U.S. patent application number 11/797045 was filed with the patent office on 2007-09-06 for sheet-processing apparatus.
Invention is credited to Masayuki Nakagiri, Yasuhisa Watanabe.
Application Number | 20070204572 11/797045 |
Document ID | / |
Family ID | 32776825 |
Filed Date | 2007-09-06 |
United States Patent
Application |
20070204572 |
Kind Code |
A1 |
Nakagiri; Masayuki ; et
al. |
September 6, 2007 |
Sheet-processing apparatus
Abstract
A processing system which enables automation of processing of
sheet bodies with a view to raising efficiency of operations, from
stacking to packing. A plurality of paper sheaves, which have been
produced by cutting and chopping, are transported in a width
direction, sequentially fed to a transfer conveyor, transported
from the transfer conveyor in a length direction, and fed to a
cover sheet application device. At the cover sheet application
device, the paper sheaves are superposed with cover sheets, and fed
to an inversion apparatus. At the inversion apparatus, the paper
sheaves are inverted such that the cover sheets are at upper sides,
and are fed out to another cover sheet application device. At this
cover sheet application device, the cover sheets are superposed
with lower face sides of the paper sheaves. Hence, the paper
sheaves, with the cover sheets superposed at both upper and lower
faces thereof, are bagged.
Inventors: |
Nakagiri; Masayuki;
(Shizuoka-ken, JP) ; Watanabe; Yasuhisa;
(Shizuoka-ken, JP) |
Correspondence
Address: |
BIRCH STEWART KOLASCH & BIRCH
PO BOX 747
FALLS CHURCH
VA
22040-0747
US
|
Family ID: |
32776825 |
Appl. No.: |
11/797045 |
Filed: |
April 30, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10786077 |
Feb 26, 2004 |
|
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11797045 |
Apr 30, 2007 |
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Current U.S.
Class: |
53/520 |
Current CPC
Class: |
B65H 2301/33214
20130101; B65H 2301/4263 20130101; B65H 35/02 20130101; B65H 35/04
20130101; B65H 15/02 20130101; B65H 2301/4381 20130101; B65H
2301/42172 20130101; B65H 39/10 20130101; B65H 31/3054 20130101;
Y10T 83/202 20150401; B65H 31/3081 20130101 |
Class at
Publication: |
053/520 |
International
Class: |
B65B 63/00 20060101
B65B063/00 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 27, 2003 |
JP |
2003-50630 |
Jun 23, 2003 |
JP |
2003-178208 |
Jul 17, 2003 |
JP |
2003-198303 |
Claims
1. A stacking and transport apparatus comprising: a stacking
section including a plurality of sheet-receiving portions, each
sheet-receiving portion stacking a plurality of substantially
rectangular sheets, which are fed therein in a first direction, for
forming sheet sheaves, in which each sheet is inclined, and the
plurality of sheet-receiving portions being disposed substantially
in a row in a second direction, which is substantially
perpendicular to the first direction, in plan view; and a transport
section for transporting the sheet sheaves which are formed at each
sheet-receiving portion in a transport direction which is
substantially parallel to the first direction.
2. The apparatus of claim 1, wherein each sheet-receiving portion
forms the sheet sheaf in which each sheet is inclined to one side
in the first direction and is also inclined to one side in the
second direction.
3. The apparatus of claim 1, wherein each sheet-receiving portion
comprises a pair of guide plates on which the sheet sheaf is
formed.
4. The apparatus of claim 1, wherein each sheet-receiving portion
comprises a standing wall capable of abutting against and aligning
a side face of the sheet sheaf at one side in the second
direction.
5. The apparatus of claim 1, wherein each sheet-receiving portion
comprises a corresponding stopping plate portion capable of
abutting against and aligning a side face of the sheet sheaf at one
side in the first direction.
6. The apparatus of claim 5, wherein the stopping plate portions
are all structured by a single stopping plate.
7. The apparatus of claim 6, wherein the stopping plate is movable
between an abutting position, at which abutting against the sheet
sheaves of all the sheet-receiving portions is possible, and a
withdrawn position, at which this abutting does not occur and the
stopping plate does not obstruct transport of the sheet sheaves by
the transport section.
8. The apparatus of claim 1, wherein the transport section
comprises a pushing movement apparatus capable of pushing the sheet
sheaves of all the sheet-receiving portions for moving the sheet
sheaves in parallel in the transport direction.
9. The apparatus of claim 1, wherein the transport section
comprises a plurality of guide portions, each guide portion
receiving the seat sheaf from the corresponding sheet-receiving
portion and guiding the sheet sheaf in the transport direction.
10. The apparatus of claim 9, wherein each guide portion comprises
a pair of guide members which slide against and guide the sheet
sheaf, the guide members being inclined to a transport direction
downstream side and also inclined to one side in a direction
substantially perpendicular to the transport direction.
11. The apparatus of claim 10, wherein the inclination to the one
side in the direction substantially perpendicular to the transport
direction eases off in accordance with progress toward the
transport direction downstream side.
12. The apparatus of claim 1, further comprising: a transport belt
for transporting the sheet sheaves, which is disposed at an outer
side, in the transport direction, of the transport section; and a
stopping member for positioning the sheet sheaves on the transport
belt substantially in a row along a direction of progress of the
belt.
13. The apparatus of claim 12, wherein the transport direction of
the transport section and the direction of progress of the belt
substantially intersect.
14. A stacking and transport method comprising the steps of:
stacking a plurality of substantially rectangular sheets, which are
fed in in a predetermined direction, for forming a sheet sheaf in
which each sheet is inclined; and transporting the sheet sheaf in a
transport direction which is substantially parallel to the
predetermined direction.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. .sctn. 120
from U.S. application Ser. No. 10/786,077, filed Feb. 26, 2004, and
under 35 USC 119 from Japanese Patent Application Nos. 2003-50630,
2003-178208, and 2003-198303, the disclosures of which are
incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a sheet-processing
apparatus.
[0004] 2. Description of the Related Art
[0005] In recent years, with the spread of digital cameras, the
spread of inkjet-type printers and the like, demand for inkjet
paper has risen. Hence, increases in efficiency of a series of
operations, from cutting and chopping of inkjet paper to packing
(bagging up predetermined numbers of sheets), are sought after.
[0006] Sheets of inkjet paper are formed by cutting sheets, which
have been drawn out from an original web (for example, an original
material in the form of a roll), to a width matching a width
dimension of the sheets, and chopping to a length matching a length
dimension of the sheets. These sheets are then stacked and
packed.
[0007] For example, Japanese Patent Application Laid-Open (JPA) No.
10-58384 discloses a sheet-processing process in which large
sheets, which are produced by chopping a long sheet, are piled up,
sheaves of sheets with a predetermined size are produced by cutting
a sheaf of these large sheets, and these sheet sheaves are bagged
up.
[0008] However, operations to move the sheaf of large sheets before
steps of cutting and chopping are rather troublesome, and moreover,
there are problems such as equipment becoming larger in accordance
with the size of the large sheets, and the like.
[0009] As another example, JP-A No. 5-39140 discloses a sheet sheaf
transport apparatus which includes gripping means, at which a
gripping pawl is attached, for gripping, lifting and transporting
an end portion of a sheaf of sheets which have been placed on a
transport table. In this apparatus, in order to prevent a lowermost
sheet from sticking to the conveyance table, air is fed between
that sheet and an upper face of the transport table.
[0010] However, transporting sheaves of sheets, whose end portions
are susceptible to becoming uneven, with the gripping pawl is
rather difficult. Moreover, there is room for improvement in the
area of transport efficiency.
SUMMARY OF THE INVENTION
[0011] An object of the present invention is to provide a
sheet-processing apparatus capable of performing reasonable sheet
transport.
[0012] Further, another object of the present invention is to
provide a sheet-processing apparatus capable of efficiently
performing a series of operations such as sheet-cutting, chopping
and stacking, up to packing.
[0013] In order to achieve these objects, according to a first
aspect of the present invention, a sheet-processing apparatus is
provided which includes: a cutting apparatus which slits a long
sheet member into a plurality of narrower strips; a chopping
apparatus which chops the strips with a predetermined spacing, for
forming pluralities of sheets; a stacking apparatus which piles up
a predetermined number of the sheets for each strip, for forming
sheet sheaves; a transport apparatus which transports the sheet
sheaves; and a packing apparatus which packs the sheet sheaves.
[0014] According to a second aspect of the present invention, a
stacking and transport apparatus is provided which includes: a
stacking section including a plurality of sheet-receiving portions,
each sheet-receiving portion stacking a plurality of substantially
rectangular sheets, which are fed therein in a first direction, for
forming sheet sheaves, in which each sheet is inclined, and the
plurality of sheet-receiving portions being disposed substantially
in a row in a second direction, which is substantially
perpendicular to the first direction, in plan view; and a transport
section for transporting the sheet sheaves which are formed at each
sheet-receiving portion in a transport direction which is
substantially parallel to the first direction.
[0015] According to a third aspect of the present invention, a
stacking and transport method is provided which includes: stacking
a plurality of substantially rectangular sheets which are fed in in
a predetermined direction for forming a sheet sheaf in which each
sheet is inclined; and transporting the sheet sheaf in a transport
direction which is substantially parallel to the predetermined
direction.
[0016] The foregoing, and other objects, features and advantages of
the present invention will be apparent from the following
description of preferred embodiments of the invention as
illustrated in the accompanying drawings, and the accompanying
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is an overall schematic perspective view showing a
flow of processing in a processing system of a first
embodiment.
[0018] FIG. 2 is a schematic structural view of a principal portion
of the processing system of the first embodiment.
[0019] FIG. 3 is an overall schematic perspective view of a
stacking apparatus.
[0020] FIG. 4 is an overall schematic plan view of the stacking
apparatus.
[0021] FIG. 5 is a schematic side view of a stacking section and an
alignment movement section, viewed from a horizontal direction
which substantially intersects a transport direction.
[0022] FIG. 6 is a schematic perspective view showing principal
portions of the system, from the stacking apparatus to a bagging
apparatus.
[0023] FIG. 7 is a schematic plan view showing a transport conveyor
and a transfer conveyor.
[0024] FIG. 8 is a schematic perspective view of a cover paper
application device.
[0025] FIG. 9 is a schematic side view of the cover paper
application device, viewed from a paper width direction side.
[0026] FIG. 10 is a schematic view of the cover paper application
device, viewed from a paper transport direction downstream
side.
[0027] FIG. 11 is a schematic side view of an inversion apparatus,
viewed from a paper width direction side.
[0028] FIG. 12 is a schematic plan view of the inversion apparatus
FIG. 13 is a schematic sectional view along line 13-13 of FIG.
11.
[0029] FIG. 14 is a schematic structural view of a principal
portion of a processing system of a second embodiment.
[0030] FIG. 15 is a schematic perspective view showing principal
portions of the system, from cutting to transport.
[0031] FIG. 16 is an overall schematic perspective view of a
stacking and transport apparatus.
[0032] FIG. 17 is a schematic side view of principal portions of
the stacking and transport apparatus.
[0033] FIG. 18 is a schematic structural view of the stacking and
transport apparatus, a stacking section side thereof being viewed
from a feeding direction side.
[0034] FIG. 19 is a schematic plan view of a principal portion of
the stacking and transport apparatus.
[0035] FIG. 20 is a schematic plan view of the stacking and
transport apparatus and an alignment conveyor.
[0036] FIG. 21 is a schematic plan view showing a transport
conveyor and a transfer conveyor.
[0037] FIG. 22 is a schematic structural view of a processing
system of a third embodiment.
[0038] FIG. 23 is a schematic view of production of paper with this
processing system.
[0039] FIG. 24 is a perspective view of principal portions which
shows general structure of a stacking apparatus provided at the
processing system.
[0040] FIG. 25 is a schematic structural view of a detection
apparatus provided at the stacking apparatus.
[0041] FIG. 26 is a schematic view of a tray section, viewed from a
CCD camera side (an upper side).
[0042] FIG. 27A is a schematic view in which an image captured by
the CCD camera has been binarized, and is a view showing an example
of a satisfactory stacking state.
[0043] FIG. 27B is a schematic view in which an image captured by
the CCD camera has been binarized, and is a view showing an example
of a state in which a stacking failure has occurred.
[0044] FIG. 28 is a schematic view of the tray section, viewed from
an upper side, which shows another example of a detection region
for judging stacking failures.
DETAILED DESCRIPTION OF THE INVENTION
[0045] Herebelow, a first embodiment of the present invention will
be described with reference to the drawings. FIG. 1 shows schematic
structure of a processing system 10 relating to the first
embodiment.
[0046] The processing system 10 implements, on an original web 14,
a cutting process and a chopping process of papers 12, which are
sheets of inkjet paper or the like. The processing system 10
produces the papers 12 in predetermined sizes, and bags up (packs)
sets of predetermined numbers of these papers 12 in wrappers 16.
Thus, the processing system 10 produces packages 18 of the papers
12. Further, the packages 18 of the papers 12 that are produced by
the processing system 10 are prepared for shipping by being
packaged in cardboard boxes or the like (outer packing).
[0047] As shown in FIGS. 1 and 2, the processing system 10 is
equipped with a feeding apparatus 20, a cutting apparatus 22, a
chopping apparatus 24 and a stacking apparatus 26. The original web
14 is loaded at the feeding apparatus 20.
[0048] The original web 14 is formed by winding a web-form sheet
material, which forms the papers 12 (below referred to as a `web
14A`) in the form of a roll. The feeding apparatus 20 draws out the
web 14A from an outer periphery end of this original web 14.
[0049] As shown in FIG. 2, a plurality of path rollers 28 (path
rollers 28A to 28F) are provided at the feeding apparatus 20. A
transport path of the web 14A is formed by the path rollers 28A to
28F. The feeding apparatus 20 winds the web 14A that is drawn out
from the original web 14 round the path rollers 28A to 28F in
sequence, and transports the web 14A. At this feeding apparatus 20,
unillustrated curl-removing means is provided partway along the
transport path of the web 14A. By transporting the web 14A while
winding the web 14A round the path rollers 28A to 28F, the
curl-removing means eliminates curl which is caused by the web 14A
having been wound up in the roll.
[0050] At the feeding apparatus 20, a pair of feed rollers 34 are
disposed upward of the path roller 28F. The two feed rollers 34 are
rotated by driving force of unillustrated driving means while
nipping the web 14A, and feed the web 14A at a predetermined
speed.
[0051] The cutting apparatus 22 is provided at a downstream side of
the pair of feed rollers 34. At the cutting apparatus 22, as an
example of cutting means, slitting blades 30 and 32 are provided as
a plurality of pairs. The slitting blades 30 and 32 are disposed in
pairs sandwiching the transport path of the web 14A from above and
below, respectively. The slitting blades 30 and 32 are formed so as
to cut along a length direction of the web 14A when the web 14A
passes therebetween.
[0052] Specifically, as shown in FIG. 1, the slitting blades 30 and
32 are disposed with a predetermined spacing along a width
direction of the web 14A, which is a direction intersecting the
transport direction of the web 14A. The web 14A is cut (slitted) to
the predetermined spacing by being passed between the slitting
blades 30 and 32, and slits 36 are formed in the web 14A. Here, the
spacing of the slitting blades 30 is a lateral dimension of the
papers 12 that are being produced by the processing system 10.
[0053] Therefore, in accordance with characteristics of inkjet
printers and the like which will use the papers 12, the length
dimension of the web 14A which is wound in a roll will be the
length dimension of the papers 12.
[0054] As shown in FIG. 2, a web edge control sensor 38 is provided
at the feeding apparatus 20. A position of the original web 14
along an axial direction is controlled such that a width direction
end portion of the web 14A, which is detected by this web edge
control sensor 38, passes the web edge control sensor 38 at a
certain position. Consequently, the slits 36 can be formed by the
slitting blades 30 and 32 at predetermined positions along the
width direction of the web 14A.
[0055] As shown in FIG. 1, the web 14A in which the slits 36 have
been formed (i.e., webs 14B) is fed toward the chopping apparatus
24, which is disposed at a downstream side of the cutting apparatus
22.
[0056] As shown in FIG. 2, a pair of feed rollers 40 is provided at
the chopping apparatus 24, at the cutting apparatus 22 side
thereof. Moreover, a plurality of path rollers 42 (path rollers
42A, 42B and 42C) are disposed between the cutting apparatus 22 at
the upstream side of the chopping apparatus 24 and the feed rollers
34. The web 14A that has been fed by the feed rollers 34 is wound
round the path rollers 42A, 42B and 42C in sequence, and
transported.
[0057] The feed rollers 40, which are provided at the chopping
apparatus 24, grip the webs 14B and feed the webs 14B in units of a
certain amount. Here, a certain tension can be applied to the webs
14B to absorb variations in length of the webs 14B by, for example,
moving the path roller 42B in a direction of lengthening/shortening
a length along the transport path of the web 14A. Thus, slackness
will not occur. The feed amount of the webs 14B is set to a length
in accordance with a dimension along the length direction of the
papers 12 (a longitudinal dimension).
