U.S. patent application number 10/433406 was filed with the patent office on 2004-04-08 for bag-making and packaging machine.
Invention is credited to Ichikawa, Makoto, Miyamoto, Hideshi, Sugimura, Kazuya.
Application Number | 20040065047 10/433406 |
Document ID | / |
Family ID | 19011497 |
Filed Date | 2004-04-08 |
United States Patent
Application |
20040065047 |
Kind Code |
A1 |
Miyamoto, Hideshi ; et
al. |
April 8, 2004 |
Bag-making and packaging machine
Abstract
When replacing film rolls, a film holding mechanism fixedly
holds a film of a pre-replacement film roll. At the same time, a
film suction mechanism holds a film by suction. A film storing
mechanism pulls the end of the film up to the film suction
mechanism. Furthermore, the end of the film that is held by the
film suction mechanism by suction and the head of the film of the
post-replacement film roll are joined using an adhesive tape. Also,
once it is detected based on the output from the load cell that the
film has been entirely unrolled, the control device stops the
operations of an items supply portion and motor. Accordingly, the
items that have been supplied to a bag-manufacturing and packaging
portion from the items supply portion at the time the items supply
portion is stopped are packaged using film stored in a film storing
mechanism. Then, the control device stops the operation of the
bag-manufacturing and packaging portion.
Inventors: |
Miyamoto, Hideshi;
(Ritto-shi, JP) ; Sugimura, Kazuya; (Ritto-shi,
JP) ; Ichikawa, Makoto; (Ritto-shi, JP) |
Correspondence
Address: |
Shinjyu Global IP Counselors
Suite 700
1233 Twentieth Street NW
Washington
DC
20036
US
|
Family ID: |
19011497 |
Appl. No.: |
10/433406 |
Filed: |
June 4, 2003 |
PCT Filed: |
December 12, 2002 |
PCT NO: |
PCT/JP02/05463 |
Current U.S.
Class: |
53/64 ;
53/551 |
Current CPC
Class: |
B65H 2301/4631 20130101;
B65B 41/12 20130101; B65B 41/16 20130101; B65B 9/20 20130101; B65B
9/2028 20130101; B65H 2511/142 20130101; B65H 2801/69 20130101;
B65B 57/08 20130101; B65H 20/34 20130101; B65H 2511/142 20130101;
B65H 19/1852 20130101; B65H 2801/81 20130101; B65H 2301/4621
20130101; B65H 2406/351 20130101; B65H 2220/03 20130101 |
Class at
Publication: |
053/064 ;
053/551 |
International
Class: |
B65B 057/02; B65B
009/06 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 5, 2001 |
JP |
2001-169424 |
Claims
1. A bag-manufacturing and packaging apparatus that packages items
while manufacturing bags from a film roll in which an elongated
film is wound in a roll shape, said bag-manufacturing and packaging
apparatus comprising: a film roll support portion that supports the
film roll; a film conveyance mechanism that conveys film sent from
the film roll; and a film joining device that is disposed between
said film roll support portion and said film conveyance mechanism,
said film joining device being for, at the time of replacement of
the film roll, joining an end of a film conveyance mechanism side
film and a head of the film of a post-replacement film roll; said
film joining device having a film storing mechanism for pulling in
the film that is disposed on an upstream side relative to a film
joining position.
2. The bag-manufacturing and packaging apparatus as set forth in
claim 1, wherein said film storing mechanism includes a fixed
roller that guides the conveyed film, a movable roller that changes
a running distance of the conveyed film, and a moving mechanism
that moves said movable roller toward and away from said fixed
roller.
3. The bag-manufacturing and packaging apparatus as set forth in
claim 2, wherein said film storing mechanism has a plurality of
pairs of said fixed and movable rollers that are disposed
alternately.
4. The bag-manufacturing and packaging apparatus as set forth in
claim 2, wherein said moving mechanism includes a fixed frame for
supporting both ends of said fixed roller, a movable frame for
supporting both ends of said movable roller, and a rotational axis
supported in parallel with said fixed roller for supporting an end
of said movable roller such that said movable roller is rotatable
about said fixed frame, and said movable roller moves relative to
said fixed roller by allowing said movable frame to rotate about
said rotational axis relative to said fixed frame.
5. The bag-manufacturing and packaging apparatus as set forth in
claim 1, wherein said film joining device further includes a film
suction retaining mechanism that is disposed on an upstream side
from said film storing mechanism in a film conveyance direction,
said film suction retaining mechanism retaining by suction the film
that is severed from a pre-replacement film roll at a time of film
joining.
6. The bag-manufacturing and packaging apparatus as set forth in
claim 1, wherein said film joining device further includes a film
fixedly holding mechanism disposed on a downstream side from said
film storing mechanism in the film conveyance direction, said film
fixedly holding mechanism being for fixedly holding the film
conveyance mechanism side film at the time of joining the
films.
7. A bag-manufacturing and packaging apparatus that packages items
while manufacturing bags from a film roll in which an elongated
film is wound in a roll shape, said bag-manufacturing and packaging
apparatus comprising: a bag-manufacturing and packaging portion for
manufacturing bags while packaging items; an items supply portion
for supplying the items to said bag-manufacturing and packaging
portion; a film roll support portion for supporting the film roll;
a driving device for sending out the film from the film roll that
is supported by said film roll support portion; a film conveyer
mechanism for conveying the film that is sent out from the film
roll to said bag-manufacturing and packaging portion; a film
storing mechanism for sending out film while storing the film that
is to be conveyed by said film conveyance mechanism; a detecting
device for detecting that the film of the film roll is exhausted;
and a control portion for stopping operations of said items supply
portion and said driving device in response to an output from said
detecting device, and for stopping an operation of said
bag-manufacturing and packaging portion after the film stored in
said film storing mechanism is sent out by an amount that
corresponds to a predetermined numbers of bags.
8. The bag-manufacturing and packaging apparatus as set forth in
claim 7, wherein said detecting device includes a tension detecting
device that detects a tensile force of the film, and said control
portion stops the operations of said items supply portion and said
driving device when the output from said tension detecting device
exceeds a predetermined value.
9. The bag-manufacturing and packaging apparatus as set forth in
claim 8, wherein said control portion controls said driving device
such that the tensile force of the film is constant when the output
from said tension detecting device is below the predetermined
value.
10. The bag-manufacturing and packaging apparatus as set forth in
claim 7, wherein said film storing mechanism includes a fixed
roller for guiding the conveyed film, a movable roller for changing
a running distance of the conveyed film, and a moving mechanism
that moves said movable roller toward and away from said fixed
roller.
11. The bag-manufacturing and packaging apparatus as set forth in
claim 7, further comprising a film joining device disposed between
said film roll support portion and said film conveyance mechanism,
said film joining device joining, at the time of replacing the film
roll, an end of the film on the film conveyance mechanisms side and
a head of a post-replacement film roll, said film storing mechanism
being disposed on a downstream side from a film joining position of
said film joining device.
12. The bag-manufacturing and packaging apparatus as set forth in
claim 11, wherein said film storing mechanism includes a fixed
roller for guiding the conveyed film, a movable roller for changing
a running distance of the conveyed film, and a moving mechanism
that moves said movable roller close to and away from said fixed
roller.
13. The bag-manufacturing and packaging apparatus as set forth in
claim 12, wherein said moving mechanism includes a fixed frame for
supporting both ends of said fixed roller, a movable frame for
supporting both ends of said movable roller, and a rotational axis
supported in parallel with said. fixed roller for supporting an end
of said movable roller such that said movable roller is rotatable
about said fixed frame, and said movable roller moves relative to
said fixed roller by allowing said movable frame to rotate about
said rotational axis relative to said fixed frame.
