JP7713698B2 - Optical sensor predictive maintenance device and optical sensor predictive maintenance method - Google Patents
Optical sensor predictive maintenance device and optical sensor predictive maintenance methodInfo
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Description
本発明は、横ピロー包装機、縦ピロー包装機、上包み包装機、深絞り包装機等の包装機械における光センサ予兆保全装置及び光センサ予兆保全方法に関するものである。 The present invention relates to an optical sensor predictive maintenance device and an optical sensor predictive maintenance method for packaging machines such as horizontal pillow packaging machines, vertical pillow packaging machines, overwrap packaging machines, and deep draw packaging machines.
包装機械には、筒状に成形された包材の中に食品、医薬品等の被包装品を順次充填し、シールや切断等を施して包装体を製造するピロー包装機、薄葉包装材料で１個または複数個の被包装品を覆う上包み包装機、フラットシートを容器状に成形して被包装品を充填した後蓋材でシールする深絞り包装機等があり、ピロー包装機には、包材を上下方向（縦方向）に送って被包装品を充填する縦ピロー包装機と、包材を左右方向（横方向）に送って被包装品を充填する横ピロー包装機等がある。
このような包装機械においては、ロール状に巻き取られた巻取り包材から送りローラによって連続した包材（包装フィルム）が繰り出され、被包装品が供給された後、一定のタイミングで連続する包材にシールと切断が行われ、被包装品が充填された包装体が生成される。
この場合、包材のシール・切断位置にシールと切断が行われるようにするため、包材に印刷されたレジスターマーク等の位置合わせ用マークを光センサで検知し、包材の送り量の調整が行われる。
ここで、包装機械を長期間使用すると、光センサの劣化や汚れ等により、光センサの機能が低下し、光センサが位置合わせ用マークを検知しないという動作不良となり、包材のシール・切断位置にシールと切断が行われない等の事故が生じて、光センサを交換しなければならなくなり、大きな生産阻害となる場合がある。
このため、光センサの劣化等による動作不良を予測し、光センサが動作不良となる前に、光センサの交換を行い、包装機械の生産阻害を防ぐことが望まれる。
Packaging machines include pillow packaging machines, which sequentially fill cylindrical packaging material with packaged products such as food, medicines, etc. and then seal or cut the material to produce a package; overwrap packaging machines, which cover one or more packaged products with thin packaging material; and deep draw packaging machines, which form a flat sheet into a container, fill it with the packaged products, and then seal it with a lid. Pillow packaging machines include vertical pillow packaging machines, which feed the packaging material up and down (vertically) to fill it with the packaged products, and horizontal pillow packaging machines, which feed the packaging material left and right (horizontally) to fill it with the packaged products.
In this type of packaging machine, a continuous packaging material (packaging film) is unwound by a feed roller from a roll of wound packaging material, and after the packaged products are supplied, the continuous packaging material is sealed and cut at a specific timing to produce a package filled with the packaged products.
In this case, to ensure that sealing and cutting are performed at the sealing and cutting positions of the packaging material, alignment marks such as register marks printed on the packaging material are detected by an optical sensor and the amount of packaging material fed is adjusted.
Here, when a packaging machine is used for a long period of time, the function of the optical sensor decreases due to deterioration or dirt, etc., causing the optical sensor to malfunction and not detect the alignment marks, resulting in accidents such as sealing and cutting not being performed at the sealing and cutting positions of the packaging material. This makes it necessary to replace the optical sensor, which can cause a major disruption to production.
For this reason, it is desirable to predict malfunctions due to deterioration or the like of the optical sensor, and replace the optical sensor before it malfunctions, thereby preventing production interruptions in the packaging machine.
ところで、光センサによりマークを検知して位置合わせを行うことは、包装機械以外の装置である印刷装置でも行われ、印刷装置においても、光センサの劣化を検出することが提案されている。
例えば、特許文献１（特開２０１５－２４５０５号公報）には、用紙上のマークを光学式センサ（フォトセンサ）で検出し、用紙の位置決めを行う印刷装置（サーマルプリンタ）において、用紙なし時のフォトセンサの出力レベルの履歴に基づいてフォトセンサの劣化を検出すること（特許文献１の請求項１１、段落［００５４］）、あるいは、フォトセンサの発光部の電圧低下による発光量の減少を検出することにより、発光部の劣化を検出すること（特許文献１の請求項１０、段落［００７８］）が開示されている。
しかしながら、特許文献１の印刷装置（サーマルプリンタ）では、フォトセンサの出力レベルの低下の変動が、マークの濃度むらによるものがフォトセンサの劣化によるものかを判断するために、フォトセンサの劣化を検出しているのであり、特許文献１の印刷装置は、フォトセンサが動作不良となる状態を予測するものではない。
また、包装機械においては、連続した包材（包装フィルム）にジスターマークが印刷されており、特許文献１の印刷装置のような用紙なし（包材なし）の状態が存在せず、特許文献１におけるフォトセンサの劣化の検出方法を包装装置に適用することはできない。
さらに、包装機械の光センサの動作不良は、発光部の劣化の他汚れや受光部の劣化、光ファイバセンサの場合は光ファイバの劣化等によっても生じ、特許文献１のように発光部の劣化を検出しただけでは、光センサの動作不良を予測することはできない。
Incidentally, detection of marks by optical sensors for alignment is also performed in printing devices, which are devices other than packaging machines, and it has been proposed to detect deterioration of optical sensors in printing devices as well.
For example, Patent Document 1 (JP 2015-24505 A) discloses that in a printing device (thermal printer) that detects marks on paper with an optical sensor (photosensor) and positions the paper, deterioration of the photosensor is detected based on the history of the output level of the photosensor when there is no paper (claim 11 of Patent Document 1, paragraph [0054]), or deterioration of the light-emitting part of the photosensor is detected by detecting a decrease in the amount of light emitted due to a voltage drop in the light-emitting part (claim 10 of Patent Document 1, paragraph [0078]).
However, in the printing device (thermal printer) of Patent Document 1, deterioration of the photosensor is detected to determine whether fluctuations in the decrease in the photosensor output level are due to uneven density of the mark or deterioration of the photosensor, and the printing device of Patent Document 1 does not predict a state in which the photosensor will malfunction.
Furthermore, in packaging machines, the Gister mark is printed on a continuous packaging material (packaging film), and there is no state where there is no paper (no packaging material) like in the printing device of Patent Document 1, so the method of detecting deterioration of the photosensor in Patent Document 1 cannot be applied to packaging machines.
Furthermore, malfunctions of the optical sensor of the packaging machine can occur due to deterioration of the light-emitting part as well as dirt or deterioration of the light-receiving part, and in the case of optical fiber sensors, deterioration of the optical fiber, etc., and malfunctions of the optical sensor cannot be predicted by simply detecting deterioration of the light-emitting part as in Patent Document 1.
