewed from the left Y1 to the right Y2 (or from the right Y2 to the left Y1).

[0022] Figure 2 is a perspective view of the strapping machine 100 from above Z1. Figure 3 is a top view of the strapping machine 100 from above Z1 (top view of the strapping machine 100), Figure 4 is a side view of the strapping machine 100 from the Y2 direction, and Figure 5 is a side view of the strapping machine 100 from the Y1 direction.

[0023] As shown in Figures 2, 4, and 5, the stapling machine 100 includes a grip portion 120 that extends vertically so as to be grasped by the user and is equipped with a switch for driving the stapling machine 100, a magazine 140 configured to support (hold) a plurality of staples S (sometimes referred to as "connected staples S") stacked and connected vertically, and a stapling section configured to fasten two objects, a first object G and a second object P, using one staple S. Here, the part of the stapling machine 100 including the grip portion 120 and the stapling section, excluding the detachably provided magazine 140, is sometimes referred to as the main body portion 150. The stapling machine 100 further includes a magazine mounting portion 160 configured to detachably attach the magazine 140 to the main body portion 150.

[0024] [Configuration of the Binding Section] Below, an example of the configuration of the binding section of a binding machine 100 for bending the staple S shown in Figure 1A as shown in Figure 1B will be described. However, other known configurations may be used as means for deforming the staple.

[0025] The fastening machine 100 includes a fastening section in addition to the magazine 140 and the like described above. The fastening section is the part that bends staples to fasten objects together. The fastening section of this embodiment includes a first displacement section 200 that displaces the first leg S1 of the staple S so as to be able to engage with the first object G, and a second displacement section 300 that displaces the second leg S2 of the staple S so as to be able to engage with the first object G.

[0026] The first displacement portion 200 is located in front of the first leg portion S1 and has a hole with an inner wall surface including a cylindrical surface. With the first object G inserted on the central axis of this cylindrical surface, the stapling machine 100 causes the tip S1P of the first leg portion S1 of the staple S, which is advanced by the driver 142 (see Figure 3, etc.), to come into contact with (collide with) the inner wall surface, deforming the tip portion ST into a spiral shape so as to surround the first object G, thereby engaging the tip portion ST with the first object G. On the other hand, the second displacement portion 300 has a wall portion located in front of the second leg portion S2. The stapling machine 100, with the first leg S1, second leg S2, and main body S3 of the staple S surrounding the second object P, uses the driver 142 to advance the staple S, causing the second leg S2 to come into contact with (collide with) the wall, bending the hook portion S24 of the second leg S2 so that it engages with the first object G, thereby engaging the hook portion S24 with the first object G. The stapling machine 100 is configured to fasten the first object G and the second object P together by engaging both ends of the staple S with the first object G while the staple S surrounds the second object P.

[0027] Specifically, the stapling machine 100 includes a driver 142 that pushes the staple S located at the upper end forward X1, coinciding with the opening direction DR1, thereby separating the staple S located at the upper end from other staples S and moving it forward X1; a moving mechanism for moving the driver 142; a first displacement part 200 for curving and spirally deforming the first leg portion S1 of the staple S; and a second displacement part 300 for deforming the second leg portion S2 of the staple S by curving or bending it.

[0028] [Driver and Driver Movement Mechanism] As described in Patent Document 3 and other documents, the binding machine 100 is configured to move the nut component and the driver 142 fixed thereto forward X1 and backward X2 by rotating a ball screw, which is installed extending in the front-rear direction from approximately the center of the binding machine 100, in the forward or reverse direction using a built-in motor 54 (Figure 7). Here, the nut component and the driver 142 are configured to move forward X1 and backward X2, so they are sometimes called the moving parts. The motor 54 moves the driver 142 forward X1 by rotating the ball screw in the forward direction, and moves the driver 142 backward X2 by rotating the ball screw in the reverse direction, so it is sometimes called the drive unit.

[0029] The driver 142 moves forward X1 (an example of a first direction) and presses the staple S, thereby moving the staple S forward X1 and engaging (fastening) the staple S to the first object G.

[0030] In this embodiment, the driver 142 is configured to separate the uppermost staple S from the other staples S, which are stacked vertically in the magazine 140, while maintaining a front-to-back relationship where the opening of the staple S is in the front and the main body S3 is in the back, and to move it forward X1. Furthermore, the driver 142 is configured to move the separated staple S further forward X1, causing the first leg S1 to come into contact with the first displacement part 200, thereby plastically deforming the first leg S1, and causing the second leg S2 to come into contact with the guide wall included in the second displacement part 300, thereby plastically deforming the second leg S2 and engaging it with the first object G.

[0031] Furthermore, the binding machine 100 is equipped with a control unit 500 for controlling the motor 54, which is the drive unit. The configuration including the control unit 500 will be described later.