14. The bag-manufacturing and packaging apparatus as set forth in
claim 12, wherein said film joining device further includes a film
suction retaining mechanism that is disposed on an upstream side
from said film storing mechanism in the film conveyance direction,
said film suction retaining mechanism retaining by suction the film
that is severed from the pre-replacement film roll at a time of
film joining.
15. The bag-manufacturing and packaging apparatus as set forth in
claim 14, wherein said control portion activates said film suction
retaining mechanism during the film joining.
16. The bag-manufacturing and packaging apparatus as set forth in
claim 11, wherein said film joining device further includes a film
fixedly holding mechanism disposed on an upstream side from said
film storing mechanism in the film conveyance direction, said film
fixedly holding mechanism being for fixedly holding a
film-conveyance-mechanism-side film at the time of joining the
films.
17. The bag-manufacturing and packaging apparatus as set forth in
claim 16, wherein said control portion activates said film fixedly
holding mechanism in response to an output from said detecting
device.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a film pulling device and a
bag-manufacturing and packaging apparatus having the film pulling
device.
BACKGROUND INFORMATION
[0002] Conventionally, a bag-manufacturing and packaging apparatus,
which fills and packages items while manufacturing bags, utilizes
as packaging material a film roll, in which an elongated film is
wound around a roll core.
[0003] A film is pulled out as a motor rotates a supporting shaft
that supports the film roll. The film is then sent to a
bag-manufacturing and packaging portion. Once the film that is
wound about the roll core of the film roll is pulled out through
the end, the film is severed with a knife at a film joining portion
that is furnished at a position apart from the film roll by a
predetermined distance. Then, the finished film roll is replaced
with a new film roll. Thereafter, a predetermined length of film is
pulled out from the new film roll.
[0004] The end of the severed film left in a film joining portion
and the head of the film pulled out of the new film roll are joined
using an adhesive tape. Alternatively, the end of the severed film
and the head of the film of the new film roll are joined by heat
fusion.
[0005] In this manner, the end of the film that is left in the film
joining portion and the film that is pulled out of a new film roll
can be joined together and conveyed to the bag-manufacturing and
packaging portion.
[0006] However, since the film joining portion and the installation
position of the film roll are separated, when the film is severed
at the film joining portion, the portion of the film in between the
roll core and the film joining portion is discarded.
[0007] The length of the unused portion of the film varies
depending on the size of bags. Normally, such an unused portion is
about the size of three to five bags. The accumulated amount of
such unused portions represents a large amount of waste.
Furthermore, since such unused portions are discarded, they also
cause an increase in the amount of trash, which must be
disposed.
[0008] Furthermore, when the film that is rolled in a film roll is
entirely unrolled, it is necessary to stop the operation of the
bag-manufacturing and packaging apparatus. In that case, even when
releasing items from the items supplying portion is stopped at the
same time, items that have been released reach the
bag-manufacturing and packaging portion only after a predetermined
period of time passes. Therefore, when they reach the
bag-manufacturing and packaging portion, the bag-manufacturing and
packaging apparatus has already stopped, and accordingly, these
items cannot be packaged. As a result, such packages are
wasted.
DISCLOSURE OF THE INVENTION
[0009] A purpose of the present invention is to provide a
bag-manufacturing and packaging apparatus that allows film rolled
in a film roll to be entirely unraveled without having to waste any
of the film, and that allows easy replacement of film rolls and
easy joining of film.
[0010] Another purpose of the present invention is to provide a
bag-manufacturing and packaging apparatus that can securely package
items that have been released from the items supplying portion,
even when the film can no longer be unrolled from the film
roll.
[0011] The bag-manufacturing apparatus in accordance with a first
aspect of the invention is a bag-manufacturing apparatus that
packages items while manufacturing bags from a film roll in which
an elongated film is wound in a roll shape. The bag-manufacturing
apparatus includes a film roll support portion that supports the
film roll; a film conveyance mechanism that conveys the film sent
from the film roll; and a film joining device that is disposed
between the film roll support portion and the film conveyer
mechanism, the film joining device being provided to, at the time
of replacement of the film roll, join an end of the film conveyor
mechanism side film and a head of the film of a post-replacement
film roll. The film joining device has a film storing mechanism for
pulling in the film that is disposed on an upstream side relative
to a film joining position.
[0012] In the bag-manufacturing and packaging apparatus of the
present invention, the film sent from the film roll is conveyed by
the film conveyer mechanism. At the time of replacement of the film
roll, after the film sent from the pre-replacement film roll is
severed at a portion near the film roll, the end of the severed
film is pulled toward the film storing mechanism. In this manner,
the severed end of the film can be guided onto the film joining
device. Therefore, the end of the film conveyance mechanism side
film roll and the head of the film of the post-replacement film
roll can be joined at the film joining device.
[0013] Accordingly, it is possible to use the film of the
pre-replacement film roll up to the roll core, and use the film
through the end. Also, since the film that is discarded as a reject
is eliminated, the amount of trash can be reduced. Accordingly, the
cost of bag-manufacturing and packaging can be reduced.
[0014] The film storing mechanism can include a fixed roller that
guides the conveyed film, a movable roller that changes a running
distance of the conveyed film, and a moving mechanism that moves
the movable roller toward and away from the fixed roller.
[0015] Accordingly, at the time of replacement of film roll, the
moving mechanism moves the movable roller relative to the fixed
roller, such that the severed end can be guided onto the film
storing mechanism.
[0016] The film storing mechanism can have a plurality of pairs of
the fixed and movable rollers that are disposed alternately. In
this case, the film storing mechanism can be made small.
Accordingly, the film storing mechanism can be stored in a smaller
space.
[0017] Furthermore, at the time of joining the films, the plurality
of fixed rollers and movable rollers contact different surfaces of
the film alternately. Accordingly, it is possible to minimize the
change in the tensile force of the film when the operation is
resumed after film replacement. It is also possible to prevent the
film from becoming loose and snaking. As a result, it is possible
to prevent malfunctioning from happening at the time of bag
manufacturing.
[0018] The moving mechanism can include a fixed frame for
supporting both ends of the fixed roller, a movable frame for
supporting both ends of the movable roller, and a rotational axis
supported in parallel with the fixed roller to support an end of
the movable roller such that the movable roller is rotatable about
the fixed frame. The movable roller moves relative to the fixed
roller by allowing the movable frame to rotate about the rotational
axis relative to the fixed frame.
[0019] Furthermore, by allowing the movable frame to pivot relative
to the fixed frame about the rotational axis, the movable roller
moves relative to the fixed roller. Accordingly, the severed end of
the film can be guided onto the film storing mechanism. In this
manner, the film storing mechanism can be embodied with a simple
structure.
[0020] Particularly, where there is a plurality of pairs of the
movable rollers and the fixed rollers, by pivoting the movable
frame relative to the fixed frame about the rotational axis, it is
possible to make the amount of displacement of the movable roller
that is on the downstream side in the conveyance direction greater
than the amount of displacement of the movable roller on the
upstream side. As a result, there is smaller resistance in
conveyance of the film to the downstream side, while there is
greater resistance in conveyance in the reverse direction.
[0021] The film joining device further includes a film suction
retaining mechanism that is disposed on an upstream side from the
film storing mechanism in the film conveyance direction. The film
suction retaining mechanism retains by suction the film that is
severed from a pre-replacement film roll at a time of film
joining.
[0022] In this manner, the end of the film can be retained by
suction. Accordingly, the film on the downstream side can be stored
in the film storing mechanism.