本発明が解決しようとする課題は、包装機械において、位置合わせ用マークを検知する光センサの機能が低下して動作不良となる前に、その予兆を示す変化を取得して、光センサの保全が図れるようにすることである。 The problem that this invention aims to solve is to obtain changes that indicate a precursor to a deterioration in the function of an optical sensor that detects alignment marks in a packaging machine before the sensor malfunctions, thereby enabling the maintenance of the optical sensor.
請求項１の発明は、包装機械において供給される連続した包材に印刷された位置合わせ用マークを検知する光センサの予兆保全装置であって、前記位置合わせ用マークと該位置合わせ用マークの背景部に反射する光から前記光センサが受光する光の受光量を取得する受光量取得手段と、前記光センサの初期状態において前記受光量取得手段が取得した前記受光量である初期受光量を記憶する初期受光量記憶手段と、前記包装機械の運転中に前記受光量取得手段が取得する前記受光量である現在受光量と、前記初期受光量記憶手段に記憶された前記初期受光量を比較し、前記現在受光量が前記光センサの初期状態において前記初期受光量に基づいて設定された閾値より高く前記光センサが正常に動作している状態において、前記光センサの機能が低下して前記初期受光量に対する前記現在受光量の低下が所定範囲を超えている場合に、前記現在受光量が前記閾値より低くなり前記光センサが動作不良となる予兆ありとの判定をする予兆判定手段と、前記予兆判定手段の判定結果を出力する判定結果出力手段とを備えた光センサ予兆保全装置を提供して、上記課題を解決するものである。 The invention of claim 1 is a predictive maintenance device for an optical sensor that detects an alignment mark printed on continuous packaging material supplied by a packaging machine, comprising: a received light amount acquiring means for acquiring an amount of light received by the optical sensor from the alignment mark and light reflected from a background portion of the alignment mark; an initial received light amount storing means for storing an initial received light amount, which is the amount of received light acquired by the received light amount acquiring means in an initial state of the optical sensor; a current received light amount, which is the amount of received light acquired by the received light amount acquiring means while the packaging machine is in operation, and an initial received light amount storing means for storing a current received light amount, which is the amount of received light acquired by the received light amount acquiring means while the packaging machine is in operation, The above problem is solved by providing an optical sensor predictive maintenance device that includes an indication determination means that compares the initial amount of received light and, when the current amount of received light is higher than a threshold value set based on the initial amount of received light in the initial state of the optical sensor and the optical sensor is operating normally, determines that there are indications that the current amount of received light has fallen below the threshold value and the optical sensor will malfunction when the function of the optical sensor deteriorates and the decrease in the current amount of received light relative to the initial amount of received light exceeds a predetermined range, and a determination result output means that outputs the determination result of the indication determination means.
請求項２の発明は、前記光センサは光ファイバセンサであり、前記予兆判定手段は、前記光センサの機能低下の度合に応じた予兆を判定する光センサ予兆保全装置を提供して、上記課題を解決するものである。 The invention of claim 2 solves the above problem by providing an optical sensor predictive maintenance device in which the optical sensor is an optical fiber sensor and the predictive judgment means judges predictive signs according to the degree of functional deterioration of the optical sensor.
請求項３の発明は、前記予兆判定手段は、前記現在受光量と前記閾値との差が前記初期受光量と前記閾値との差の一定割合以下となった場合に前記初期受光量に対する前記現在受光量の低下が所定範囲を超えたとして前記光センサに動作不良が生ずる予兆ありとの判定をする光センサ予兆保全装置を提供して、上記課題を解決するものである。 The invention of claim 3 solves the above-mentioned problem by providing an optical sensor predictive maintenance device in which the predictive determination means determines that there are predictive signs of an operational malfunction in the optical sensor when the difference between the current amount of received light and the threshold value becomes less than a certain percentage of the difference between the initial amount of received light and the threshold value, based on the fact that the decrease in the current amount of received light relative to the initial amount of received light has exceeded a predetermined range.
請求項４の発明は、前記現在受光量を表示する現在受光量表示手段と、前記所定範囲を設定する所定範囲設定手段をさらに備えた光センサ予兆保全装置を提供して、上記課題を解決するものである。 The invention of claim 4 solves the above problem by providing an optical sensor predictive maintenance device further comprising a current light receiving amount display means for displaying the current light receiving amount, and a predetermined range setting means for setting the predetermined range.
請求項５の発明は、包装機械において供給される連続した包材に印刷された位置合わせ用マークを検知する光センサの予兆保全方法であって、受光量取得手段が、前記包装機械の運転中に前記位置合わせ用マークと該位置合わせ用マークの背景部に反射する光から前記光センサが受光する光の受光量を取得し、予兆判定手段が、前記受光量取得手段が取得した前記受光量である現在受光量と、前記光センサの初期状態において前記受光量取得手段が取得した前記光センサの初期受光量を比較して、前記現在受光量が前記光センサの初期状態において前記初期受光量に基づいて設定された閾値より高く前記光センサが正常に動作している状態において、前記光センサの機能が低下して前記初期受光量に対する前記現在受光量の低下が所定範囲を超えている場合に、前記現在受光量が前記閾値より低くなり前記光センサが動作不良となる予兆ありと判定し、判定結果出力手段が、前記予兆判定手段の判定結果を出力するステップを備えた光センサ予兆保全方法を提供して、上記課題を解決するものである。
The invention of claim 5 provides an optical sensor predictive maintenance method for detecting an alignment mark printed on continuous packaging material supplied by a packaging machine, the optical sensor comprising: a received light amount acquisition means for acquiring an amount of light received by the optical sensor from light reflected by the alignment mark and a background of the alignment mark while the packaging machine is in operation; an indication determination means for comparing a current received light amount, which is the amount of received light acquired by the received light amount acquisition means, with an initial received light amount of the optical sensor acquired by the received light amount acquisition means in an initial state of the optical sensor, and determining that, when the current received light amount is higher than a threshold value set based on the initial received light amount in the initial state of the optical sensor and the optical sensor is operating normally , if the function of the optical sensor has deteriorated and the decrease in the current received light amount relative to the initial received light amount exceeds a predetermined range, the current received light amount becomes lower than the threshold value, indicating that there is an indication that the optical sensor will malfunction; and an indication output means for outputting the determination result of the indication determination means, thereby solving the above-mentioned problems.
請求項１に記載の発明の光センサ予兆保全装置においては、位置合わせ用マークを検知する光センサの機能が低下して動作不良となる前に、その予兆を示す変化を取得して、光センサの保全が図れるという効果を奏する。 The optical sensor predictive maintenance device of the invention described in claim 1 has the effect of obtaining a change indicating a predictive effect before the function of the optical sensor for detecting the alignment mark deteriorates and causes a malfunction, thereby enabling the optical sensor to be maintained.
請求項２に記載の発明の光センサ予兆保全装置は、請求項１の発明と同様の効果を奏する。 The optical sensor predictive maintenance device of the invention described in claim 2 has the same effect as the invention described in claim 1.