[0058] As shown in FIGS. 1 and 2, an upper blade 44 and a lower
blade 46, which opposes the upper blade 44, are provided at the
chopping apparatus 24 to serve as chopping means. The feed rollers
40 feed the webs 14B to between the upper blade 44 and the lower
blade 46.
[0059] In the chopping apparatus 24, when a certain length of the
webs 14B has been fed between the upper blade 44 and the lower
blade 46 by the feed rollers 40 and the predetermined length of the
webs 14B has emerged from between the upper blade 44 and the lower
blade 46, the upper blade 44 is moved downward, and the plurality
of webs 14B are respectively chopped.
[0060] Here, by setting the feed amount of the webs 14B by the path
rollers 42 to an amount corresponding to the longitudinal dimension
of the papers 12, the papers 12 are produced with a predetermined
size (the predetermined lateral direction and longitudinal
direction).
[0061] Further, in the processing system 10, the stacking apparatus
26 is provided adjacent to a downstream side of the chopping
apparatus 24.
[0062] As shown in FIGS. 1 and 3, the stacking apparatus 26 is
formed by a stacking section 50, an alignment movement section 52
and an alignment conveyor 54. Now, an example of the stacking
apparatus 26 which can be utilized subsequent to the cutting
apparatus 22 and the chopping apparatus 24 in the processing system
10 will be described with reference to FIGS. 3 to 5.
[0063] As shown in FIGS. 3 and 4, tray portions 56 are provided at
the stacking section 50 of the stacking apparatus 26. The papers
12, which have been formed by the webs 14B being chopped by the
upper blade 44, drop down and are thus placed in the tray portions
56.
[0064] As shown in FIG. 3, the tray portions 56 are provided so as
to respectively oppose the small-width webs 14B that are produced
by the cutting apparatus 22 (which is not shown in FIGS. 3 and 4).
At the stacking apparatus 26, a plurality of the papers 12 that are
formed at the same time by the plurality of webs 14B being chopped
by the chopping apparatus 24 can be respectively placed on the
individual tray portions 56.
[0065] The tray portions 56 are disposed with an inclination such
that one end sides of the papers 12 in the lateral direction
thereof are lower. Further, at each of the tray portions 56, a
standing wall 58 is formed at a lower end side of the inclination
along the lateral direction of the papers 12. The papers 12 that
fall into the respective tray portions 56 move along the lateral
direction inclinations, and are disposed in the tray portions 56 in
a state in which one lateral direction end abuts against the
standing wall 58.
[0066] Therefore, in the stacking section 50, the respective papers
12 do not straddle between neighboring tray portions 56 in the
lateral direction, and when the plurality of papers 12 are placed
in the tray portions 56, the respective lateral direction one end
sides of the papers 12 are aligned.
[0067] As shown in FIG. 5, the tray portions 56 are inclined such
that a downstream side thereof in the transport direction of the
papers 12, which is a side thereof away from the upper blade 44 in
the length direction of the papers 12, is lower. A stopper 60 is
also provided at the stacking section 50, at an upper side of the
tray portions 56. This stopper 60 is equipped with a stopping plate
64, which is extendable/retractable by an air cylinder 62, and this
stopping plate 64 is coupled with a rod 62A.
[0068] The stopping plate 64 is disposed with a length direction
thereof along the lateral direction of the papers 12, such that the
stopping plate 64 faces the respective tray portions 56. A lower
end portion of the stopping plate 64 has a substantially sawtooth
form whose teeth are inclined along the inclinations of the
respective tray portions 56 along the lateral direction of the
papers 12 (not shown in FIG. 5).
[0069] At the stacking section 50, when the papers 12 are to be
stacked at the respective tray portions 56, the rod 62A of the air
cylinder 62 extends, and a lower end of the stopping plate 64 abuts
against paper placing surfaces of the tray portions 56. Here, when
the papers 12 are placed in the tray portions 56, the stopping
plate 64 of the stopper 60 faces positions which are at lower ends
(transport direction downstream side end portions) of the papers
12.
[0070] In the tray portions 56, length direction distal ends of the
papers 12 that have dropped down are placed so as to abut against
the stopping plate 64. That is, in the stacking section 50, because
the papers 12 are abutted against the stopping plate 64, the papers
12 in the respective tray portions 56 are aligned in the length
direction.
[0071] Thus, in the stacking section 50, predetermined numbers of
the papers 12 are stacked while being aligned in the width
direction and length direction (transport direction) of the papers
12. Thus, sheaves 12A of the papers 12 are formed. Hereafter, the
sheaves 12A of predetermined numbers of the papers 12 are referred
to as paper sheaves 12A. Stacking numbers of the papers 12 at this
time are specified in advance in correspondence with the size of
the papers 12 or the like.
[0072] At the stacking section 50, when the rod 62A of the air
cylinder 62 is contracted and the stopping plate 64 is raised, the
papers 12 that have been stacked in the tray portions 56 (the paper
sheaves 12A) descend along the inclination of the tray portions 56
in the paper length direction.
[0073] As shown in FIGS. 3 and 4, substantially channel-like guides
66 are provided at the alignment movement section 52. The guides 66
communicate the respective tray portions 56 provided at the
stacking section 50 with the alignment conveyor 54.
[0074] As shown in FIG. 5, the guides 66 are gently inclined such
that the alignment conveyor 54 sides thereof are lower, and the
paper sheaves 12A that have been stacked in the tray portions 56
move along these guides 66 onto the alignment conveyor 54. When the
stopping plate 64 moves upward and the paper sheaves 12A that have
been stacked in the tray portions 56 descend along the inclination
of the tray portions 56, the sheaves 12A stop upon reaching the
guides 66.
[0075] As shown in FIGS. 3 and 4, the guides 66 are formed by guide
plates 68 and guide plates 70. The guide plates 68 face one width
direction end portions of the papers 12 and the guide plates 70
face the other width direction end portions of the papers 12. The
paper sheaves 12A straddle between these guide plates 68 and 70 and
are supported thereat.
[0076] At these guides 66, upper faces of the guide plates 68 and
70 are inclined such that the guide plate 68 sides of the guides
66, which correspond to the standing wall 58 sides of the tray
portions 56, are lower. Furthermore, at the guides 66, standing
walls 72 are formed between end portions of the guide plates 68 and
end portions of the guide plates 70 of the guides 66 that are
adjacent to the corresponding guide plates 68. The standing walls
72 are continuous with the standing walls 58 of the tray portions
56. Further, the inclinations of the guides 66 along the width
direction of the papers 12 gradually ease off toward the alignment
conveyor 54 side, and the guides 66 become substantially horizontal
at the alignment conveyor 54 side thereof.
[0077] Therefore, when the paper sheaves 12A are fed into the
guides 66, the width direction one ends thereof abut against the
standing walls 72 and the width directions are aligned.
Furthermore, when the paper sheaves 12A move toward the alignment
conveyor 54 side, the inclinations of the papers 12 along the width
direction gradually level off, and the sheaves 12A are fed onto the
alignment conveyor 54 in substantially horizontal states.
[0078] Channel portions 74 are formed between the guide plates 68
and the guide plates 70 at the guides 66. These channel portions 74
oppose central portions of the papers 12 along the width direction
thereof, and reach from the guides 66 to the tray portions 56. As
shown in FIG. 5, pushers 76 are provided at the alignment movement
section 52. These pushers 76 are equipped with pushing arms 78 and
stopping arms 80. As shown in FIGS. 3 and 4, the pushers 76 are
respectively provided in correspondence with the channel portions
74 formed in the guides 66 (only portions of the pushers 76 are
shown in FIG. 3).
[0079] The respective pushers 76 are vertically movable as a unit
by unillustrated raising/lowering means such as, for example, a
plurality of air cylinders or the like, and are also movable along
the channel direction of the channel portions 74 as a unit, between
the alignment conveyor 54 and the tray portions 56, by
unillustrated moving means.
[0080] Accordingly, as shown in FIG. 5, distal end portions of the
pushing arms 78 and stopping arms 80 of the pushers 76 can be
protruded/retracted from the channel portions 74 to an upper face
side of the guide plates 68 and 70, and can be moved along the
channel portions 74 toward the alignment conveyor 54.
[0081] As shown in FIG. 4, at the alignment movement section 52,
because the inclinations of the guides 66 along the width direction
of the papers 12 gradually ease off, widths of the guides 66 are
wider at the alignment conveyor 54 side than at the tray portions
56 side. As a result, inclinations relative to the transport
direction of the papers 12 differ slightly between the guides 66.
The channel portions 74 formed at the guides 66 are formed such
that the pushers 76 can be moved in straight lines.
[0082] At the alignment movement section 52, before the stopping
plate 64 of the stopper 60 is raised, the pushers 76 move and the
distal end portions of the stopping arms 80 protrude from the
channel portions 74 at the paper 12 transport direction downstream
side relative to the stopping plate 64.
[0083] Accordingly, when the stopping plate 64 of the stopper 60 is
raised, the paper sheaves 12A stacked at the tray portions 56 abut
against the distal end portions of the stopping arms 80 and
downward movement due to the inclinations of the tray portions 56
along the transport direction is blocked.
[0084] In the state in which the paper sheaves 12A abut against the
distal end portions of the stopping arms 80, the pushers 76 move in
the channel portions 74 toward the alignment conveyor 54 side, as
far as a predetermined position. Accordingly, the paper sheaves 12A
are moved into the guides 66 due to the inclinations of the tray
portions 56, and the sheaves 12A are supported by the guide plates
68 and 70.
[0085] Subsequently, the pushers 76 retract the stopping arms 80
into the channel portions 74, move the distal end portions of the
pushing arms 78 so as to face transport direction upstream sides of
the papers 12, and protrude the distal end portions of the pushing
arms 78 from the channel portions 74. In this state, the pushing
arms 78 move toward the alignment conveyor 54 side.
[0086] Accordingly, the paper sheaves 12A are pushed by the pushing
arms 78 and moved in the guides 66 toward the alignment conveyor
54. At this time, the width direction one end sides of the paper
sheaves 12A abut against the standing walls 72, and length
direction one end sides (transport direction upstream sides) of the
paper sheaves 12A abut against the pushing arms 78. As a result,
the aligned state is preserved.
[0087] As shown in FIG. 4, a conveyor belt 82 is provided at the
alignment conveyor 54. The conveyor belt 82 is arranged so as to be
movable along the width direction of the papers 12. As shown in
FIG. 5, the paper sheaves 12A that have been pushed by the pushers
76 and moved along the guides 66 are pushed onto the conveyor belt
82 of the alignment conveyor 54.
[0088] As shown in FIG. 4, a stopper 84 is disposed at the
alignment conveyor 54, at an upper face side of the conveyor belt
82. This stopper 84 is formed substantially in a strip plate shape,
and is disposed with a length direction thereof along the width
direction of the papers 12. Length direction distal ends of the
paper sheaves 12A, which are fed onto the conveyor belt 82 from the
guides 66 by the pushers 76 (the pushing arms 78), abut against
this stopper 84, and thus the sheaves 12A are placed on the
conveyor belt 82 with the length direction distal ends thereof in
an aligned state.
[0089] A pair of shafts 86 span across the alignment conveyor 54 at
a side upward of the conveyor belt 82. These shafts 86 are disposed
such that axial directions thereof are along the length direction
of the papers 12, which is a direction intersecting the movement
direction of the conveyor belt 82. A baseplate 88 spans across
between the pair of shafts 86. The baseplate 88 is movable in the
axial direction of the shafts 86, and the stopper 84 is mounted at
this baseplate 88.
[0090] Accordingly, at the alignment conveyor 54, the stopper 84 is
disposed at a position corresponding to the dimension of the papers
12 along the length direction thereof. Thus, whatever the dimension
along the length direction, the sheaves 12A can be placed on the
stopper 84 such that the length direction one end sides thereof are
at a predetermined position.
[0091] Thus, in the processing system 10, by changing the spacing
of the slitting blades 30 and 32 provided at the cutting apparatus
22 (a cutting spacing) and a chopping spacing of the papers 12 at
the chopping apparatus 24, it is possible to produce the papers 12
with freely selected longitudinal and lateral dimensions. At the
same time, because the tray portions 56 and guides 66 at the
stacking apparatus 26 are disposed in accordance with the lateral
dimension of the papers 12 being produced and the stopper 84 is
disposed at a position according to the longitudinal dimension of
the papers 12 being produced, it is possible to stack arbitrary
sizes of the papers 12.
[0092] At the alignment conveyor 54, the plurality of paper sheaves
12A that are placed on the conveyor belt 82 in the aligned state
can be sequentially fed out when the conveyor belt 82 is driven by
unillustrated driving means.
[0093] Anyway, as shown in FIG. 1, packing processing is carried
out in the processing system 10 for accommodating the paper sheaves
12A in the wrappers 16. As shown in FIG. 6, a bagging apparatus 90
is provided in the processing system 10 at a downstream side of the
stacking apparatus 26. The paper sheaves 12A are fed out from the
alignment conveyor 54 and hence transported to the bagging
apparatus 90.
[0094] However, in the processing system 10, before the paper
sheaves 12A are collected in the wrappers 16, cover sheets 92 are
superposed on upper and lower faces of the paper sheaves 12A, with
the intention of protecting surfaces of the papers 12, and
preventing damage such as creasing and the like. Accordingly, two
cover sheet application devices 94A and 94B are provided in the
processing system 10, partway along a transport path to the bagging
apparatus 90. An inversion apparatus 96 is also provided in the
processing system 10, between the two cover sheet application
devices 94A and 94B. Devices having the same functionality can be
employed for the cover sheet application devices 94A and 94B (which
are hereafter referred to when speaking generally as "cover sheet
application devices 94"). Thus, the sheaves 12A are sandwiched by
the cover sheets 92.
[0095] Below, a process for packing of the papers 12 (the paper
sheaves 12A) in the processing system 10 relating to the first
embodiment will be described.
[0096] As shown in FIG. 6, from the alignment conveyor 54 provided
at the stacking apparatus 26, the paper sheaves 12A can be fed out
in two directions by switching a direction of driving of the
conveyor belt 82. Hence, by employing two of the bagging apparatus
90 in the processing system 10, the sheaves 12A of the papers 12
can be divided into two lines for implementing the packing process.
Here, the respective lines may be for applying the packing process
to a common size of the papers 12, and may be for applying the
packing process to different sizes of the papers 12. Because basic
structures of the lines can be the same, explanations are given for
one line hereafter, as is shown in FIG. 1.
[0097] As shown in FIGS. 6 and 7, a transport conveyor 100 and a
transfer conveyor 102 are provided at a downstream side of the
alignment conveyor 54, which is provided at the stacking apparatus
26 of the processing system 10. Note that the transport conveyor
100 may be omitted, with the transfer conveyor 102 being disposed
adjacent to the alignment conveyor 54.
[0098] As shown in FIG. 7, a transport belt 104 is provided at the
transport conveyor 100. When the conveyor belt 82 at the alignment
conveyor 54 is driven to turn, the paper sheaves 12A are
transported in the width direction, and are sequentially fed onto
the transport belt 104 of the transport conveyor 100.
[0099] When the transport belt 104 of the transport conveyor 100 is
driven to turn by driving force of unillustrated driving means, the
paper sheaves 12A that are fed from the alignment conveyor 54 are
transported further in the width direction, and are fed to the
transfer conveyor 102.
[0100] Here, a transport speed at the transport conveyor 100 (a
cycling rate of the transport belt 104) is higher than a transport
speed at the alignment conveyor 54. Consequently, spacing between
the paper sheaves 12A is greatly increased while the paper sheaves
12A are being fed to the transfer conveyor 102.
[0101] A plurality of small rollers 106 are provided at the
transfer conveyor 102 with a predetermined spacing. The small
rollers 106 are respectively disposed such that axial directions
thereof are along the length direction of the papers 12 that are
fed in from the transport conveyor 100 (the left-right direction of
the drawing of FIG. 7). The small rollers 106 are rotated by
driving force of unillustrated driving means.
[0102] Accordingly, the paper sheaves 12A that are fed to the
transfer conveyor 102 from the transport conveyor 100 are supported
by the small rollers 106 and transported in the width direction
(the vertical direction in the drawing of FIG. 7).
[0103] Further, at the transfer conveyor 102, a stopper 108 is
provided at a predetermined position at a downstream side relative
to the direction of transport of the papers 12 by the small rollers
106. The stopper 108 is formed in a strip plate form, and is
disposed such that a length direction thereof is along the length
direction of the papers 12, which is the axial direction of the
small rollers 106. Width direction end portions of the paper
sheaves 12A that are transported by the small rollers 106 abut
against the stopper 108. Thus, the paper sheaves 12A are stopped at
a predetermined position on the transfer conveyor 102.
[0104] Pushing members 110 are also provided at the transfer
conveyor 102, between mutually adjacent small rollers 106. The
pushing members 110 move in the axial direction of the small
rollers 106. These pushing members 110 are provided at, for
example, predetermined positions of an endless chain. When this
chain is driven to turn, the pushing members 110 protrude at one
end side in the axial direction of the small rollers 106, move
toward the other end side thereof, and then withdraw downward.