[0023] At this time, the severed end of the film can be guided onto
the film joining device, such that the end of the film can be
joined with the head of the post-replacement film easily without
letting it loose. As a result, it is possible to reduce the amount
of change in the tensile force of the film after the joining of the
films.
[0024] The film joining device includes a film fixedly holding
mechanism disposed on a downstream side from the film storing
mechanism in the film conveyance direction. The film fixedly
holding mechanism is provided to fixedly hold the film of the
pre-replacement film roll at the time of joining the films.
[0025] As discussed above, according to the present invention, the
film sent from the film roll is conveyed by the film conveyer
mechanism. At the time of replacing the film roll, the film on the
film conveyance mechanism side is severed at a portion near the
film roll. Then, the severed film is stored in the film storing
mechanism. Accordingly, it is possible to guide the end of the
severed film onto the film joining device. Therefore, it is
possible to join the end of the film conveyance mechanism side film
with the head of the post-replacement film roll at the film joining
device.
[0026] Accordingly, it is possible to use the film of the
pre-replacement film roll up to the roll core, and use the film
through the end. Also, since the film that is discarded as a reject
is eliminated, the amount of trash can be reduced. Accordingly, the
cost of bag-manufacturing and packaging can be reduced.
[0027] The bag-manufacturing and packaging apparatus in accordance
with another aspect of the present invention is a bag-manufacturing
and packaging apparatus that packages items while manufacturing
bags from a film roll in which an elongated film is wound in a roll
shape. The bag-manufacturing and packaging apparatus includes a
bag-manufacturing and packaging portion for manufacturing bags
while packaging items, an items supply portion for supplying the
items to the bag-manufacturing and packaging portion, a film roll
support portion for supporting the film roll, a driving device for
sending out the film from the film roll that is supported by the
film roll support portion, a film conveyance mechanism for
conveying the film that is sent out from the film roll to the
bag-manufacturing and packaging portion, a film storing mechanism
for sending out film while storing the film that is conveyed by the
film conveyance mechanism, a detecting device for detecting that
the film of a film roll is consumed through an end, and a control
portion for stopping operations of the items supply portion and the
driving device in response to an output from the detecting device,
and for stopping an operation of the bag-manufacturing and
packaging portion after a film stored in the film storing mechanism
is sent out by an amount that corresponds to a predetermined
numbers of bags.
[0028] In the bag-manufacturing and packaging apparatus of the
present invention, the film is sent out from the film roll to be
conveyed to the bag-manufacturing and packaging portion by the film
conveyer mechanism. At this time, the film is sent out while a
portion of the film is stored in the film storing mechanism.
Furthermore, every time the items supply portion supplies items to
the bag-manufacturing and packaging portion, the bag-manufacturing
and packaging portion packages the items.
[0029] Then the film of the film roll is entirely used. In
response, the control portion stops the operations of the items
supply portion and the driving device.
[0030] At this point, however, a few items that are conveyed are in
between the items supply portion and the bag-manufacturing and
packaging portion. Accordingly, the bag-manufacturing and packaging
portion packages the items that are conveyed, using the film stored
in the film storing mechanism. In this manner, even when the film
roll cannot send out the film, the items that are being conveyed
can be packaged by the bag-manufacturing and packaging portion.
Then, once the packaging is conducted for these items and the
packaging is finished, the control portion stops the operation of
the bag-manufacturing and packaging portion.
[0031] In this manner, it is possible to package the items that are
supplied to the bag-manufacturing and packaging portion from the
items supply portion even when the items supply portion is stopped,
using the film stored in the film storing mechanism.
[0032] The detecting device can include a tension detecting device
that detects a tensile force of the film. The control portion can
stop the operations of the items supply portion and the driving
device when the output from the tension detecting device exceeds a
predetermined value.
[0033] With this structure, since the tensile force of the film
always exceeds the predetermined value when the film of the film
roll is exhausted, it is possible to stop the operations of the
items supply portion and the driving device.
[0034] The control portion controls the driving device such that
the tensile force of the film is constant when the output from the
tension detecting device is below the predetermined value.
[0035] With. this structure, the tensile force of the film can be
maintained at a constant level during the normal operation based on
the output from the tension detecting device.
[0036] Preferably, the length of the film stored in the film
storing portion should be the length of film necessary to package
the items that are already supplied to the bag-manufacturing and
packaging portion from the items supply portion when the operation
of the items supply portion is stopped.
[0037] Accordingly, it is possible to package securely the items
that are supplied to the bag-manufacturing and packaging portion
from the items supply portion when the operation of the items
supply portion is stopped.
[0038] The film storing mechanism includes a fixed roller for
guiding the conveyed film, a movable roller for changing a running
distance of the conveyed film, and a moving mechanism that moves
the movable roller close to and away from the fixed roller.
[0039] With this structure, since the movable roller moves relative
to the fixed roller based on the tensile force of the film, it is
possible to send film to the bag-manufacturing and packaging
portion while adjusting the tensile force of the film and storing
an adequate amount of film at the same time.
[0040] Also, when the items supply portion is stopped, the moving
mechanism moves the movable roller relative to the fixed roller,
such that the film stored in the film storing mechanism can be sent
to the bag-manufacturing and packaging portion. At the time of
replacement of film roll, the severed end of the film can be guided
onto the film storing mechanism, which no longer has as much film
stored, such that the film storing portion can store more film. In
this manner, the film storing mechanism can supply the film after
the items supply portion has stopped, and store film in the film
storing portion when the film is replaced.
[0041] The bag-manufacturing and packaging apparatus can further
include a film joining device disposed between the film roll
support portion and the film conveyance mechanism, the film joining
device joining, at the time of replacing the film roll, an end of
the film on the film conveyance mechanisms side and a head of a
post-replacement film roll. The film storing mechanism can be
disposed on a downstream side from a film joining position of the
film joining device.
[0042] In this case, at the time of replacement of the film roll,
after the film sent from the pre-replacement film roll is severed
at a portion near the film roll, the end of the severed film is
pulled toward the film storing mechanism. In this manner, the
severed end of the film can be guided onto the film joining device.
Therefore, the end of the film conveyance mechanism side film roll
and the head of the film of the post-replacement film roll can be
joined at the film joining device.
[0043] Accordingly, it is possible to use the film through the end,
and reduce the waste of the film. Also, since the film that is
discarded as a reject is eliminated, the amount of trash can be
reduced. Accordingly, the cost of bag-manufacturing and packaging
can be reduced.
[0044] Furthermore, the items that are being supplied to the
bag-manufacturing and packaging portion from the items supply
portion when the items supply portion is stopped can be packaged
using the film stored in the film storing mechanism, which is
provided with the film joining device.
[0045] The film storing mechanism can include a fixed roller that
guides the conveyed film, a movable roller that changes a running
distance of the conveyed film, a moving mechanism that moves the
movable roller toward and away from the fixed roller.
[0046] Accordingly, since the movable roller moves relative to the
fixed roller based on the tensile force of the film, it is possible
to send the film to the bag-manufacturing and packaging portion,
while at the same time adjusting the tensile force of the film and
storing an adequate amount of the film.
[0047] When the items supply portion is stopped, the moving
mechanism moves the movable roller relative to the fixed roller,
such that the film stored in the film storing mechanism can be sent
to the bag-manufacturing and packaging portion. Furthermore, at the
time of replacing the film roll, the severed end of the film can be
pulled toward the film storing mechanism. In this manner, the film
storing mechanism can send out the film after the items supply
portion is stopped, and stored the film at the time of film
replacement.
[0048] The movable frame can have at least one movable roller. The
fixed frame can have at least one fixed roller. The movable roller
and the fixed roller can be disposed alternately in the film
conveyance direction.