請求項３に記載の発明の光センサ予兆保全装置は、請求項１の発明と同様の効果を奏する。 The optical sensor predictive maintenance device of the invention described in claim 3 has the same effect as the invention described in claim 1.
請求項４に記載の発明の光センサ予兆保全装置は、請求項１の発明と同様の効果を奏する。 The optical sensor predictive maintenance device of the invention described in claim 4 has the same effect as the invention described in claim 1.
請求項５に記載の発明の光センサ予兆保全方法においては、位置合わせ用マークを検知する光センサの機能が低下して動作不良となる前に、その予兆を示す変化を取得して、光センサの保全が図れるという効果を奏する。 The optical sensor predictive maintenance method of the invention described in claim 5 has the effect of obtaining a change indicating a predictive effect before the function of the optical sensor for detecting the alignment mark deteriorates and malfunctions, thereby enabling the optical sensor to be maintained.
［光センサ予兆保全システム、予兆保全装置の構成］
図１は、本発明の光センサ予兆保全装置を備えた光センサ予兆保全システムの構成を示すブロック図である。
図中、１は光センサ予兆保全システム、１０は光センサ、１１は光センサ本体、１２は受光素子、１３は投光素子、１４は制御部、１５はファイバケーブル、１５ａは受光用光ファイバ、１５ｂは投光用光ファイバ、１６はファイバ頭部、２０は光センサ予兆保全装置、２１は受光量取得部、２１ａは送信部、２１ｂは受信部、２１ｃは通信回線、２２は演算制御装置、２２ａは予兆判定部、２２ｂは初期受光量記憶部、２３は警報器、Ｆｉは包材（フィルム）である。
図１に示すように、光センサ予兆保全システム１は、光センサ１０と光センサの予兆保全装置２０から構成される。
光センサ１０は、光センサ本体１１、ファイバケーブル１５及びファイバ頭部１６から構成され、光センサ本体１１は、受光素子１２、投光素子１３及び制御部１４を備えている。
受光素子１２は、ファイバケーブル１５の受光用光ファイバ１５ａから入る光を受光し、電気信号に変換して出力する。
投光素子１３は、ＬＥＤであり、発光してファイバケーブル１５の投光用光ファイバ１５ｂから投光する。
制御部１４は、受光素子１２が出力する出力信号に基づいて、包材Ｆｉに印刷されたレジスターマークを検知する検知信号を出力し、投光素子１３の発光を制御すると共に、光センサ本体１１の動作全体を制御する。
ファイバケーブル１５は、受光用光ファイバ１５ａと投光用光ファイバ１５ｂを備え、受光用光ファイバ１５ａは、ファイバ頭部１６に入る光を受光素子に導き、投光用光ファイバ１５ｂは、投光素子１３が発する光をファイバ頭部１６に導く。
ファイバ頭部１６は、包材Ｆｉに近接して設置され、投光用光ファイバ１５ｂに導かれた光をその先端部から包材Ｆｉのレジスターマーク（後述する）とその背景部に投光し、その反射光を受光用光ファイバ１５ａの先端部で受光する。
[Configuration of optical sensor predictive maintenance system and predictive maintenance device]
FIG. 1 is a block diagram showing the configuration of an optical sensor predictive maintenance system including an optical sensor predictive maintenance device according to the present invention.
In the figure, 1 is an optical sensor predictive maintenance system, 10 is an optical sensor, 11 is an optical sensor main body, 12 is a light receiving element, 13 is a light emitting element, 14 is a control unit, 15 is a fiber cable, 15a is a light receiving optical fiber, 15b is a light emitting optical fiber, 16 is a fiber head, 20 is an optical sensor predictive maintenance device, 21 is a received light amount acquisition unit, 21a is a transmission unit, 21b is a reception unit, 21c is a communication line, 22 is an arithmetic and control device, 22a is a predictive judgment unit, 22b is an initial received light amount memory unit, 23 is an alarm, and Fi is a packaging material (film).
As shown in FIG. 1 , an optical sensor predictive maintenance system 1 is composed of an optical sensor 10 and an optical sensor predictive maintenance device 20 .
The optical sensor 10 is composed of an optical sensor body 11, a fiber cable 15, and a fiber head 16. The optical sensor body 11 includes a light receiving element 12, a light emitting element 13, and a control unit .
The light receiving element 12 receives light entering from a light receiving optical fiber 15a of the fiber cable 15, converts it into an electrical signal, and outputs it.
The light-projecting element 13 is an LED that emits light and projects the light from a light-projecting optical fiber 15 b of the fiber cable 15 .
The control unit 14 outputs a detection signal to detect the register mark printed on the packaging material Fi based on the output signal output by the light receiving element 12, controls the light emission of the light emitting element 13, and also controls the overall operation of the optical sensor main body 11.
The fiber cable 15 comprises a light receiving optical fiber 15a and a light projecting optical fiber 15b. The light receiving optical fiber 15a guides the light entering the fiber head 16 to the light receiving element, and the light projecting optical fiber 15b guides the light emitted by the light projecting element 13 to the fiber head 16.
The fiber head 16 is installed close to the packaging material Fi, and projects light guided to the light-projecting optical fiber 15b from its tip onto a register mark (described later) and the background of the packaging material Fi, and receives the reflected light at the tip of the light-receiving optical fiber 15a.
光センサ予兆保全装置２０は、包装機械の動作の制御する制御コンピュータ、操作パネルのコンピュータ等のコンピュータ機器により構成され、受光量取得部２１、演算制御装置２２及び警報器２３を備えている。
受光量取得部２１は、送信部２１ａ、受信部２１ｂ、通信回線２１ｃを備え、受光素子１２が受光する光の量である受光量（以下適宜「光センサ１０の受光量」という。）（数値）を制御部１４から取得する。
すなわち、受光量取得部２１においては、送信部２１ａが、制御部１４から光センサ１０の受光量を連続的に取得して、通信回線２１ｃを介して受信部２１ｂに送信し、受信部１５ｂが受信した受光量を演算制御装置２２に送る。
この受光量取得部２１は、送信部２１ａ、受信部２１ｂ、通信回線２１ｃを備えたものに代えて、光センサ１０の受光量を制御部１４からアナログ信号で取り出して伝送線等を介して演算制御装置２２に送るようにしたものであってもよい。
演算制御装置２２は、予兆判定部２２ａと初期受光量記憶部２２ｂを備え、受信部２１の動作や警報器２３の動作を制御する。
初期受光量記憶部２２ｂは、受光量取得部２１から演算制御装置２２が取得した初期状態の光センサ１０の受光量を初期受光量として記憶する。
予兆判定部２２ａは、包装機械（後述する）の運転中に、受光量取得部２１が取得した光センサ１０の受光量である現在受光量と、初期受光量記憶部２２ｂに記憶されている初期受光量を比較し、初期受光量に対する現在受光量の低下が所定範囲を超えた場合に、光センサ１０に動作不良の予兆ありの判定をする。
警報器２３は、前記制御コンピュータや操作パネル等のディスプレイ等により構成され、予兆判定部２２ａの判定結果に基づいて、光センサ１０に動作不良の予兆がある旨等の警報表示を行う。
また、光センサ予兆保全装置２０において、受光量取得部２１が取得した現在受光量を前記制御コンピュータや操作パネル等のディスプレイに表示する現在受光量表示部（図示せず）と、前記所定範囲を設定する所定範囲設定部（図示せず）を設け、現在受光量表示部に表示された現在受光量から、所定範囲設定部により前記所定範囲を設定できるようにしてもよい。
The optical sensor predictive maintenance device 20 is composed of computer equipment such as a control computer that controls the operation of the packaging machine and a computer for an operation panel, and is provided with a received light amount acquisition unit 21, an arithmetic and control device 22 and an alarm 23.