[0032] The bundling machine 100 may further include a reduction gear connected to the output shaft of the motor and a printed circuit board on which the control unit 500 of the motor 54 is mounted.

[0033] [First Displacement Section] The first displacement section 200 (an example of the "displacement section") has the function of displacing the first leg portion S1 of the staple S, which is moved forward X1 by the driver 142, in a spiral shape so as to surround the first object G, thereby enabling engagement with the first object G. As shown in Figures 2 to 5, the first displacement section 200 is located to the left (Y1 direction) of the binding machine 100.

[0034] The first displacement portion 200 according to this embodiment includes a hole with a cylindrical inner wall surface into which the tip S1P of the straight portion S12 of the first leg portion S1 of the staple S is inserted as it moves forward by the driver 142, causing the tip ST of the first leg portion S1 to advance downward Z2 (downward in the stacking direction) while curving in an arc or spiral shape, and a groove that guides the tip of the first leg portion S1 into the hole. The hole is provided in front of the first leg portion S1 X1 such that the axial direction of the cylindrical surface is parallel to the vertical direction Z, so that as the staple S moves forward, the tip S1P of the straight portion S12 comes into contact with the inner wall surface of the hole, and the tip ST is displaced so that it advances spirally according to the shape of the inner wall surface. Furthermore, in order to facilitate the downward movement of the tip ST, the binding machine 100 may be provided with a lid portion 250 (sometimes called a "cover portion 250") that closes the upper part of the hole (the top surface of the cylinder), and the lid portion may have a tapered surface that slopes downward Z2 along the circumferential direction in order to facilitate the downward movement of the tip S1P.

[0035] With this configuration, for example, by positioning the first object G, which is a guide string, so as to extend vertically along the central axis of the hole, and inserting the tip S1P of the first leg S1 into the hole, the tip S1P moves in a spiral motion along the cylindrical inner wall surface of the hole. This causes the tip ST to deform spirally around the first object G, making it possible to engage the tip ST with the first object G. In this embodiment, the hole described here is realized by the clincher portion 210.

[0036] [Second Displacement Section] The second displacement section 300 (an example of a "displacement section") has the function of displacing the second leg portion S2 of the staple S, which is moved forward X1 by the driver 142, so that it can engage with the first object G. As shown in Figures 2 to 5, the second displacement section 300 is provided in the Y2 direction of the binding machine 100.

[0037] A detailed explanation will be omitted as it can be easily implemented by those skilled in the art based on the state of the art at the time of this application, including the above-mentioned Patent Document 3, etc. However, the second displacement part 300 according to this embodiment is configured to displace the second leg portion S2 inward of the staple S as the driver 142 moves forward X1. Specifically, the second displacement part 300 is provided on the outside of the second leg portion S2 in the initial state before the staple S starts to be displaced, and has a first guide wall that causes the second leg portion S2 to bend when it comes into contact with the second leg portion S2 of the staple S moving in the opening direction DR1 (forward X1). This first guide wall has a recess that is recessed toward the outside of the staple S.

[0038] Furthermore, the second displacement section 300 is provided in front of the second leg portion S2 X1 in the initial state before the staple S begins to be displaced, and includes a second guide wall that bends the second leg portion S2 when it comes into contact with the second leg portion S2 of the staple S moving in the opening direction DR1. This second guide wall has a wall surface facing rear X2 and a protrusion that further protrudes rear X2. In the initial state, this protrusion is provided in front of the second leg portion S2 in the front-rear direction and inward of the second leg portion S2 in the left-right direction, and is provided at the inner end of the second guide wall such that the amount of protrusion to the rear X2 increases as it moves inward.

[0039] With this configuration, the second leg portion S2 of the staple S, which is advanced by the driver 142, comes into contact (collides) with the first guide wall and the inner wall surface of the second guide wall, making it possible to bend the third portion S23 of the second leg portion S2 so that it curves significantly. This makes it possible to displace the hook portion S24 in a direction that approaches the first object G and hook it onto the first object G.

[0040] As described above, of the staples S advanced by the driver 142, the first leg portion S1 is deformed spirally by the first displacement portion 200 and engages with the first object G, and the second leg portion S2's hook portion S24 is hooked onto the first object G by the second displacement portion 300 and engages with it, making it possible to fasten the first object G and the second object P together.

[0041] [Configuration of the Control Unit] The configuration including the control unit of this embodiment will be described below. Figure 6 is a functional block diagram of the binding machine 100 according to this embodiment.