[0049] With this structure, when the items supply portion is
stopped, the moving mechanism moves the movable roller relative to
the fixed roller, such that the film stored in the film storing
mechanism can be sent to the bag-manufacturing and packaging
portion. Furthermore, at the time of replacing the film roll, the
severed end of the film can be pulled toward the film storing
mechanism. In this manner, the film storing mechanism can send out
the film after the items supply portion is stopped, and store the
film at the time of film replacement.
[0050] The moving mechanism can include a fixed frame for
supporting both ends of the fixed roller, a movable frame for
supporting both ends of the movable roller, and a rotational axis
supported in parallel with the fixed roller for supporting an end
of the movable roller such that the movable roller is rotatable
about the fixed frame. The movable roller moves relative to the
fixed roller by allowing the movable frame to rotate about the
rotational axis relative to the fixed frame.
[0051] With this structure, when the items supply portion is
stopped, the movable frame moves about the rotational axis away
from and closed to the fixed frame. Accordingly, it is possible to
send the film stored in the film storing mechanism to the
bag-manufacturing and packaging portion. Also, at the time of
replacing the film roll, the movable frame pivots about the
rotational axis relative to the fixed frame. Accordingly, the
severed end of the film can be pulled toward the film storing
mechanism.
[0052] The film joining device can further include a film suction
retaining mechanism that is disposed on an upstream side from the
film storing mechanism in the film conveyance direction. The film
suction retaining mechanism retains by suction the film that is
severed from a pre-replacement film roll at a time of film
joining.
[0053] In this case, the end of the film can be retained by suction
by the film suction retaining mechanism which is disposed on the
upstream side from the film storing mechanism in the film
conveyance direction. At the same time, the severed end of the film
can be stored in the film storing mechanism.
[0054] In this manner, it is possible to maintain the posture of
the severed film and guide the end of the film onto the film
joining device. Accordingly, it is possible to join easily the end
of the film with the head of the post-replacement film roll without
letting loose the end of the film.
[0055] The control portion can activate the film suction retaining
mechanism during the film joining operation. Accordingly, it is
possible to prevent securely misalignment of the films at the time
of film joining.
[0056] The film joining device includes a film fixedly holding
mechanism disposed on an upstream side from the film storing
mechanism in the film conveyance direction, the film fixedly
holding mechanism being for fixedly holding the film of the
pre-replacement film roll at the time of joining the films.
[0057] With this structure, it is possible to supply the film
stored in the film storing mechanism to the bag-manufacturing
portion without imposing a tensile burden on the film roll. As a
result, it is possible to prevent breakage of the film due to the
tensile burden imposed on the film roll.
[0058] The control portion may operate the film fixedly holding
mechanism in response to the output from the detecting device.
Accordingly, it is possible to prevent breakage of the film due to
the tensile burden imposed on the film roll.
[0059] As discussed above, with the present invention, it is
possible to package items that are being supplied to the
bag-manufacturing and packaging portion from the items supply
portion when the items supply portion is stopped, using the film
stored in the film storing mechanism. Therefore, there is no waste
of items.
BRIEF DESCRIPTION OF DRAWINGS
[0060] FIG. 1 is a schematic lateral view showing a
bag-manufacturing and packaging apparatus in accordance with the
first embodiment of the present invention.
[0061] FIG. 2 is a schematic rear view showing the structure of the
bag-manufacturing and packaging apparatus of FIG. 1, viewed from
the film roll portion side.
[0062] FIG. 3 is a schematic plan view showing the structure of the
bag-manufacturing and packaging apparatus of FIG. 1, viewed from
above.
[0063] FIG. 4 is a schematic perspective view showing the schematic
conveyance path of the film shown in FIG. 1.
[0064] FIG. 5 is a perspective view showing the structure of the
bag-manufacturing and packaging portion of FIG. 1.
[0065] FIG. 6 is a schematic lateral view showing the detailed
structure of the film roll portion of the bag-manufacturing and
packaging apparatus of FIG. 3.
[0066] FIG. 7 is a schematic cross-sectional view showing the first
process in the replacement of film roll.
[0067] FIG. 8 is a schematic cross-sectional view showing the
second process in the replacement of film roll.
[0068] FIG. 9 is a schematic cross-sectional view showing the third
process in the replacement of film roll.
[0069] FIG. 10 is a schematic cross-sectional view showing the
fourth process in the replacement of film roll.
[0070] FIG. 11 is a schematic cross-sectional view showing the
fifth process in the replacement of film roll.
[0071] FIG. 12 is an enlarged view of the portion X in FIG. 10.
[0072] FIG. 13 is a schematic view showing the structure of the
film storing mechanism in accordance with another embodiment of the
present invention.
[0073] FIG. 14 is a schematic view showing the structure of the
film storing mechanism in accordance with still another embodiment
of the present invention.
[0074] FIG. 15 is a schematic view showing the structure of the
film storing mechanism in accordance with still another embodiment
of the present invention.
[0075] FIG. 16 is a block view showing the control of the
bag-manufacturing and packaging portion in accordance with the
embodiment of the present invention.
[0076] FIG. 17 is a flow chart showing the operation of the control
device where the film stored in the dancer roller is used to
package the items at the time of replacing a film roll.
[0077] FIG. 18 is a flow chart showing the operation of the control
device where the film stored in the dancer roller is used to
package the items at the time of replacing the film roll.
[0078] FIG. 19 is a schematic view of the operation of the dancer
roller during normal operation and at the time of replacing film
roll exchange.
[0079] FIG. 20 is a flow chart of the operation of the control
device where the film stored in the film storing mechanism of the
film joining device is used to package the items at the time of
film roll exchange.
[0080] FIG. 21 is a flow chart of the operation of the control
device where the film stored in the film storing mechanism of the
film joining device is used to package the items at the time of the
film roll exchange.
[0081] FIG. 22 is a schematic cross-sectional view of the operation
of the film storing mechanism of the film joining device at the
time of normal operation and the film roll exchange.
[0082] FIG. 23 is a schematic cross-sectional view of the operation
of the film storing mechanism of the film joining device at the
time of normal operation and the film roll exchange.
[0083] FIG. 24 is a schematic cross-sectional view of the operation
of the film storing mechanism of the film joining device during
normal operation and at the time of the film roll exchange.
[0084] FIG. 25 is a schematic cross-sectional view of the operation
of the film storing mechanism of the film joining device during
normal operation and at the time of replacing the film roll.
[0085] FIG. 26 is a schematic cross-sectional view of the operation
of the film storing mechanism of the film joining device during
normal operation and at the time of the film roll exchange.
DETAILED DESCRIPTION OF EMBODIMENT
[0086] FIG. 1 is a schematic side view showing the structure of a
bag-manufacturing and packaging apparatus in accordance with a
first embodiment of the present invention. FIG. 2 is a schematic
rear view showing the structure the bag-manufacturing and packaging
apparatus of FIG. 1 viewed from the film roll portion side. FIG. 3
is a schematic plan view showing the structure of the
bag-manufacturing and packaging apparatus of FIG. 1 viewed from
above. FIG. 4 is a schematic perspective view showing a conveyance
path of film 2.
[0087] In FIG. 1, a bag-manufacturing and packaging apparatus 1000
includes a film roll portion 100, a film conveyer portion, and a
bag-manufacturing and packaging portion 300.
[0088] As shown in FIG. 3, the film roll portion 100 includes a
film roll support portion 101 and a film joining device 102. The
film roll support portion 101 includes a support shaft 3, a
disk-shaped roll stopper 4, and a motor 6.