The light receiving amount acquisition unit 21 includes a transmitting unit 21a, a receiving unit 21b, and a communication line 21c, and acquires the amount of light received by the light receiving element 12 (hereinafter referred to as the “amount of light received by the optical sensor 10”) (numerical value) from the control unit 14.
That is, in the light receiving amount acquisition unit 21, the transmitter 21a continuously acquires the amount of light received by the optical sensor 10 from the control unit 14 and transmits it to the receiver 21b via the communication line 21c, and sends the amount of light received by the receiver 15b to the arithmetic and control device 22.
This light receiving amount acquisition unit 21 may be equipped with a transmitting unit 21a, a receiving unit 21b, and a communication line 21c, or may be configured to extract the amount of light received by the optical sensor 10 as an analog signal from the control unit 14 and send it to the arithmetic and control device 22 via a transmission line or the like.
The arithmetic and control device 22 includes a sign determination section 22 a and an initial light reception amount storage section 22 b , and controls the operation of the receiving section 21 and the operation of the alarm device 23 .
The initial amount of received light storage unit 22b stores the amount of received light of the optical sensor 10 in the initial state, which is acquired by the arithmetic and control unit 22 from the amount of received light acquisition unit 21, as the initial amount of received light.
The sign determination unit 22a compares the current amount of received light, which is the amount of light received by the optical sensor 10 acquired by the light received amount acquisition unit 21, with the initial amount of received light stored in the initial light received amount memory unit 22b during operation of the packaging machine (described later), and determines that there are signs of a malfunction in the optical sensor 10 if the decrease in the current amount of received light relative to the initial amount of received light exceeds a specified range.
The alarm 23 is constituted by a display of the control computer, an operation panel, or the like, and displays an alarm indicating that there is a sign of a malfunction in the optical sensor 10 based on the result of the judgment by the sign judging section 22a.
Furthermore, the optical sensor predictive maintenance device 20 may be provided with a current received light amount display unit (not shown) that displays the current received light amount acquired by the received light amount acquisition unit 21 on a display of the control computer, operation panel, etc., and a specified range setting unit (not shown) that sets the specified range, so that the specified range can be set by the specified range setting unit from the current received light amount displayed on the current received light amount display unit.
［位置合わせ用マーク］
図２は、位置合わせ用マークとしてのレジスターマークの一例が印刷された包材Ｆｉの平面図であり、図中、Ｒ１、Ｒ２、Ｒｎはレジスターマーク、ＢＧは背景部である。
図２に示すように、連続した包材Ｆｉの一方の端部には背景部ＢＧが帯状に印刷され、背景部ＢＧの中に一定間隔ＬでレジスターマークＲ１、Ｒ２・・・Ｒｎが連続的に印刷され、包材Ｆｉは左から右に移動する。
背景部ＢＧは、一般的には白色または白っぽい色で印刷され、図にはおいては白っぽい灰色で印刷されている。
レジスターマークＲ１、Ｒ２、Ｒｎは、一般的には黒色または黒っぽい色でスリット状に印刷され、図においては黒色でされている。
なお、包材Ｆｉに印刷される位置合わせ用マークと背景部は、反射光に対する光センサ１０の受光量に差があればよく、位置合わせマークが白色または白っぽい色で、背景部が黒色または黒っぽい色であってもよい。
[Alignment mark]
FIG. 2 is a plan view of a packaging material Fi on which an example of a register mark as a mark for alignment is printed. In the figure, R1, R2, and Rn are register marks, and BG is a background portion.
As shown in FIG. 2, a background portion BG is printed in a band shape at one end of a continuous packaging material Fi, and register marks R1, R2, ... Rn are printed continuously at regular intervals L within the background portion BG, and the packaging material Fi moves from left to right.
The background portion BG is generally printed in white or a whitish color, and in the drawing it is printed in a whitish gray color.
The register marks R1, R2, and Rn are generally printed in slits in black or a blackish color, and are shown in black in the drawing.
In addition, the alignment mark and the background portion printed on the packaging material Fi only need to have a difference in the amount of reflected light received by the optical sensor 10, and the alignment mark may be white or a whitish color and the background portion may be black or a blackish color.
［光センサ１０の受光量］
図３は、レジスターマークＲ１、Ｒ２、Ｒｎと背景部ＢＧが印刷された包材Ｆｉに対する光センサの１０の受光量と制御部１４が出力する検知信号を説明する説明図であり、同図（ａ）は光センサ１０の受光量と経過時間の関係を表し、同図（ｂ）は検知信号と検知信号の関係を表している。図中、ＬＲは受光量曲線、Ｓ１、Ｓ２、Ｓｎは検知信号、ＳＨは閾値、ｔは経過時間である。
背景部ＢＧに反射する光からの光センサの１０の受光量の最大値（初期状態における光センサの１０の受光量）を１００とし、実際に背景部ＢＧに反射する光からの光センサの１０の受光量ＨＩ、レジスターマークＲ１、Ｒ２、Ｒｎに反射する光からの光センサの１０の受光量ＬＯとする。
今、包材Ｆｉが移動し、光センサの１０が包材Ｆｉの端部からの反射光を受光し、経過時間ｔ１、ｔ２、ｔｎで、レジスターマークＲ１、Ｒ２、Ｒｎが光センサの１０ファイバ頭部１７の真下を通過するものとすると、光センサの１０がレジスターマークＲ１、Ｒ２、Ｒｎからの反射光を受光している間は、光センサの１０の受光量はＬＯであり、それ以外は背景部ＢＧから反射光を受光し、光センサの１０の受光量はＨＩとなる。
これより光センサの１０の受光量の時間的変化は、図３（ａ）に示す受光曲線ＬＲで表される。
このとき光センサ１０の制御部１４には検知信号用の閾値ＳＨが設定されており、光センサの１０の受光量が閾値ＳＨより高い状態から低い状態に変化したときに、制御部１４が検知信号を出力し、出力した検知信号は包材Ｆｉを繰り出して送る送りローラ（後述する）の制御装置に送られ、包材Ｆｉの送り量が調整される。
図３（ａ）に示すように閾値ＳＨが６０に設定されているとすると、光センサの１０の受光量ＨＩは閾値ＳＨより高く、受光量ＬＯは閾値ＳＨより低いことから、図３（ｂ）に示すように、制御部１４は、経過時間ｔ１、ｔ２、ｔｎにおいて検知信号Ｓ１、Ｓ２、Ｓｎを出力する。
[Amount of light received by the optical sensor 10]
3 is an explanatory diagram illustrating the amount of light received by the optical sensor 10 for a packaging material Fi on which register marks R1, R2, and Rn and a background portion BG are printed, and the detection signal output by the control unit 14, where (a) shows the relationship between the amount of light received by the optical sensor 10 and the elapsed time, and (b) shows the relationship between the detection signals. In the diagram, LR is the light receiving amount curve, S1, S2, and Sn are detection signals, SH is a threshold, and t is the elapsed time.