[0105] When the pushing members 110 protruding from between the
small rollers 106 move between the small rollers 106, the paper
sheaf 12A that has been stopped at the predetermined position of
the transfer conveyor 102 by the stopper 108 is pushed by the
pushing members 110, moves in the length direction, and is fed out
from the transfer conveyor 102.
[0106] At this time, because the small rollers 106 are being driven
to rotate, one width direction end side of the paper sheaf 12A
abuts against the stopper 108 while the paper sheaf 12A is moving.
Thus, the paper sheaf 12A is fed out from the transfer conveyor 102
in a state in which the length direction and width direction
thereof are aligned. Furthermore, because the paper sheaf 12A abuts
against the stopper 108 in this manner, the paper sheaf 12A is fed
out from the transfer conveyor 102 in a state in which the paper
sheaf 12A is positioned in the width direction.
[0107] Thus, consequent to the paper sheaves 12A that have been
lined up along the width direction on the alignment conveyor 54
being fed in at the transfer conveyor 102, the paper sheaves 12A
are transported in the length direction and fed out.
[0108] Anyway, as shown in FIG. 6, the cover sheet application
device 94A (94), the inversion apparatus 96 and the cover sheet
application device 94B (94) are provided in the processing system
10, at a downstream side in the direction in which the paper
sheaves 12A are fed out by the transfer conveyor 102, and the
bagging apparatus 90 is provided at a downstream side of the cover
sheet application device 94B. As mentioned above, the cover sheet
application devices 94A and 94B have the same basic structure, and
are described as the cover sheet application device 94 for the
present embodiment.
[0109] As shown in FIGS. 8 to 10, the cover sheet application
device 94 is equipped with a transport conveyor 112. At both of end
portions of this transport conveyor 112, sprockets 114 (only one of
which is shown in FIGS. 9 and 10) are provided. An endless
transport belt 116 is wound round these sprockets 114. As shown in
FIG. 10, the sprockets 114 are provided, for example, as pairs
along the width direction of the papers 12. At the transport belt
116, unillustrated chains are wound around the respective sprockets
114, and the transport belt 116 is driven to turn by driving force
of driving means (not shown).
[0110] As shown in FIGS. 8 and 9, the paper sheaf 12A is fed in to
the cover sheet application device 94A by a transport conveyor 118,
which is provided between the cover sheet application device 94A
and the transfer conveyor 102, and this paper sheaf 12A is placed
on the transport conveyor 112.
[0111] Hence, when the paper sheaf 12A has been placed on the
transport belt 116 of the transport conveyor 112, the transport
conveyor 112 transports this paper sheaf 12A in the length
direction. It is also possible to feed the paper sheaf 12A onto the
transport conveyor 112 from the transfer conveyor 102 without
utilizing the transport conveyor 118.
[0112] As shown in FIGS. 8 to 10, pushing blocks 120 are provided
at the transport belt 116 with a predetermined spacing. The pushing
blocks 120 move integrally with the transport belt 116 in
accordance with the turning of the transport belt 116. It is also
possible for two transport belts to be joined by the pushing blocks
120 and moved integrally to serve as the transport conveyor
112.
[0113] The transport conveyor 112 is mounted at a frame 122 of the
cover sheet application device 94. A cover sheet loading section
124 is provided adjacent to the transport conveyor 112 at the cover
sheet application device 94. In FIG. 8, the frame 122 is only
partially shown in the drawing.
[0114] As shown in FIGS. 8 and 10, a baseplate 126 is provided at
the cover sheet loading section 124. The cover sheets 92, with a
size corresponding to the size of the papers 12, are stacked and
loaded on this baseplate 126. The cover sheet application device 94
takes the topmost of these cover sheets 92 and superposes the same
with the sheaf 12A of the papers 12 that has been fed to the
transport conveyor 112 by placing that cover sheet 92 on the
transport conveyor 112.
[0115] The cover sheet application device 94 is formed such that
the paper sheaf 12A is transported along the length direction
thereof by the transport conveyor 112. The cover sheet loading
section 124 is disposed adjacent to this transport conveyor 112,
and the cover sheets 92 are disposed with a length direction
thereof along the transport direction of the paper sheaf 12A.
[0116] The baseplate 126 is joined to a pair of guide shafts 128,
at a lower face of the baseplate 126, and a distal end of a lead
screw 130. The pair of guide shafts 128 and the lead screw 130 are
disposed with length directions thereof parallel with one another
along a vertical direction. The guide shafts 128 are vertically
movably mounted at the frame 122.
[0117] A gearbox 132 is also mounted at the frame 122. The lead
screw 130 passes through this gearbox 132. An unillustrated feed
nut is provided inside the gearbox 132. The lead screw 130 is
vertically movably supported by screwingly engaging with this feed
nut. The baseplate 126 is supported to be vertically, levelly
movable by the lead screw 130 and the guide shafts 128.
[0118] As shown in FIG. 10, a raising/lowering motor 134 is coupled
with the gearbox 132. This raising/lowering motor 134 drives the
feed nut in the gearbox 132 to rotate, and thus vertically moves
the lead screw 130 and the baseplate 126.
[0119] In the cover sheet loading section 124, the raising/lowering
motor 134 drives such that the topmost of the cover sheets 92 that
are stacked on the baseplate 126 is substantially at a certain
height. In other words, in the cover sheet loading section 124, the
topmost of the cover sheets 92 is set substantially to the certain
height by driving of the raising/lowering motor 134 in accordance
with a quantity of the cover sheets 92 that are piled up on the
baseplate 126.
[0120] As shown in FIG. 10, a guide plate 136 is provided at the
cover sheet loading section 124, at the transport conveyor 112 side
thereof. A movable guide 138, which is horizontally movable in a
direction toward/away from this guide plate 136, is provided facing
the guide plate 136. As shown in FIG. 9, a guide plate 140 is
provided at the cover sheet loading section 124, at an upstream
side in the direction of transport of the papers 12. A movable
guide 142, which is horizontally movable in a direction toward/away
from this guide plate 140, is provided facing the guide plate
140.
[0121] Thus, in the cover sheet loading section 124, the guide
plate 136 serves as a width direction reference point, and the
guide plate 140 serves as a length direction reference point, and
the cover sheets 92 are positioned when loaded. Further, by moving
the movable guide 138 and the movable guide 142 of the cover sheet
loading section 124, positioning is possible when loading the cover
sheets 92 with a freely selected size.
[0122] Anyway, as shown in FIGS. 8 to 10, a leaf unit 144 is
disposed at the cover sheet application device 94, above the
baseplate 126. At the cover sheet application device 94, this leaf
unit 144 is movable between a drawing position, which opposes the
topmost of the cover sheets 92 that are loaded in the cover sheet
loading section 124, and a placing position, which opposes the
transport conveyor 112.
[0123] A plurality of suction pads 146 are provided at this leaf
unit 144. In the cover sheet application device 94, the topmost of
the cover sheets 92 that are stacked on the baseplate 126 is
suction-adhered and drawn out by the suction pads 146 at the
drawing position, and transported onto the transport conveyor
112.
[0124] The leaf unit 144 of the present embodiment is provided
with, as an example, two suction pads 146A and 146B (below referred
to when speaking generally as "the suction pads 146"). The suction
pads 146A and 146B are respectively attached to distal ends of rods
148A of air cylinders 148. These air cylinders 148 are attached to
support plates 150 such that the rods 148A are oriented
downward.
[0125] Accordingly, it is possible to raise the plurality of
suction pads 146 respectively individually by retracting the rods
148A of the air cylinders 148.
[0126] The support plates 150 at which the suction pads 146 are
provided are attached to bases 152A and 152B. The bases 152A and
152B are respectively attached to a joining plate 154. Here, the
base 152B, at which the suction pad 146B is attached, is attached
to the joining plate 154 so as to be movable in the length
direction of the cover sheets 92 (and of the papers 12).
[0127] Accordingly, a spacing of the suction pad 146A and the
suction pad 146B at the leaf unit 144 can be altered in accordance
with a length dimension of the cover sheets 92 without changing a
position of the suction pad 146A, such that both end portions in
the length direction of the cover sheets 92 will be
suction-adhered. Further, when the leaf unit 144 moves to the
drawing position, the suction pads 146 oppose the guide plate 136
side end portion of the cover sheets 92.
[0128] A raising/lowering cylinder 156 is disposed upward of the
joining plate 154. The raising/lowering cylinder 156 is equipped
with a rod 156A and a pair of shafts 156B. Distal ends of the rod
156A and the shafts 156B are joined to the joining plate 154. Thus,
the leaf unit 144 is supported.
[0129] The suction pads 146 of the leaf unit 144 descend when the
rod 156A of the raising/lowering cylinder 156 is extended. Thus,
suction-adherence of the cover sheet 92 is enabled.
[0130] Further, at the leaf unit 144, brackets 158 are attached to
the air cylinders 148. As shown in FIGS. 8 and 10, pins 160 are
attached at these brackets 158. When the leaf unit 144 is lowered
and the cover sheet 92 is suction-adhered by the suction pads 146,
distal ends of the pins 160 abut against the cover sheet 92.
[0131] At the leaf unit 144, when the cover sheet 92 has been
suction-adhered by the suction pads 146, the rods 148A of the air
cylinders 148 are retracted and the suction pads 146 are raised. At
this time, because the distal ends of the pins 160 abut against the
cover sheet 92, the suction pads 146 can lift a width direction end
portion of the cover sheet 92 while the next cover sheet 92 is
separated from the topmost cover sheet 92, which is suction-adhered
by the suction pads 146. Thus, the topmost of the cover sheets 92
can be reliably drawn out alone.
[0132] As shown in FIG. 10, a sliding unit 162 is provided at the
frame 122. Bases 164 are disposed, as a pair, at the transport
conveyor 112 side and the cover sheet loading section 124 side of
the sliding unit 162. A rodless cylinder 166 and a pair of guide
shafts 168 are disposed between these bases 164. The rodless
cylinder 166 and the guide shafts 168 are mounted so as to be
parallel with one another along the width direction of the papers
12.
[0133] A driving block 170 is provided at the rodless cylinder 166
and the guide shafts 168. The driving block 170 is moved along the
width direction of the papers 12 by operation of the rodless
cylinder 166.
[0134] As shown in FIGS. 9 and 10, a substantially `L`-shaped
bracket 172 is attached to the driving block 170. The
raising/lowering cylinder 156 is mounted at this bracket 172.
[0135] Thus, the leaf unit 144 is moved between the drawing
position and the placing position by operation of the rodless
cylinder 166.
[0136] Meanwhile, as shown in FIGS. 8 and 10, guide plates 174 and
176 are disposed at the frame 122, as a pair sandwiching the
transport conveyor 112. The guide plate 174, at the cover sheet
loading section 124 side of the transport conveyor 112, is fixed at
a predetermined position relative to the transport conveyor 112.
The guide plate 176, which opposes the guide plate 174, is movable
toward and away from the guide plate 174.
[0137] In the cover sheet application device 94, a spacing between
the guide plates 174 and 176 is adjusted in accordance with the
width dimension of the papers 12 by moving the guide plate 176.
[0138] A support plate 178 is provided extending from the guide
plate 176 toward the transport conveyor 112.
[0139] At the cover sheet application device 94, before the sheaf
12A of the paper 12 is fed on to the transport conveyor 112, the
cover sheet 92 which has been loaded at the cover sheet loading
section 124 is drawn out by the leaf unit 144, transported to
between the guide plates 174 and 176, and brought down on to the
transport conveyor 112. At this time, positioning of the cover
sheet 92 in the width direction is implemented by the guide plates
174 and 176.
[0140] The cover sheet 92 that has been disposed between the guide
plates 174 and 176 is supported at the support plate 178. Thus,
mispositioning of the cover sheet 92 due to movement of the
transport belt 116 of the transport conveyor 112 is prevented.
[0141] In the cover sheet application device 94, the cover sheet 92
is disposed on the transport conveyor 112 before the paper sheaf
12A is fed on to the transport conveyor 112, and when the sheaf 12A
of the papers 12 is fed on to the transport conveyor 112, the sheaf
12A of the papers 12 is superposed with the cover sheet 92. At this
time, the sheaf 12A of the papers 12 and the cover sheet 92 are
aligned by the guide plates 174 and 176.
[0142] In this state, when the transport belt 116 is driven to
turn, the cover sheet 92, together with the sheaf 12A of the papers
12, is pushed by the pushing block 120, removed from the support
plate 178 and placed on the transport belt 116, and transported in
a state which has been aligned in the length direction.
[0143] The transport conveyor 112 provided at the cover sheet
application device 94 feeds this paper sheaf 12A toward the
inversion apparatus 96.
[0144] As shown in FIGS. 11 and 12, the inversion apparatus 96 is
joined to, for example, a downstream side end portion of the
transport conveyor 112. The paper sheaf 12A with the cover sheet 92
disposed at the lower face thereof is transported and fed to the
inversion apparatus 96 by the transport conveyor 112. Here, guides
180 are disposed at the transport conveyor 112, as a pair at both
sides in the width direction of the papers 12. Thus, the paper
sheaf 12A is fed in to the inversion apparatus 96 while being
positioned in the width direction.
[0145] As shown in FIGS. 11 to 13, the inversion apparatus 96 is
equipped with a pair of side plates 182, which are respectively
disposed along the length direction of the papers 12. The paper
sheaf 12A is fed in between this pair of side plates 182.
[0146] As shown in FIGS. 11 and 12, a shaft 184 spans between the
side plates 182 at an end portion thereof at a downstream side in
the transport direction of the papers 12 (the right side of the
drawings of FIGS. 11 and 12), and a shaft 186 spans between the
side plates 182 at the upstream side thereof.
[0147] As shown in FIG. 12, three of small rollers 188 are mounted
at the shaft 184 with a predetermined spacing, so as to rotate
integrally. Transport belts 190A are wound round at the small
rollers 188 which are at the two end sides in the axial direction
of the shaft 184, and a transport belt 190B is wound round at the
small roller 188 in the middle.
[0148] Another of the small rollers 188 is mounted at a central
portion of the shaft 186 in the length direction thereof, and the
transport belt 190B is wound round at this small roller 188.
Rollers 192 are axially supported at the side plates 182 in
opposition with the small rollers 188 that are at the two end sides
in the axial direction of the shaft 184. The transport belts 1 90A
are wound round at the respective rollers 192.
[0149] At the inversion apparatus 96, the paper sheaf 12A is placed
on these transport belts 190A and 190B (below referred to when
speaking generally as transport belts 190). Here, as shown in FIG.
12, the rollers 192 protrude at the transport conveyor 112 side
relative to the shaft 186. Thus, in plan view, the transport belt
116 of the transport conveyor 112 approaches so as to enter in
between the rollers 192. As a result, the paper sheaf 12A is
reliably fed on to the transport belts 190 from the transport
conveyor 112.
[0150] A pulley 194 is mounted at a distal end portion of the shaft
184, which protrudes through one of the side plates 182. A
transport motor 196 is mounted at this side plate 182. An endless
timing belt 200 is wound round between a pulley 198, which is
mounted at a driving shaft of this transport motor 196, and the
pulley 194 of the shaft 184.
[0151] Accordingly, at the inversion apparatus 96, when the
transport motor 196 drives, the shaft 184 rotates and drives the
transport belts 190. Thus, the paper sheaf 12A that has been placed
on the transport belts 190 is transported.
[0152] Further, as shown in FIGS. 11 to 13, a rotary shaft 202
spans between the pair of side plates 182 in the inversion
apparatus 96. This rotary shaft 202 is axially supported at a side
upward of the transport belts 190.
[0153] As shown in FIG. 12, a pulley 204 is mounted at a distal end
portion of the rotary shaft 202, which protrudes through the one of
the side plates 182. An inversion motor 206 is mounted at this side
plate 182, adjacent to the transport motor 196. An endless timing
belt 210 is wound round between a pulley 208, which is mounted at a
driving shaft of this inversion motor 206, and the pulley 204.
[0154] Accordingly, when the inversion motor 206 operates, the
rotary shaft 202 rotates in the direction of arrow A in FIG. 11
(clockwise in the drawing of FIG. 11).
[0155] As shown in FIGS. 11 to 13, a paper-gripping portion 212 is
formed at the rotary shaft 202. The paper-gripping portion 212 is
equipped with four support bars 214 sets, which are respectively
equipped with the support bars 214.
[0156] As shown in FIG. 11, the support bars 214 are respectively
provided standing perpendicularly from length direction central
portions of strip plate-like base portions 216, and are assembled
in substantial `T` shapes. Each of the base portions 216 is mounted
such that one end side thereof opposes the length direction central
portion of a neighboring one of the base portions 216.
[0157] Thus, the support bars 214 that are adjacent in the
direction of rotation of the rotary shaft 202 are substantially
perpendicular, and each of the support bars 214 is mounted so as to
be substantially parallel to the base portion 216 that is adjacent
at the downstream side thereof in the direction of rotation.
[0158] As shown in FIGS. 12 and 13, the support bars 214 are
disposed in pairs along the axis of the rotary shaft 202, and
respectively oppose gaps between the transport belts 190A and
190B.