[0089] The support shaft 3 is supported on a rear portion of the
bag-manufacturing and packaging apparatus 1000 by a support
mechanism 50 shown in FIG. 2, such that the support shaft 3 is
pivotable between directions parallel to and perpendicular to an
installation surface E of the bag-manufacturing and packaging
apparatus 1000. The roll stopper 4 is fixed to an end portion of
the support shaft 3 that is closer to the support mechanism 50 such
that the roll stopper 4 is perpendicular to the support shaft
3.
[0090] The support shaft 3 is rotationally driven by the motor 6
via a timing belt (not shown in Figures). The support mechanism 50
includes stoppers (not shown in Figures) that support the support
shaft 3 in the parallel and perpendicular directions as described
above.
[0091] To attach a film roll 1, the support shaft 3 needs to be
inserted into the roll core 31 of the film roll 1 while the support
shaft 3 is positioned parallel to the installation surface E of the
bag-manufacturing and packaging apparatus 1000. The film roll 1
needs to be pushed in until an end surface of the film roll 1
touches the roll stopper 4. Then, by a locking operation, stoppers
5 are made to protrude from the peripheral surface of the shaft 3,
such that the roll core 31 of the film roll engages these stoppers
5. In this manner, the film roll 1 is fixed to the support shaft
3.
[0092] Then, the support shaft 3 is rotated in a direction of an
arrow A. The support shaft 3 and the film roll 1 are fixated in a
position where the support shaft 3 is perpendicular to the
installation surface E of the bag-manufacturing and packaging
apparatus 1000. At this time, the roll stopper 4 is parallel to the
installation surface E, and the film roll 1 is supported by the
roll stopper 4.
[0093] During the bag-manufacturing packaging operation, the film 2
is pulled out of the film roll 1 as the motor 6 rotates the support
shaft 3 and the roll stopper 4.
[0094] The film 2 pulled out of the film roll support portion 101
is conveyed to the film conveyer portion through the film joining
device 102 shown in FIG. 3.
[0095] As seen in FIGS. 2 and 3, the film conveyer portion includes
a first guide roller 7, a second guide roller 8, a turn bar 9, a
turn bar up-down mechanism 10, a plurality of roll bars 11, and a
dancer roller 12. The first guide roller 7 and the second guide
roller 8 are disposed vertically, while the plurality of roll bars
11 and the dancer roller 12 are disposed horizontally. The turn bar
9 is disposed so as to intersect with the first guide roller 7 and
the guide roll 8 at a 45.degree. angle.
[0096] When the film 2 passes through the bag-manufacturing and
packaging portion 300, which will be described later, the inner
surface of the film 2 has to face upward, since the film 2 is
formed into a tubular shape to fill items therein. Therefore, the
film 2, which is wound with its outer surface outside, needs to be
conveyed through the bag-manufacturing and packaging apparatus with
its inner surface facing upward.
[0097] This reversing of the film is effected by letting the film
through the first and second guide rolls 7 and 8, and the turn bar
9.
[0098] As seen in FIG. 4, the film 2, after passing the first guide
roller 7, is bent at the second guide roller 8. Thus, the direction
of conveyance of the film 2 is turned by 180.degree., leading the
film 2 to the turn bar 9. The film 2 is further bent at the turn
bar 9. This turns the conveyance direction of the film 2 by
90.degree., and flips the film 2 upside down. In this way, the film
2 is conveyed upward with its width direction being horizontal.
Thereafter, as shown in FIG. 3, the film 2 is conveyed into the
bag-manufacturing and packaging portion 300 with its inner surface
upward.
[0099] The turn bar 9 is shiftable up and down by the turn bar
up-down mechanism 10 shown in FIG. 2, as seen in an arrow B. By
shifting the turn bar 9 up and down, it is possible to adjust the
width direction position of the film 2. For example, when the width
of the film 2 changes, the film 2 that is conveyed into the
bag-manufacturing and packaging portion 300 needs to be conveyed
with the width-direction center portion being aligned with the
center portion of a hopper 22. The hopper 22 will be described
later. In the bag-manufacturing and packaging apparatus 1000, since
the height direction position of the lower end surface of the film
roll 1 from which the film 2 is conveyed is fixated, the film 2 is
centered by moving the turn bar 9 upward or downward.
[0100] The dancer roller 12 shown in FIGS. 1 and 3 detects the
tension of the film 2 in the following manner. The film 2 is always
conveyed at a controlled speed by a pull down belt 19 of the
bag-manufacturing and packaging portion 300, which will be
described below.
[0101] When the tension of the film 2 fluctuates, the position of
the dancer roller 12, which is urged downward, shifts upward and
downward from a reference position. The dancer roller 12 is coupled
to a load cell, which is fixed to the frame of the film conveyer
portion 200 via a tension spring. This load cell detects the
displacement of the dancer roller 12 from the reference position,
in other words the tension of the film 2, based on the tensile
force of the spring. The above-described motor 6, which unrolls the
film 2, is controlled based on the detected tensile force. In other
words, when the tensile force is large, the rotational speed of the
motor 6 increases. When the tensile force is small, the rotational
speed of the motor 6 decreases. In this manner, a feed back control
is performed to keep the dancer roller 12 at the reference
position.
[0102] The film 2 that passed through the dancer roller 12 is
guided horizontally by a plurality of roll bars 11 that extends
horizontally. As shown in FIG. 3, the film 2 is conveyed in the
direction of arrow C on the upper portion of the bag-manufacturing
and packaging apparatus 1000 up to the bag-manufacturing and
packaging portion 300, with the inner surface (the surface that
will be an inner side of the bag) up.
[0103] FIG. 5 is a perspective view showing the detailed structure
of the bag-manufacturing and packaging portion shown in FIG. 1.
[0104] In FIG. 5, the bag-manufacturing and packaging portion 300
includes a former 15, a tube 16, a longitudinal sealing mechanism
18, a pair of pull down belts 19, a lateral sealing mechanism 20,
and a hopper 22. In the bag-manufacturing and packaging portion
300, the film 2 is formed into a tubular shape by passing through a
gap between the former 15 and the tube 16. The tubularly-shaped
film 2 is by the pull down belts 19 conveyed between the tube 16
and the pair of pull down belts 19, while keeping the tubular
shape. In the mean time, overlapping side edges 17 of the film 2
are sealed longitudinally by the longitudinal sealing mechanism
18.
[0105] Furthermore, items that are supplied to the hopper 22 from
an items supply portion above (not shown in Figures) pass through
the inner side of the tube 16, and are inserted into the film 2
that is shaped in the tubular form. The film 2 with the items
filled therein is sealed and severed laterally by the lateral
sealing mechanism 20. A bag 21 with items filled therein is thus
manufactured.
[0106] FIG. 6 is a lateral view showing a detailed structure of the
film pulling device in the bag-manufacturing and packaging
apparatus shown in FIG. 3. FIGS. 7-11 are schematic cross-sectional
views showing the first through fifth processes performed by the
film pulling device at the time of film roll replacement. FIG. 12
is an enlarged view of portion X in FIG. 10.
[0107] Further, FIGS. 13-14 are schematic structural views showing
structures of the film storing mechanism in accordance with other
embodiments of the present invention.
[0108] As shown in FIGS. 6 and 7, the film joining device 102 has a
film holding mechanism 60 that holds and fixates the films when
films are joined, a film suction mechanism 70 that holds the film 2
by suction, and a film storing mechanism 80.
[0109] The film storing mechanism 80 includes three fixed rollers
25, two movable rollers 26, a pair of fixed frames 27, a pair of
movable frames 28, a rotational axis 29, and a guide roller 30.