[0042] The strapping machine 100 includes a control unit 500 that generates control commands for controlling the motor 54, a speed acquisition unit 502 that acquires information indicating the speed of movement of the driver 142 in front of it X1, a position acquisition unit 504 that acquires position information of the driver 142 in the front-rear direction X (or forward X1), a stop target position setting unit 506 that sets and stores the stop target position of the driver 142 moving forward X1 for each strapping machine 100, a rotation amount acquisition unit 508 that acquires information indicating the amount of rotation of the motor 54, a rotation speed acquisition unit 510 that acquires information indicating the rotation speed of the motor 54, a current amount acquisition unit 512 that acquires information indicating the current of the motor 54, and a dry-fire detection unit 514 that detects dry-fire (described later). Details will be described below. The control unit 500, speed acquisition unit 502, position acquisition unit 504, stop target position setting unit 506, rotation amount acquisition unit 508, rotation speed acquisition unit 510, current amount acquisition unit 512, and dry-fire detection unit 514 are all components for controlling the binding machine 100, and therefore these components may be collectively referred to as the binding machine control unit.

[0043] The control unit 500 generates a control command for controlling the motor 54 to control the motor 54. When the motor 54 is, for example, a three-phase DC brushless motor, the control unit 500 may include an inverter circuit including a total of six switching elements each having two switching elements connected to each phase between DC buses for supplying a power supply voltage, a driver circuit and a logic circuit for generating control signals for turning on and off each switching element of the inverter circuit, and a non-volatile semiconductor memory for storing a computer program (which may be called "firmware") for generating different control signals according to an operation mode. In the present embodiment, the computer program includes a first computer program in a binding mode (an example of "the first mode") for controlling the motor 54 so as to move the driver 142 forward in the X1 direction at a high speed (an example of "the first speed") and execute a binding operation, and a second computer program in a stop target position setting mode (an example of "the second mode") for controlling the motor 54 so as to move the driver 142 forward in the X1 direction at a low speed (an example of "the second speed") and set a stop target position.

[0044] The first computer program for executing the binding mode includes a deceleration control program for controlling the motor 54 so as to decelerate the driver 142 moving in the forward X1 direction, and a stop control program for controlling the motor 54 so as to stop the decelerated driver 142.

[0045] As will be described later, the control unit 500 calculates a deceleration start position of the driver 142 based on information indicating a stop target position acquired from a stop target position setting unit 506 that stores information indicating a stop target position set for each binding machine, and information indicating a moving speed of the driver 142 in the forward X1 direction acquired from a speed acquisition unit 502, and when it is determined that the driver 142 has reached the acquired deceleration start position based on the calculation result and position information of the driver 142 in the front-rear direction X acquired from a position acquisition unit 504, the control unit 500 is configured to execute a deceleration control program to control the motor 54 so that the driver 142 decelerates.

[0046] According to such a configuration, since the stop target position is set for each bundling machine, it is possible to set the stop position reflecting the individual differences of the bundling machines. Further, since the deceleration start position is obtained based on the moving speed of the driver 142, for example, when the moving speed of the driver 142 is high because the power supply voltage is high and when the moving speed of the driver 142 is low because the power supply voltage is low, different deceleration start positions can be obtained, or the deceleration start position can be obtained according to the decrease in the moving speed of the driver 142 due to aging deterioration or the like. Therefore, it is possible to position the driver 142 according to the state of the bundling machine 100.

[0047] The speed acquisition unit 502 acquires information indicating the moving speed of the driver 142 at the front X1. A known configuration can be adopted for the configuration for acquiring information indicating the moving speed of the driver 142 at the front X1. The speed acquisition unit 502 in the present embodiment is configured to acquire the moving speed of the driver 142 based on the information indicating the rotational speed of the motor 54 acquired by the rotational speed acquisition unit 510. That is, in the bundling machine 100 of the present embodiment, the motor 54 rotates the ball screw in the forward or reverse direction, so that the nut component and the driver 142 fixed thereto can be moved in the forward X1 and the rear X2. Therefore, the rotational speed of the motor 54 and the moving speed of the driver 142 are in a predetermined relationship (for example, a proportional relationship). Therefore, the speed acquisition unit 502 can acquire the moving speed of the driver 142 based on the information indicating the rotational speed of the motor 54.

[0048] However, the speed acquisition unit 502 may be realized from other known configurations for acquiring information indicating the moving speed of the driver 142.

