Abstract:
Provided is a fully automatic gravure preparation processing system having high degrees of freedom, which is capable of manufacturing a gravure printing roll more quickly as compared to a conventional case, achieving space saving, performing an unattended operation even in the nighttime, flexibly customizing a manufacturing line, and satisfying various customer needs. The fully automatic gravure preparation processing system includes: a processing room-A having a handling area of a first industrial robot for chucking and handling a roll to be prepared; and a processing room-B having a handling area of a second industrial robot for chucking and handling the roll to be prepared. The first industrial robot and the second industrial robot are configured to transfer the roll to be prepared therebetween when preparation processing is performed.

Description:
TECHNICAL FIELD  
       [0001]    The present invention relates to a gravure preparation processing system, and more particularly, to a fully automatic gravure preparation processing system capable of performing an unattended operation even in the nighttime. 
       BACKGROUND ART 
       [0002]    Conventionally, gravure preparation plants described in Patent Documents 1 to 6 have been known. 
         [0003]    As can be seen from the drawings of Patent Documents 1 to 3, a manufacturing line for a gravure printing roll has conventionally been constructed of an industrial robot and a stacker crane used in combination. 
         [0004]    In the manufacturing line using the stacker crane, processing is performed in each of various processing units under a state in which a roll to be prepared is chucked at the stacker crane with use of a cassette-type roll chuck rotary transportation unit. 
         [0005]    However, in the case of such a manufacturing line using the stacker crane, the roll to be prepared is sequentially transferred to the various processing units under the state in which the roll to be prepared is chucked with use of the cassette-type roll chuck rotary transportation unit, and hence there arises a problem in that a longer time period is required accordingly. 
         [0006]    Further, in recent years, there have been customer needs for more flexible customization of the manufacturing line. 
       PRIOR ART DOCUMENTS  
     Patent Documents 
       [0007]    Patent Document 1: JP 10-193551 A 
         [0008]    Patent Document 2: WO 2007/135898 
         [0009]    Patent Document 3: WO 2007/135899 
         [0010]    Patent Document 4: JP 2004-223751 A 
         [0011]    Patent Document 5: JP 2004-225111 A 
         [0012]    Patent Document 6: JP 2004-232028 A 
         [0013]    Patent Document 7: JP 2008-221589 A 
       SUMMARY OF INVENTION  
     Technical Problem 
       [0014]    The present invention has been made in view of the above-mentioned circumstances of the conventional technologies, and it is therefore an object thereof to provide a fully automatic gravure preparation processing system having high degrees of freedom, which is capable of manufacturing a gravure printing roll more quickly as compared to a conventional case, achieving space saving, performing an unattended operation even in the nighttime, flexibly customizing a manufacturing line, and satisfying various customer needs. 
         [0015]    In order to achieve the above-mentioned object, a fully automatic gravure preparation processing system according to the present invention includes: a processing room-A having a handling area of a first industrial robot for chucking and handling a roll to be prepared; a processing room-B having a handling area of a second industrial robot for chucking and handling the roll to be prepared, the processing room-A and the processing room-B being communicable to each other; at least one processing apparatus arranged within the handling area of the first industrial robot of the processing room-A, the at least one processing apparatus being selected from among a roll stock apparatus, a photosensitive film coating apparatus, an electronic engraving apparatus, a laser exposure latent image forming apparatus, a degreasing apparatus, a grinding wheel polishing apparatus, an ultrasonic cleaning apparatus, a copper plating apparatus, a surface hardening film forming apparatus, a developing apparatus, an etching apparatus, a resist image removal apparatus, and a paper polishing apparatus; and at least one processing apparatus arranged within the handling area of the second industrial robot of the processing room-B, the at least one processing apparatus being excluded in the arrangement of the processing room-A, the at least one processing apparatus of the processing room-A and the at least one processing apparatus of the processing room-B being installable and dismantlable. The first industrial robot and the second industrial robot are configured to transfer the roll to be prepared therebetween when preparation processing is performed. 