[0110] The three fixed rollers 25, two movable rollers 26, the
rotational axis 29, and the guide roller 30 are disposed
vertically, so as to be perpendicular to the direction of
conveyance of the film 2. The three fixed rollers 25, two movable
rollers 26, the rotational axis 29, and the guide roller 30 are
also disposed so as to be parallel to each other. The pair of fixed
frames 27 is disposed with a predetermined gap therebetween and in
parallel with the conveyance direction of the film 2. The pair of
fixed frames 27 is fixed to the main frame 600.
[0111] The pair of movable frames 28 is disposed with a
predetermined gap therebetween, and in parallel with the conveyance
direction of the film 2. The pair of movable frames 28 is supported
by the rotational axis 29 so as to be pivotable about the
rotational axis 29 relative to the pair of fixed frames 27.
[0112] Both ends of the three fixed rollers 25 and the guide roller
30 are axially supported by the pair of fixed frames 27 such that
each of the three fixed rollers 25 and the guide roller 30 is
rotatable. Both ends of the two movable rollers 26 are attached to
the pair of movable frames 28, such that each of the movable
rollers 26 is rotatable relative to the movable frames 28. Also,
the two movable rollers 26 are rotationally movable about the
rotational axis 29 in synchronization with the movement of the pair
of movable frames 28.
[0113] The film 2 is guided by the rotational axis 29, passes
through the film suction mechanism 70, and is further guided
through the outer surface of the first fixed roller 25, the inner
surface of the first movable roller 26, the outer surface of the
second fixed roller 25, and the inner surface of the second movable
roller 26. Then, the conveyance direction of the film 2 is changed
by the outer surface of the third fixed roller 25. Thereafter, the
film 2 is guided to the film conveyer portion.
[0114] The processes in which the film 2 is pulled out of the film
roll 1 through the end, the film roll 1 is replaced, and the film 2
is joined with a new one are explained referring to FIGS. 7-12. In
FIGS. 8-12, the film 2 of the old film roll 1 before the
replacement is referred to as film 2a, while the film of the film
roll 1 after the replacement is referred to as film 2b, in order to
distinguish them from each other.
[0115] At the time of bag-manufacturing and packaging, as seen in
FIG. 7, the film 2 which is conveyed from the film roll 1 in the
direction of an arrow Y passes through the fixed rollers 25 and the
movable rollers 26 of the film storing mechanism 80 of the film
joining device 102, and is conveyed to the film conveyer portion.
At this time, the film holding mechanism 60 and the film suction
mechanism 70 are not activated.
[0116] As shown in FIG. 8, once the film 2a of the film 1 is pulled
out through the end, the film 2a is fixedly held to the film
joining device 102 by the film holding mechanism 60. In the mean
time, the film suction mechanism 70 holds the film 2a by
suction.
[0117] Furthermore, the film 2a is severed at the end as shown in
an arrow D. In this manner, the film 2a and the roll core 31 of the
film roll 1 are severed.
[0118] Next, as seen in FIG. 9, the pair of movable frames 28,
along with the movable rollers 26, is pivoted in the direction of
an arrow F relative to the pair of fixed frames 27 of the film
storing mechanism 80. In this way, the two movable rollers 26 are
separated from the three fixed rollers 25. At this time, the film
2a is fixedly held by the film holding mechanism 60. Therefore, as
the two movable rollers 26 move, a portion of the film 2a that has
not entered the film holding mechanism 60 is pulled in the film
joining device 102. Accordingly, the severed end of the film 2a is
guided toward the film suction mechanism 70.
[0119] In this case, since the film holding mechanism 60 fixedly
holds the film 2a, the film 2a will not be conveyed in the
conveyance direction of the film 2a toward the film conveyer
portion. Therefore, when the conveyance of the film 2a is resumed,
the film 2a can be conveyed smoothly.
[0120] Also, since the suction mechanism 70 holds the whole width
of the film 2a by suction, the meandering of the film can be
prevented when the film storing mechanism 80 pulls the film 2a.
Instead, the film can be pulled in while maintaining the tension of
the film. Therefore, it is possible to prevent the end of the film
2a from getting jammed inside the film storing mechanism 80.
[0121] Subsequently, the support shaft 3 shown in FIG. 1 is pivoted
into the direction parallel to the installation surface E of the
bag-manufacturing and packaging apparatus 1000. The stoppers 5 that
engage the roll core 31 of the film roll 1 are disengaged. Then,
the roll core 31 is taken out of the support shaft 3.
[0122] Furthermore, the new film roll 1 is coupled to the support
shaft 3. The roll core 31 of the new film roll 1 is engaged with
the stoppers 5, thereby engaging the roll core 31 with the support
shaft 3. The support shaft 3 is pivoted into and fixated at the
direction perpendicular to the installation surface E of the
bag-manufacturing and packaging apparatus 1000.
[0123] As shown in FIGS. 10 and 12, after the new film roll 1 is
put in the upright position, the head of the film 2b which is wound
about the new film roll 1 is pulled out until the head reaches the
film suction mechanism 70. The head of the film 2b is overlapped
with the end of the film 2a that is held by suction by the film
suction mechanism 70. The head of the film 2b and the end of the
film 2a are joined by an adhesive tape 24 as shown in FIG. 12.
Thereafter, as shown in FIG. 11, the film holding mechanism 60 and
the film suction mechanism 70 are inactivated.
[0124] After the film 2a and film 2b are thus joined, the support
shaft 3 and the roll stopper 4 are again rotated by the motor 6.
The film is pulled out in the direction of the arrow Y. In this
way, the bag-manufacturing packaging is resumed. At this time, the
film 2b that is joined with the film 2a is conveyed. The pair of
movable frames 28 along with the movable rollers 26 is moved in the
direction of an arrow G due to the tension of the film 2b, which is
pulled by the film 2a.
[0125] As described above, the end of the film 2a can be pulled up
to the film suction mechanism 70 at the time of replacement of film
roll 1, while the film 2a of the pre-replacement film roll 1 is
fixedly held by the film holding mechanism 60 and by the film
suction mechanism 70 by suction.
[0126] In this manner, the end of the film 2a held by the film
suction mechanism 70 by suction and the head of the film 2b of the
post-replacement film roll 1 can be joined easily by the adhesive
tape 24.
[0127] Consequently, the film 2a of the pre-replacement film 1 can
be used through the end. Therefore, the waste of films can be
prevented. Also, since there will be no film that is discarded as a
reject, the amount of trash can be reduced.
[0128] Furthermore, since the end of the film 2a and the head of
the film 2b can be joined while the film 2a is fixedly held by the
film holding mechanism 60 and the film suction mechanism 70, the
film 2a and the film 2b can be joined easily and securely without
causing loosening of the films.
[0129] In the present embodiment, the films 2 are joined by using
the adhesive tape 24. However, the films 2 can also be joined by
heat fusion. For instance, the film suction mechanism 70 applies
heat fusion, instead of the adhesive tape 24, in the width
direction at the overlapping portion of the film 2a and the film
2b.
[0130] In the present embodiment, the film is pulled in by moving
the two movable rollers 26 relative to the three fixed rollers 25
in the direction of the arrow H. Alternatively, the film can be
pulled in by moving one movable roller 26 relative to two fixed
rollers 25, as shown in FIG. 13.
[0131] Nonetheless, when two movable rollers 26 are moved relative
to three fixed rollers 26, as in the present invention, more film
can be pulled in with a small amount of movement of each of the two
movable rollers 26. Therefore, it is more preferable to have a
plurality of fixed rollers 25 and movable rollers 26, and move the
plurality of movable rollers 26 relative to the plurality of fixed
rollers 25.