[0159] Consequently, when the support bars 214 rotate integrally
with the rotary shaft 202, interference with the transport belts
190 is avoided, and the sheaf 12A of the papers 12 that spans
across and is supported by the transport belts 190 can be received
from the transport belts 190 and supported by the support bars
214.
[0160] As shown in FIG. 11, at the inversion apparatus 96, the
inversion motor 206 is driven such that the rotary shaft 202
rotates in 90.degree. increments, such that the support bars 214
are either parallel or perpendicular with respect to the transport
belts 190. As shown in FIG. 13, a slit plate 222 and a sensor 224
are provided. The slit plate 222 is provided at a distal end of the
rotary shaft 202, at a side thereof that is opposite to the end at
which the pulley 204 is provided. The sensor 224 detects
unillustrated slit holes which are formed with a certain spacing at
an outer peripheral portion of the slit plate 222. By rotating the
rotary shaft 202 in accordance with results of detection from this
sensor 224, the support bars 214 can be stopped at predetermined
positions.
[0161] At the inversion apparatus 96, when a set of the support
bars 214 are substantially parallel to the transport belts 190, the
base portion 216 at which those support bars 214 are mounted
protrudes substantially perpendicularly from between the transport
belts 190 (the transport belts 190A and the transport belt
190B).
[0162] Further, in the inversion apparatus 96, when a set of the
support bars 214 are parallel with the transport belts 190 at the
upstream side in the transport direction of the papers 12, upper
faces of the support bars 214 are substantially coplanar with the
transport belts 190 or slightly lower than upper faces of the
transport belts 190, and when the support bars 214 are parallel
with the transport belts 190 at the downstream side in the
transport direction of the papers 12, a spacing between the support
bars 214 and the upper faces of the transport belts 190 is slightly
wider than a thickness of the sheaf 12A of the papers 12 at which
the cover sheet 92 has been superposed.
[0163] Accordingly, the paper sheaf 12A, which has been fed in from
the cover sheet application device 94A, placed on the transport
belts 190 and transported, abuts against the base portion 216 at a
position at which the cover sheet 92 at the lower face side of the
sheaf 12A opposes the support bars 214, and the paper sheaf 12A
stops.
[0164] Air cylinders 218 are provided at the respective base
portions 216 and oppose the support bars 214 that are at the
rotation direction upstream side thereof. At the air cylinders 218,
rods 218A and guide shafts 218B are disposed in pairs. At
respective distal ends of the air cylinders 218, facing plates 220
are mounted. The respective facing plates 220 oppose the support
bars 214 that are adjacent at the rotation direction upstream side,
and are substantially parallel therewith.
[0165] Thus, when one of the air cylinders 218 operates and the
rods 218A extend, the facing plates 220 move toward the support
bars 214, being parallel therewith, and the paper sheaf 12A that
has stopped abutting against the base portion 216 is sandwichingly
retained (gripped) by being pushed against the support bars
214.
[0166] When the paper sheaf 12A is gripped by the support bars 214
and the facing plates 220 in the inversion apparatus 96, the
inversion motor 206 drives and rotates the rotary shaft 202. As a
result, the paper sheaf 12A is inverted, and at the same time is
opposed with the transport belts 190 at the paper transport
direction downstream side relative to the rotary shaft 202.
[0167] At this time, operation of the air cylinders 218 stops and
gripping force on the paper sheaf 12A is released. Hence, the paper
sheaf 12A is placed on the transport belts 190 with the cover sheet
92 at the upper face side of the paper sheaf 12A. The paper sheaf
12A is transported by driving of the transport belts 190, and is
fed out from the inversion apparatus 96 to, for example, a
transport conveyor 228.
[0168] Tension coil springs 226 are provided adjacent to the air
cylinders 218 at the base portions 216. When the operation of the
air cylinders 218 is released, the rods 218A and the guide shafts
218B are promptly retracted by urging force of these tension coil
springs 226. Thus, the facing plates 220 are separated from the
paper sheaf 12A.
[0169] Hence, it is possible to commence transport by the transport
belts 190 without disrupting the paper sheaf 12A.
[0170] The paper sheaf 12A that has been inverted in this manner
and fed out from the inversion apparatus 96 is fed to the cover
sheet application device 94B, which is disposed at a downstream
side of the inversion apparatus 96. Specifically, at the cover
sheet application device 94B, the transport conveyor 118 shown in
FIGS. 8 and 9 is equivalent to the transport conveyor 228 which
feeds the paper sheaf 12A out from the inversion apparatus 96. Note
that the transport conveyor 228 need not be provided and the paper
sheaf 12A may be fed to the cover sheet application device 94B
(i.e., the transport conveyor 112 thereof) by the transport belts
190 of the inversion apparatus 96.
[0171] At the cover sheet application device 94B, the cover sheets
92 are superposed with lower faces of the paper sheaves 12A that
have been fed in from the inversion apparatus 96, and are fed out.
Thus, the cover sheets 92 are superposed with both upper and lower
face sides of the paper sheaves 12A that are fed out from the cover
sheet application devices 94.
[0172] As shown in FIG. 6, the bagging apparatus 90 is provided at
a downstream side of the cover sheet application device 94B. Note
that a bagging apparatus is not limited to the apparatus shown, and
freely selected structures may be employed (although not described
herein).
[0173] At this bagging apparatus 90, wrapping pouches (the wrappers
16) are formed using a long belt of wrapping film 230 with a
predetermined width. A wrapping material roll 232, in which the
wrapping film 230 is wound up in the form of a roll, is loaded at
the bagging apparatus 90. The wrapping film 230 is drawn out from
this wrapping material roll 232 and is fed to a folding section
234.
[0174] At the folding section 234, the wrapping film 230 is folded
over at a width direction central portion thereof and superposed.
Here, because the folding direction is longer, a cap portion 236 is
formed.
[0175] A sealing tape application device 238 is provided at a
downstream side of the folding section 234 (i.e., a downstream side
in a transport direction of the wrapping film 230). The sealing
tape application device 238 draws out sealing tape, such as an
adhesive tape or the like, from a tape roll 242, and adheres the
sealing tape along the length direction of the wrapping film 230 at
a width direction end portion thereof at the cap portion 236 side,
at which the wrapping film 230 is superposed with itself.
[0176] A sealing section 244 is also disposed at the downstream
side of the folding section 234. A melt-adhesion device 246 is
provided at the sealing section 244. At the sealing section 244,
upper and lower layers of the superposed wrapping film 230 are
melt-adhered and joined continuously along the length direction of
the wrapping film 230, at a position which is separated by
precisely a predetermined distance from the folded portion of the
wrapping film 230.
[0177] A punching section 248 is provided at a downstream side of
the sealing section 244. A buffer section 250 is formed between the
sealing section 244 and the punching section 248.
[0178] A puncher 252 is provided at the punching section 248. The
wrapping film 230 is fed into the punching section 248 in
increments of a certain amount. At the punching section 248, punch
holes 254 are formed between the folded portion of the wrapping
film 230 and the joined portion that has been formed by the
melt-adhesion device 246.
[0179] Here, the feed amount of the wrapping film 230 is an amount
corresponding to the width dimension of the papers 12. Accordingly,
the punch holes 254 are formed with a spacing corresponding to the
width dimension of the papers 12. The buffer section 250 absorbs a
difference in speed of the wrapping film 230 between the folding
section 234 and the punching section 248 (a difference in transport
amounts).
[0180] A cutting section 256 is provided at a downstream side of
the punching section 248. The cutting section 256 is equipped with
a sealing cutter 258, which is disposed along the width direction
of the wrapping film 230. The cutting section 256 chops the
wrapping film 230, which is transported in increments of the
certain amount. At this time, the sealing cutter 258 joins together
the chopped position of the wrapping film 230.
[0181] Thus, the cap portion 236 side is open, and the wrappers 16
are formed in accordance with the size of the papers 12.
[0182] These wrappers 16 are transported in the width direction of
the papers 12, which is the length direction of the wrapping film
230, and the wrappers 16 are fed to a packing section 260 in a
state in which the cap portion 236 sides of the wrappers 16 are
oriented toward the upstream side in the direction of transport of
the papers 12.
[0183] At the packing section 260, the paper sheaf 12A that has
been sandwiched between the cover sheets 92 is fed in from the
cover sheet application device 94B. In the packing section 260, the
paper sheaf 12A is fed into the wrapper 16 through the cap portion
236 side opening thereof. Thereafter, the cap portion 236 is folded
over by the packing section 260 so as to close the opening, the
opening is closed, and sealing tape 240 is applied to the
folded-over cap portion 236. Thus, the packages 18 in which the
paper sheaves 12A are packed in the wrappers 16 are produced. The
packages 18 are fed out from the packing section 260, are packaged
in cardboard boxes or the like in predetermined numbers to complete
packaging, and are stored, shipped and the like.
[0184] In the processing system 10 of the papers 12 that is
structured thus, when the long web 14A is drawn out from the
original web 14 that is loaded at the feeding apparatus 20, this
web 14A is wound round the path rollers 28A to 28F while being
transported, with a view to eliminating curl, and is then fed into
the cutting apparatus 22 by the feed rollers 34.
[0185] The pluralities of slitting blades 30 and 32, which are
disposed with a spacing corresponding to the width dimension of the
papers 12 that are being produced, are provided at the cutting
apparatus 22. The web 14A is nipped by these slitting blades 30 and
32, and the slits 36 are formed. As a result, the webs 14B with
widths corresponding to the width dimension of the papers 12 are
produced. These webs 14B are fed to the chopping apparatus 24 as a
unit.
[0186] At the chopping apparatus 24, the webs 14B are fed in
between the upper blade 44 and the lower blade 46 by the feed
rollers 40 in increments of an amount corresponding to the length
dimension of the papers 12. Further, at the chopping apparatus 24,
when the webs 14B have been fed between the upper blade 44 and the
lower blade 46 in the amount corresponding to the length dimension
of the papers 12, the upper blade 44 operates and the plurality of
webs 14B are chopped simultaneously.
[0187] Hence, when the papers 12 with the predetermined width
dimension and length dimension have been produced, the produced
papers 12 are stacked in the stacking apparatus 26.
[0188] At the stacking apparatus 26, the tray portions 56 and
guides 66 corresponding to the width dimension of the papers 12 are
provided in the same number as the webs 14B that were produced by
the cutting apparatus 22. At the stacking section 50, the papers 12
that have been formed by being chopped by the chopping apparatus 24
respectively drop to the tray portions 56. Hence, these papers 12
are stacked in the inclined state.
[0189] Therefore, at the stacking section 50, the papers 12 can be
stacked while overlapping of the papers 12 that have been produced
from neighboring webs 14B is prevented.
[0190] When the papers 12 have been stacked in predetermined
numbers at the respective tray portions 56, the stacking apparatus
26 causes the stopping arms 80 of the pushers 76 to protrude at the
downstream side of the stopping plate 64, and by raising the
stopping plate 64, allows the papers 12 that have been stacked in
the tray portions 56 to move in the form of the paper sheaves 12A
and abut against the stopping arms 80.
[0191] Thereafter, by moving the stopping arms 80 along the channel
portions 74 to the predetermined position at the guides 66 side,
the respective paper sheaves 12A move in the guides 66 while the
inclination eases off, without the paper sheaves 12A being
disrupted. Then, the pushing arms 78 of the pushers 76 are caused
to oppose the tray portion 56 sides of the paper sheaves 12A, and
these pushing arms 78 move toward the alignment conveyor 54.
[0192] Accordingly, the paper sheaves 12A are respectively pushed
against the pushing arms 78, move in the guides 66 toward the
alignment conveyor 54, and are pushed onto the conveyor belt 82 of
the alignment conveyor 54.
[0193] At the alignment conveyor 54, the stopper 84 is disposed at
the position corresponding to the length dimension of the papers
12. The papers 12 that have been fed onto the conveyor belt 82 by
the pushing arms 78 are abutted against the conveyor belt 82, and
thus the papers 12 are lined up along the width direction when
placed on the conveyor belt 82.
[0194] Thus, in the processing system 10, by providing the cutting
apparatus 22, which cuts the web 14A to match the width dimension
of the papers 12, and the chopping apparatus 24, which chops the
webs 14B to match the length dimension of the papers 12, the papers
12 can be produced smoothly and efficiently at the predetermined
size.
[0195] In the stacking apparatus 26, the papers 12 that have been
produced in parallel in this manner are stacked in the separate
tray portions 56. At this time, because the respective tray
portions 56 are inclined along the width direction of the papers
12, the papers 12 can be aligned in the width direction when
stacked, while the papers 12 are prevented from straddling across
neighboring tray portions 56 and overlapping.
[0196] Further, at the stacking apparatus 26, because the tray
portions 56 are inclined along the length direction of the papers
12, the papers 12 can be aligned in both the width direction and
the length direction when stacked.
[0197] At the stacking apparatus 26, when the paper sheaves 12A
have been thus arranged on the conveyor belt 82, the conveyor belt
82 is driven, and the paper sheaves 12A are moved in the width
direction and fed to the transport conveyor 100.
[0198] At the transport conveyor 100, the transport belt 104 is
driven at a speed which is faster than a speed of movement of the
conveyor belt 82, and the paper sheaves 12A that are fed onto the
transport belt 104 are fed out to the transfer conveyor 102. Thus,
the paper sheaves 12A are fed to the transfer conveyor 102 one
after another while intervals between the paper sheaves 12A are
widened.
[0199] At the transfer conveyor 102, the paper sheaf 12A that is
fed in from the transport conveyor 100 is placed on the small
rollers 106 and moved in the width direction, and is positioned in
the width direction by being stopped at the stopper 108. Then, the
paper sheaf 12A is moved in the length direction and fed out by
movement of the pushing members 110.
[0200] Thus, in the processing system 10, because the transfer
conveyor 102 is provided, the plurality of paper sheaves 12A which
have been lined up along the width direction on the alignment
conveyor 54 can be transported along the length direction one after
another, and fed out to the next stage.
[0201] The cover sheet application device 94 (94A) is provided in
the processing system 10 at the downstream side of the transfer
conveyor 102. The paper sheaves 12A are fed in to the cover sheet
application device 94.
[0202] At the cover sheet application device 94, the cover sheets
92 are stacked in the cover sheet loading section 124. At the cover
sheet application device 94, when the topmost of the cover sheets
92 is suction-adhered and drawn out by the suction pads 146 of the
leaf unit 144, this cover sheet 92 is transported to the frame 122
side and disposed between the guide plates 174 and 176. At this
time, the cover sheet 92 is placed on and supported by the support
plate 178 which is provided extending from the guide plate 176.
[0203] At the cover sheet application device 94, the spacing of the
guide plates 174 and 176 matches the width dimension of the paper
sheaves 12A. The paper sheaf 12A is fed in between the guide plates
174 and 176.
[0204] Hence, in the cover sheet application device 94, the paper
sheaf 12A is superposed on the cover sheet 92 while being
positioned in the width direction of the paper sheaves 12A.
[0205] The paper sheaf 12A that has been superposed on the cover
sheet 92 is pushed against by the pushing block 120 which is formed
at the transport belt 116 when the transport conveyor 112 is driven
and, having been aligned in the length direction, the paper sheaf
12A is placed on the transport belt 116, transported and fed out to
the inversion apparatus 96.
[0206] At the inversion apparatus 96, the paper sheaf 12A that has
been fed in from the cover sheet application device 94 is placed on
the transport belts 190 and transported in the length direction of
the paper sheaf 12A.
[0207] The paper-gripping portion 212 is provided at the inversion
apparatus 96. The paper-gripping portion 212 is formed to include
the base portions 216, the support bars 214 and the facing plates
220. The base portions 216 are provided protruding substantially
perpendicularly from between the transport belts 190. The support
bars 214 are mounted at the base portions 216 and rotatingly move
between the transport belts 190, and the facing plates 220 oppose
the support bars 214. The paper sheaf 12A is transported by the
transport belts 190, abuts against the base portion 216 and stops.
Thus, the paper sheaf 12A is disposed between the support bars 214
and the facing plates 220.
[0208] When an unillustrated sensor in the inversion apparatus 96
detects that the paper sheaf 12A has abutted against the base
portion 216 and stopped, the air cylinders 218 operate, the facing
plates 220 move toward the support bars 214, and the paper sheaf
12A is gripped between the support bars 214 and the facing plates
220. Then, the rotary shaft 202 at which the paper-gripping portion
212 is provided is rotated by driving of the inversion motor
206.
[0209] As a result, the paper sheaf 12A rotates about the rotary
shaft 202, the cover sheet 92 that was disposed at the lower face
side of the paper sheaf 12A is oriented to the upper face side
thereof, and the paper sheaf 12A is placed on the transport belts
190 at the downstream side of the rotary shaft 202. Here, the
operation of the air cylinders 218 is terminated by the inversion
apparatus 96 at the time at which the inverted paper sheaf 12A
makes contact with the transport belts 190, and the gripping by the
support bars 214 and the facing plates 220 is released.