[0049] The position acquisition unit 504 acquires position information of the driver 142 in the front-rear direction X (or forward X1). Known configurations can be used to acquire information indicating the speed of movement of the driver 142 in the forward X1 direction. In this embodiment, the position acquisition unit 504 is configured to acquire position information of the driver 142 based on information indicating the amount of rotation of the motor 54 acquired by the rotation amount acquisition unit 508. That is, in this embodiment, the binding machine 100 is configured so that the nut component and the driver 142 fixed thereto can move forward X1 and backward X2 by rotating the ball screw in the forward or reverse direction with the motor 54, so the amount of rotation of the motor 54 and the amount of movement of the driver 142 are in a predetermined relationship (for example, a proportional relationship). For example, when the motor 54 rotates once in the forward direction, the nut component and the driver 142 fixed thereto move a certain distance forward X1. Therefore, the position acquisition unit 504 can acquire, for example, information from the rotation amount acquisition unit 508 indicating the total amount of rotation of the motor 54 from when the driver 142 is stationary at the origin position to when the driver 142 is moving forward X1, thereby acquiring the distance the driver 142 has moved forward X1 relative to the origin position at that time (i.e., the position information of the driver 142 in the X direction).

[0050] However, the position acquisition unit 504 may be implemented from other known configurations for acquiring information indicating the position of the driver 142. For example, the position acquisition unit 504 may be implemented from a configuration comprising one or more Hall ICs installed in positions capable of detecting the magnetic material embedded in the driver 142.

[0051] The stop target position setting unit 506 is configured to set and store the stop target position of the driver 142 that moves forward X1 for each strapping machine 100. The stop target position setting mode for setting the stop target position of the driver 142 that moves forward X1 for each strapping machine 100 will be described later.

[0052] The rotation amount acquisition unit 508 acquires information indicating the rotation amount of the motor 54. A known configuration can be adopted for acquiring information indicating the rotation amount of the motor 54. In this embodiment, the rotation amount acquisition unit 508 is configured to acquire the rotation amount of the motor 54 based on information indicating the rotation speed of the motor 54 acquired by the rotation speed acquisition unit 510. That is, since the rotation amount of the motor 54 corresponds to the time integral of the rotation speed of the motor 54, it is possible to acquire information indicating the rotation amount of the motor 54 by acquiring information indicating the rotation speed of the motor 54 from the rotation speed acquisition unit 510 and integrating this over time.

[0053] The rotation speed acquisition unit 510 acquires information indicating the rotation speed of the motor 54. Known configurations can be used for acquiring information indicating the rotation speed of the motor 54. For example, the rotation speed acquisition unit 510 may be realized with a configuration that includes one or more Hall ICs for detecting the magnetic field of the motor 54, which is a magnetic material. Alternatively, the rotation speed acquisition unit 510 may be realized with a configuration that acquires the number of commutations of the motor 54 based on the induced voltage generated by the rotation of the motor 54, or with a configuration that acquires the number of commutations of the motor 54 based on the motor current.

[0054] The current acquisition unit 512 acquires information indicating the current of the motor 54. For example, the current acquisition unit 512 may be composed of a current detection circuit that includes a resistive element inserted between the stator and the DC bus in order to acquire information indicating the current flowing through the windings, which are the stator of the motor 54.

[0055] When attempting to perform a stapling action, but all staples supported by the magazine are used up, or when the staples are not properly set, the driver moves in the intended direction without pressing down on the staples. This is called a dry run.

[0056] The inventors of this application focused on the fact that the current flow rate of the motor 54 during normal binding operation differs from the current flow rate of the motor 54 during idle operation. They conceived a configuration in which idle operation is detected based on the current flow rate acquired by the current flow rate acquisition unit 512 when the driver 142 is in a predetermined position. Furthermore, since the driver 142 is moving at a higher speed than usual when idle operation is detected by the idle operation detection unit 514, they conceived a configuration in which a deceleration control program is executed at a position earlier than the deceleration start position acquired by the control unit 500 to control the motor 54 so that the driver 142 starts decelerating at an earlier timing compared to during binding operation.

[0057] The binding machine control unit described above may be implemented with a configuration (for example, a computer such as a CPU (Central Processing Unit)) that includes a non-volatile semiconductor memory for storing a computer program for executing calculations, excluding circuits such as resistors that may be included in the current quantity acquisition unit 512, circuits such as inverters that may be included in the control unit 500, and sensors such as Hall elements that may be included in the rotation speed acquisition unit 510, and a processor for reading and executing this computer program.

[0058] [Stop Target Position Setting Mode] A method for setting the stop target position for each strapping machine using the strapping machine control unit described above will now be explained. The stop target position setting mode may be executed before the strapping machine 100 is shipped, so that the strapping machine 100 is shipped with information indicating the stop target position already stored in the stop target position setting unit. Furthermore, the strapping machine 100 may be configured to allow the stop target position setting mode to be executed even after shipment, so that the stop target position can be reset taking into account the effects of aging due to use. For example, if the stop target position is not stored in the stop target position setting unit 506 when the main power of the strapping machine 100 is turned on, the stop target position setting mode may be automatically executed. Alternatively, the stop target position setting mode may be executed when the trigger is pressed and another special switch is turned on. In this embodiment, the stop target position setting mode is executed when staples S are not loaded into the strapping machine 100.