[0132] Furthermore, as shown in FIG. 14, it is possible to place a
suction mechanism in between the two fixed rollers 25 that guide
the film, such that the film can be pulled in when the suction
mechanism sucks the film in the direction of an arrow I.
[0133] Still furthermore, the film 2 that passes through the three
fixed rollers 25 and the two movable rollers 26 as shown in FIG.
15(a) can be pulled in by shifting the two film rollers 26 in
parallel in the direction of an arrow J, as shown in FIG.
15(b).
[0134] The embodiments described above pertain to cases that
utilize a longitudinal pillow packaging apparatus, in which a film
is moved vertically while bags are manufactured. The present
invention can be similarly applied to a latitudinal pillow
packaging apparatus, in which the film is moved horizontally while
bags are manufactured.
[0135] In the bag-manufacturing and packaging apparatus 1000 of the
present embodiment, when the film is entirely unrolled, as shown in
FIG. 8, the film 2 can no longer be unrolled. Therefore, it is
necessary to stop the entire apparatus. However, even when the
operation of supplying items from the items supply portion to the
bag-manufacturing and packaging portion 300 is stopped, several
items 23 (see FIG. 5) have already been released from the items
supply portion at that point. Unless these items 23 that are
falling can be packaged, these items will have to be collected as
unpackaged items.
[0136] In view of this, the bag-manufacturing and packaging
apparatus 1000 of the present embodiment uses a method of packaging
with a film stored in the dancer roller 12 shown in FIG. 1, and a
method of packaging with a film stored in the film storing
mechanism 80 of the film joining device 102, such that the falling
items can be packaged even after the items supply portion is
stopped.
[0137] Below, the control of the bag-manufacturing and packaging
apparatus 1000 of the present embodiment will be explained. Then,
the control for packaging items with the film 2 stored in the
dancer roller 12 at the time of exchanging the film roll 1, and the
control for packaging items with the film 2 stored in the film
storing mechanism 80 at the time of exchanging the film roll 1 will
be explained in this order.
[0138] FIG. 16 is a block view showing the control system of the
bag-manufacturing and packaging apparatus 1000 in accordance with
the present embodiment. In FIG. 16, the items supply portion 700 is
disposed above the bag-manufacturing and packaging portion 300
shown in FIG. 1, and supplies a predetermined amount items 23 (FIG.
5) to the bag-manufacturing and packaging portion 300. The items
supply portion 700 is, for instance, an automatic weighing device
that weighs a predetermined weight of items and discharges the
predetermined weight of items to the bag-manufacturing and
packaging portion 300.
[0139] As describe above, a load cell 210 is coupled to the dancer
roller 12 shown in FIG. 1 via a tensile spring 12. The load cell
210 detects the amount of displacement of the dancer roller 12 from
the reference position. This amount of displacement corresponds to
the tensile force of the film 2.
[0140] A control device 500 includes elements such as a CPU
(Central Processing Unit). The control device 500 controls the
rotations of the motor 6 based on the output from the load cell
210, such that the tensile force of film 2 is constant. The control
device 500 also controls the operations of the items supply portion
700, the bag-manufacturing and packaging portion 300, the film
holding mechanism 60, and the film suction mechanism 70, as
discussed below.
[0141] The operation of packaging items using the film 2 stored in
the dancer roller 12 at the time of replacing film roll 1 will now
be explained.
[0142] FIGS. 17 and 18 are flow charts showing the operation of the
control device 500 where the film 2 stored in the dancer roller 12
is used to package the items at the time of replacing the film roll
1. FIG. 19 is schematic views of the operations of the dancer
roller 12 during normal operation and at the time of replacing film
roll 1.
[0143] During normal operation (step S1), the control device 500
controls the rotations of the motor 6 based on the output of the
load cell 210 as described above, such that the tension of the film
2 is constant.
[0144] As shown in FIG. 19, the dancer roller 12 is urged downward
by the tension spring 220. During the normal operation, as shown in
FIG. 19(a), the dancer roller 12 shifts upward and downward as
indicated by the arrow H, according to the tensile force of the
film 2. The output value of the load cell 210 changes accordingly.
In this case, since the dancer roller 12 is separated from the roll
bars 11 in a downward direction, the dancer roller 12 stores a
portion of the film 2.
[0145] The control device 500 determines whether or not the film 2
is entirely pulled out from the film roll 1 (step S2). If the film
2 is entirely pulled out, the tensile force of the film 2 exceeds
the predetermined value. Accordingly, the control device 500
determines that the film 2 has been exhausted when the output value
from the load cell 210 exceeds the predetermined value.
[0146] As shown in FIG. 19(b), when the film 2 is exhausted, the
dancer roller 12 moves upward beyond a predetermined position P0
against the urging force of the tension spring 220 due to an
increase in the tensile force of the film 2. Then, the output value
from the load cell 210 exceeds the predetermined value.
[0147] When the film 2 is exhausted, the control device 500 stops
the items supply portion 700 and the motor 6 (step S3).
Accordingly, the supply of items from the items supply portion 700
to the bag-manufacturing and packaging portion 300 stops. At this
point, some of the items 23 have already been released in the
air.
[0148] The control device 500 activates the film holding mechanism
60 of the film joining device 102 (step S4). The control device 500
activates the film suction mechanism 70 of the film joining device
102 (step S5).
[0149] At this time, the operation of the bag-manufacturing and
packaging portion 300 is continuing. In other words, the
longitudinal sealing mechanism 18, the pull down belts 19, and the
lateral sealing mechanism 20 shown in FIG. 5 are in operation.
Accordingly, the film 2 stored in the dancer roller 12 is conveyed
to the bag-manufacturing and packaging portion 300 by the pull down
belts 19.
[0150] As shown in FIG. 19(c), as the dancer roller 12 moves upward
past the position between the roll bars 11 against the urging force
of the tension spring 220, the film 2 stored in the dancer roller
12 is conveyed to the bag-manufacturing and packaging portion 300.
Accordingly, the items 23 that have been released to the air from
the items supply portion 700 are packaged at the bag-manufacturing
and packaging portion 300.
[0151] The control device 500 determines whether each of the items
that have been falling is packaged (step S6). The number of items
that are falling is determined by the operational speed and the
distance between the items supply portion 700 and the lateral
sealing mechanism 20. For instance, when the operational speed is
200 times per minute, two bags worth of items are falling. The
length of film to be used varies depending on the size of the bags.
In the above-described embodiment, the dancer roller 12 is
preconfigured such that the film 2 stored in the dancer roller 12
is sufficient. In this case, the control device 500 keeps count of
every release of items from the items supply portion 700. The count
is decreased when packaging for the items is finished. The
packaging operation is maintained until the count of items released
becomes zero. Once the count reaches zero, it is determined that
all the items that have been falling are packaged. Accordingly, the
operation of the bag-manufacturing and packaging portion 300 is
stopped (step S7).
[0152] On the other hand, at the end of step S5, the operator can
perform the replacement operation of the film roll 1 shown in FIGS.
7-11, using the film joining device 102. Once the joining of the
film 2 shown in FIG. 10 is finished, the operator notifies the
control device 500 that the joining of the film 2 has been
finished, using devices such as an operational switch (not shown in
figures).
[0153] Once the control device 500 acknowledges that the joining of
the film 2 has been finished (step S8), the control device 500
deactivates the film holding mechanism 60 of the film joining
device 102 (step S9). The control device 500 also deactivates the
film suction mechanism 70 of the film joining device 102 (step
S10). Accordingly, the operation can now be resumed using the
replaced film roll 1.
[0154] The operator, using the operational switch (not shown in
figures), sends a command to the control device 500 to resume the
operation. The control device 500 determines whether the operation
can be performed (step S11). If the operation can be performed, the
control returns to step S1 to perform normal operation.