The maximum amount of light received by the optical sensor 10 from light reflected by the background portion BG (the amount of light received by the optical sensor 10 in the initial state) is set to 100, and the amount of light actually received by the optical sensor 10 from light reflected by the background portion BG is set to HI, and the amount of light received by the optical sensor 10 from light reflected by the register marks R1, R2, and Rn is set to LO.
Now, assuming that the packaging material Fi moves and the optical sensor 10 receives reflected light from the end of the packaging material Fi, and that the register marks R1, R2, and Rn pass directly below the fiber head 17 of the optical sensor 10 at elapsed times t1, t2, and tn, the amount of light received by the optical sensor 10 is LO while the optical sensor 10 is receiving reflected light from the register marks R1, R2, and Rn, and otherwise it receives reflected light from the background portion BG, and the amount of light received by the optical sensor 10 is HI.
Thus, the change over time in the amount of light received by the optical sensor 10 is represented by a light reception curve LR shown in FIG.
At this time, a threshold value SH for the detection signal is set in the control unit 14 of the optical sensor 10, and when the amount of light received by the optical sensor 10 changes from a state higher than the threshold value SH to a state lower than the threshold value SH, the control unit 14 outputs a detection signal, and the output detection signal is sent to a control device for a feed roller (described later) that pays out and feeds the packaging material Fi, and the feed amount of the packaging material Fi is adjusted.
Assuming that the threshold value SH is set to 60 as shown in FIG. 3(a), the amount of light received HI of the optical sensor 10 is higher than the threshold value SH, and the amount of light received LO is lower than the threshold value SH. Therefore, as shown in FIG. 3(b), the control unit 14 outputs detection signals S1, S2, and Sn at elapsed times t1, t2, and tn.
図４は、光センサの１０がレジスターマークＲ１、Ｒ２、Ｒｎを検知する場合の、受光曲線の変化を説明する説明図であり、同図（ａ）は光センサの１０の初期状態の受光曲線を表し、同図（ｂ）は光センサの１０の受光量がやや低下した状態の受光曲線を表し、同図（ｃ）は光センサの１０の受光量が大きく低下した状態の受光曲線を表している。
図４（ａ）に示すように、光センサの１０の初期状態において、包材Ｆｉの背景部ＢＧからの反射光を受光する光センサの１０の受光量を１００とし、レジスターマークＲ１等からの反射光を受光する光センサの１０の受光量を４０とすると、光センサの１０の受光曲線は曲線ＬＲ０となる。
図４（ｂ）に示すように、光センサの１０の受光量は初期状態から下がってその受光曲線が曲線ＬＲ１となっている場合、背景部ＢＧからの反射光を受光する光センサの１０の受光量が閾値ＳＨ（６０）より高く、光センサ１０は、レジスターマークＲ１等を検知し、正常に動作している。
ところが、図４（ｃ）に示すように、光センサの１０の受光量が初期状態から大きく下がってその受光曲線が曲線ＬＲ２となっている場合、背景部ＢＧからの反射光を受光する光センサの１０の受光量は閾値ＳＨ（６０）より低くなり、光センサ１０は、レジスターマークＲ１等を検知できず、正常に動作しないこととなる。
本発明の光センサ予兆保全装置２０は、光センサの１０の受光量は初期状態から下がっているが、レジスターマークを検知して正常に動作している状態（図４（ｂ）の状態）において、光センサ１０の機能が低下して動作不良となる状態（図４（ｃ）の状態）の予兆を示すようにするものである。
FIG. 4 is an explanatory diagram showing the change in the light reception curve when the optical sensor 10 detects the register marks R1, R2, and Rn, where FIG. 4(a) shows the light reception curve of the optical sensor 10 in the initial state, FIG. 4(b) shows the light reception curve of the optical sensor 10 in a state where the amount of light received by the optical sensor 10 has slightly decreased, and FIG. 4(c) shows the light reception curve of the optical sensor 10 in a state where the amount of light received by the optical sensor 10 has significantly decreased.
As shown in Figure 4 (a), in the initial state of the optical sensor 10, if the amount of light received by the optical sensor 10 receiving reflected light from the background portion BG of the packaging material Fi is 100, and the amount of light received by the optical sensor 10 receiving reflected light from the register mark R1, etc. is 40, then the light receiving curve of the optical sensor 10 will be the curve LR0.
As shown in FIG. 4B, when the amount of light received by the optical sensor 10 drops from the initial state and the light reception curve becomes the curve LR1, the amount of light received by the optical sensor 10 receiving reflected light from the background portion BG is higher than the threshold value SH (60), and the optical sensor 10 detects the register mark R1, etc., and is operating normally.
However, as shown in Figure 4 (c), when the amount of light received by the optical sensor 10 drops significantly from the initial state and the light reception curve becomes the curve LR2, the amount of light received by the optical sensor 10 receiving the reflected light from the background part BG becomes lower than the threshold value SH (60), and the optical sensor 10 cannot detect the register mark R1, etc., and will not operate normally.
The optical sensor predictive maintenance device 20 of the present invention is configured to indicate a predictive state in which the function of the optical sensor 10 has deteriorated and it will malfunction (the state in FIG. 4(c)) when the amount of light received by the optical sensor 10 has decreased from the initial state but the register mark has been detected and the sensor is operating normally (the state in FIG. 4(b)).