[0059] The stop target position setting mode is started when the stop target position setting unit 506 of the binding machine control unit executes a second computer program for the stop target position setting mode. The control unit 500 generates control commands according to the second computer program to drive and control the motor 54.

[0060] Figure 7A is a flowchart showing the process of the stop target position setting mode. Figure 7B is a schematic diagram showing the movement of the driver 142.

[0061] In the initial state, the driver 142 is pre-positioned at the origin OR. For the sake of explanation, the position of the origin OR in the front-to-back direction X (sometimes called the "X-axis direction") is set to 0 (zero). In the initial state, the position of the driver 142 in front X1 (in the X-axis direction) is zero. The position of the driver 142 refers to the position of the driver 142 at a predetermined reference part (for example, the front end of the driver 142, the rear end, or the part fixed to the nut component).

[0062] When the stop target position setting mode is started, the control unit 500 generates a control command to drive the motor 54, which rotates in the forward direction at a low speed (an example of "second speed"), and controls the motor 54 (STEP 10). As a result, the motor 54 starts to rotate, and the driver 142 starts to move forward X1 at a low speed.

[0063] The stop target position setting unit 506 of the binding machine control unit determines at predetermined intervals whether or not a load has been applied and the motor 54 has stopped (STEP 12). If it is not determined that the motor 54 has stopped ("No"), the control unit 500 continues forward low-power drive, rotating the motor 54 in the forward direction at a low speed (STEP 10).

[0064] As shown in Figure 7B, a guide plate GP (an example of a "stopper") is installed in front of the driver 142 at X1, preventing the driver 142 from moving any further forward X1. As a result, the front end of the driver 142, for example, when moving forward X1, comes into contact with the surface of the guide plate GP and stops due to the load received from the guide plate GP, and the motor 54 also stops rotating as a result.

[0065] If the stop target position setting unit 506 determines that the motor 54 has stopped ("Yes"), it obtains information from the rotation amount acquisition unit 508 indicating the amount of rotation of the motor 54 from the start of rotation to that point and stores it (STEP 14). The amount of rotation at this time corresponds to information indicating the position of the movable front end (movable front end) of the driver 142 in the X-axis direction. In this embodiment, the information indicating the amount of rotation of the motor 54 is stored as the commutation number of the motor 54, and the information indicating the movable front end position of the driver 142 is stored as the front end commutation number.

[0066] Next, the control unit 500 generates a control command to execute a reverse drive that rotates the motor 54 in the opposite direction, and drives the motor 54 (STEP 16), and returns the driver 142 to the origin OR (STEP 18).

[0067] Next, the stop target position setting unit 506 calculates the stop target position of the driver 142 in the binding mode based on the front end commutation number acquired based on the driver 142 contacting the guide plate GP (STEP 20). Specifically, it calculates the commutation number corresponding to position XB, which is a predetermined distance backward from the front end position corresponding to the front end commutation number, and the commutation number corresponding to position XA, which is a predetermined distance backward from position XB. The range of commutation numbers corresponding to the region between XA and XB in the X-axis direction is calculated as information indicating the stop target position. Here, the range of commutation numbers corresponding to the region between XA and XB in the X-axis direction is acquired based on the front end commutation number acquired based on the driver 142 contacting the guide plate GP, and therefore is information acquired that reflects individual differences of the binding machine 100.

[0068] Next, the stop target position setting unit 506 determines whether the calculated range of commutation numbers is within the normal range (STEP 22). That is, since the range of values ​​that the calculated commutation numbers can take, taking into account the effects of errors due to individual differences, the stop target position setting unit 506 can determine whether the calculated range of commutation numbers is within the normal range by determining whether the calculated range of commutation numbers falls within the range of possible values.

[0069] For example, the stop target position setting mode of this embodiment is assumed to be performed when the staples S are not loaded. However, if it is performed when the staples S are mistakenly loaded, the motor 54 may stop rotating before the driver 142 contacts the surface of the guide plate GP due to the load caused by the driver 142 moving the staples S forward at a low speed.

[0070] This step helps to prevent the setting of a stop target position that deviates significantly from the actual position in such cases.

[0071] If the value is outside the normal range (i.e., "No"), the stop target position setting unit 506 does not update the stop target position (STEP 24).

[0072] If the value is within the normal range ("Yes"), the stop target position setting unit 506 sets the calculated commutation range as the stop target position and stores it (STEP 26).

[0073] Through the above process, the stop target position setting unit 506 can set a different stop target position for each strapping machine. Here, the control unit 500 moves the driver 142 at a low speed, which helps to prevent damage to the strapping machine 100 when it comes into contact with the guide plate GP.

[0074] [Binding Mode] A method for performing a binding operation using the binding machine 100, in which the stop target position has been set as described above, will now be explained.