[0155] In this manner, the items 23 that had been falling when the
end of the film 2 is detected can be packaged using the film 2 that
is stored in the dancer roller 12.
[0156] Next, operation of each portion at the time when items that
have been falling are packaged using the film 2 stored in the film
storing mechanism 80 of the film joining mechanism 102 is
explained.
[0157] FIGS. 20 and 21 are flow charts showing the operation of the
control device 500 at the time when items that have been falling
are packaged using the film 2 stored in the film storing mechanism
80 of the film joining mechanism 102. FIGS. 22-26 are schematic
cross-sectional views showing the operation of the film storing
mechanism 80 of the film joining device 102 during the normal
operation and at the time when the film roll 1 is replaced. In
FIGS. 22-26 also, the film of the pre-replacement film roll 1 is
referred to as 2a, while the film of the post-replacement film roll
1 is referred to as 2b.
[0158] In this example, as shown in FIG. 22, the film holding
mechanism 60 is attached to the position of the upstream side fixed
roller 25. The load cell 210 is coupled to the movable frame 28 of
the film storing mechanism 80 via the tension spring 220. The load
cell 210 detects the amount of displacement of the movable frames
28 from the reference positions. This amount of displacement
corresponds to the tensile force of the film 2. The control device
500 of FIG. 16 controls the rotations of the motor 6 based on the
output from the load cell 210, such that the tensile force of the
film 2a is constant.
[0159] In this embodiment, the film storing mechanism 80 also
functions as the dancer roller. Accordingly, the dancer roller 12
shown in FIG. 1 is not necessary. Also in this embodiment, the film
roll 1 is supported such that the roll core 31 extends in the
horizontal direction. Also, the film joining device 102 is
installed such that the fixed rollers 25, the movable rollers 26,
the rotational axis 29, and the guide roller 30 extend in
horizontal directions. Accordingly, the movable frame 28 pivots
upward and downward about the rotational axis 29. In this case, the
first guide roller 7, the second guide roller 8, the turn bar 9,
and the turn bar up-down mechanism 10 shown in FIG. 4 are not
necessary.
[0160] During the normal operation (step S21), the control device
500 controls the rotations of the motor 6 based on the output from
the load cell 210, such that the tensile force of the film 2a is
constant.
[0161] As shown in FIG. 22, while the operation is stopped, the
movable frame 28 is positioned at the most bottom end due to its
own weight and the downward urging force of the tension spring 220.
During normal operation, as shown in FIG. 22, the movable frame 28
pivots up and down as shown in the arrow h, due to the tensile
force of the film 2a. The output from the load cell 210 changes
accordingly. In this case, since the movable rollers 26 are
separated from the fixed rollers 25 in the downward direction, the
film storing mechanism 80 stores a portion of the film 2a.
[0162] The control device 500 determines based on the output from
the load cell 210 whether or not the film 2a has been pulled out
from the film roll 1 (step S22). If the film 2a is exhausted, the
tensile force of the film 2a exceeds the predetermined value.
Therefore, the control device 500 determines that the film 2a is
exhausted when the output from the load cell 210 exceeds the
predetermined value.
[0163] FIG. 23 shows the situation where the output from the load
cell 210 exceeds the predetermined value.
[0164] Once the film 2a is exhausted, the control device 500 stops
the items supply portion 700 and the motor 6 (step S23).
Accordingly, the supply of items from the items supply portion 700
to the bag-manufacturing and packaging portion 300 stops. However,
at this point, a few items 23 have already been release from the
items supply portion 700, and are now falling.
[0165] Next, the control device 500 activates the film holding
mechanism 60 of the film joining device 102 (step S24).
[0166] At this time, the operation of the bag-manufacturing and
packaging portion 300 is not stopped. The longitudinal sealing
mechanism 18, the pull down belts 19, and the lateral sealing
mechanism 20 shown in FIG. 5 are in operation. The film 2 stored in
the film storing mechanism 80 is conveyed to the bag-manufacturing
and packaging portion 300 via the pull down belts 19.
[0167] At this point, as shown in FIG. 24, because the movable
frame 28 having the movable roller 26 move upward about the
rotational axis 29 against the urging force of the tension spring
220, the film 2a stored in the film storing mechanism 80 is
conveyed to the bag-manufacturing and packaging portion 300 as
shown in the arrow z. The bag-manufacturing and packaging portion
300 packages the items 23, which are falling, using this film.
[0168] The control device 500 determines whether or not all of the
items that have been falling are packaged, by reducing the count of
the releases of the items as described above (step S25).
[0169] Once all the items that have been falling are packaged, the
control device 500 stops the operation of the bag-manufacturing and
packaging portion 300 (step S26). Then, the control device 500
activates the film suction mechanism 70 of the film joining device
102 (step S27). The operator cuts the film 2a at the end position
shown in the arrow D, and severs the film 2a from the roll core
31.
[0170] The control device 500 deactivates the film holding
mechanism 60 of the film joining device 102 (step S28).
Accordingly, as shown in FIG. 25, the movable rollers 26 and the
movable frame 28 rotate downward about the rotational axis 29 as
shown in the arrow F, due to their own weights and the urging force
of the tension spring 220. Accordingly, the movable rollers 26
become separated from the fixed rollers 25 in the downward
direction. The film 2a on the upstream side of the film joining
device 102 is pulled toward the film joining device 102 to be
stored in the film storing mechanism 80. As a result, the end of
the severed film 2a is guided toward the film suction mechanism
70.
[0171] As shown in FIG. 26, after installing a new film roll 1 to
the support shaft, the operator pulls out the head of the film 2b
of the new film roll 1 up to the film suction mechanism 70. The
head of the film 2b is attached to the rear end of the film 2a,
which is sucked into the film suction mechanism 70. Then the rear
end of the film 2a and the head of the film 2b are joined.
[0172] Once the joining of the film 2 is finished, the operator
notifies the controller 500 that the joining of the films 2a and 2b
is finished, using the operational switch (not shown in
figures).
[0173] Once the control device 500 confirms that the joining of the
film 2 has been finished (step S29), the control device 500
deactivates the film suction mechanism 70 of the film joining
device 102 (step S30). Accordingly, operation can be resumed with
the replaced film roll 1.
[0174] The operator, using the operational switch (not shown in
figures), sends a command to the control device 500 to start the
operation. The control device 500 determines whether the operation
can be performed (step S31). If the operation can be performed, the
control returns to step S21 to perform normal operation.
[0175] In this manner, the items 23 that have been falling when the
end of the film 2 is detected can be packaged using the film 2 that
is stored in the film storing mechanism 80.
[0176] In this embodiment, the support shaft 3 corresponds to the
film roll support portion, the film conveyer portion 200
corresponds to the film conveyance mechanism, and the film joining
device 102 corresponds to the film joining device. The film storing
mechanism 80 and the dancer roller 12 correspond to the film
storing mechanism. Furthermore, the film suction mechanism 70
corresponds to the film suction retaining mechanism. The film
holding mechanism 60 corresponds to the film fixedly holding
mechanism. The motor 6 corresponds to the driving device. The load
cell 210 corresponds to the detecting device and tension detecting
device. The control device 500 corresponds to the control
portion.
[0177] Since this embodiment has a mechanism that retains the
movable rollers 26 such that the movable rollers 26 project upward
from the fixed rollers 25, when the film is installed through each
of the rollers 25 and 26, it is only necessary to insert the film
between the rollers 26 and the rollers 25. Therefore, the present
embodiment is meritorious in that it has better operability.
* * * * *