[0210] In the state in which the paper sheaf 12A that has been
inverted in this manner has the cover sheet 92 superposed at the
upper face side, the paper sheaf 12A is transported by the
transport belts 190, and is fed out to the cover sheet application
device 94 that is disposed at the downstream side of the inversion
apparatus 96 (the cover sheet application device 94B).
[0211] At the cover sheet application device 94B, one of the cover
sheets 92 is taken out from the cover sheet loading section 124 and
is disposed between the guide plates 174 and 176. When the paper
sheaf 12A is fed in from the inversion apparatus 96 to between
these guide plates 174 and 176, the paper sheaf 12A is superposed
with this cover sheet 92.
[0212] Accordingly, the paper sheaf 12A is superposed at both upper
and lower sides by the cover sheets 92, and is fed out from the
cover sheet application device 94B.
[0213] Thus, in the processing system 10, the two cover sheet
application devices 94 (94A and 94B) for applying the cover sheets
92 to the paper sheaves 12A are provided, in addition to which the
inversion apparatus 96 is provided between the two cover sheet
application devices 94.
[0214] Accordingly, with the processing system 10, the paper
sheaves 12A can be smoothly superposed with the cover sheets 92 at
both upper and lower faces, utilizing the cover sheet application
devices 94 that have the same basic structure.
[0215] The paper sheaves 12A to which the cover sheets 92 have been
applied are fed to the packing section 260 of the bagging apparatus
90. At the bagging apparatus 90, the wrappers 16 are formed using
the wrapping film 230, and the wrappers 16 are also fed to the
packing section 260.
[0216] At the packing section 260, the paper sheaf 12A is fed into
the wrapper 16 through the opening formed in the wrapper 16. Then,
the cap portion 236 of the wrapper 16 is folded over, the opening
is closed, and the wrapper 16 is sealed by the folded-over cap
portion 236 being joined up by the sealing tape 240. Thus, the
packages 18, in which the paper sheaves 12A with the cover sheets
92 applied to both upper and lower faces are sealed, are
formed.
[0217] Thus, in the processing system 10 of the present embodiment,
processing of the long, broad web 14A--from production of the
papers 12 of the predetermined size from the original web 14,
stacking, and application of the cover sheets 92 to the sheaves
(paper sheaves) 12A of the stacked papers 12, to subsequent sealing
of the paper sheaves 12A in the wrappers 16 to produce the packages
18--an be implemented smoothly with automatic transportation.
[0218] Further, because the inversion apparatus 96 is provided
between the two cover sheet application devices 94A and 94B in the
processing system 10, the cover sheets 92 can be reliably and
smoothly applied to both upper and lower faces of the paper sheaves
12A using the cover sheet application devices 94 that have the same
structure.
[0219] Further still, because the winding direction of the web 14A
is set to be the length direction of the papers 12 in the
processing system 10, inkjet paper which is produced in the form of
the papers 12 facilitates smooth printing by inkjet printers.
[0220] Note that the embodiment described above simply illustrates
an example of the present invention and is not limiting to the
present invention. For example, although an example in which the
papers 12 are produced as inkjet paper or the like has been
described, the present invention is not limited to kinds of
recording paper such as inkjet paper and the like. The present
invention may be applied to a freely selected structure for
producing sheet members of predetermined size from a long belt of
sheet material with a broad width.
[0221] Furthermore, each of the feeding apparatus 20, the cutting
apparatus 22, the chopping apparatus 24, the stacking apparatus 26,
the transfer conveyor 102, the bagging apparatus 90, the cover
sheet application devices 94 and the inversion apparatus 96 of the
present embodiment does not limit a corresponding stage: i.e., a
cutting stage, a chopping stage, a stacking stage, a transporting
stage and a packing stage, respectively, and numerous variations
thereof are possible.
[0222] According to the present invention as described above,
numerous sheets with predetermined sizes are produced in parallel
by the cutting process and the chopping process, while being
stacked, and sheaves of the stacked sheets are packaged while being
transported in sequence. Because large area sheets, which are
troublesome to handle, are not produced as intermediate products,
an excellent effect is obtained in that smooth, automated
operations, from processing of the sheets to packing, are
enabled.
[0223] Further yet, with the present invention, because inverting
means is provided between application means, cover sheets can be
simply and smoothly applied to both upper and lower faces of the
sheet sheaves.
[0224] Next, a second embodiment of the present invention will be
described with reference to FIGS. 14 to 21. A processing system 310
of the present embodiment is equipped with a drawing apparatus 316,
a cutting apparatus 318 and a chopping apparatus 320.
[0225] In the processing system 310, as an example of a sheet
material, the original web 14 is loaded in the drawing apparatus
316. Hence, the web 14A, which is drawn out from this original web
14, is processed to the sheet-form papers 12 with predetermined
sizes. Using inkjet paper as this web 14A (the original web 14),
the papers 12 may be produced in various sizes, such as L-size,
postcard size, etc. The sheet material is not limited to inkjet
paper, and various recording papers, printing papers, photographic
light-sensitive materials such as film or the like, and the like
may be utilized.
[0226] A plurality of path rollers 324A, 324B, 324C, 324D, 324E,
324F and 324G are provided in the drawing apparatus 316. The web
14A that is drawn out from the original web 14 is wound round each
of the path rollers 324A to 324G in that order. With this drawing
apparatus 316, curl of the web 14A that is drawn out from the
original web 14 is eliminated while the web 14A is being fed to the
cutting apparatus 318.
[0227] At the cutting apparatus 318, slitting blades 326 and 328
are disposed as pairs sandwiching the transport path of the web 14A
from above and below. The web 14A that has wound round the path
roller 324G is nipped by the slitting blades 326 and 328. A pair of
feed rollers 330 are provided at a downstream side of the slitting
blades 326 and 328. The web 14A is nipped at the feed rollers
330.
[0228] These feed rollers 330 are driven to rotate by driving force
of unillustrated driving means, and feed out the web 14A. Thus, the
web 14A is drawn out from the original web 14 while being
transported toward the cutting apparatus 318, and is fed out from
the cutting apparatus 318.
[0229] The slitting blades 326 and 328 oppose predetermined
positions along the width direction of the web 14A, and are driven
to rotate by driving force of unillustrated driving means. By
forming slits 332 (see FIG. 15) in the web 14A that is being
transported by the feed rollers 330, the web 14A is cut (slitted)
to predetermined widths. Thus, by providing at least one pair of
the slitting blades 326 and 328 at the cutting apparatus 318, the
web 14A drawn out from the original web 14 is slitted into at least
two divisions.
[0230] A web edge control sensor 334 is provided at the drawing
apparatus 316. A position of the web 14A along an axial direction
is controlled such that a width direction end portion of the web
14A, which is detected by this web edge control sensor 334, passes
the web edge control sensor 334 at a certain position. Thus, slits
can be formed by the slitting blades 326 and 328 at constant
positions along the width direction of the web 14A.
[0231] A pair of feed rollers 336 is provided at the chopping
apparatus 320. Path rollers 338A, 338B and 338C are disposed
between these feed rollers 336 and the feed rollers 330. The web
14A that is fed out from the feed rollers 330 is wound round the
path rollers 338A, 338B and 338C and hence transported, and is
nipped by the feed rollers 336.
[0232] These feed rollers 336 are driven to rotate by driving force
of unillustrated driving means, and feed out the web 14A in
increments of a certain amount. Here, a certain tension can be
applied to the web 14A such that slackness will not occur by, for
example, moving the path roller 338B in a direction of
lengthening/shortening a length along the transport path of the web
14A.
[0233] A cutting blade 340 and a lower blade 342 are provided at a
downstream side of the feed rollers 336 in the chopping apparatus
320 (the leftward side in the drawing of FIG. 14). The lower blade
342 opposes the cutting blade 340. The web 14A is fed to between
the cutting blade 340 and the lower blade 342 by the feed rollers
336.
[0234] The cutting blade 340 descends toward the lower blade 342 in
a state in which a predetermined amount of the web 14A has been fed
between the cutting blade 340 and the lower blade 342. As a result,
the web 14A is sandwiched between the cutting blade 340 and the
lower blade 342, and the web 14A is chopped along the width
direction.
[0235] In the processing system 310, the web 14A is slitted to
predetermined widths by the formation of the slits 332 in the web
14A at the slitting blades 326 and 328, and the web 14A is chopped
into predetermined lengths by the cutting blade 340. Thus, sheets
of predetermined sizes are processed and the papers 12 are
formed.
[0236] In other words, as shown in FIG. 15, in the processing
system 310, the web 14A is drawn out from the original web 14 that
has been loaded in the drawing apparatus 316, the web 14A is
slitted to the predetermined widths by the plurality of pairs of
slitting blades 326 and 328 provided at the cutting apparatus 318,
the web 14A that has been slitted to the predetermined widths is
cut along the width direction by the cutting blade 340 provided at
the chopping apparatus 320, and the papers 12 are produced.
[0237] Here, because the web 14A is cut to size along the width
direction, which is a direction intersecting the length direction
of the papers 12, by the cutting apparatus 318 and is cut to size
along the length direction of the papers 12 by the chopping
apparatus 320, the length direction of the papers 12 corresponds to
the length direction of the web 14A, and when these papers 12 are
loaded in, for example, a printer (such as an inkjet printer) or
the like, even if some curl remains in the papers 12, smooth
printing processing of the papers 12 is possible.
[0238] In the present embodiment, six pairs of the slitting blades
326 and 328 are provided, as an example, and six of the slits 332
are formed. Therefore, the papers 12 are produced in sets of seven
sheets. However, production numbers of the papers 12 are not
limited to this.
[0239] Next, stacking of the papers 12 that are produced by the
processing system 310 and transport of the stacked papers 12 are
described.
[0240] As shown in FIGS. 15 and 16, a stacking and transport
apparatus 350 is provided in the processing system 310, at a
downstream side of the chopping apparatus 320. This stacking and
transport apparatus 350 is equipped with a stacking section 352 and
a transport section 354. As shown in FIGS. 14 to 16, the stacking
section 352 is disposed adjacent to the downstream side of the
chopping apparatus 320. In the following descriptions, the
transport direction of the web 14A is the length direction of the
papers 12 (arrow L), and a direction intersecting this transport
direction is the width direction of the papers 12 (the direction of
arrow W).
[0241] As shown in FIG. 16, the papers 12 that have been chopped to
the predetermined size by the chopping apparatus 320 are stacked at
the stacking section 352. An alignment conveyor 356 is provided at
a downstream side of the stacking and transport apparatus 350. The
transport section 354 moves the sheaves 12A of the papers 12, which
have been formed by the papers 12 being stacked in predetermined
numbers in the stacking section 352, toward the alignment conveyor
356, and feeds the sheaves 12A out from the alignment conveyor 356
to subsequent stages, such as a packing stage and the like.
[0242] Now, the stacking and transport apparatus 350 will be
described with reference to FIGS. 17 to 21.
[0243] As shown in FIGS. 19 and 20, the stacking and transport
apparatus 350 is equipped with a frame 360, which is formed in a
rectangular box shape. As shown in FIG. 17, the stacking section
352 and transport section 354 are formed at an upper portion of the
frame 360 (the upward side of the drawing of FIG. 17).
[0244] As shown in FIGS. 16 and 18, trays 362 are formed at the
stacking section 352 to match the number of the papers 12 that are
produced in parallel by the chopping apparatus 320 (which is not
shown in FIG. 18). Further, as shown in FIG. 20, guide channels 364
are formed at the transport section 354 in respective
correspondence with the trays 362. Basic structures of the trays
362 and guide channels 364 are the same. Thus, a single pair of the
trays 362 and guide channels 364 will be principally described
hereafter.
[0245] As shown in FIGS. 17, 18 and 20, guide plates 366 and 368,
which are separated by predetermined spacings, are disposed at the
trays 362, in pairs along the width direction of the papers 12. The
guide plates 366 and 368 are formed to be mounted at the frame 360
via brackets 370 (see FIGS. 17 and 18). When the papers 12 drop to
the trays 362, the papers 12 are supported straddling the guide
plates 366 and 368.
[0246] The guide plates 366 and 368 are respectively inclined such
that the transport section 354 sides thereof are lower, as shown in
FIG. 17, and are inclined substantially in parallel such that, of
the guide plates 366 and 368, the guide plates 366 are lower, as
shown in FIG. 18.
[0247] Further, as shown in FIGS. 18 and 20, standing walls 372 are
provided between each guide plate 366 and the guide plate 368 of
the tray 362 that is adjacent to the guide plate 366.
[0248] Therefore, when the papers 12 are supported at the guide
plates 366 and 368, the papers 12 are inclined so as to be lowest
at one end sides in the width direction, at the transport section
354 sides thereof. Here, the one end sides in the width direction
of the papers 12 abut against the standing walls 372. As a result,
the papers 12 are aligned in the width direction. In addition,
overlapping of the papers 12 with the neighboring papers 12 in the
width direction is prevented.
[0249] As shown in FIGS. 17 and 18, a stopper 374, which serves as
a stopping plate, is provided upward of the trays 362 at the
stacking section 352. As shown in FIG. 18, the stopper 374 is
formed substantially in a strip plate shape, a width direction of
which is substantially along the vertical direction and a length
direction of which is along the width direction of the papers 12.
The stopper 374 is disposed to oppose predetermined positions at
the transport section 354 side (the paper front side of the drawing
of FIG. 18) of the guide plates 366 and 368.
[0250] Cutaways 376 are formed in the stopper 374, at a width
direction end portion thereof which opposes the trays 362, so as to
be angled along upper faces of the guide plates 366 and 368. Thus,
the stopper 374 substantially has a sawblade shape.
[0251] As shown in FIGS. 17 and 18, support pillars 378 are
provided standing at both sides, in the width direction of the
papers 12, of the frame 360. A support bar 380 spans across at
upper end portions of the pair of support pillars 378. An air
cylinder 382 is provided at a central portion in a length direction
of this support bar 380.
[0252] The air cylinder 382 is mounted at the support bar 380 in a
state in which a rod 382A thereof is oriented substantially
downward. An upper end portion of the stopper 374 is joined to a
distal end of this rod 382A. Thus, the stopper 374 is
supported.
[0253] Guide shafts 384 are disposed along the vertical direction
at the respective support pillars 378. Sliders 386 are attached to
the stopper 374 at both end portions in the length direction
thereof. These sliders 386 are engaged with the guide shafts 384 so
as to be movable along an axial direction of the guide shafts
384.
[0254] Accordingly, when the rod 382A of the air cylinder 382
extends or retracts, the stopper 374 moves in a substantially
vertical direction, which is a direction of approaching or moving
away from the upper faces of the guide plates 366 and 368 in
accordance with the extension or retraction of the rod 382A.
[0255] Now, in a state in which the rod 3 82A of the air cylinder
382 is retracted, the stopper 374 has moved to upward of the trays
362 (the guide plates 366 and 368). Accordingly, the trays 362
communicate with the guide channels 364, and the papers 12 that
have dropped onto the guide plates 366 and 368 can move into the
guide channels 364.
[0256] When the rod 382A of the air cylinder 382 extends, the
stopper 374 moves downward, approaches the upper faces of the guide
plates 366 and 368, and divides the trays 362 from the guide
channels 364. Accordingly, the papers 12 that drop to the trays 362
and straddle between the guide plates 366 and 368 abut against the
standing walls 372 at length direction distal ends of the papers
12, and downward movement of the papers 12 is obstructed.
[0257] Hence, at the stacking section 352, the stopper 374 is
caused to descend and the papers 12 are stacked. At this time,
because the length direction distal ends of the papers 12 abut
against the stopper 374, the length direction distal ends of the
papers 12 are substantially uniformly aligned. In other words, at
the trays 362 formed in the stacking section 352, because width
direction one end sides of the papers 12 are abutted against the
standing walls 372 and length direction one end sides of the papers
12 are abutted against the stopper 374, the papers 12 are stacked
while being aligned in the length direction and in the width
direction. Then, when the stopper 374 is raised, the papers 12 that
have stacked in the trays 362 are allowed to descend into the guide
channels 364 along the inclination of the guide plates 366 and
368.
[0258] Note that although the stopper 374 is moved in a vertical
direction in the present embodiment, this is not limiting. For
example, a stopper which moves along a direction which is
substantially perpendicular to the upper faces of the guide plates
366 and 368 on which the papers 12 are placed is also possible.
[0259] Anyway, as shown in FIG. 20, the guide channels 364 are
formed by guide members 388, which are disposed in pairs along the
width direction of the papers 12. The guide members 388 are
disposed along the length direction of the papers 12, so as to
communicate the trays 362 with the alignment conveyor 356. Guide
portions 390 are formed at the respective guide members 388, at one
end sides thereof in the width direction of the papers 12, and
guide portions 392 are formed at the other end sides of the same.
The guide portions 390 and 392 are disposed to be separated by
predetermined intervals along the width direction of the papers 12.
Thus, the guide channels 364 are formed.
[0260] Sidewalls 394 are formed at the guide members 388 between
the guide portions 390 and 392. That is, the guide members 388 are
formed with the sidewalls 394 interposed between the guide portions
390 and 392.