[0075] The bundling mode is started, for example, when the user presses the trigger on the bundling machine 100 and the control unit 500 executes a first computer program for bundling mode. The control unit 500 generates control commands according to the first computer program to drive and control the motor 54.

[0076] Figure 8 is a flowchart showing the process of the binding mode. Figures 9A and 9B are graphs where the horizontal axis represents the position of the driver 142 in the X-axis direction and the vertical axis represents the rotational speed of the motor 54, when the power supply voltage is high voltage and low voltage, respectively.

[0077] In the initial state, the driver 142 is pre-positioned at the origin OR.

[0078] When the binding mode is initiated, the control unit 500 generates a control command to execute a forward high-power drive that rotates the motor 54 in the forward direction at high speed (an example of the "first speed"), and drives the motor 54 (STEP 30). As a result, the motor 54 starts to rotate, and the driver 142 starts moving forward X1 at high speed.

[0079] The control unit 500 calculates the deceleration start position of the moving driver 142 based on the target stop position obtained from the stop target position setting unit 506 and the forward (in the X-axis direction) movement speed of the driver 142 obtained from the speed acquisition unit 502 (STEP 32).

[0080] For example, when the power supply voltage is high (Figure 9A), the rotational speed of the motor 54 acquired by the rotational speed acquisition unit 510 is high, and therefore the moving speed of the driver 142 acquired by the speed acquisition unit 502 is high, so the deceleration start position XB1 is calculated as a position relatively close to the origin OR.

[0081] On the other hand, when the power supply voltage is low (Figure 9B), the rotational speed of the motor 54 acquired by the rotational speed acquisition unit 510 is small, and therefore the moving speed of the driver 142 acquired by the speed acquisition unit 502 is small, so the deceleration start position XB2 is calculated as a position relatively far from the origin OR.

[0082] The control unit 500 determines whether the position of the driver 142 in the X-axis direction, as acquired by the position acquisition unit 504, has reached the deceleration start position (STEP 34). If it determines that it has reached the position ("Yes"), it executes a deceleration control program to control the motor 54 so that the driver 142 starts to decelerate (brake) (STEP 36). On the other hand, if it determines that it has not reached the position ("No"), it recalculates the deceleration start position of the moving driver 142 (STEP 32) and determines again whether the position of the driver 142 in the X-axis direction, as acquired by the position acquisition unit 504, has reached the deceleration start position (STEP 34).

[0083] With this configuration, since a target stopping position is set for each binding machine, it is possible to set the stopping position to reflect individual differences in binding machines. Furthermore, it is possible to acquire a deceleration start position that compensates for fluctuations in the moving speed of the driver 142, which fluctuates according to the magnitude of the power supply voltage and aging deterioration, thereby improving the positioning accuracy of the driver 142.

[0084] Furthermore, since the deceleration start position is recalculated based on the driver 142's immediate movement speed until it reaches the deceleration start position, it is possible to further improve the positioning accuracy of the driver 142.

[0085] Next, the control unit 500 determines whether the rotational speed of the motor 54, as acquired by the rotational speed acquisition unit 510, has decelerated to a target speed (sometimes called the "deceleration brake interruption speed") and fallen below the target speed (STEP 38). If it determines that the motor has not decelerated to the target speed ("No"), it determines whether the position of the driver 142 in the X-axis direction, as acquired by the position acquisition unit 504, has reached the position where stop control should be initiated (sometimes called the "second brake position") (STEP 40). If it determines that the driver 142 has not reached this position ("No"), it controls the motor 54 so that the driver 142 continues to decelerate (brake) according to the deceleration control program. If it determines that the driver 142 has reached this position ("Yes"), it executes the stop control program to stop the driver 142.

[0086] On the other hand, in STEP 38, if the control unit 500 determines that the rotational speed of the motor 54 acquired by the rotational speed acquisition unit 510 has decreased to the target speed and is below the target speed ("Yes"), it stops the deceleration control to suppress the deceleration of the driver 142 and restarts the motor 54 at low output (STEP 42). Figures 9A and 9B show graphs that show the reduction in rotational speed suppressed as a result of stopping the deceleration control and restarting the motor 54 at low output. Note that the rotational speed at which the deceleration control is stopped (an example of a "predetermined value") and the rotational speed at which the motor 54 is restarted (an example of a "second predetermined value") may be the same or different.

[0087] The control unit 500 then determines whether the position of the driver 142 in the X-axis direction, as acquired by the position acquisition unit 504, has reached the second brake position where stop control should be initiated (STEP 40). If it determines that the position has not reached the second brake position, it continues to drive the motor 54 at a low output until the rotational speed of the motor 54, as acquired by the rotational speed acquisition unit 510, falls below the target speed.