         [0016]    In this manner, the roll to be prepared is transferred between the first industrial robot and the second industrial robot, and thus the gravure printing roll can be manufactured more quickly as compared to the conventional manufacturing line for a gravure printing roll using a stacker crane. Further, the roll to be prepared is transferred between the first industrial robot and the second industrial robot, and hence the stacker crane becomes unnecessary, which leads to such an advantage that space saving can be achieved. Further, the series of processing can be performed fully automatically based on predetermined programs, and hence there is also such an advantage that an unattended operation can be performed even in the nighttime. 
         [0017]    Further, the processing apparatus can be installed and dismantled within the handling areas. Accordingly, through replacement and arrangement performed by installing or dismantling the processing apparatus, the manufacturing line can be customized flexibly and various customer needs can be satisfied. Thus, the fully automatic gravure preparation processing system has high degrees of freedom. Conventionally, the stacker crane has been installed, and hence there is a limit to the location of the manufacturing line and the installation places of the processing apparatus. In contrast, according to the present invention, the processing apparatus only need to be installed within the handling areas of the first industrial robot and the second industrial robot, and hence there is such an advantage that the manufacturing line can be customized flexibly in response to the customer demands. 
         [0018]    Further, it is preferred that: the processing room-A be arranged as a clean room; the processing room-A be provided with a roll entrance; the roll stock apparatus be arranged in the vicinity of the roll entrance so as to stock the roll to be prepared; the roll stock apparatus, the photosensitive film coating apparatus, the laser exposure latent image forming apparatus, the grinding wheel polishing apparatus, and the paper polishing apparatus be arranged within the handling area of the first industrial robot of the processing room-A; the degreasing apparatus, the ultrasonic cleaning apparatus, the copper plating apparatus, the surface hardening film forming apparatus, the developing apparatus, the etching apparatus, and the resist image removal apparatus be arranged within the handling area of the second industrial robot of the processing room-B; the processing room-A or the processing room-B include a roll transfer placement table; and the first industrial robot and the second industrial robot be configured to transfer the roll to be prepared therebetween via the roll transfer placement table when the preparation processing is performed. 
         [0019]    It is preferred that the surface hardening film forming apparatus be a chromium plating apparatus, a DLC film forming apparatus, or a silicon dioxide film forming apparatus. For example, the diamond-like carbon (DLC) film forming apparatus for forming a DLC film as described in Patent Document 2, the silicon dioxide film forming apparatus for forming a silicon dioxide film as described in Patent Document 3, or the chromium plating apparatus as described in Patent Document 1 is applicable. 
       Advantageous Effects of Invention 
       [0020]    The present invention produces a remarkable effect that it becomes possible to provide a fully automatic gravure preparation processing system having high degrees of freedom, which is capable of manufacturing a gravure printing roll more quickly as compared to a conventional case, achieving space saving, performing an unattended operation even in the nighttime, flexibly customizing a manufacturing line, and satisfying various customer needs. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS  
         [0021]    [ FIG. 1 ] A schematic plan view illustrating a fully automatic gravure preparation processing system according to an embodiment of the present invention. 
       
    
    
     DESCRIPTION OF EMBODIMENTS  
       [0022]    Embodiments of the present invention are described below, but those embodiments are described as examples, and hence it is understood that various modifications may be made thereto without departing from the technical spirit of the present invention. 
         [0023]    A fully automatic gravure preparation processing system for a gravure printing roll according to the present invention is described with reference to the accompanying drawing. In  FIG. 1 , reference symbol  10  represents the fully automatic gravure preparation processing system for a gravure printing roll according to the present invention. The fully automatic gravure preparation processing system  10  includes a processing room-A and a processing room-B. The processing room-A and the processing room-B are partitioned by a wall  12 , and are communicable to each other via an openable and closable shutter  14 . 
         [0024]    A configuration of the processing room-A is described. In the processing room-A, reference symbol  16  represents a first industrial robot, which includes a turnable multi-axis robotic arm  18 . The first industrial robot  16  is controlled by operating a control panel  28 . Reference symbol Q represents a turnable range of the robotic arm  18 , which corresponds to a handling area of the first industrial robot  16 . 