[0261] The guide portions 390 are inclined such that upper face
sides thereof become gradually lower away from the guide plate 366
sides thereof, and the guide portions 392 are inclined such that
upper face sides thereof become gradually lower away from the guide
plate 368 sides thereof. The sidewalls 394 are formed between these
guide portions 390 and 392.
[0262] The inclinations of the upper faces of the guide portions
390 and 392 along the length direction of the papers 12 are
shallower than the inclinations of the upper faces of the guide
plates 366 and 368. Further, the inclinations of the upper faces of
the guide portions 390 and 392 become even shallower at the guide
plates 366 and 368 sides thereof (the trays 362 side). Accordingly,
when the papers 12 slide down from the trays 362, these papers 12
stop upon reaching the guide portions 390 and 392.
[0263] The upper faces of the guide portions 390 and 392 become
horizontal, with substantially the same height, at the alignment
conveyor 356 side thereof. At an intermediate portion of the guide
portions 390 and 392 along the length direction of the papers 12,
the guide portions 392 are higher than the guide portions 390. At
this portion, the guide portions 390 and 392 are inclined such that
lines along and joining both the upper faces are straight
lines.
[0264] That is, at the trays 362 side, the upper faces of the guide
portions 390 and 392 are inclined to match the upper faces of the
guide plates 366 and 368. However, toward the alignment conveyor
356 side, these inclinations gradually ease off, and become
horizontal in the vicinity of the alignment conveyor 356.
[0265] A spacing of the sidewalls 394 of the guide members 388,
which is a width of the guide channels 364, gradually broadens in
accordance with the easing of the width direction inclinations of
the upper faces of the guide portions 390 and 392. At the alignment
conveyor 356 side end portions of the sidewalls 394, the spacing of
the sidewalls 394 is wider than the width dimension of the stacked
papers 12.
[0266] Therefore, when the sheaves 12A of the papers 12 that have
been stacked in predetermined numbers at the trays 362 are moved in
the guide channels 364 from the trays 362 toward the alignment
conveyor 356 side, inclinations of the sheaves 12A along the width
direction of the papers 12 are gradually eased.
[0267] At this time, because the sidewalls 394 are formed at the
guide members 388, shifting of the papers 12 in the width direction
is prevented.
[0268] Along the trays 362 and the guide channels 364, the guide
plates 366 and guide plates 368 of the trays 362 are spaced apart,
and the guide portions 390 and 392 formed at the guide channels 364
are spaced apart. Thus, channels 396 are formed with straight line
forms along the length direction of the papers 12.
[0269] As shown in FIGS. 17 and 18, pushers 400 are provided in the
frame 360 at the stacking and transport apparatus 350. Pushing arms
402 and support arms 404 of these pushers 400 are formed so as to
pass through the channels 396.
[0270] As shown in FIG. 19, guide rails 406 are mounted in the
frame 360 as a pair. Length directions of the respective guide
rails 406 are disposed along the length direction of the papers 12,
and distal ends of the guide rails 406 protrude to below the
alignment conveyor 356. A baseplate 408 spans across and is
supported between this pair of guide rails 406.
[0271] A shaft 410 is disposed at one end side of the guide rails
406, and a shaft 412 is disposed at the other end side of the guide
rails 406. Two pulleys 414 are mounted at each of the shafts 410
and 412.
[0272] Endless belts 416 are disposed as a pair between the guide
rails 406. Each of these endless belts 416 is wound round between
one of the pulleys 414 at the shaft 410 and one of the pulleys 414
at the shaft 412.
[0273] As shown in FIGS. 18 and 19, mounting members 418 are
attached to a lower face side (the paper rear side of the drawing
of FIG. 19) of the baseplate 408. The endless belts 416 are fixed
to the baseplate 408 by these mounting members 418.
[0274] As shown in FIG. 19, a pulley 420 is mounted at one end side
in an axial direction of the shaft 410. An endless timing belt 426
is wound round between this pulley 420 and a pulley 424 which is
attached to a driving shaft 422A of a motor 422.
[0275] Hence, when the motor 422 drives, the baseplate 408 is moved
along the guide rails 406 in the length direction of the papers
12.
[0276] As shown in FIGS. 18 and 19, in the frame 360, sensor rails
428 are mounted at outer sides of the guide rails 406. The sensor
rails 428 are mounted in parallel with the guide rails 406 and
separated therefrom by a predetermined spacing. Pluralities of
position detection sensors 430 are attached to the respective
sensor rails 428 at predetermined positions.
[0277] Arms 434 are attached to the baseplate 408 at predetermined
positions. Detected portions 432 are attached at distal ends of
these arms 434. When the baseplate 408 moves along the guide rails
406, the detected portions 432 oppose the position detection
sensors 430.
[0278] The respective position detection sensors 430 are attached
at positions which detect the detected portions 432 when the
baseplate 408 moves to predetermined positions. Thus, in the
stacking and transport apparatus 350, a movement position of the
baseplate 408 is judged by these position detection sensors 430,
and driving, stopping and driving force of the motor 422 are
controlled accordingly.
[0279] Further, as shown in FIGS. 18 and 19, an air cylinder 440 is
mounted at the baseplate 408. As shown in FIG. 18, this air
cylinder 440 is equipped with a rod 444 between a pair of guide
shafts 442, and the rod 444 is disposed so as to extend upward.
[0280] An intermediate base 446 is disposed upward of the air
cylinder 440. Distal ends of the pair of guide shafts 442 and the
rod 444 are joined to the intermediate base 446, and support the
intermediate base 446.
[0281] An air cylinder 448 is mounted at the intermediate base 446.
The air cylinder 448 is provided with a rod 452 between a pair of
guide shafts 450. The rod 452 is disposed so as to extend
upward.
[0282] A support bar 454 is disposed upward of this air cylinder
448 such that a length direction of the support bar 454 is along
the width direction of the papers 12. Distal ends of the guide
shafts 450 and rod 452 are joined to this support bar 454. Thus,
the support bar 454 is supported to be vertically movable.
[0283] The sets of pushing arms 402 and 404 are provided at the
pushers 400 in correspondence with the sets of trays 362 and guide
channels 364 (see FIGS. 18 and 20). These pushing arms 402 and 404
are mounted at the support bar 454, at positions corresponding to
the respective channels 396.
[0284] As shown in FIG. 17, the pushing arms 402 are attached to
substantially L-shaped brackets 456. Distal end portions of the
pushing arms 402, toward the alignment conveyor 356 sides thereof,
are again inflected upward. These inflected distal end portions
serve as pushing portions 402A, which oppose the sheaves 12A of the
papers 12.
[0285] Distal end portions of the support arms 404, toward the
chopping apparatus 320 sides thereof, are formed in substantial `L`
shapes which are inflected upward. These upward inflected distal
end portions serve as support portions 404A, which oppose the
sheaves 12A of the papers 12.
[0286] As shown by solid lines in FIG. 17, in a state in which the
rod 444 of the air cylinder 440 and the rod 452 of the air cylinder
448 are retracted, the pushing portions 402A and support portions
404A of the pushing arms 402 and the support arms 404 are
accommodated in the channels 396.
[0287] As shown by broken lines in FIG. 17, when the rod 444 of the
air cylinder 440 and/or the rod 452 of the air cylinder 448 are
extended, the respective pushing arms 402 and support arms 404 move
upward, and the pushing portions 402A and support portions 404A
protrude from the guide channels 364. Accordingly, the pushing
portions 402A of the pushing arms 402 and the support portions 404A
of the support arms 404 can face the length direction end portions
of the sheaves 12A of the papers 12.
[0288] As shown in FIG. 18, incisions 458 are formed in the stopper
374 at positions opposing the support portions 404A of the support
arms 404. As a result, interference of the stopper 374 with the
pushing arms 402 and support arms 404, particularly the support
portions 404A of the support arms 404, is prevented.
[0289] At the pushers 400, the rods 444 and 452 of the air
cylinders 440 and 448 are usually retracted. However, when the
stopper 374 rises, the support portions 404A of the support arms
404 are moved toward the guide channels 364 side of the stopper 374
and protruded.
[0290] Thus, when the stopper 374 is raised, the sheaves 12A of the
papers 12 that have been stacked in the trays 362 abut against the
support portions 404A of the support arms 404. The papers 12, which
have been aligned and stacked on the trays 362 (the guide plates
366 and 368), descend smoothly on the guide plates 366 and 368, and
disturbance of the papers 12 is avoided.
[0291] Then, the pushers 400 move the support arms 404 to
predetermined positions at which the distal end portions of the
papers 12 have been removed from the guide plates 366 and 368.
Thus, the sheaves 12A of the papers 12 are stopped, while
disruption of the sheaves 12A of the papers 12 is prevented.
[0292] In this state, the pushers 400 move the pushing arms 402
toward the alignment conveyor 356 in a state in which the pushing
portions 402A of the pushing arms 402 are caused to oppose the
chopping apparatus 320 sides (the right side in the drawing of FIG.
17) of the sheaves 12A of the papers 12. Hence, the sheaves 12A of
the papers 12 are pushed by the pushing arms 402, and moved along
the guide channels 364. In other words, the sheaves 12A of the
papers 12 are transported along the guide channels 364. Here, the
papers 12 and the sheaves 12A are not shown in FIG. 17.
[0293] As shown in FIG. 20, a belt 462, which guides between a pair
of side frames 460, is provided at the alignment conveyor 356. One
of these side frames 460 is provided at the stacking and transport
apparatus 350 side of the alignment conveyor 356. The transport
belt 462 is moved along the width direction of the papers 12 by
driving force of an unillustrated motor.
[0294] At this alignment conveyor 356, an upper face of the side
frame 460 at the stacking and transport apparatus 350 side and an
upper face of the transport belt 462 are at substantially the same
height. This height is slightly lower than the upper faces of the
guide portions 390 and 392 near the side frame 460. At the pushing
arms 402 of the pushers 400, the pushing portions 402A are slightly
higher than the upper face of the side frame 460.
[0295] Accordingly, the sheaves 12A of the papers 12 that are
pushed by the pushing arms 402 and transported in the guide
channels 364 are pushed out onto the transport belt 462 from in the
guide channels 364 by the pushing arms 402, and are received by the
alignment conveyor 356 (see FIG. 17).
[0296] Shafts 464 are disposed at the alignment conveyor 356 at an
upper side of the transport belt 462. The shafts 464 are
respectively mounted such that axial directions (length directions)
thereof are along the length direction of the papers 12, which is a
width direction of the transport belt 462.
[0297] A rectangular plate-form baseplate 466 spans across between
the shafts 464. Sliders 468 are attached to the baseplate 466 at
positions which oppose the pair of shafts 464, respectively. These
sliders 468 engage with the shafts 464 so as to be movable along
the axial direction thereof. Thus, the baseplate 466 is
supported.
[0298] A stopper 470 is provided at this baseplate 466. The stopper
470 serves as stopping means and opposes the upper face of the
transport belt 462. This stopper 470 is formed in a strip plate
shape. The stopper 470 is mounted such that a length direction of
the stopper 470 runs along the width direction of the papers 12,
which is a direction intersecting the axial direction of the shafts
464, and so as to face respective openings of the guide channels
364 of the transport section 354.
[0299] When the baseplate 466 moves along the axial direction of
the shafts 464, a separation of the stopper 470 from a transport
section 354 side end portion of the transport belt 462 changes.
[0300] Thus, at the stacking and transport apparatus 350,
alterations of the guide plates 366, the guide plates 368, the
guide members 388 (the guide portions 390 and 392) and the pushers
400 (the pushing arms 402 and support arms 404) and changes in
position of the stopper 470 of the alignment conveyor 356 are
implemented in accordance with the size of the papers 12 that are
to be stacked.
[0301] At the alignment conveyor 356, the position of this stopper
470 is fixed to correspond with the length of the papers 12 in the
length direction. Hence, the sheaves 12A of the papers 12 that are
pushed from the guide channels 364 of the transport section 354
onto the transport belt 462 by the pushing arms 402 are abutted
against the stopper 470.
[0302] Thus, at the alignment conveyor 356, the sheaves 12A of the
papers 12 are respectively stopped and placed in a state in which
the length direction distal ends thereof are lined up. In other
words, the sheaves 12A of the papers 12 are aligned and placed on
the transport belt 462 in a state in which both the width
directions and length directions thereof are aligned.
[0303] The alignment conveyor 356 feeds out the sheaves 12A of the
papers 12 by moving the transport belt 462.
[0304] A transport conveyor 472 is disposed at a downstream side in
a direction of movement of the papers 12 by the alignment conveyor
356. This transport conveyor 472 is equipped with a transport belt
474 which is driven to turn (rotatingly moved) by driving force of
an unillustrated motor. When the sheaves 12A of the papers 12 that
are fed from the alignment conveyor 356 are placed on this
transport belt 474, the sheaves 12A are transported by the
transport belt 474.
[0305] A movement speed of the transport belt 474 of the transport
conveyor 472 is greater (faster) than a movement speed of the
transport belt 462 provided at the alignment conveyor 356. As a
result, the sheaves 12A of the papers 12 are transported on the
transport belt 474 with a spacing therebetween being opened up.
[0306] A transfer conveyor 476 is disposed adjacent to this
transport conveyor 472, and the sheaves 12A of the papers 12 are
fed from the transport conveyor 472 to the transfer conveyor 476.
Note that, as shown in FIG. 16, the transport conveyor 472 may be
not provided, with the sheaves 12A of the papers 12 being fed from
the alignment conveyor 356 to the transfer conveyor 476.
[0307] As shown in FIG. 21, the transfer conveyor 476 is equipped
with a plurality of small rollers 478. The small rollers 478 are
disposed such that axial directions thereof are along the length
direction of the papers 12, and are mounted with a predetermined
spacing in the width direction of the papers 12.
[0308] Further, at the transfer conveyor 476, a stopper 480 is
provided at an end portion of the transfer conveyor 476 at a side
opposite to the side thereof at which the transport conveyor 472 is
disposed. The stopper 480 is disposed such that a length direction
thereof is along the length direction of the papers 12, which is
the axial direction of the small rollers 478.
[0309] The small rollers 478 are rotated by driving force of
unillustrated driving means. The sheaves 12A of the papers 12 that
are fed from the transport conveyor 472 are moved toward the
stopper 480. Accordingly, at the transfer conveyor 476, the sheaves
12A of the papers 12 are abutted against the stopper 480 and
stopped.
[0310] Pushing members 482 protrude from between mutually adjacent
small rollers 478 at the transfer conveyor 476. The pushing members
482 are respectively attached to an endless belt. When this endless
belt is driven to turn, the pushing members 482 move between the
small rollers 478 from one end side in the axial direction of the
small rollers 478 toward the other end side thereof.
[0311] When the pushing members 482 move at transfer conveyor 476,
the sheaves 12A of the papers 12, which have abutted against the
stopper 480 and stopped, are pushed, and move while sliding against
the stopper 480. Hence, the sheaves 12A of the papers 12 are
provided to a transport conveyor 484, which is provided extending
to the next stage.
[0312] Next, operation of the present embodiment will be
described.
[0313] In the processing system 310 of the present embodiment, the
web 14A is drawn out from an outer peripheral end of the original
web 14 that has been loaded in the drawing apparatus 316, and at
the same time the web 14A is transported to the cutting apparatus
318 at a predetermined speed.
[0314] At the cutting apparatus 318, this web 14A is nipped by the
slitting blades 326 and 328, and slitting processing to form the
slits 332 in the web 14A with the predetermined spacing is
implemented by the slitting blades 326 and 328 being driven to
rotate. Also at the cutting apparatus 318, the web 14A that has
been slitted to the predetermined widths is nipped by the feed
rollers 330 and fed out toward the chopping apparatus 320, while
overlapping of the web 14A with itself is prevented.
[0315] At the chopping apparatus 320, the web 14A that has been fed
in from the cutting apparatus 318 is nipped by the feed rollers 336
and fed toward the cutting blade 340 and lower blade 342. In
addition, at the chopping apparatus 320, transportation of the web
14A is stopped each time a predetermined amount of the web 14A has
been transported, and the web 14A is chopped by the cutting blade
340 being operated. That is, at a time at which the predetermined
amount of the web 14A has been fed through between the cutting
blade 340 and lower blade 342, the lower blade 342 is operated
(lowered) and the web 14A is chopped. Thus, sets of a plurality
(for example in the present embodiment, seven) of the papers 12
with the predetermined size are formed.
[0316] The stacking and transport apparatus 350 is provided in the
processing system 310, and the stacking section 352 of this
stacking and transport apparatus 350 is disposed adjacent to the
chopping apparatus 320.
[0317] At the stacking section 352, the trays 362 are formed to
match the number of the papers 12 which have been produced in
parallel by the chopping apparatus 320. The papers 12 that have
been produced by operation of the cutting blade 340 respectively
descend onto the corresponding trays 362.
[0318] The respective trays 362 are equipped with the guide plates
366 and 368, which are inclined at a predetermined angle, and the
papers 12 are sequentially stacked on the guide plates 366 and 368.