[0088] The control unit 500 determines whether the position of the driver 142 in the X-axis direction, as acquired by the position acquisition unit 504, has reached the second brake position where stop control should be initiated (STEP 40). If it determines that the position has reached the second brake position ("Yes"), it executes a stop control program to control the motor 54 to decelerate the driver 142 and stop the driver 142 at the target stop position (STEP 46).

[0089] The binding process is completed after the above steps (STEP 48).

[0090] As described above, the control unit 500 is configured to start deceleration control before starting stop control to stop the driver 142, and to stop deceleration control if the deceleration is relatively large, while continuing deceleration control if the deceleration is relatively small. Specifically, when the control unit 500 is decelerating the motor 54, it determines whether the rotational speed of the motor 54 acquired by the rotational speed acquisition unit 510 has fallen below the target speed. If it determines that the motor has decelerated to below the target speed, it stops deceleration control to suppress deceleration, while if it determines that the motor has not decelerated to below the target speed, it controls the motor 54 so that the driver 142 continues to decelerate (brake) according to the deceleration control program until it reaches the second brake position. With this configuration, it is possible to suppress fluctuations in the rotational speed of the motor 54 when it reaches the second brake position for executing stop control. Here, since the rotational speed of the motor 54 has decreased sufficiently at the second brake position for executing stop control, it is possible to improve the accuracy of the stopping position of the driver 142 compared to when stop control is executed without executing deceleration control. Therefore, it is possible to improve the accuracy of the binding operation by the binding machine 100. Furthermore, by improving the precision of the driver's stopping position, the need for excessively large dimensional margins is eliminated, making it possible to suppress the need to increase the size of the strapping machine.

[0091] In addition, since there is no need to significantly reduce the movement speed of the driver 142 in order to improve the accuracy of the driver's stopping position, it is also possible to suppress a decrease in work efficiency.

[0092] The control method for decelerating the motor 54 can be any known method. For example, a short-circuit brake control may be used, in which all switching elements on one arm of the inverter circuit are turned off while all elements on the other arm are turned on. Alternatively, an intermittent brake control may be used, in which all switching elements on one arm of the inverter circuit are turned off while all elements on the other arm are repeatedly turned on and off. Or, intermittent brake control may be performed when deceleration control begins, and short-circuit brake control may be performed when the motor 54 falls below a predetermined rotational speed.

[0093] [Detection of misfires] Next, the configuration for detecting misfires of the binding machine 100 will be described.

[0094] As mentioned above, if the stapling operation is performed when all the staples supported by the magazine 140 are used up, or when the staples S are not set correctly, dry firing may occur. Dry firing occurs because there is no load from the staples S, causing the driver 142 to move at a higher speed than usual, which could lead to situations such as the driver 142 colliding with the guide plate GP and damaging the stapling machine 100.

[0095] The inventors of this application focused on the fact that the current flow rate of the motor 54 during normal binding operation differs from the current flow rate of the motor 54 during idle operation, and conceived a configuration in which idle operation is detected based on the current flow rate acquired by the current flow rate acquisition unit 512 when the driver 142 is in a predetermined position.

[0096] Figures 10A and 10B are graphs showing the position of the driver 142 in the X-axis direction on the horizontal axis and the current value of the motor 54 on the vertical axis, during normal binding operation and dry firing.

[0097] As shown in these graphs, the current value of the motor 54 does not differ significantly in both cases immediately after the driver 142 begins to move forward X1. However, in the region forward X1 from a predetermined position XC, where the driver 142 has advanced a certain distance forward X1, the two differ in that the current value increases during normal stapling operation, while it does not increase during dry firing. This is because during normal stapling operation, the load on the motor 54 increases because it is necessary to deform the staple S, whereas during dry firing, there is no staple S to deform, so the load on the motor 54 does not increase.

[0098] Therefore, the drowning detection unit 514 of the stapling machine 100 is configured to determine the presence or absence of staples S based on the current value of the motor 54, using the current amount acquisition unit 512, when the driver 142 reaches a predetermined position XC based on the position information of the driver 142 in the front-rear direction X acquired from the position acquisition unit 504.

[0099] Specifically, the dry-fire detection unit 514 may be configured to detect a dry-fire based on the fact that the driver 142 calculates the derivative of the current value of the motor 54 at a position X1 in front of a predetermined position XC, and the derivative is not positive.

[0100] Alternatively, the dry-firing detection unit 514 may be configured to detect dry-firing if it detects no increase in current value when it repeatedly compares the current value of the motor 54 with the current value of the motor 54 from the current amount acquisition unit 512 at predetermined intervals.

[0101] The control unit 500 is configured to control the motor 54 so that when the dry-fire detection unit 514 detects a dry-fire, the driver 142 decelerates at a position earlier than the deceleration start position calculated in STEP 32.