         [0025]    Reference symbol  20  represents a roll to be prepared, and reference symbols  22   a  and  22   b  represent roll stock apparatus, respectively. As the roll stock apparatus, for example, the roll stock apparatus disclosed in Patent Documents 4 to 6 may be used. 
         [0026]    Reference symbol  24  represents a photosensitive film coating apparatus, and reference symbol  26  represents a laser exposure apparatus. In the example of  FIG. 1 , the photosensitive film coating apparatus  24  is provided above the laser exposure apparatus  26 . As those apparatus, conventionally known apparatus are applicable, and for example, the photosensitive film coating apparatus and the laser exposure apparatus as disclosed in Patent Documents 4 to 6 may be used. Reference symbol  50  represents a roll transfer placement table, on which the roll  20  to be prepared is placeable for transfer. Below the roll transfer placement table  50 , a paper polishing apparatus  21  is provided so as to perform paper polishing. As the paper polishing apparatus  21 , for example, the paper polishing apparatus as disclosed in Patent Documents 4 to 6 may be used. Further, in the processing room-A, a main control panel  52  is provided so as to control the fully automatic gravure preparation processing system  10 . 
         [0027]    In the example of  FIG. 1 , there is described a case where the photosensitive film coating apparatus  24  is installed and the laser exposure apparatus  26  performs laser exposure, but there may be employed a method in which an electronic engraving apparatus is installed so as to perform electronic engraving. As the electronic engraving apparatus, a conventionally known apparatus is applicable, and for example, the electronic engraving apparatus as disclosed in Patent Documents 4 to 6 may be used. 
         [0028]    Next, a configuration of the processing room-B is described. In the processing room-B, reference symbol  30  represents a second industrial robot, which includes a turnable multi-axis robotic arm  32 . The second industrial robot  30  is controlled by operating a control panel  29 . Reference symbol P represents a turnable range of the robotic arm  32 , which corresponds to a handling area of the second industrial robot  30 . 
         [0029]    Reference symbol  34  represents a grinding wheel polishing apparatus, and reference symbol  36  represents an ultrasonic cleaning apparatus. As the grinding wheel polishing apparatus  34 , a conventionally known apparatus is applicable, and for example, the grinding wheel polishing apparatus as disclosed in Patent Documents 4 to 6 may be used. Further, the ultrasonic cleaning apparatus  36  includes a reservoir for storing cleaning water, and an ultrasonic transducer provided below the reservoir. The ultrasonic cleaning apparatus  36  is capable of performing cleaning by vibrating the cleaning water through ultrasonic vibration of the ultrasonic transducer. 
         [0030]    Reference symbol  38  represents a degreasing apparatus, and reference symbol  40  represents a copper plating apparatus. As those apparatus, conventionally known apparatus are applicable, and for example, the degreasing apparatus and the copper plating apparatus as disclosed in Patent Documents 4 to 6 may be used. 
         [0031]    Reference symbol  42  represents a developing apparatus, and reference symbol  44  represents an etching apparatus. As those apparatus, conventionally known apparatus are applicable, and for example, the developing apparatus and the etching apparatus as disclosed in Patent Documents 4 to 6 may be used. 
         [0032]    Reference symbol  46  represents a resist removal apparatus, and reference symbol  48  represents a chromium plating apparatus. As the resist removal apparatus, a conventionally known apparatus is applicable, and for example, the resist removal apparatus as disclosed in Patent Documents 4 to 6 may be used. As the chromium plating apparatus, a conventionally known apparatus may be used, and for example, the chromium plating apparatus as disclosed in Patent Document 1 may be used. Further, in the example of  FIG. 1 , the chromium plating apparatus is used as an example of a surface hardening film forming apparatus, but alternatively, a DLC film forming apparatus or a silicon dioxide film forming apparatus is applicable as the surface hardening film forming apparatus. As the DLC film forming apparatus, for example, the DLC film forming apparatus as described in Patent Document 2 may be used, and as the silicon dioxide film forming apparatus, for example, the silicon dioxide film forming apparatus as described in Patent Document 3 may be used. 