Here, because the papers 12 are respectively inclined along the
width direction and length direction thereof, the papers 12 will
not overlap between neighboring trays 362.
[0319] Further, at the trays 362, the standing walls 372 are
provided at the lower side of the inclination of the guide plates
366 and 368, and the stopper 374 is lowered. The width direction
end portions of the papers 12 abut against the standing walls 372,
the length direction end portions thereof abut against the stopper
374, and the papers 12 are stacked with the width directions and
length directions aligned.
[0320] At the stacking and transport apparatus 350, when the
predetermined number of the papers 12 have been stacked at each of
the trays 362, the support portions 404A of the support arms 404
provided at the pushers 400 are protruded from the channels 396
between the guide plates 366 and 368 at the transport section 354
side of the stopper 374. Here, the support portions 404A (the
support arms 404) may have been protruded in advance, during
stacking of the papers 12.
[0321] At the stacking and transport apparatus 350, from this
state, the air cylinder 382 is operated and raises the stopper 374.
Consequently, the distal end portions of the sheaves 12A of the
papers 12 abut against the support portions 404A of the support
arms 404. In this state, by moving the support arms 404 to the
predetermined position of the transport section 354, the sheaves
12A of the papers 12 are slid on the guide plates 366 and 368, are
transferred to the upper faces of the guide portions 390 and 392
that form the guide channels 364, and stop.
[0322] When, by moving the support portions 404A of the support
arms 404 to the predetermined position, the pushers 400 have moved
the sheaves 12A of the papers 12 into the guide channels 364 and
stopped the sheaves 12A, both the support arms 404 and the pushing
arms 402 are moved downward. Hence, the support arms 404 and
pushing arms 402 are withdrawn from inside the channels 396 and
moved toward the chopping apparatus 320 side, and the pushing
portions 402A of the pushing arms 402 are caused to oppose the
sheaves 12A of the papers 12 from the tray 362 sides thereof.
[0323] Thereafter, the motor 422 operates and moves the pushing
arms 402 toward the alignment conveyor 356. As a result of these
pushing arms 402 moving in the channels 396 between the guide
portions 390 and 392, the sheaves 12A of the papers 12 that have
been transferred to the guide portions 390 and 392 are pushed by
the pushing portions 402A and transported in the guide channels
364.
[0324] At this time, at the guide portions 390 and 392, the
inclination along the width direction of the papers 12 is gradually
eased off. As a result, the sheaves 12A of the papers 12 have
returned substantially to the horizontal when the sheaves 12A reach
the alignment conveyor 356 side end portions of the guide portions
390 and 392. Further, the sidewalls 394 are provided at the guide
members 388 that form the guide portions 390 and 392. Because the
papers 12 move while width direction end portions thereof are in
contact with the sidewalls 394, shifting of the papers 12 in the
sheaves 12A will not occur.
[0325] The sheaves 12A of the papers 12, which have been made
horizontal by passing along the guide channels 364, are pushed out
from the guide channels 364 onto the transport belt 462 of the
alignment conveyor 356 by the pushing portions 402A provided at the
pushing arms 402 of the pushers 400 protruding toward the alignment
conveyor 356.
[0326] The stopper 470 is provided at the alignment conveyor 356.
This stopper 470 has been fixed beforehand at a predetermined
position corresponding to the size of the papers 12 (i.e., the size
along the length direction).
[0327] The plurality of the sheaves 12A of the papers 12 that have
been pushed out onto the transport belt 462 of the alignment
conveyor 356 are stopped by the respective length direction end
portions thereof abutting against the stopper 470, and are
alignedly placed on the transport belt 462.
[0328] When the sheaves 12A of the papers 12 are fed in from the
stacking and transport apparatus 350, the alignment conveyor 356
drives the transport belt 462 and these sheaves 12A of the papers
12 are sequentially fed to the transport conveyor 472.
[0329] The transport conveyor 472 feeds the sheaves 12A of the
papers 12 that have been received from the alignment conveyor 356
to the transfer conveyor 476. The transfer conveyor 476 moves these
sheaves 12A of the papers 12 along the width direction, the sheaves
12A of the papers 12 are re-aligned by abutting against the stopper
480, and are pushed out to the transport conveyor 484 by the
pushing members 482. Thus, the sheaves 12A of the papers 12 are
transported by the transport conveyor 484 and fed to the next stage
in the state in which width directions and length directions
thereof are aligned.
[0330] With the present embodiment structured thus, because the
plurality of the papers 12 that are produced in parallel by the
chopping apparatus 320 are respectively stacked in inclined states
in the trays 362, the sheaves 12A of the papers 12 can be formed
with both the width direction and the length direction uniformly
aligned.
[0331] Furthermore, according to the stacking and transport
apparatus 350, large numbers of the papers 12 which form the
sheaves 12A can be fed while maintaining the aligned states
thereof.
[0332] Note that, although the guide plates 366 and 368 are
respectively inclined in the width direction and the transport
direction (the length direction) of the papers 12, it is sufficient
that the guide plates 366 and 368 are inclined at least in the
width direction. If such is the case, because the stopper 374
suppresses shifting along the length direction of the papers 12,
when these sheaves 12A of the papers 12 are pushed to move by the
pushing portions 402A, the length direction of the sheaves 12A of
the papers 12 can be aligned.
[0333] Further, for the present embodiment, production of the
papers 12, which are inkjet paper, has been described as an
example, but this is not limiting. The present invention may be
applied to stacking and transport when producing various kinds of
sheet body, such as various recording papers, printing papers,
photographic light-sensitive materials such as film or the like,
and the like.
[0334] According to the present invention as described above, sheet
bodies are stacked while being aligned at least in a width
direction thereof, and pushing members are abutted against sheaves
of these sheet bodies and moved to push in a transport direction.
Thus, alignment in both the width direction and the transport
direction and transportation are possible.
[0335] Furthermore, with the stacking and transport apparatus of
the present invention, excellent effects can be obtained in that
each of a plurality of sheet bodies, which are produced in
parallel, is uniformly aligned and stacked and can be transported
to subsequent stages while maintaining the aligned states
thereof.
[0336] Below, a third embodiment of the present invention will be
described with reference to FIGS. 22 to 28.
[0337] FIG. 22 shows an example of a processing system which forms
sheet bodies with a predetermined size. In a processing system 510,
the web 14A, which is drawn out from the original web 14, is
processed to sheet bodies of the predetermined size, and the sheet
bodies are produced as the papers 12, which are inkjet paper or the
like, in various sizes such as L-size, postcard size and the like.
The papers 12 that are produced by the processing system 510 are
not limited to inkjet paper, and various recording papers, printing
papers, photographic light-sensitive materials such as film or the
like, and the like may be utilized.
[0338] This processing system 510 is equipped with a feeding
apparatus 516, a cutting apparatus 518 and a chopping apparatus
520.
[0339] The original web 14 is loaded at the feeding apparatus 516,
and the web 14A is drawn out from the original web 14 by the
feeding apparatus 516. A plurality of path rollers 522A, 522B,
522C, 522D, 522E and 522F is provided at the feeding apparatus 516.
The web 14A is wound round the path rollers 522A to 522F in
sequence. In the feeding apparatus 516, while the web 14A of the
original web 14 is transported, curl is eliminated therefrom.
[0340] A pair of feed rollers 524 is provided at a downstream side
of the path roller 522F. The web 14A that has passed the path
roller 522F is nipped by these feed rollers 524.
[0341] The feed rollers 524 are driven to rotate by driving force
of unillustrated driving means, and feed the web 14A at a certain
speed. Thus, the web 14A is drawn out from the original web 14, is
transported in the feeding apparatus 516, and is fed toward the
cutting apparatus 518 at the downstream side.
[0342] At the cutting apparatus 518, slitting blades 526 and 528
are disposed in pairs sandwiching the transport path of the web 14A
from above and below. Path rollers 530A, 530B and 530C are provided
between the feed rollers 524 and the slitting blades 526 and
528.
[0343] The web 14A that has been drawn out through the feed rollers
524 is transported while being wound round the path rollers 530A,
530B and 530C, is fed in between the slitting blades 526 and 528,
and is nipped by the slitting blades 526 and 528. The path roller
530B is moveable so as to lengthen/shorten the transport path of
the web 14A. Hence, a predetermined tension is applied to the web
14A, and a difference in transport speed of the web 14A between the
feeding apparatus 516 side (the feed rollers 524) and the cutting
apparatus 518 and subsequent apparatuses can be absorbed.
[0344] The slitting blades 526 and 528 oppose one another at
predetermined positions along the width direction of the web 14A.
The slitting blades 526 and 528 are driven to rotate by
unillustrated driving means, and cut (slit) the web 14A with a
predetermined spacing by forming slits 526A in the original web 14
(see FIG. 23).
[0345] The slitting blades 526 and 528 are arranged as a plurality
of pairs along the width direction of the original web 14, at
intervals corresponding to the width dimension of the papers 12.
Thus, in the cutting apparatus 518, the web 14A that has been drawn
out from the original web 14 is cut in accordance with the width
dimension of the papers 12, and a plurality of webs 14B is
produced.
[0346] A web edge control sensor 532 is provided at the feeding
apparatus 518. A position of the original web 14 along an axial
direction thereof is controlled such that a width direction end
portion of the web 14A, which is detected by this web edge control
sensor 532, passes the web edge control sensor 532 at a certain
position. Thus, constant positions along the width direction of the
web 14A can be slitted by the slitting blades 526 and 528.
[0347] The chopping apparatus 520 is provided at the downstream
side of the cutting apparatus 518. A pair of feed rollers 534 is
provided at this chopping apparatus 520. The plurality of webs 14B,
which have been formed by slitting by the slitting blades 526 and
528, are nipped by the feed rollers 534 as an integral unit.
[0348] These feed rollers 534 are driven to rotate by driving force
of unillustrated driving means, and feed out the webs 14B in
increments of a certain amount. Here, a certain tension can be
applied to the web 14A such that slackness will not occur by moving
the aforementioned path roller 530B in a direction of
lengthening/shortening the length of the transport path of the web
14A. The feed amount of the webs 14B by the feed rollers 534 is an
amount corresponding to the length of the papers 12.
[0349] An upper blade 536 and a lower blade 538 are provided as a
pair at a downstream side of the feed rollers 534 in the chopping
apparatus 520 (the leftward side in the drawing of FIG. 22). The
lower blade 538 opposes the upper blade 536. The webs 14B are fed
in between the upper blade 536 and the lower blade 538 by the feed
rollers 534.
[0350] In a state in which a predetermined amount of the webs 14B
has been fed between the upper blade 536 and the lower blade 538,
the upper blade 536 descends toward the lower blade 538. As a
result, the webs 14B are sandwiched between the upper blade 536 and
the lower blade 538, and the webs 14B are chopped along the width
direction as a unit.
[0351] Thus, in the processing system 510, pluralities of the
papers 12 are produced in parallel.
[0352] That is, in the processing system 510, as shown in FIG. 23,
the web 14A is drawn out from the original web 14 that has been
loaded in the feeding apparatus 516, the web 14A is slitted to
predetermined widths by the plurality of pairs of slitting blades
526 and 528 provided at the cutting apparatus 518 to produce the
webs 14B, and the respective webs 14B are chopped by the upper
blade 536 and lower blade 538 provided at the chopping apparatus
520 to produce the papers 12.
[0353] Here, because the webs 14B are formed by cutting to a size
along the width direction, which is a direction intersecting the
length direction of the papers 12, in the cutting apparatus 518 and
are chopped to a size along the length direction of the papers 12
by the chopping apparatus 520, the length direction of the papers
12 corresponds to the length direction of the web 14A. Thus, when
these papers 12 are loaded in, for example, a printer (such as an
inkjet printer) or the like, even if some curl remains in the
papers 12, smooth printing processing of the papers 12 is
possible.
[0354] In the present embodiment, six pairs of the slitting blades
526 and 528 are provided, as an example, and six of the slits 526A
are formed. Accordingly, the papers 12 are produced in sets of
seven sheets. However, production numbers of the papers 12 are not
limited to this.
[0355] Next, stacking of the papers 12 that are produced by the
processing system 510 will be described.
[0356] As shown in FIGS. 22 to 24, a stacking apparatus 540 is
provided in the processing system 510, at a downstream side of the
chopping apparatus 520. As shown in FIGS. 23 and 24, the stacking
apparatus 540 is equipped with tray portions -542 in a number
corresponding to the webs 14B that are produced by slitting at the
cutting apparatus 518. The papers 12 that have been produced by
chopping each of the webs 14B with the upper blade 536 and lower
blade 538 of the chopping apparatus 520 are stacked in the tray
portions 542, which are provided in respective correspondence with
the webs 14B.
[0357] As shown in FIGS. 24 and 25, guide plates 544 and 546 are
provided at the respective tray portions 542. These guide plates
544 and 546 are arranged in pairs in the width direction of the
papers 12, which is the width direction of the webs 14B. Each of
the papers 12 that have been produced by chopping the webs 14B with
the chopping apparatus 520 (not shown in FIG. 25) is placed to
straddle between the guide plates 544 and 546.
[0358] At each of the tray portions 542, the guide plate 544 is
inclined such that one end side thereof in the width direction of
the webs 14B (which are not shown in FIG. 25) is lower. Further,
between a distal end of this guide plate 544 (i.e., a distal end
thereof in the width direction of the papers 12) and a distal end
of the guide plate 546 of the neighboring tray portion 542, a
standing wall 548 is formed so as to join the guide plate 544 and
the guide plate 546.
[0359] Consequently, when the papers 12 drop to the respective tray
portions 542 and are placed on the guide plates 544 and 546, the
papers 12 move along the inclinations of the guide plates 544 and
546 toward the standing walls 548. Width direction end portions of
the papers 12 abut against the standing walls 548, and thus the
papers 12 are aligned in the width direction for stacking.
[0360] As shown in FIG. 24, the guide plates 544 and 546 are
inclined in the length direction of the papers 12 such that a side
thereof which is further away from the chopping apparatus 520
(i.e., the upper blade 536 and the lower blade 538) is lower. Thus,
the papers 12 can move along this inclination on the guide plates
544 and 546.
[0361] A stopper 550 is provided at the stacking apparatus 540, at
a downstream side of the inclinations of the guide plates 544 and
546. This stopper 550 straddles the tray portions 542 provided in
the stacking apparatus 540. The stopper 550 is moveable in a
direction of approaching/moving away from upper faces of the guide
plates 544 and 546, by unillustrated raising/lowering means
employing an air cylinder or the like.
[0362] At the stacking apparatus 540, when the papers 12 are to be
stacked in the tray portions 542, the stopper 550 is brought close
to the guide plates 544 and 546, and respective length direction
distal ends of the papers 12 that are placed on the guide plates
544 and 546 abut against the stopper 550. Thus, the papers 12 are
stacked in the tray portions 542 in a state in which the length
direction distal ends thereof are aligned.
[0363] Thus, the tray portions 542 enable stacking of the papers 12
while the papers 12 are aligned in the width direction and the
length direction.
[0364] Hence, at the tray portions 542, when the stopper 550 is
moved away from the guide plates 544 and 546, the papers 12 can
move downward along the inclination of the guide plates 544 and
546.
[0365] In the stacking apparatus 540, when predetermined numbers of
the papers 12 have been stacked in the tray portions 542 and the
sheaves 12A of the papers 12 have been formed, the stopper 550 is
withdrawn upward, and the sheaves 12A of the papers 12 are fed out
from the tray portions 542.
[0366] Further, in the stacking apparatus 540, transport guide
portions 552 are formed continuously with the tray portions 542.
The transport guide portions 552 are provided with guide plates 554
and 556, which are disposed so as to be continuous with the guide
plates 544 and 546 of the tray portions 542, and with standing
walls 558, which join so as to be continuous with the standing
walls 548 between the tray portions 542.
[0367] At the transport guide portions 552, the guide plates 554
and 556 are inclined along the width direction of the papers 12
such that the guide plate 554 sides (the standing wall 558 sides)
thereof are lower. Consequently, the sheaves 12A can move on the
guide plates 554 and 556 while one end sides in the width direction
of the papers 12 slidingly contact the standing walls 558.
[0368] The inclinations of the guide plates 554 and 556 gradually
ease off in accordance with distance from the tray portions 542.
Therefore, when the papers 12 move on the guide plates 554 and 556,
inclinations of the papers 12 along the width direction gradually
ease off and the papers 12 are returned to a substantially
horizontal state.
[0369] At a downstream side of the transport guide portions 552,
for example, a transport conveyor 560 is provided. The sheaves 12A
of the papers 12 are respectively fed out from the transport guide
portions 552 to a conveyor belt 562 of the transport conveyor 560.
At the transport conveyor 560, a stopper 564 is provided on the
conveyor belt 562. When the length direction end portions of the
papers 12 abut against this stopper 564, the sheaves 12A of the
papers 12 are positioned, and are placed on the conveyor belt 562
in a state in which the papers 12 are aligned in the length
direction. The sheaves 12A of the papers 12 are fed out from the
transport conveyor 560 to subsequent stages by driving of the
conveyor belt 562.