[0102] This configuration makes it possible to prevent situations in which the driver 142 collides with parts such as the guide plate GP and damages the bundling machine 100.

[0103] Furthermore, the present invention is capable of various modifications without departing from its essence. For example, within the ordinary creative ability of those skilled in the art, some components of one embodiment can be added to other embodiments. Also, some components of one embodiment can be replaced with corresponding components of other embodiments.

[0104] Although various embodiments have been described above with reference to the drawings, it goes without saying that the present invention is not limited to these examples. It is clear to those skilled in the art that various modifications or alterations can be conceived within the scope of the claims, and these will naturally also fall within the technical scope of the present invention. Furthermore, the components of the above embodiments may be combined in any way without departing from the spirit of the invention.

[0105] This application is based on Japanese Patent Application No. 2024-208274 filed on November 29, 2024, the contents of which are incorporated by reference within this application.

[0106] This disclosure has the effect of enabling highly accurate positioning of the driver while suppressing a decrease in the work efficiency of the strapping machine, and is useful for strapping machines and the like.

[0107] 54 Motor (motor section) 100 Binding machine 140 Magazine 142 Driver (driver section) 150 Main body 200 First displacement section 300 Second displacement section 500 Control unit 502 Speed ​​acquisition section 504 Position acquisition section 506 Stop target position setting section 508 Rotation amount acquisition section 510 Rotation speed acquisition section 514 Dry firing detection section DR1 Opening direction DR2 Connection direction GP Guide plate (stopper section) S Staple X1 Forward X2 Rearward Y1 Left Y2 Right Z1 Upward Z2 Downward

Claims

A driver unit for fastening staples to an object by moving in a first direction and pressing the staples, A motor unit for moving the aforementioned driver unit, A control unit for controlling the motor section, A speed acquisition unit for acquiring the moving speed of the driver unit in the first direction, A position acquisition unit for acquiring the position of the driver unit in the first direction, A binding machine equipped with, The control unit, Based on the stop target position set for each binding machine and the moving speed acquired by the speed acquisition unit, the deceleration start position of the driver unit during movement is calculated. Based on the position information of the driver unit obtained from the position acquisition unit, when the driver unit determines that it has reached the deceleration start position, it controls the motor unit to decelerate. Binding machine. 　 A stopper portion that prevents the driver portion from moving in the first direction, A stop target position setting unit that can set the stop target position for each binding machine based on the contact between the driver unit and the stopper unit moving in the first direction, The binding machine according to claim 1, further comprising the following: 　 The control unit, A first mode in which the motor unit is controlled to move the driver unit in the first direction at a speed of first speed or higher to perform a binding operation, A second mode in which the motor unit is controlled to move the driver unit in the first direction at a second speed or less, which is less than the first speed, to set the target stopping position, It is configured to be executable. The binding machine according to claim 2. 　 The motor unit is further provided with a rotation amount acquisition unit that acquires the rotation amount of the motor unit, The stop target position setting unit is configured to set the stop target position when the amount of rotation of the motor unit, acquired by the rotation amount acquisition unit, is within a predetermined range before the motor unit stops rotating. The binding machine according to claim 2. 　 The motor section is further provided with a rotation speed acquisition unit that acquires the rotation speed of the motor section. The speed acquisition unit is configured to acquire the moving speed of the driver unit based on the rotational speed of the motor unit acquired by the rotational speed acquisition unit. The binding machine according to claim 1. 　 The binding machine according to claim 5, wherein the control unit is configured to stop the deceleration control when the rotational speed of the motor unit, as obtained by the rotational speed acquisition unit, falls below a predetermined value while the driver unit is controlling the motor unit to decelerate. 　 The binding machine according to claim 6, wherein the control unit is configured to restart the motor unit when the rotational speed of the motor unit obtained by the rotational speed acquisition unit after the deceleration control has stopped falls below a second predetermined value. 　 The motor unit is further provided with a rotation amount acquisition unit that acquires the rotation amount of the motor unit, The position acquisition unit is configured to acquire position information of the driver unit based on the amount of rotation of the motor unit detected by the rotation amount acquisition unit. The binding machine according to claim 1. 　 The binding machine according to claim 1, further comprising a dry-fire detection unit that detects when the driver unit moves in the first direction without pressing the staple. 　 The motor section is equipped with a current quantity acquisition unit that acquires the current quantity of the motor section, The dry-firing detection unit is configured to detect dry firing based on the current amount acquired by the current amount acquisition unit when the driver unit is in a predetermined position. The binding machine according to claim 9. 　 The binding machine according to claim 10, wherein the control unit is configured to control the motor unit so that the driver unit decelerates at a position prior to the deceleration start position when a dry run is detected by the dry run detection unit.

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