         [0033]    Reference symbol  70  represents a washing and drying apparatus, which is configured to perform washing and drying for each processing as necessary. 
         [0034]    In the example of  FIG. 1 , the processing room-A is arranged as a clean room. The processing room-A and the processing room-B may be arranged as clean rooms, respectively, as necessary. 
         [0035]    Doors  58  and  60  are provided on a wall  56  of the processing room-A, through which a prepared roll is carried outside and a roll to be prepared (printing base material) is newly carried inside. The prepared roll is placed on any one of the roll stock apparatus  22   a  and  22   b,  and the roll to be prepared is placed on the other roll stock apparatus. A computer  62  is installed outside the processing room-A so as to check and manage various kinds of information, perform settings for various kinds of programs, and perform other operations. Reference symbol  64  represents a prepared roll that is manufactured. 
         [0036]    Referring to  FIG. 1 , actions of the fully automatic gravure preparation processing system according to the present invention are described. The first industrial robot  16  chucks the roll  20  to be prepared, which is placed on any one of the roll stock apparatus  22   a  and  22   b,  and places the roll  20  to be prepared on the roll transfer placement table  50  so that the roll  20  to be prepared is transferred to the second industrial robot  30 . The second industrial robot  30  chucks the roll  20  to be prepared, and transports the roll  20  to be prepared to the degreasing apparatus  38 . Then, the second industrial robot  30  releases the roll  20  to be prepared, and sets the roll  20  to be prepared onto the degreasing apparatus  38 . 
         [0037]    When a degreasing work is finished at the degreasing apparatus  38 , the second industrial robot  30  chucks the roll  20  to be prepared, and transports the roll  20  to be prepared to the copper plating apparatus  40 . Then, the second industrial robot  30  releases the roll  20  to be prepared, and sets the roll  20  to be prepared onto the copper plating apparatus  40 . 
         [0038]    When a plating work is finished at the copper plating apparatus  40 , the second industrial robot  30  chucks the roll  20  to be prepared, and transports and places the roll  20  to be prepared onto the roll transfer placement table  50  so that the roll  20  to be prepared is transferred to the first industrial robot  16 . The first industrial robot  16  chucks the roll  20  to be prepared, and transports the roll  20  to be prepared to the grinding wheel polishing apparatus  34 . Then, the first industrial robot  16  releases the roll  20  to be prepared, and sets the roll  20  to be prepared onto the grinding wheel polishing apparatus  34 . 
         [0039]    When a grinding wheel polishing work is finished at the grinding wheel polishing apparatus  34 , the first industrial robot  16  chucks the roll  20  to be prepared, and transports the roll  20  to be prepared to the ultrasonic cleaning apparatus  36 . Then, the first industrial robot  16  releases the roll  20  to be prepared, and sets the roll  20  to be prepared onto the ultrasonic cleaning apparatus  36 . 
         [0040]    When an ultrasonic cleaning work is finished at the ultrasonic cleaning apparatus  36 , the first industrial robot  16  chucks the roll  20  to be prepared, and transports the roll  20  to be prepared to the photosensitive film coating apparatus  24 . Then, the first industrial robot  16  releases the roll  20  to be prepared, and sets the roll  20  to be prepared onto the photosensitive film coating apparatus  24 . 
         [0041]    When a photosensitive film coating work is finished at the photosensitive film coating apparatus  24 , the first industrial robot  16  chucks the roll  20  to be prepared, and transports the roll  20  to be prepared to the laser exposure apparatus  26 . Then, the first industrial robot  16  releases the roll  20  to be prepared, and sets the roll  20  to be prepared onto the laser exposure apparatus  26 . 
         [0042]    When a laser exposure work is finished at the laser exposure apparatus  26 , the first industrial robot  16  chucks the roll  20  to be prepared, and places the roll  20  to be prepared onto the roll transfer placement table  50  so that the roll  20  to be prepared is transferred to the second industrial robot  30 . The second industrial robot  30  chucks the roll  20  to be prepared, and transports the roll  20  to be prepared to the developing apparatus  42 . Then, the second industrial robot  30  releases the roll  20  to be prepared, and sets the roll  20  to be prepared onto the developing apparatus  42 . 