[0370] Channel portions 566 are formed between the guide plates 554
and 556 of the transport guide portions 552, from between the guide
plates 544 and 546 of the tray portions 542. Unillustrated pushers,
which are provided to be protrudable/retractable in the channel
portions 566, move from the tray portions 542 toward the transport
conveyor 560. Consequently, the sheaves 12A of the papers 12 that
have been stacked in the tray portions 542 are pushed by the
pushers, move in the transport guide portions 552, and are fed out
onto the conveyor belt 562 of the transport conveyor 560.
[0371] Anyway, as shown in FIGS. 22, 24 and 25, a detection
apparatus 570 (not shown in FIG. 23) is provided at the processing
system 510. The detection apparatus 570 detects stacking states of
the papers 12 at the tray portions 542 of the stacking apparatus
540. The detection apparatus 570 is equipped with a CCD camera 572,
which employs a CCD area sensor or the like as image-capturing
means. Note that the image-capturing means is not limited to the
CCD camera 572, and a freely selected structure which is capable of
capturing images can be employed.
[0372] The CCD camera 572 is disposed to be capable of
image-capturing the guide plates 544 and 546 of the plurality of
tray portions 542. Hence, the detection apparatus 570 is capable of
image-capturing plan view images of a predetermined region which
includes both the papers 12 (the sheaves 12A) that are stacked in
the tray portions 542 and portions of the guide plates 544 and 546
that are exposed at surroundings of the papers 12.
[0373] As shown in FIG. 25, the detection apparatus 570 is also
equipped with an image acquisition section 574 and a binarization
processing section 576. Image data of a plan view image of the tray
portions 542 that has been image-captured by the CCD camera 572 is
converted to digital data, and is them converted to binary data on
the basis of, for example, a pre-specified threshold value.
[0374] At the tray portions 542, the guide plates 544 and 546 and
the like have color tones which contrast with the papers 12. As a
result, when the image that is captured by the CCD camera 572 is
converted to binary data, regions which are the papers 12 and
regions which are not the papers 12 are clearly distinguished.
[0375] As shown in FIGS. 25 and 26, because, at the tray portions
542, the guide plates 544 and 546 are inclined along the paper 12
width direction and the papers 12 are stacked thereon, there are
predetermined gaps between the papers 12 that are stacked in
neighboring tray portions 542.
[0376] That is, when the papers 12 are properly aligned and stacked
in the tray portions 542, predetermined regions of the guide plates
546 are exposed. Further, as shown in FIG. 27A, these regions are
clearly distinguished when the image data of the image captured by
the CCD camera 572 is binarized.
[0377] Now, when the papers 12 are stacked at the tray portions
542, if one of the papers 12 is out of alignment, this paper 12
will stick out over the guide plate 546 that is usually
exposed.
[0378] Therefore, as shown in FIG. 27B, in the image captured by
the CCD camera 572, the area of a region which is the papers 12 is
larger, and the area of a region which is not the papers 12 is
smaller. In particular, if the paper 12 sticks out in the width
direction, the area of a region which is not the papers 12 and
which corresponds to the guide plate 546 is smaller.
[0379] As shown in FIG. 25, an area calculation section 578 and a
comparison and judgment section 580 are provided at the detection
apparatus 570. The comparison and judgment section 580 judges
whether or not stacking states of the papers 12 are satisfactory on
the basis of calculation results from the area calculation section
578.
[0380] On the basis of the binary data, this area calculation
section 578 calculates areas of regions that are not the papers 12
at width direction end portions of the papers 12. Here, the area
calculation section 578 calculates, within a predetermined region
of each guide plate 546 that should be exposed when the papers 12
are properly aligned and stacked (a region shown by broken lines in
FIG. 26, which is below referred to as "judgment region 582"), the
area of a region which is the papers 12 (below referred to as paper
portion 582A), and/or the area of a region which is not the papers
12 (below referred to as non-paper portion 582B). The area
calculation section 578 also calculates a ratio of the area of the
paper portion 582A to the area of the non-paper portion 582B, or a
proportion of the area of the paper portion 582A in the judgment
region 582 (see FIGS. 27A and 27B).
[0381] At this time, if the papers 12 have been properly stacked,
as shown in FIG. 27A, the area of the papers 12 that stick out into
the judgment region 582 (the paper portion 582A) is virtually zero.
However, if the papers 12 are misaligned, as shown in FIG. 27B, the
area of the paper portion 582A sticking out into the judgment
region 582 of the corresponding tray portion 542 will be
larger.
[0382] At the comparison and judgment section 580, the proportional
area of the paper portion 582A that has been calculated by the area
calculation section 578 is compared with a reference value
determined in advance for when the papers 12 are stacked in a
satisfactory state (a threshold value), and it is judged whether or
not the stacking state of the papers 12 is within a satisfactory
range.
[0383] Now, when a plan view image of the plurality of tray
portions 542 is captured by the single CCD camera 572, the areas of
the judgment regions 582 differ according to the positions of the
tray portions 542 relative to the CCD camera 572. Accordingly, the
areas of the judgment regions 582 and the threshold values are
specified separately for each of the tray portions 542.
[0384] Furthermore, in the processing system 510, the sizes of the
papers 12 that are produced can be altered by changing the cutting
widths of the web 14A at the cutting apparatus 518 (the widths of
the webs 14B that are produced) and/or the chopping intervals of
the webs 14B at the chopping apparatus 520. At the stacking
apparatus 540, the tray portions 542 and the like are changed in
accordance with the sizes of the papers 12 that are to be
produced.
[0385] Hence, at the detection apparatus 570, specifications of the
judgment regions 582, and of the threshold values relating to the
proportional areas of the paper portions 582A in the judgment
regions 582, are changed in accordance with the sizes of the papers
12 that are to be stacked in the stacking apparatus 540.
[0386] Results of judgments at the comparison and judgment section
580 are inputted to, for example, an unillustrated production
management computer or the like which administers operations of the
processing system 510 and production of the papers 12. If it is
judged by the comparison and judgment section 580 that a stacking
state of the papers 12 is unsatisfactory, processing of the papers
12 is stopped temporarily or the like, and error processing is
carried out.
[0387] Next, operation of the present embodiment will be
described.
[0388] In the processing system 510, the web 14A that has been
drawn out from the original web 14 loaded at the feeding apparatus
516 is fed toward the cutting apparatus 518 at a constant speed by
the feed rollers 524.
[0389] The cutting apparatus 518 nips the web 14A with the slitting
blades 526 and 528 and feeds the web 14A out to the chopping
apparatus 520. In the cutting apparatus 518, the webs 14B with
predetermined widths are produced by slitting the web 14A with the
slitting blades 526 and 528. These webs 14B are fed out to the
chopping apparatus 520 as a unit.
[0390] The chopping apparatus 520 nips the webs 14B with the feed
rollers 534 and feeds the webs 14B between the upper blade 536 and
lower blade 538 in units of a predetermined amount, while
preventing the webs 14B from overlapping with one another. Also at
the chopping apparatus 520, the upper blade 536 is operated
synchronously with the transport of the webs 14B by the feed
rollers 534.
[0391] Thus, the webs 14B are respectively chopped to the
predetermined length, and the papers 12 of the predetermined size
are produced.
[0392] Further, in the processing system 510, the stacking
apparatus 540 is provided at the downstream side of the chopping
apparatus 520. At the stacking apparatus 540, the tray portions 542
are provided in respective correspondence with the webs 14B that
are produced at the cutting apparatus 518. The respective
pluralities of the papers 12 that are produced in parallel by the
chopping apparatus 520 are stacked by dropping into the tray
portions 542.
[0393] At the tray portions 542, the papers 12 are placed on the
guide plates 544 and 546, which are inclined such that one end
sides thereof in the width direction of the papers 12 are lower.
Further, the guide plates 544 and 546 are respectively inclined
such that a length direction side thereof in the length direction
of the papers 12 (the downstream side in the transport direction of
the web 14A) is lower. The stopper 550 is also provided at the tray
portions 542.
[0394] Therefore, the width direction one end sides of the papers
12 that have fallen to the tray portions 542 abut against the
standing walls 548, and the length direction one end sides of these
papers 12 abut against the stopper 550. Thus, these papers 12 are
stacked by being aligned in the width direction and the length
direction and placed on the guide plates 544 and 546.
[0395] At the stacking apparatus 540, when predetermined numbers of
the papers 12 have been stacked in the tray portions 542, the
stopper 550 is raised and the sheaves 12A of these papers 12 move
to the transport guide portions 552. Subsequently, the sheaves 12A
of the papers 12 are pushed and moved on the guide plates 554 and
556 of the transport guide portions 552 toward the transport
conveyor 560 by the unillustrated pushers. At this time, width
direction end portions of the papers 12 move while sliding against
the standing walls 558, so the sheaves 12A move whilst width
directions thereof remain aligned.
[0396] In accordance therewith, the inclinations along the paper 12
width direction of the sheaves 12A of the papers 12 that are moving
on the guide plates 554 and 556 gradually level off, and the
sheaves 12A of the papers 12 are pushed out onto the conveyor belt
562 of the transport conveyor 560. At this time, each of the
plurality of sheaves 12A is aligned in the length direction by the
stopper 564, and is placed on the conveyor belt 562 at a
predetermined position. The sheaves 12A of the papers 12 are
respectively fed out in order to subsequent stages, by driving of
the conveyor belt 562, and are subjected to processing for packing
and the like.
[0397] Thus, in the processing system 510, production of the papers
12 with predetermined sizes from the web 14A that is drawn out from
the original web 14, stacking of the papers 12 that have been
produced, and feeding of the papers 12 that have been stacked can
be carried out automatically.
[0398] Anyway, when automation of stacking of the papers 12 and
feeding of the stacked papers 12 is implemented, and the sheaves
12A of the papers 12 are packed and made into a finished product,
if there are misalignments of the papers 12 within the sheaves 12A,
reductions in product quality, due to transport problems, packing
problems and the like, will occur.
[0399] In order to prevent such reductions of product quality, it
is necessary to at least confirm whether or not the papers 12 are
uniformly aligned and stacked.
[0400] Herein, the detection apparatus 570 is provided in the
processing system 510, and the stacking states of the papers 12 in
the respective tray portions 542 of the stacking apparatus 540 are
detected.
[0401] The detection apparatus 570 is equipped with the CCD camera
572. At the detection apparatus 570, a plan view image of the
plurality of tray portions 542 in which the papers 12 are stacked
is captured by the CCD camera 572.
[0402] Both the image acquisition section 574 and the binarization
processing section 576 are also provided at the detection apparatus
570. A plan view image captured by the CCD camera 572 is acquired
with a predetermined timing, and the acquired plan view image is
converted to digital signals and is processed for binarization.
Hence, the paper portion 582A and non-paper portion 582B are
clearly distinguished for each of the tray portions 542.
[0403] At each of the tray portions 542 of the stacking apparatus
540 employed in the present embodiment, the guide plates 544 and
546 on which the papers 12 are placed are colored to contrast with
the papers 12. Accordingly, the detection apparatus 570 can clearly
identify regions which are the papers 12 and regions which are not
the papers 12. Note that, in the detection apparatus 570 which is
employed in the present embodiment, the binarization processing is
performed after the image captured by the CCD camera 572 has been
acquired.
[0404] At the stacking apparatus 540, when the papers 12 are
stacked at the proper positions in the tray portions 542, the
non-paper portions 582B are formed with predetermined areas at one
end sides in the paper 12 width direction. In such a case, the
areas of the non-paper portions 582B substantially correspond to
the areas of the judgment regions 582.
[0405] In the area calculation section 578 provided at the
detection apparatus 570, the area of the paper portion 582A and the
area of the non-paper portion 582B in the judgment region 582
corresponding to each tray portion 542 are calculated from the
binarization-processed image data. From the results of these
calculations, a proportional area of the paper portion 582A is
calculated.
[0406] In the comparison and judgment section 580, it is judged
whether or not the area of the paper portion 582A calculated in the
area calculation section 578 exceeds a pre-specified proportion,
that is, whether or not the proportional area of the paper portion
582A exceeds a pre-specified threshold value, and hence whether or
not there is a misalignment of the papers 12 stacked in the
corresponding tray portion 542.
[0407] That is, as shown in FIGS. 25 and 26, when the papers 12 are
aligned and stacked within a predetermined area, the guide plate
546 is exposed at the paper 12 width direction one end side.
Accordingly, as shown in FIG. 27A, when the papers 12 are in the
properly stacked state, of the image of the tray portion 542 that
is obtained by the image capture by the CCD camera 572 and the
binarization processing, the area of the paper portion 582A is
virtually zero or extremely small, and the area of the non-paper
portion 582B is large.
[0408] In contrast, if the papers 12 are such that the area of the
papers 12 is aberrant and there is a misalignment among the stacked
papers 12, as shown by broken lines in FIG. 26, this paper 12
protrudes over the guide plate 546 corresponding to the tray
portion 542.
[0409] Therefore, as shown in FIG. 27B, in the image that has been
captured by the CCD camera 572 and binarization-processed, the
paper portion 582A protrudes into the judgment region 582 and the
area of the non-paper portion 582B is smaller.
[0410] Hence, when the area of the paper portion 582A within the
judgment region 582 is calculated for the respective tray portion
542 and this area of the paper portion 582A exceeds the
pre-specified value, it is judged by the detection apparatus 570
that a failure in stacking of the papers 12 has occurred at the
corresponding tray portion 542.
[0411] Here, erroneous judgments due to noise and the like can be
reliably prevented by suitably specifying the threshold values of
the ratios of the areas of the paper portions 582A to the areas of
the judgment regions 582, and it is possible to judge the stacking
states of the papers 12 in the tray portions 542 reliably.
[0412] In the processing system 510, when a stacking failure of the
papers 12 at any of the tray portions 542 is detected by the
detection apparatus 570, an operation specified for error
processing, such as, for example, halting drawing out of the web
14A from the original web 14, halting transport of the web 14A (and
webs 14B) by the feed rollers 524 and 534 and temporarily halting
production of the papers 12, is carried out.
[0413] Hence, it is possible to carry out error processing, such as
taking out paper from any of the tray portions 542 in which
stacking failures have occurred, rectifying stacking states or the
like. When this error processing has been completed, production of
the papers 12 is resumed. Thus, the occurrence of reductions in
product quality of the papers 12 that are produced can be reliably
prevented.
[0414] Incidentally, because, at the detection apparatus 570, the
image capture region of the CCD camera 572 covers the plurality of
tray portions 542, it is easy to reserve space for provision of the
CCD camera 572 at the stacking apparatus 540. That is, if the CCD
camera 572 was provided separately for each of the plurality of
tray portions 542, this would lead to an increase in costs of the
detection apparatus 570, and it would be necessary to reserve
separate spaces for provision of the CCD cameras 572. However,
because an image of the plurality of tray portions 542 can be
captured by the single CCD camera 572, the CCD camera 572 can be
disposed in a relatively small space.
[0415] Note that the present embodiment as described above does not
limit structures of the present invention. For example, in the
present embodiment, the judgment regions 582 are specified for the
width direction end portions of the papers 12 that are stacked in
the respective tray portions 542, and it is judged whether or not
the stacking states of the papers 12 are satisfactory from the
areas of the paper portions 582A that stick out into the judgment
regions 582. However, in addition to the width direction of the
papers 12, states in which the papers 12 stick out in the length
direction may be detected too.
[0416] For example, as shown in FIG. 28, when the papers 12 are
abutted against the standing walls 548 in the width direction and
abutted against the stopper 550 in the length direction for
stacking, predetermined regions which include outer sides in both
the width direction and the length direction, at opposite sides of
the papers 12 from the standing walls 548 and the stopper 550, may
be specified as judgment regions 584, and stacking states can be
judged from areas of the paper portions 582A in these judgment
regions 584.
[0417] That is, it is possible to set the judgment regions 584 as
detection windows, and to judge the stacking states of the papers
12 from areas or proportional areas of the paper portions 582A in
these detection windows.
[0418] Further, for the present embodiment, an example has been
described in which the stacking apparatus 540 is equipped with the
tray portions 542 which are inclined along both the width direction
and the length direction for stacking the papers 12. However, the
present invention is not limited to this, and it is possible to
employ stacking apparatuses which carry out stacking of the papers
12 using arbitrary stacking methods.
[0419] Further yet, the present embodiment has been described as
utilizing the papers 12 as sheet members. However, the present
invention is not limited thus, and may be applied to stacking of
sheet bodies with arbitrary structures, such as sheet members and
sheet bodies of various materials which are thinly formed utilizing
photographic photosensitive materials such as photographic film,
printing paper and the like, and metals, resins and the like, and
photosensitive materials such as printing plates in which
photosensitive layers are formed on such sheet bodies, and the
like.
[0420] According to the present invention as described above, the
following excellent effects are provided. Because stacking states
of sheet bodies are judged from areas of sheet bodies in
pre-specified judgment regions, within plan view images captured by
image-capturing means, accurate judgment is possible. Furthermore,
because plan view images of a plurality of sheet body stacking
portions are captured by the image-capturing means, it is possible
to simplify a detection structure and save space.
* * * * *