［横ピロー包装機］
図５は、図１に示す光センサ予兆保全システム１を取り付けた横ピロー包装機の概略構成を表した図であり、同図（ａ）は正面図、同図（ｂ）は平面図である。
図において、３０は横ピロー包装機、３１は包材（包装材料）供給部、３２は包材送り部、３２ａは駆動ローラー、３２ｂは押えローラー、３３は被包装品供給部、３３ａは供給コンベア、３４は製筒部、３４ａは製筒器（フォーマ）、３５は紙引き部、３５ａは駆動ローラー、３５ｂは押えローラー、３６はセンターシール部、３６ａ、３６ｂはセンターシールブロック、３７は目付け部、３７ａ、３７ｂは目付けローラー、３８はエンドシール・切断部、３８ａ、３８ｂはエンドシールブロック、３９は包装体排出部、３９ａは排出コンベア、ＣＰは被包装品、ｇｒａ、ｇｒｂ、ｇｒｃはガイドローラー、ＭＲは巻取り包材、Ｐｃは包装体、ＴＦは筒状包材、ｃｓはセンターシール部分、ｅｓはエンドシール部分である。
図５に示すように、横ピロー包装機３０は、包材（包装材料）供給部３１、包材送り部３２、被包装品供給部３３、製筒部３４、紙引き部３５、センターシール部３６、目付け部３７、エンドシール・切断部３８、包装体排出部３９等から構成される。
包材供給部３１は、巻取り包材ＭＲを繰り出す巻取り包材供給装置（図示せず）等を備え、巻取り包材ＭＲから包材Ｆｉを繰り出す。
包材送り部３２は、駆動ローラー３２ａと押えローラー３２ｂで包材Ｆｉを挟み込み、モータ（図示せず）により駆動ローラー３２ａを回転させて、包材Ｆｉを一定長さだけ送り出す。
製筒部３３は、製筒器（フォーマ）３４ａにより包材Ｆｉを筒状包材ＴＦに成形（製筒）する。
被包装品供給部３４は、ベルトコンベア３４ａ上に被包装品ＣＰを載せ、筒状包材ＴＦの中に被包装品ＣＰを充填する。
紙引き部３５は、駆動ローラー３５ａと押えローラー３５ｂで筒状包材ＴＦの重ね合せされた端部を挟み込み、モータ（図示せず）により駆動ローラー３５ａを回転させて、筒状包材ＴＦを一定長さだけ送り出す。
センターシール部３６は、ヒータ（図示せず）で加熱したセンターシールブロック３６ａ、３６ｂで重ね合せされた筒状包材ＴＦの端部を挟み込み、筒状包材ＴＦにセンターシールｃｓを施す。
目付け部３７は、目付けローラー３７ａ、３７ｂで筒状包材ＴＦのセンターシールｃｓを挟み込み、モータ（図示せず）により一方の目付けローラー３７ａを回転させてセンターシールｃｓに目付けを施す。
エンドシール・切断部３８は、ヒータ（図示せず）で加熱したエンドシールブロック３８ａ、３８ｂで筒状包材ＴＦの先端部を挟み込んでエンドシールを施してエンドシール部分ｅｓを形成し、エンドシール部分ｅｓの中央部を切断して、被包装品ＣＰが袋詰めされた包装体Ｐｃを生成する。
包装体排出部３９は、包装体Ｐｃを排出コンベア３９ａにより排出する。
ここで、光センサ１０のファイバ頭部１６は、駆動ローラー３２ａとガイドローラーｇｒｂの間を通る包材Ｆｉの近傍に設置され、レジスターマークＲ１、Ｒ２、Ｒｎを検知し、制御部１４から検知信号が出力される。
そして、制御部１４から出力される検知信号は、包材送り部３２や紙引き部３５等の制御部に送られ、包材Ｆｉや筒状包材ＴＦの送り量等が調整される。
[Horizontal pillow packaging machine]
5A and 5B are diagrams showing the schematic configuration of a horizontal pillow packaging machine to which the optical sensor predictive maintenance system 1 shown in FIG. 1 is attached, with FIG. 5A being a front view and FIG. 5B being a plan view.
In the figure, reference numeral 30 denotes a horizontal pillow packaging machine, 31 denotes a packaging material (packaging material) supply section, 32 denotes a packaging material feed section, 32a denotes a drive roller, 32b denotes a pressure roller, 33 denotes a packaged product supply section, 33a denotes a supply conveyor, 34 denotes a tube making section, 34a denotes a tube former, 35 denotes a paper drawing section, 35a denotes a drive roller, 35b denotes a pressure roller, 36 denotes a center seal section, 36a and 36b are center seal blocks, 37 denotes a mesh section, 37a and 37b are mesh rollers, 38 denotes an end seal/cutting section, 38a and 38b are end seal blocks, 39 denotes a package discharge section, 39a denotes a discharge conveyor, CP denotes a packaged product, gra, grb, and grc are guide rollers, MR denotes a rolled packaging material, Pc denotes a package, TF denotes a tubular packaging material, cs denotes a center seal section, and es denotes an end seal section.
As shown in Figure 5, the horizontal pillow packaging machine 30 is composed of a packaging material (packaging material) supply section 31, a packaging material feed section 32, a packaged product supply section 33, a tube making section 34, a paper drawing section 35, a center sealing section 36, a meshing section 37, an end sealing/cutting section 38, a package discharge section 39, etc.
The packaging material supply section 31 includes a rolled packaging material supply device (not shown) that pays out the rolled packaging material MR, and pays out the packaging material Fi from the rolled packaging material MR.
The packaging material feed section 32 sandwiches the packaging material Fi between a drive roller 32a and a pressure roller 32b, and feeds out a fixed length of the packaging material Fi by rotating the drive roller 32a using a motor (not shown).
The tube forming section 33 forms (forms) the packaging material Fi into a tubular packaging material TF using a tube former 34a.
The packaged product supply section 34 places packaged products CP on a belt conveyor 34a and fills the packaged products CP into a tubular packaging material TF.
The paper pulling unit 35 pinches the overlapped ends of the tubular packaging material TF between a drive roller 35a and a pressure roller 35b, and sends out a fixed length of the tubular packaging material TF by rotating the drive roller 35a using a motor (not shown).
The center seal section 36 sandwiches the ends of the overlapped tubular packaging material TF between center seal blocks 36a, 36b heated by a heater (not shown), and applies a center seal cs to the tubular packaging material TF.
The setting unit 37 clamps the center seal cs of the tubular packaging material TF between setting rollers 37a and 37b, and applies a setting to the center seal cs by rotating one of the setting rollers 37a using a motor (not shown).
The end sealing and cutting section 38 uses end sealing blocks 38a, 38b heated by a heater (not shown) to clamp the tip of the tubular packaging material TF and apply an end seal to form an end sealed portion es, and then cuts the center of the end sealed portion es to produce a packaged body Pc in which the packaged product CP is packed.
The packaging material discharge section 39 discharges the packaging material Pc by means of a discharge conveyor 39a.
Here, the fiber head 16 of the optical sensor 10 is placed in the vicinity of the packaging material Fi passing between the drive roller 32a and the guide roller grb, detects the register marks R1, R2, and Rn, and a detection signal is output from the control unit 14.
The detection signal output from the control unit 14 is sent to the control units of the packaging material feed unit 32, the paper drawing unit 35, etc., and the feed amount of the packaging material Fi and the tubular packaging material TF, etc. are adjusted.