         [0043]    When a developing work is finished at the developing apparatus  42 , the second industrial robot  30  chucks the roll  20  to be prepared, and transports the roll  20  to be prepared to the etching apparatus  44 . Then, the second industrial robot  30  releases the roll  20  to be prepared, and sets the roll  20  to be prepared onto the etching apparatus  44 . 
         [0044]    When an etching work is finished at the etching apparatus  44 , the second industrial robot  30  chucks the roll  20  to be prepared, and transports the roll  20  to be prepared to the resist removal apparatus  46 . Then, the second industrial robot  30  releases the roll  20  to be prepared, and sets the roll  20  to be prepared onto the resist removal apparatus  46 . 
         [0045]    When a resist removal work is finished at the resist removal apparatus  46 , the second industrial robot  30  chucks the roll  20  to be prepared, and transports the roll  20  to be prepared to the chromium plating apparatus  48 . Then, the second industrial robot  30  releases the roll  20  to be prepared, and sets the roll  20  to be prepared onto the chromium plating apparatus  48 . Then, chromium plating is performed at the chromium plating apparatus  48 . Note that, the roll  20  to be prepared is washed and dried for each processing at the washing and drying apparatus  70 . 
         [0046]    When a plating work is finished at the chromium plating apparatus  48 , the second industrial robot  30  chucks the roll  20  to be prepared, and transports the roll  20  to be prepared to the paper polishing apparatus  21 . Then, the second industrial robot  30  releases the roll  20  to be prepared, and sets the roll  20  to be prepared onto the paper polishing apparatus  21 . When paper polishing (automatic polishing) is performed at the paper polishing apparatus  21 , the prepared roll  64  is obtained and, in the example of  FIG. 1 , placed on the roll stock apparatus  22   b.    
         [0047]    The prepared roll  64  thus obtained is carried outside the processing room-A as a final product. 
         [0048]    Note that, the above-mentioned actions are an example of the fully automatic gravure preparation processing system according to the present invention, and the manufacturing line can be customized flexibly in response to customer needs so as to be constructed as a preparation line of various arrangements. 
         [0049]    In the example of  FIG. 1 , as each of the first industrial robot  16  and the second industrial robot  30 , the industrial robot as disclosed in Patent Documents 1 to 6 is used for transporting the roll  20  to be prepared to each processing apparatus, and releasing and setting the roll  20  to be prepared onto the processing apparatus. Then, the roll to be prepared is rotated by drive means provided in the processing apparatus. 
         [0050]    On the other hand, there may be employed the following configuration. That is, as each of the first industrial robot and the second industrial robot, the industrial robot including drive means as disclosed in Patent Document 7 is used for transporting the roll  20  to be prepared to each processing apparatus, and setting the roll  20  to be prepared onto the processing apparatus while gripping the roll  20  to be prepared. Then, the roll to be prepared is rotated by the drive means provided in the industrial robot. 
       REFERENCE SIGNS LIST  
       [0051]      10 : fully automatic gravure preparation processing system,  12 : wall,  14 : shutter,  16 : first industrial robot,  18 ,  32 : robotic arm,  20 : roll to be prepared,  21 : paper polishing apparatus,  22   a,    22   b:  roll stock apparatus,  24 : photosensitive film coating apparatus,  26 : laser exposure apparatus,  28 ,  29 : control panel,  30 : second industrial robot,  34 : grinding wheel polishing apparatus,  36 : ultrasonic cleaning apparatus,  38 : degreasing apparatus,  40 : copper plating apparatus,  42 : developing apparatus,  44 : etching apparatus,  46 : resist removal apparatus,  48 : chromium plating apparatus,  50 : roll transfer placement table,  52 : main control panel,  56 : wall,  58 ,  60 : door,  62 : computer,  64 : prepared roll,  70 : washing and drying apparatus, A: processing room, B: processing room, P, Q: turnable range.