［光センサ予兆保全装置２０の動作］
図６は、光センサ予兆保全装置２０の動作を示すフローチャートであり、以下、光センサ予兆保全装置２０の動作を説明する。
まず、横ピロー包装機３０を運転させ、光センサの１０が包材Ｆｉに印刷されたレジスターマークを検知して検知信号を出力し、正常に動作している状態において、受光量取得部２１が、光センサ１０の受光量（現在受光量）を制御部１４から取得し、取得した受光量（現在受光量）を演算制御装置２２に送る（Ｓ１）。
具体的には、受光量取得部２１において、送信部２１ａが、制御部１４から光センサ１０の受光量（現在受光量）を連続的に取得して、通信回線２１ｃを介して受信部２１ｂに送信し、受信部１５ｂが受信した受光量（現在受光量）を演算制御装置２２に送る。
また、受光量取得部２１が取得して演算制御装置２２に送る現在受光量は、例えば、図４（ｂ）の曲線ＬＲ１で表される。
次いで、演算制御装置２２の予兆判定部２２ａが、受光量取得部２１が取得する光センサ１０の受光量（現在受光量）と、初期受光量記憶部２２ｂに記憶されている初期受光量を比較し、初期受光量に対する現在受光量の低下が所定範囲を超えているか否かを判断し（Ｓ２）、超えていると判断した場合は、光センサ１０に動作不良の予兆ありと判定し（Ｓ３）、この判定結果が警報器２７に送られ、警報器２３において、動作不良の予兆がある旨等の警報が表示され（Ｓ４）、処理を終了する。
一方、ステップＳ２で、予兆判定部２２ａが、初期受光量に対する現在受光量の低下が所定範囲を超えていないと判断した場合、光センサ１０に動作不良の予兆なしと判定し（Ｓ５）、警報器２３における警告表示を行わず処理を終了する。
この場合、ステップＳ２の判断における所定範囲の具体例としては、初期受光量と閾値ＳＨの差の２０パーセントが挙げられる。
すなわち、現在受光量と閾値ＳＨの差が、初期受光量と閾値ＳＨの差の２０パーセント以下となった場合に、予兆判定部２２ａは、初期受光量に対する現在受光量の低下が所定範囲を超えていると判断する。
また、ステップＳ３における光センサ１０に動作不良の予兆ありとの判定は段階的に行ってもよい。
具体的には、現在受光量と閾値ＳＨの差が、初期受光量と閾値ＳＨの差の３０パーセント以下となった場合に、レベル１の動作不良の予兆ありとの判定をし、現在受光量と閾値ＳＨの差が、初期受光量と閾値ＳＨの差の２０パーセント以下となった場合に、レベル２の動作不良の予兆ありとの判定をし、現在受光量と閾値ＳＨの差が、初期受光量と閾値ＳＨの差の１０パーセント以下となった場合に、レベル３の動作不良の予兆ありとの判定をするようにしてもよい。
さらに、現在受光量表示部が、図４（ｂ）の曲線ＬＲ１で表されるような現在受光量を表示し、所定範囲設定部が、予兆判定部２２ａが光センサ１０に動作不良の予兆ありとの判定する基準となる所定範囲を設定するようにしてもよい。
このように光センサの１０が正常に動作している状態であっても、光センサの１０の機能が低下し始めるとその受光量が低下することから、光センサの１０の受光量の低下が所定範囲を超えれば光センサの１０に動作不良の予兆があると判定し、光センサの１０の保全を図ることができる。
[Operation of the optical sensor predictive maintenance device 20]
FIG. 6 is a flowchart showing the operation of the optical sensor predictive maintenance device 20. The operation of the optical sensor predictive maintenance device 20 will be described below.
First, the horizontal pillow packaging machine 30 is operated, and the optical sensor 10 detects the register mark printed on the packaging material Fi and outputs a detection signal. When the machine is operating normally, the received light amount acquisition unit 21 acquires the amount of light received by the optical sensor 10 (current amount of light received) from the control unit 14 and sends the acquired amount of light received (current amount of light received) to the arithmetic and control device 22 (S1).
Specifically, in the light receiving amount acquisition unit 21, the transmitter 21a continuously acquires the amount of light received by the optical sensor 10 (current amount of light received) from the control unit 14 and transmits it to the receiver 21b via the communication line 21c, and sends the amount of light received (current amount of light received) received by the receiver 15b to the arithmetic and control device 22.
The current amount of received light acquired by the amount-of-received-light acquiring unit 21 and sent to the arithmetic and control device 22 is represented by, for example, a curve LR1 in FIG.
Next, the sign determination unit 22a of the arithmetic and control unit 22 compares the amount of light received by the optical sensor 10 (current amount of light received) acquired by the light received amount acquisition unit 21 with the initial amount of light stored in the initial light received amount memory unit 22b, and determines whether the decrease in the current amount of light received relative to the initial amount of light received exceeds a predetermined range (S2).If it is determined that it does, it determines that there are signs of a malfunction in the optical sensor 10 (S3), this determination result is sent to the alarm 27, and the alarm 23 displays a warning indicating that there are signs of a malfunction (S4), and the processing ends.
On the other hand, in step S2, if the sign determination unit 22a determines that the decrease in the current amount of received light relative to the initial amount of received light does not exceed a predetermined range, it determines that there are no signs of a malfunction in the optical sensor 10 (S5), and terminates the processing without displaying a warning on the alarm 23.
In this case, a specific example of the predetermined range in the judgment in step S2 is 20 percent of the difference between the initial amount of received light and the threshold value SH.
In other words, when the difference between the current amount of received light and the threshold value SH becomes 20 percent or less of the difference between the initial amount of received light and the threshold value SH, the sign determination unit 22a determines that the decrease in the current amount of received light relative to the initial amount of received light exceeds a predetermined range.
Furthermore, the determination in step S3 that there is a sign of a malfunction in the optical sensor 10 may be made in stages.
Specifically, if the difference between the current amount of received light and the threshold value SH is 30% or less of the difference between the initial amount of received light and the threshold value SH, it may be determined that there is a sign of a level 1 operational malfunction; if the difference between the current amount of received light and the threshold value SH is 20% or less of the difference between the initial amount of received light and the threshold value SH, it may be determined that there is a sign of a level 2 operational malfunction; and if the difference between the current amount of received light and the threshold value SH is 10% or less of the difference between the initial amount of received light and the threshold value SH, it may be determined that there is a sign of a level 3 operational malfunction.
Furthermore, the current light receiving amount display unit may display the current light receiving amount as represented by the curve LR1 in Figure 4 (b), and the specified range setting unit may set a specified range that serves as a criterion for the precursor determination unit 22a to determine that there is a precursor of a malfunction in the optical sensor 10.
Thus, even if optical sensor 10 is operating normally, when the function of optical sensor 10 begins to deteriorate, the amount of light it receives will decrease. Therefore, if the decrease in the amount of light received by optical sensor 10 exceeds a predetermined range, it can be determined that optical sensor 10 is indicating a malfunction, and measures can be taken to preserve optical sensor 10.
本発明の駆動機器の光センサ予兆保全装置及び光センサ予兆保全方法は、包装機械において、位置合わせ用マークを検知する光センサの機能が低下して動作不良となる前に、その予兆を示す変化を取得して、光センサの保全を図ることができるものであり、横ピロー包装機、縦ピロー包装機、上包み包装機、深絞り包装機等に利用できる。 The optical sensor predictive maintenance device and optical sensor predictive maintenance method for driving equipment of the present invention can obtain changes that indicate a predictive failure of the optical sensor that detects alignment marks in packaging machines before the sensor's function deteriorates and causes a malfunction, thereby preserving the optical sensor. It can be used in horizontal pillow packaging machines, vertical pillow packaging machines, overwrap packaging machines, deep draw packaging machines, etc.
１ 光センサ予兆保全システム
１０ 光センサ
１１ 光センサ本体
１２ 受光素子
１３ 投光素子
１４ 制御部
１５ ファイバケーブル
１５ａ 受光用光ファイバ
１５ｂ 投光用光ファイバ
１６ ファイバ頭部
２０ 光センサ予兆保全装置
２１ 受光量取得部
２１ａ 送信部
２１ｂ 受信部
２１ｃ 通信回線
２２ 演算制御装置
２２ａ 予兆判定部
２２ｂ 初期受光量記憶部
２３ 警告器
３０ 横ピロー包装機
３１ 包材（包装材料）供給部
３２ 包材送り部
３２ａ 駆動ローラー
３２ｂ 押えローラー
３３ 被包装品供給部
３３ａ 供給コンベア
３４ 製筒部
３４ａ 製筒器（フォーマ）
３５ 紙引き部
３５ａ 駆動ローラー
３５ｂ 押えローラー
３６ センターシール部
３６ａ、３６ｂ センターシールブロック
３７ 目付け部
３７ａ、３７ｂ 目付けローラー
３８はエンドシール・切断部
３８ａ、３８ｂ エンドシールブロック
３９ 包装体排出部
３９ａ 排出コンベア
Ｆｉ 包材
Ｒ１、Ｒ２、Ｒｎ レジスターマーク
ＢＧ 背景部
ＬＲ 受光量曲線
Ｓ１、Ｓ２、Ｓｎ 検知信号
ＳＨ 閾値
1 Optical sensor predictive maintenance system 10 Optical sensor 11 Optical sensor body 12 Light receiving element 13 Light emitting element 14 Control unit 15 Fiber cable 15a Light receiving optical fiber 15b Light emitting optical fiber 16 Fiber head 20 Optical sensor predictive maintenance device 21 Received light amount acquisition unit 21a Transmitting unit 21b Receiving unit 21c Communication line 22 Arithmetic and control device 22a Prediction determination unit 22b Initial received light amount memory unit 23 Alarm 30 Horizontal pillow packaging machine 31 Packaging material (packaging material) supply unit 32 Packaging material feed unit 32a Drive roller 32b Presser roller 33 Packaged product supply unit 33a Supply conveyor 34 Cylinder making unit 34a Cylinder making machine (former)
35 Paper drawing section 35a Drive roller 35b Presser roller 36 Center seal section 36a, 36b Center seal block 37 Weighting section 37a, 37b Weighting roller 38 End seal and cutting section 38a, 38b End seal block 39 Package discharge section 39a Discharge conveyor Fi Packaging material R1, R2, Rn Register mark BG Background section LR Light receiving amount curve S1, S2, Sn Detection signal SH Threshold
Claims (5)
前記位置合わせ用マークと該位置合わせ用マークの背景部に反射する光から前記光センサが受光する光の受光量を取得する受光量取得手段と、
前記光センサの初期状態において前記受光量取得手段が取得した前記受光量である初期受光量を記憶する初期受光量記憶手段と、
前記包装機械の運転中に前記受光量取得手段が取得する前記受光量である現在受光量と、前記初期受光量記憶手段に記憶された前記初期受光量を比較し、前記現在受光量が前記光センサの初期状態において前記初期受光量に基づいて設定された閾値より高く前記光センサが正常に動作している状態において、前記光センサの機能が低下して前記初期受光量に対する前記現在受光量の低下が所定範囲を超えている場合に、前記現在受光量が前記閾値より低くなり前記光センサが動作不良となる予兆ありとの判定をする予兆判定手段と、
前記予兆判定手段の判定結果を出力する判定結果出力手段と
を備えたことを特徴とする光センサ予兆保全装置。 A predictive maintenance device using an optical sensor that detects alignment marks printed on continuous packaging material supplied in a packaging machine, comprising:
a light receiving amount acquiring means for acquiring an amount of light received by the optical sensor from the alignment mark and light reflected from a background portion of the alignment mark;
an initial light-receiving amount storage means for storing an initial light-receiving amount, which is the amount of light received by the light-receiving amount acquisition means in an initial state of the optical sensor;
a sign determination means for comparing a current amount of received light, which is the amount of received light acquired by the amount of received light acquisition means while the packaging machine is in operation, with the initial amount of received light stored in the initial amount of received light storage means, and determining that there is a sign that the current amount of received light will fall below the threshold value and that the optical sensor will malfunction when the function of the optical sensor deteriorates and the decrease in the current amount of received light relative to the initial amount of received light exceeds a predetermined range while the current amount of received light is higher than a threshold value set based on the initial amount of received light in an initial state of the optical sensor and the optical sensor is operating normally;
and a determination result output means for outputting a determination result of the predictive maintenance device.
受光量取得手段が、前記包装機械の運転中に前記位置合わせ用マークと該位置合わせ用マークの背景部に反射する光から前記光センサが受光する光の受光量を取得し、
予兆判定手段が、前記受光量取得手段が取得した前記受光量である現在受光量と、前記光センサの初期状態において前記受光量取得手段が取得した前記光センサの初期受光量を比較して、前記現在受光量が前記光センサの初期状態において前記初期受光量に基づいて設定された閾値より高く前記光センサが正常に動作している状態において、前記光センサの機能が低下して前記初期受光量に対する前記現在受光量の低下が所定範囲を超えている場合に、前記現在受光量が前記閾値より低くなり前記光センサが動作不良となる予兆ありと判定し、
判定結果出力手段が、前記予兆判定手段の判定結果を出力する
ステップを備えたことを特徴とする光センサ予兆保全方法。 A predictive maintenance method for an optical sensor that detects alignment marks printed on continuous packaging material supplied in a packaging machine, comprising:
a light receiving amount acquiring means for acquiring an amount of light received by the optical sensor from the alignment mark and light reflected from a background portion of the alignment mark during operation of the packaging machine;
an indication determination means that compares a current amount of received light, which is the amount of received light acquired by the amount of received light acquisition means, with an initial amount of received light of the optical sensor acquired by the amount of received light acquisition means in an initial state of the optical sensor, and determines that there is an indication that the current amount of received light will fall below the threshold and that the optical sensor will malfunction when the current amount of received light is higher than a threshold set based on the initial amount of received light in the initial state of the optical sensor and the optical sensor is operating normally, and the function of the optical sensor has deteriorated and the decrease in the current amount of received light relative to the initial amount of received light exceeds a predetermined range ;
13. An optical sensor predictive maintenance method comprising: a step of outputting a determination result from said predictive maintenance determining means.
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